Introduction ‘This eorvice manual procedures for anc technical feature of the VERSOOR, ‘This Modo! Specific Manuai includes every eervice pro cecure thet is of 2 specific nature to this sartiouar __modsl. Basic service provadures thst are commen to ther Honda Motorcycles/Motor ScootersiaTvs are red in the Common Service Mental, This Model 2 Service Manual should be used together with the Common Service Manual In orcer to provide com: Dlete service information on oll especte ef this. motor yet. Pacforming the fst scheduled maintenance is vety in portant, compensates for tha intel wear that occurs faring the breakin peti, ‘Section 1 ané 2 apply to the whole motorevele, Section 2 flustotes procedures for remavelinotalistion of com ponents that may_be required t0, perform service 0 oribec in the following sections. Wile Seatiod 4 through 18 describe ports of the motor yale, groupes ascording Ye locations. Find the section you want on this page, then turn t6 the table of eostente on the fret page of the 362 ‘Moet soctisne describe the service prosedure through system llvetration, Refer to the next page for detells on Fhow to use this mana. It you ate not familar with this motoreyele fat Tach al Feature in cectin 20. you don’t know the rource of the trouble go to section 21 TROUBLESHOOTING. = ‘ALLINFORMATION, ILLUSTRATIONS, DIRECTIONS [AND SPECIFICATIONS INCLUDED IN THIS PUBL! CATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF AP- PROVAL FOR PRINTING, HONDA MOTOR CO.,LTD. RESERVES THE RIGHT TO MAKE CHANGES AT —| Any Tims WITHOUT NoTICE AND wiTHoUT: INCURRING ARY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRO: DUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAIN- TENANCE ON HONDA MOTORCYCLES, MOTOR — |_ SCOOTERS OR ATVS, HONDA MOTOR CO.. LTD, SERVICE PUBLICATION OFFICE Contents ~ J Generat information é Ei a 2 | =| Maintenance Ea za Lubrication System a Fuel System [ Encine Remova/instalion | cylinder Head/Valves Ei Clutch EI | [sero untae ia |= | Santchaturioartonemicson RE | Rear Wheel/Suspension Valve stem O.D.1N x Valve guide LD. IN x Sterm-to-quide elesrance IN : x Valve guide projection above cylinder hesd IN th) Ex) Before guide Installation: 1. Chil tho valve guide in the freazer section of a ceiigerator for about an nour. 2. Heat the evlinder head to 100~150°C (212—300°F) Valve seat width IN ex Valve spring free length IN x foner IN ‘nner EX Outer IN Outer EX Recker arm 4.0. IN ex Focker arm shaft OD. IN x Rocker arm-to-rocker arm shaft clearance Valve fitter 0.0 Valve litter bore 1.2. Hydrauiic tapper adjuster assis: spring free fongth Hydraulic sappet adjuster compression stroke with kerosene Standard {BTA = 196 KPa (18.0 32.0 Kgiow, 385 + 26 ps1/200 min’ from 40 mmtig (1.8 ints) (0.12--0,18 (0.008~0.007) 0.21-0.27 (0.008—0.0111 92.717 92.987 (1.2882—1.2978) 32.428-32.668 (1.2767~1.22017 (0,040--0.082 (0.0018—0.0032) 27.939-27,980 (13000=1.1008) 28.000~28.021 (1.1024--1.1032) 4.475~4.490 (0.1762~0.1788) 4.455 4.480 (0,1758~-0.5764) 4:800—4.512 (0.1772—0.1776) 4.§00—4.612 (0.1772-0.1778) 9. 070--0.037 (0,0004—0.0075) (0,020--0.087 {0.0008--0.0019] 10 (0.44 10 (0.41 ] 1.79-2.20 (0.087--0.081 1,702.30 (0.087—0.081) 21.4 (7.24) 31.4 4.24) 24.4 (1.35) 34.4 (1.95) 8.500--8.516 (0.3346—0.9352) 8.500—£.515 0.3846--0.2952) 8.486—8.484 (0.3333 —0.5340) 2.466—8.484 [0.3333-0.9960) HAW oy 0.10 (0.004) 42,67 (1.288) 32.58 (1.275) (0.03 (0.001) 0.082 10.0036! 27.93 (1.010 | 28.03 [1.104) 4.47.(0.176) 0.46 (0.1758) 456 (0.180) 4.56 (0.180) 0.08 16.008) 0.12 (0.005) 30.2 (3.19) 30.2 11.19) 33.2 (1.31) 332 (1.31) 2,53 (0.336) 8.83 (0.336) 8.48 (0.333) 2.48 10.333)General Information [— Cylinder! Piston em Standard mm in} a Service Limit Cylinder 1D. Cylinder out of round Cylinder taper Cylinder warpage Piston mark direction Piston 0.0. (D| Fiston 0.9. measurement point (H) '§5,000—85.015 (2. 1654—2,1658) “IN merk facing toward the intake side | 34.970 ~54.990 (2,1842—2.1650) | 1010.4) 56.07 (2.168) | 0.10 10.004) 0.10 (0,094) 0310 10.008}, 54.92 (2.168) | Paton pin hoe Ib ah 14.002—-14.008 (0.5513--0.5515) 14.02 (0.582) | eee, : | 225) je i —T : 1 | | | | cytinderto-iston clearance 0.010-0.045 (0.0004—0.0018) 0.10 (0.004) | Piston pin 0. 18.934—14,000 (0.8809 -0.5612) j 15.38 (0.5850) | Fistorsto-piston pin clearance 0.002-~0.0%4 (0.0001 ~0.0008) 0.04 (0.002) Connesting rod-to-piston pin clearance _ 0.016 —0.040 (0,0005—0.0016) | 0.06 (0.002) “op siig-tovting groove clearance 9.018-0.050 (0.0008 0.0020) |, 9.10 10.008}, Second ring tring groove clearance 0.015~0.048 0.0006-0,0018) 2:10 1.008) | Top ring end gap 0.18~-0.33 10.007-0.013) 0.65 (0.028) | Second tng end gaa 0.18-0.88 10.007-0.013) 0.65 10.028} | OW ring {side rai end gap 0.20--0.80 (0.008-0,031) 0.95 (0.037) | ema mer “Remark facing up — Second ring mati |e mane facing up = 7 Crankshate == Connecting rod stall end 1D. 14.016—14.034 (0.8518-0.5525) 14.05 0.859) | Connecting od big end side clearance 0.400 50 (0.000.012), 0.40.02) | ‘adie clerance = , | Cranianeft renout = | 0.03 0.001) i e | ae 1 we a | | U | | | Crankin ot clearance 0.028~0.082 (0.0011-0.0020) 0.07 (0.003) | Grankpin bearing selection See page 1-10 — Main Journal cil clearance 0.025-0.089 (0.0010-0.0018) 0.07 10.003) Main journal bearing selection See page 110 Kiekstarter pinion gear 1.0, Kickstarter spindle OD, Kickstarter idle gear LD. Countershaft O.D. at kickstarter idle gear Kickstarter idle gear bushing 05. 1. Kickstarter - II HAGeneral information ‘unite mma (nd Standard Service Limit “Fansmiacion gear LD. MS, M6 2, C3, ca “Fansinission gear busting O.D. MS, Me 2, 63, co ‘Tansmiacion goar bushing LD. MB c2 Gear-to-bushing clearance at MS, M6 gear at C2, C3, 04 gear Mainshaft 0.0. ot MS gear bushing Coumtershatt OD. at C2 ge bushing ns eS 5 - | cearto-ehatt clearance Gear bushing-to-shaft clearance at MB geor | et C2 gear | Shite fork clow thickness | © | R | shite fore 10. L | © | R Shift fo%k shaft 9. L & A 28,000—28.021 {1.1024~1,1032) 28,000—28.021 {1.1024—1,1032) 27.989 27.980 {5.1007—1.1016) 27'959—27 980 (1.1007= 1.1016) 24,985--25 006 (0.9837 0.9846} | 24.988—28.006 (0.9837—0.9845) 0.020--0,062 (0.0008 0.0024) 0.020—-0.062 (0.0008 0.0024) 24,967 ~24.976 (0.9830—0.8824) 24.967—24.978 (0.9830-0.8834) 0.097-0.038 (0.0003—0.0015) 0.007 ~0.038 {0.0003~0.0015) 5,936.00 (0.233-0.256) 5.93~6.00 (0.233-0.295) 5,936.00 (0.233~0.230) £2,000 12,021 (0.4724--0.4733) 2.000 12.021 {0.4724--0.4733) 42,000- 12.021 (0.4724—-0.4733) $1,989— 11,980 (0.4712~0.4717) 141969~ 11.980 10.4712~0.47971 44,969 _11.880 10.4712—0.4717) 28.04 (1.104) 28.04 (1.104) 27.34 (1.100) 27.94 (1.100) 25.03 (0.985) 25.03 (0.985) 10.10 (0.004) 0:10 10.004) 24.96 (0.883) 24.96 (0.989) — | (0.06 10,0021 9.08 (0.0021 | 5.8 (0.23) 5.8 (0.23) 58 10.23) 32.04 (0.474) 12.08 (0.474) 12.04 (0.474) 11.95 (0.470) 11.98 (0.470), 11198 10.470) 1-9General information Se nie — Chtch sytem + tom | seandare __ Serie in ‘Clutch lever free play 10-20 (0.4-0.8) | — ecoandad Sth fd a cee Shae rae de 1 ao a Gutch master ton 3 : ee Giten cour LB = | 28000-20028 naai7~s24201 20.06 144) Sten outer guide 00. 2e.67 26.980 (t1abe~ 100) Beas figs) io Mave—220%8 (02088-08087 2205 800) Mainshat O. a chutch outer guide ea ss 201025 20.078 (1.1407-~1.1447) 20.01 140) i! pump drive sprocket LD. ‘Cluteh center B LD ‘One way cluteh inner OD. Clutch spring free height (As a set of Spes) Giuteh spring trae length Ciutch disc thickness CGlutoh dise thickness A 8 Clutch plate warpage Centsifugal clusch drum 1.0, bushing 0. Centefugel clutch comer guide LD. oD. Centrifugal clutch center guide collar height Centrifugal clutch spring free length Cluteh fining thickness Crankshaft O.. at clutch center J Cooting System Coolant capacity (Radiater and engine) M Medel (Reserve tank) Radiator cap relief pressure Thermostat begins to open Thermostat fully open | Thermostat valve ff 63.964~63.990 (2.5183—2.5193) 47.385 47.378 (1.8648—1.8653) 5300.21) 2.92—3.08 (0.118~0.121) 207 liters (2.22 US ft. 1.85 Imp a) 2.0.itere (2.11 US W. 1.76 imp at) 0.2 fer (0.21 US qt, 0.18 Imp at) 108-137 kPe (1101.40 kglem?, 16-20 psid | 80-8400 (176-169) 95°C 1208°F), 8.0.(0.291 min, i 4.00 (2.820) 47.38 (1.8666) 2.8 (0.19) 2.8 (0.110) 0.30 (0.012) Wy | Drive Tain Recommended tint drive oll Final drive gear oii capacity ot disassembly at draining Final crive gear backlash Final drive gear backlash difference vetween measurements Ring geur-to-stop pln clearance (A) Stop pin shim Ring gear spacer Pinion spacer Final drive gear assembly preload ‘Output gear backiash Output gear 1.0. 10. Output érive shaft 0.0. | Output gaa: damner sprig free length Output sheft adjustment shim Countershate arive shaft adjuctment shim THE H HEPESGeneral information PRR eee EEE eee ee eee ete ere Units mm find tem ; Sante = nie wed doth FA a 73 08 [ee 7 i 2.0 (0.08, | coe we pes Dive ey | ab ps 228 nen 38 “es | Driver only (RR) 225 kPa (2.28 kgiom?, 83 psi — | Bice Srdpoowengee cm) | das the Bas haere 23 i 1 Driver end passenger (RR) 260 kPa (2.50 kgiem?, 36’ pei) —_— | Fen and oar ner 22 0.0) Feta er whe! unt ad Bo 08 : asi 2010.06) Front whes! hubsosrim distance Front whee! hub standard surfece i Rear wngel hub-towim distance a eat wheel hub standard surface ‘Whoa! balance weight (Front) ‘Reae) 25 (5/81) Drive chain size fink (010) aK | i | Drive chain slack L Gas25sM6:104 Psprestiohiondy ; “TigFly wound call end facing down Fork fuie 122 mm (4.8 inl Fork spring direction Fork tube runout i Recommonded fork oi Fork 390 ce (93.2 US 62, 13.-Z Imp 62) 408 ce (13.7 US 02, 14.2 Imp o2} | Fork ail capacity | Fotk oil capacity (M Model erly) 4.01.5 kg (2.2-9.3 1b] 1 Rear Suspension —$ $$ $ $ i @$ $$ Shosk absorber spring free length Shock absorber spring free length (9) wo Damper gas pressure Damper compressed gnc Danger rod compressed force at 10 mm compressed Damper dtiing point Shack absorber spring instalied length (standars) (Adjustable range) Shock absorber spring adjuster standard position Shock absorber spring direction Recommended sheck absorber oil ‘Shock absorber ofl capacity sir pressure 188.7 (6.2 in) 98 KPa 10 kgicm?, 142 pst Nitrogen 1820 ko {95—44 Ib) See page 1313 147.7 (6.81) l60 9 (21 ox) max. 60 g (21 c2) mex 271.8 110.70) 0.20 (0.008) HEIST EU 185.5 (6.12) HI LETT — -11General information Unit: mm in} brake padol free play brake pad wear indicator ® | To the groove 2 [Brakes — - tom [ Standard | Service Line | |" Front brake thuid oT 4 — | Brake lever free play oe | Brake pad wear dicot me i! | brake disc thickness 4 (0.16) | 3.5 (0.14) brake dise runout ae 0.80 (0.012) | raster eylnder 14,000~ 14.049 10.5612 0.5620) 14.06 (0.854) master piston OD. 15.957—12.98¢ (0.8¢08—0.5506) | re.98 (isan) Caliper evlinder |= eal Salperevinder LD. (Upoen 30.280--30,200 (1.1902~ 1.1921 20.28 1.1831 tows '400—28.450 (3.0600 1.0020: ) 25.86 1103281 calipr piston 0.0 a joan Gatper piston OD. Upper 30.148—30.198 (1.1869~ 1.18801 | 30.14 1rt8661| : mer | este2s0sooeee onsen | Sesriosoes Brake drum 10 a ss brake lining thickness | esaad iaaaa fear brake tie Dor 4 = broke pede height = = With digital wpe) brake dsc thickness | 60 10.24) 5.0 (0.20) rake disc runout je 0.30 10.082) master oylinder 1D. | 14.000 14,088 10.8612-0.5829) 14.08 (0.554) master piston OD, 19'957—13.96¢ (6 5495—0.5806) 13.96 (0.849) | caper eyinder 20. | 25.400—28.460 (1.0000 1.00201 25.40 (1.0024) caliper piston OD. | 25.s18—25 368 (0.9968-0.99871 28.31 (0.998) brake drum 12 = | brake fining thickness _ | — Battory’Changing Syatem —————— Attornator charging cal resistance (At 20°C/68°F) | 07-109 aes Pegulatoreectiir regulated votagetamperage | 12.—16.5 VO—6 Ast 5,000 min tom) | a Bottery capnory wv — 6aH jee | | Maintenance Free betery: YTXTA~BS} a Specified current leakage ‘aia 1 mA max, Borery specie gravity (Fully charge) = —" | | ‘Needs charging) = jee eee Battery charging rate (Normsl) | 0.7 A’S—10 hr. oe 1 (Quick: | 80am pe = | Battory votage Fully eharged et 20°c/ee%m) | 180-182 V = ‘leeds charsing at 20°c/0a"m) | 123V = Alternator iting col resistance tat 20°/680=) | — = AC teauaterregulaced votage nth analogue type] — =General information Us — tation System ; | ier | standae Terie st [ Spore naa Sansars No! | a (Sande ND) ‘tapech = {For old cmatfvelow S2CIL1°R NGK) | EABEH = | {For calscimatsocion Svcrater np) | YaertR = (Coc enonded igh apoed nang NOR) | ERNDEH ee Foventnded hgh speed rare No} | YaIFER i | spark ouo 26-017 (0.024~0.028 a | ignition timing “"F"* mark B® BTDC at 1,200 min" (rom) eee ‘vance ste 0s 200 mi tom Foet He seer 2 | eaty aaverce Shag wroc a12000 min! tom | | Sitar excar col resatnce (as zovciseen) | =— a | ignition coil resistance (Primary: at 20°C/68°F} a 5a | (Socorary wth pg can) ] 14228 «D | | Second tno pugrean)| 14 t8 cee | re ger rian te ZOPCI = LighsiorsSwithes — [san toe Pr a) fase BATS, 10Ax9 ce Feadigh highow bear) Teveoiso ws 2 08) area Tail/brake.light 32V5/21Wx2 | cr Coane fake _ BVew ae | Position tight T2V 5 WIE, AR, 12. V4 .W IF, GI _ | Front turn signatieunaing ight _— | Front tum signal light | i — 1 | eer aum gr te "estan at eae | Ol peteve warming indemoe a ‘Tail/orake light warning indicator —_ - = —_ ! ee ctand wortngInlestor a ae (ow faa ae = Gooiant temperature indicator |— Vr ee OW temperature indicator }— Wee rerecee ee Fgh bam indoor Vrevaaw : {om a nde levi = | Newel nicer (avirw a eves tsar aa a Overtve eestor |= 7 eee = Fuel un resistence haat = a tas emt) = = Fuel pump fiow capacity (min./minute i —_— Shovmo sensor fesetanee eoecriaseF 1900 = teaser 76°) | aoe a Caoreraaseri “onaoe 7 Fan tor switch Stat t las (ON) | 2a t02tc goa—216en = ‘Stops to open (OFFI | e372 t199--207" ae — staring Svat : au Starr eriven gon 0. | ar.g7e12.00011.0528—1.0825 «a.36 1.650 | | Storter reduction gear shaft 00. | 9.88¢~ 10.000 (0.3835—0.3837) 3.90 (0.3801. | Stoner ection goa 10 36.070" 10.110 0.9965-0-9880) 70.16 10.400) eee 1-13General information —————_—-_— ———__—. Torque Values a T “Toraue Z Torque | fee Nm tom Ra ee inten, 8B) Smmhoxbotandeut ! 5 (0.6,35) | Smmamew # (04. 3) 8 mm hex bot and nut 1011.6, 72) | Emm screw 910.9, 71 Emmher bot and nut | 2212.2, 16) | 6 mm flange batt (8 mm head) 2109, 7) 10 mm hex bolt and nut | 35 (3.5, 25} | Gmm flange bolt (10 mm head} and nut 12 (1.2, 9) 12mm hex bok and mst SE (58,60) | _B'mm lange bot ane mut | gras ! | 10 am ange bot and nut | 496. 28), + Terque specifications feted below are for importem fasteners + Others should be tightened to standard torque values listed above Notes: 1. Apply looking agent tothe threads 2. Rpply ol! to the threads and flange surfoce 3. Aeply molybdenum slsuifige of to the teads and flange surtace 4 Apply seslaa tothe treads. 5 Stoke 5. Apply clean engine oli to the O-ring 7, UBS bot [ 2 ®. Engine F Tere 7 1 Thvead Torque 1 Lubrication: : CO} pump driven sprocket bolt 1 6 1501.5, Note Ot pump mounting bolt 3 6 1243.8) (Ot pump cover bolt 3 6 321129) 4 filter 3 20 1000.7) | Notes | Oi drain bot fai 38138, 27) { Oh prescure switch . 1: me | age | Nowa | Fuel system: ! | | Carburetor insustor Sand screw ler aeeeie| 10107? | Coolitig system: } Wioter pump mounting Bott 2 6 1010.0. 7) Water pur cover bot 2 6 | tono7 Note 4 Thermo sencor 3 pre 1018.0. 7 Note 4 Cylinder head/eyinderiston (Cam gear case mounting bolt 8 8 | 20086, 26) ote 2 Gam geer case sot bit 2 s | 12ua a) Note 2 Cylinder head cover Dott a 8 rowo7 | | Gamshat okter bet 32 3 ize | ' Rocker arm shatt clug a Prue. 810.8, 6) | Note 4 ylindes read speci bok, 8 mim bis| 5018 20 noe | | Cylinder head bolt, 8 mm jel 6 | “2inz'9 | ‘Spark plug 4 8 | 9 (0.8, 7) | | Clutohilgearshittfinkage: } oy \ | | itt erarkase cover jal oes 1011.0. 71 i | Cluteb tock rut Li | 2 85(8.5,6) | Now s | ewe pig ein ra 3 23123, 171 nowt | | Shite rom set pate bok 2/ 6 1242.9) |New 1 Shift fork shaft set bolt 1 6 12:(1.2, 9) 1 Note 1 ‘ 4 wera 1 | Nowe [_ Timing hole cap = 1-14General information —Engine (Cont'd) | Tread Torave ts [ow] atm | nmegetiem | Arne t rankcaselorenkshafe/ransmision: a | | Drive sprocket holt 1 10 98 6, 401 Nout! switch i 10 1211.2. 2) Connecting rod bearing cap nut a 7 | 2402.4, 17) Note 2, 9 Grankcase soit mm wis 12 (4.2, 9) B mm nu] o8 2912.3, 17) | 10 mm a] 10 40 (2.0, 28) | tower case ot bolt 7 70 2312.3, 171 | Altemator: | Fyne! batt ; to | aseesen Note 7 Starter clutch: Primary dive gear bolt ftarter clutch oth 1 10 esis.) | Noe? | Starter euteh cover bolt el 2e(2e,20; | Newt | (Frame 7 - - | Frame/body panels: 1 | Main step holder bot 4 e | 27027,20 Nor | Main step bolt 2 70 | 454539 | | Pilon step bracket bot 4) 8 | 2a720 | Sub frame mounting bot 3 %0 27 27 20) | Side stané pivot bolt \4 10 | 38 @.8, 27) | Side stan braskot bolt | 2 8 35.05, 251 Nowe 1 Exhaust system: i | | | Eaoust pe joint nut je ° 2008.6) | Ccooting system: | Fan motor itch la 48 2312.8, 77) Note 4 Fue! system: | | Fuel tank breather cheek valve 2 18 1 g4.181 | Fuel vane 1 18 3.17 | Engine mount: : | Engine mounting bot 71 40 40 18.0, 28) Engine mounting adjust bok 2 2 7(1..8) Engine mounting lock nut 2 22 855 AO) Engine mounting not 1 wo | 400,20 | | Gearshit peea tele, THES 1211.2, 9) | Front suspension: ! | Hanaiebarnoler nineh bert (eee a2s1.2, 9) ignition sviten mounting bolt 2 = 25@5 18 | Now? Fork socket bo 2 e 2012.0, 14) | Now | Fork bote 2 2 232.317 | | Unper fork pneh bot 2 7 1. 8) © Gower fork pinch ooh 2 10 4014.0, 23) ‘Steering bearing adjustment nut id 35, 50 (6.0, 33} | Note 2 Steering stem nut =) 33 1404.0, 101) | Front ave pinch Bolt 4 3 2212.2, 18) Front exe bot | 3 14 6016.0, 43) 1-15General Information ‘General informe Frame (Cont'd) i Teed Sect i tom ory | gariem | wm agente) | Female Roar suspension: | Rear whee! aut 1 18 1201120, 87) Rear exe holder ock nut ja 38 ve5 116.5, 113) | Nowe 5 | Swingarm pivot nist a 1 | "esose | Swingarm pivot adjust bolt 1 20 is) | | |_ Swingarm pivet lock nut 1 so | ao rao Ba | | Brive chain ster screw ‘ 3 4 (04, 2.8) {Driven sprocket nut l6 8 35 (3.5, 25) | | Torque boli 2 10 gece. 25 | Rear shock absorber mounting bolt 2 10 45185, 95) | Note Rear shock absorber apring edhustor lock nut a = | Soysioles | Roar shock absorber reservoir holder banc 2 — | ata 29 | Shock Iniagebekhut B} to | feaslan | tome Roar Bearing holder pinch bolt 1 16 55165, 0) | Dive on bok a] 4 feign tow | Grake/cluteh system: IMastor ovinder mounting belt 4 6 roe | Master ovlinder olf bot 2 10 3513.5, 251 | Front caliper bole @ 8 | 3813.3, 2a Note 1 Front caper oil bolt 2 | wo | 35 (3.5, 25) Front brake dae bot 2 6 | 20120, 181 Caliper mounting bot 6 8 27 (2.7.20) Caliger ped pin plug I 3 10 2.5 0.25, 1.8 Caliper bleed valve 3 8 | “S105, 4.3) | Rear beake reservar mounting bot 3 6 910.9. 7) | Resr orate resaroir hove jit screw 1 5 wois.in | nor | Boor caliper pivot pin Bolt (5 rams HEX see ! 8 130.3, 8) nowt | ow calor proto bt bil 38 pein | Moet | Rear brake bose jot net hese sie) pa} 44 (1.4, 10) | | Rear brake hose joint (caliper side} ji] % 3513.5, 25) | |_ Roar brake dice nur 4,3 35 (3.8, 25] News |Goneral Information — os mmn' Tools «The newly designed tools are indicated with * mark in the Hist Pee 1 \ owen ‘oot Number Applicaton Section | Gupredon guage anzohment 8mm | “OVRME=WROGTOO| —Crlindor compression measuremont 8 | Gipressue ore atechmart G7SNOS A250100 | Engh of proseure measurement a ter wrene | Sran~rirotoa | Otter epacement Stig wrench, 8 mm -SrRMA=Tay00300 | Spark plug Tomovanatalation Tock nt wrench OTHRA=MR70200 | _ Eine removelineteaven 7 Tave ening compat stacwnent) O7959~KMBO7O! | Gyindar peed aeasrorynesenoy | 6 | itv suds dover Srantd—ancoor00 | Valve gue weolacament fee atv guide roams, 4.5 SmHNH=MLOOTOT | Vave ques reaming ! Meee Satter Sa mm fase IN) | C77B0=0010000 —L-Vawve seat refacing Vane Se camer 22 mm (ase ex | 07780-cotG701 Vane fx cotter 24 wn (02" IN) 07700" 012800 | Vale fst evmerzise mm (a22'50 | 977800012600 + Wate Retcor or 22'mn 0° ivex)| O77e0~00:4z02 | Custer holder. 4.6 mm o77et 0010800 ' Lock nut wrench, 26% 20 mm 077160020203 —— Clutch disassembly/assembly e Extension bar | 07716-0020500 | Geer holt Oy7ecooroTO) | Peery dive gear emovalinetalaion | Fok sal ever G7a7 -KAbO100 -F- Fork a eel instalation @ Fork eal ever acachment yea xr00%00 Leck ut worehy 39% 47 ro GremanKea0100 | _Sreedog ster ut removelfnatation | Stecrng ctr socket, SraMa=uavovo0 | Sieerng beaing adurenent nut | | Somers | steering sem ever atachment | OTHMD=MR70100-L, Stoning Hoarng ower Iner race pp tame ver Or748--0030T00 1) instaotan Rees ene 2 2 pes requres) | S756 KIMB0200-1, Seeing bestng cuter ace remove | | Diver assem shat Grace kaoe09-[ insalason | Braing remover 8 | Sreae—xvsoso0 | Assembly base 07945—Krea0e00 1! | [Diver ‘07748-0010000 | Bearing xalotion 3 | feet, 62547 mn 0774800010300 -[ -Bewring hear neo bearing j ‘Attachment, 62x 68 mm 07746—0010500 —4 replecement | | Pilot, 40 mm 07746 - 0040900 ! j | Shock sbsorber compressor attachment | 07959-MB10000. Shock avsorber disassembly/essembly | | | Shock absorber compressor 07GME- 0010000 ~~" | Botng aver GRAMESNtCGO200 | Shock sbeober upper mooring | busting resassrent | Pivot adjust wrench 07908 - 4690001 ‘Swingarm pivet bolt remavelfinstaliation Driver shat Ozseo=muoore0 -L-siam swingarm pet base feel Attachment, 37 * 40 mm 07746 -0010200 —+-| installation | Pilot, 20 mm 07746 ~0020500 —~ | | | Bech eover at 07858—9710001 AL Rite ewingarn pet beeing removel || *Femever hale Sysae~ 710100 | | Bearing remover | 07936-3710800 —4 TStaing wei trnet -aotozet | || ewe bearing remover GrtiG—WN70100-1 Lat ewingarm pvt Beng | Driver shaft 07948~M00100 | replacement |) Plot, 28 mm | 07746-0041100 1) i ; 1-17General Information nae nn ra nnsenennsenssenssssomssenessensesens ss ennsesonessrrnteeonnonreeneonesneeoeinags ~T Tae Description | TostNumber | Apscaton | Seeton} Pin driver assembly 07GMD~— KT80100 ‘Shock arm needie bearing removal | 13 Bearing remover (078363710300 ~-- Shock ink noodle bearing removal Rerour nen | Sose-orr0700 +] i Sing weight | a774i—ootozo: | Bees | Grr%e=0010000 Shock am and tak nsdle basing | Attachment, 226 mm | 077480010700 —) ‘neeataton 14 Pot 17 min a7746-cosoao0 —! oe "Sse ring pore [erase aso001 | ake maser cnr darsentivy |g | assert ae | Poak voitage adaptor ‘7H1Gi~0620100 1 Peak vetage measurement | | Digital mutthester 07411 ~0020000 -| | T Universal holder | 07725~0@30000 + Fiywneot removelinsaliation a7 Fotor puller [_o7735~axz0001 | 1-18Lubrication & Seal Points General information — eS Oe ovOm"—'@"'] (Ensine Location [Valve stem (valve guide acing surtace) Connecting tod smal end baring ransmission gearshift fork groove Timing hole cap threads Connecting rod bearing Grankehatt main bearing Materiel Molybesnum disulige oil Fomarks Cylinder head bok threads ‘Connecting rad bearing cap nut Rocker arm siding suriace Camsbatt journal, cam lobo ther sliding surface (Clutch lifter rod Witter sm contacting ares) | Mattisurpose grease caution Nover appiy molybdenum aulfide al. Grankcase mating nite aad sean Bo rot apply selene nee the tna beeing, Rocker arm sate lag Seaant | Oi pressure sweh theses De nat aly sealant othe! - - its trend bess shown Samm Thar soso tveade Beem | ot er Ong Engine ot Rten Gylinde: head seating bolt threads Shift drum center belt threads Gearshift return sozing stud pin ‘Shift drum set plete bolt threads Shift fore shaft se: bolt threads Oil pump driven sprocket bolt threads Locking agent 1-19General Information Frame 7 Lecstion Material | Romarke Drive chain Gear oil 80-80 1 ‘Axte holder bearing ‘Muttipurpose grease | Side ctand pivot | Shock linkage bearing collar ‘Shock linkage bearing Seat lock hook Gearshift pode! pivot Shock absorber uppe: mounting collar Swingarm pivot bearing Steering head bearing Stop pivot Speedometer gearbox ‘Throttle pipe flange Rear brake pedal pivot : Dust seal tip Pad pin threads Pad pin plug threads | Caliper piston DOT 4 brake fluid | Caliper piston seal Caliper dust seal z Master oylinder piston ‘Master cylinder piston cup Steering bearing adjustment rut threads Engine oit | Fan motor ewitsh threads ‘Sealant Handlebar grip rubber Honda Bond A or equivalont 1 F Caper pivot in Sileone grease Caliper pivor pin boot i i ‘Side stand bracket bolt thread Lecking agent | Drive chain slider screw threads | Drive pin bole threads Fork socket bolt threads Ignition switch mounting bolt threads Main step holder bolt threads Roar calizer pivot bolt threads eer brake reservoir hose screw threadsGeneral Information Cable & Harness Routing (2) CLUTCH CABLE (4) SPEEDOMETER CABLE (8) CLUTCH CABLE (6) LEFT FRONT BRAKE HOSE (8) FUEL TANK BREATHER TUBE (7) LEFT ERONT TURN SIGNAL WIRE CONNECTORS (10) RIGHT FRONT BRAKE HOSE 1-21General Information (1) HEADLIGHT RELAY (5) RIGHT FRONT TURN SIGNAL WIRE CONNECTORS, (6) FUSE BOX (9) LEFT FRONT TURN SIGNAL WIRE CONNECTORS 14) POSITION LIGHTS: (7) SEAT LOCK CABLE (@) SPARK UNT (9) REAR TURN SIGNAL WIRE (10) BRAKEMTAILUGHT WIRE CONNECTORiy THROTTLE TABLES. ~ a) suemia ~ CLEANER TUBES 1) au rum awe see use (10) THROTTLE STOP CONTROL CABLE [10 SPEEDOMETER CABLE (12) CLUTCH CABLE (17) FAN MOTOR swiTCH ‘General Information (4) CRANKCASE BREATHER HOSE (8) REAR SHOCK ABSORBER ORAIN TURE (13) FRONT IGNITION COLL, (96) FUEL TANK DRAIN TUBE 1-23General information (5) FUEL TANK BREATHER TUBE (1) RESERVE TANK OVERFLOW TUBE OVERFLOW TUBE coy NEUTRAL switH, (8) MI BEAM RELAY (7 STARTER moTOR Cape - (3) i10| RIGHT CONNECTOR SRACKET A: IGNITION SWITCH WIRE CONNECTOR (PBL @: PULSE GENERATOR WIRE CONNECTOR (4P-BLACK} OL PRESSURE SWITCHINEUTRAL SWATCH WIRE CONNECTOR (2P-BLACK RIGHT HANDLEBAR SWITCH WIRE CONNECTOR (6P-RED) ALTERNATOR WIRE CONNECTOR spire} nay viEew®—_— 2. Frame/Body Panels/Exhaust System | Service Information Seat Cowling Removal/instaliation Upper Fairing Removaifinstallation Side Fairing Removetfinstaliation | Lower Fairing Removel/installation 24 22 23 Bt Fuel Tank Removal/installation Windshield Removal/Installation Muffler Removal/installation Exhaust Pipe Removal/installation ‘Sub-Frame Removaliinstallation Service Information = 's extremely flammable and explosive under certain conditions. Serious burns may result if the exhaust eyatem is not allowed to cock before components are removed or serviced. + Work in a well ventilated ares. Smoking of allowing Flames or sparks in the working area or where gasoline is stored can cause @ fire or explosion + Thi section cover removal and installation of the frame ody panels, fuel tank and exheust system. Frame body pane! installation Ici the reverse ordar of remeval, unless noted otherwise. + When removing the cover, be coreful not to damage any tab or groove of the caver + He carnful not to bind the wire harnesses when installing the sustrame. 2-1Frame/Body panels/exhaust System Seat Cowling Removal/Installation ‘Unlock the rear seat by turning the ignition key clockwiee Hemove the rear seat, Remave the six attaching serews. Raise the rear of the seat cowling and release the two boss- fe from the grommets, Disconnect the brake/talight wire connector and remove the seat cowling rearward, NOTE i: = Be careful not to damage the front of the cow Install the seat cowling, while incarting the hook of the ccowling under the frame, Insert the bosses into the grommet by pushing the rear of ‘the combing. Install the rear seat, signing the hook withthe cowling, ane push the seat down to leck the seat, NOTE * Grease the seat atiker and latch, + The rear seat is not installed securely if any obstruc+ | tions are under the seat + Be careful not to bind the wire hamess etc. Upper Fairing Removal/Installation Disconnect the left and ight turn signal wire connectors. Remove the following: both side fairings (page 2-3) ~ from panel (oage 2-4) ~ both rearview mirror mounting nuts. ~ both rearview rniror. = bath raarview mirror mounting rubbers = both turn signal fights. = upper fairing, Install the uppar tating in the reverse order of remévl 13) REAR SEAT | @ sosses | (2) SEAT comune TAILLIGHT ‘CONNECTOR (6) GROMMETS | (1) REARVIEW MIRROR (2) MOUNTING RUBBER (3) MOUNTING NUT | 1) Screw (2) TURN SIGNAL LIGHT (| UPPER FAIRING :4 Side Fairing Removal/Instaltation Frame/Body panels/Exhaust System Bo careful not to damage the tabs. sae eo {+ Make sure thatthe ci nut forthe tapping sorew is installed properly. Its missing, instalt securely with the threaded side facing down. Procedure Remarc a 2 a) 13) Removal Ordor Quick screw Sorow “Tagoing screw Left side faring Fight side faring Tnvalaton fs the reverse order of removal 2-3Frame/Body paneis/Exhaust System Lower Fairing Removal/Installation (7) | Cower fairing assembly CAUTION + Make sure that the cp nut for the tapping serew is insted property. I tis missing. intallR securely with the threaded side | facing down. I Procedure aw Remarks Removal Order Instaletion kh the reverse order of removal (2) | Tim olp screwinut 4 | (2) | Front pane! screw 3 | (@) } Frort pane! 1 | Note At instalation insert the top ends undar the tab of the ‘upper fating propery 28 shoo, (4) | Mounting serew 2 (6) | Mounting boivwasher 2 (6) | Mounting collar 2-4Fuel Tank Removal/Installation 7 Gasoline is extremely flammable and is explosive under cer ‘ain conditions, Workin well entTated area, Smoking oo {owing flames ot sparks in the work area oF where gasoline | {is stored can cause a fhe or explosion. + ‘Remove the seat couling (page 2-2) “um the fuel valve OFF Disconnect the fuel tank breather tube from the tank. i Remove the fue! tank mounting pol. aise the rar of the tank and disconnect the fuelline and vacuum ‘ube from the fuel vale Install the fuel tank in the reverse ercer of removal NOTE > Make gute fiat the fuel tank mounting rubber is insted ‘onto the Frame properly before installing the tank [Attar connecting the fuel ine, connect a vecuum purnp tothe auto fue! vake vacuum joint and apply vacwuen. “Tur the fuel valve ON and check the fue ine for eekooe. —— Frame/Body paneis/Exhaust System (0) BREATHER TUBE ae 2] MOUNTING BOLTFrame/Body panels/Exhaust System Windshield Removal/installation o Rd My | aa = PSE ed | ions ES | - oO a _ S mm op = Ore ais (RY <= OFS x @ 1 Purthekert aroun the cicumfer- 2 Cutthepinatthe ker being cae- 9, Install wth using new pine ence of epi, fulnot deform te pio Pu out the remaing pin,Frame/Body panels/Exhaust System 7 Be careful nat to damage the windshvek, Procedure Lew Remarks Removal Order ; Rearview mirror mouting nut 4 | NOTE i Loosen until the clearance is made, Sot pinking j 6 | Note Gut the pin to remove i Windshield La | Installation Order | Windshield 1 | ‘Set pinsting 6 | Nore | ‘Temporarily insta the set rings, postion the wiadshiekd roperiy and fi the pins | Rearview mirror mounting mt 4 | 0 @ @ a @ o 2-7Frame/Body panels/Exhaust System Muffler Removal/Installation |po Frame/Body panels/Exhaust System +_ Do not sorvica the exhaust system while Ris het. ‘CAUTION De not bend ar twist the brake hose. Support the removed right step assembly so that it doos nat hang from the brake hose. Remarks (2) | Fight steo bolt (@) | Fight step (4) | Sxhaust pipe band! boi (6 | Exhaust pipe nut (6) | Mufflegmounting bottinut 0) | Lek patton seep (6) | Mutter esserbty (9) | Gasker | Tnataliaton iin the reverse order of removal Note Remove together with the heat guard. Never hang it from the broke hose, Note Leoeen the bolts. Nore A ination, loosely install the Holt and ruts, tighten the ‘exhaust pipe rts and band bolts firs, then tighten them, Requisite Service 1+ Seet coming romova'/instaliation [page 2-21 1 Eower tating removavfnstallation ipage 2-2) Procedure Removal Ordar «| Heat guard mounting bold : 2-9Frame/Body panels/Exhaust System Exhaust Pipe Removal/installation 2-10i Frame/Body panels/Exhaust System —_———— CO Or "''’ ‘CAUTION, é e [coe ‘the radiator fins to prevent them from damaging when servicing the front exhaust pipe. 7 = oo 7 Requisite Service | Muffler removalinstaliation ipage 28) Procedure oy Romerks “Removal Order Installation isin the reverse order of removal. (2) | Rear exhaust pipe joint nat 4 {2} | Rear exhaust pipe 1 {3} | Lower radiator mounting bolt 2 | nove Remave the bolts, move the radiator forward anc holt with a sting. (4) | Front exnaust pipe 4 (6) | Front exhaust pipe 1 | _ [161 | Gasket 4 2-11Frame/Body panels/Exhaust System Sub-Frame Removal/installation 119) 8g u 92)Frame/Body panels/Exhaust System caurion. Ta tho ign awitch OFF and diconnec the batery negTve cab from the battery termina ~. | 1 Be careful not to bind the wire harness whe instaing the sub fame 1 Route the wire hamess, cable, et (page 1-21) Requisite Service + Seat cowiing remevaliinstaiaion (page 2-2) 1 Fue tank removalinstallation (page 2-5) Eatery removalnstaiation (page 15-4) ark Procedure [ | Removal Order | instalation onthe reverse dar cfenoval (1) | Spark plug capiprimary wire connector 2 | {a} | Shack absorber reservoinbrackot (2) | Regulatortectifer conaector i (@} | Tum signal relay connector i (@) | Spark unt wire connector 2 (5) | Rear tum signal wire connector 4 {6) | License light wire connector 2 (7) | use box: i (@) | Right grab rat i 1 1 (90) | Heat brake reservoir caumion | Keop the reservoir tevel to prevent ai from entering the | systor:. (19) | Rasiaror reserve tank 112} | Muffler mounting botvnut W 113) | Sub-frame mounting bolt a | nore Reroove the main wire harness from the clamp. (94) | Rear fender bet 1 2-13 ww—_———— 3. Maintenance Service Information 34 Valve Clearanco ‘ “37 Service Asooss Guide 3.2 Carburetor Synchronization 310 | Maintenance Schedule 34 Drive Chain ait Air Cleaner 35 Side Stand 312 | Spark Plus 358 BE Service Information «Refer to Commen Service Manual fr service procectures on items not included in this manual. 1 Refer to the specifications (Saction 1) for msintenance service dataMaintenance a eeeeSSSSSSSSSSSSSSSSSSSSSSSSSS Service Access Guide + The flowing shows the locations ofthe parts that must be removed for the msintenance itemslisted below. Refer to the Common, Service Manual for items not included inthis manuel. + Rotor to section 2 (Framefboay paneisiexheust system, forthe parts that must be removed for service. For exariie: AIR CLEANER (Contamination, clogging, replacement) ~ Maintenance part (zrvice Items) + Fusifonk — The parts that must be removed far savice (1) SPARK PLUG Neer, damage, color: page 3:5) + Sie feng ( ARGLEANER : ‘Contamination, cogging, replacement: page 3.5), + Fusi tank Se (12) THROTTLE GAIP (0; (2) BRAKE Hose Meakage, degredation, damage) free play) (13) BRAKELEVER (9) RESERVE TANK (Coolant lvl 19) RESERVE TANK (Coolant level) Ui babies in system) (6) BRAKE RESERVOIR (el chock, hid reviacema (6) BRAKE CALIPER (Pac wear) (6) TRE (Wear, damage, pressuxe) 7) WHEEL (Damage, uncut, coresion) J (8) RARE LIGHT SWITCH (Operation: (4)_BRAKE CAUPER (Pad wees) (15) TIRE (Wess, damage, preseure) 8) WiHeaL| Damage, runout, corrosion! (9) BRAKE PEDAL (Air bubbjes in systern) (9) BRAKE PEDAL (Air bubbies in system) gg | (M0) OWL FLLER CARDIeSCK (evel check, replacement(8) THROTTLE STOP CONTROL KNOB [1)_ CARBURETOR CHOKE (Operation) ~ a (ile speed ecfustment) 12) BRAKE MASTER CYLINDER: evel check, Pid raptacernem) 1 (@) BRAKE HOSE eskage degradation, damage) (9) HEADUGHT (alm! |) BRAKE CALIPER (Pad wear (10), DRIVE CHAIN (5) OLLFUTER Relsoarer) | Ges ply ricaton, font pane! replacement. page S-1) {6} OIL DRAIN BOET (01 replacement) + Lower tating | i Le : (14,_ SIDE STAND (Operation: page 242), AU VALVE CLEARANCE IpaQE 3: are 3-3‘Maintenance Maintenance Schedule Perform the PRE RIDE INSPECTION in the Owner's Menual af Gach séhedulad maintsiance potiod. I:tnspect and clean, adjust, Lbvicate, or replace itnecessary. Ae Replace C: Clean L: Lubricate A: Adjust “The following tes requier sore mechanical knowledge. Certain tems (particularly those marked * and **) may require more techy ‘el faformation and tools. Consult ther authorizad Honda dealer - Wiichover Odometer Rosting Wate 7 ans comes ay yom [7 | 6 | | 8 | a | 90] 36 Y — [eiocam fos, |e [12 | 16 | 20 Ee Note Months 6 | 12 | 18 | 24 | 30 + | Fast tine =| Throttie Operon | Carburexer Chake [ Air Caner Nae? I z = [i Gees ; ‘Spark Plug 1 R | Epaine On [an R Erne OF Fer ail eater Syeroion rp * | Carburetor Idle Speed | Radiator Coolant Note 3 b 1 1 =i lieccmroen roo Drive Chain t 1, L Evary 1,000 km (600 mid. Brak Fivid Note & Li Tr —rej[ife ‘Brake Light Switch i 7 | Hesatigne Aim H [ctatch System o rhrteda Side Stand i 1 [eke Sys cI 1 1 | ‘Suspension 1 =| Nats, Bots, Fosters i 1 ta =| WheelarTies| 1 rt ==" Stoning Head Bearings ta 1 rm + Should be sorvced by an authorized Honda desler, unless the owner has proper tools and service data and is mechanicaly quaified. ++ In the interest of safety, we recommend those tems be serviced only by an authorized Honds Ceater, Notes: At higher odometer readings, repeat at the frequency interval established here 2, Service more frequently when ring in unusually wer or dusty areas. 4. Replace every 2 years, of at indicated ectometer interval, whichever comes fist. Replacement requites mechanical sk 4, Refer to Common Serves Manual. ‘‘Maintenance Air Cleaner (2) Coven SCREW 1t) AIR CLEANERTCASE COVER Remove the folowing: = seat cowling (page 2-2) = fual tank tpage 2-5) = ir cleaner case cover screws, = sub sir cleaner tubes, — sic cleaner case cover. Romove the ar eleaner element, and replace i with @ nc one. Inztall the removed parts in the reverse order of removal, Spark Plug ay Fa REAR () FRONT 4 (3) SPARK PLUG WRENCH “Do not touch the exhaust pipe while i is hot. Rear Oyindar Remove the No 7 and No. 3 cylinder spark plug 63ps, an remove ‘the spark plugs withthe spark plug wrench, Front Cylinder: Alemave the folowing: both sie farings (page 2-3) wren varoR — upper radiator lower mounting bolt. ee Serta) LeFER RADY Move the upper resistor forwars, remove the No. 2 and No 4 cylinder epare plug eaps and remove the spark plugs with the spark plug wench. CAUTION *_Be careful not ta damage the radiator fas wile servicing, ' t] Note For inspection, refer to section 2 of the Commean Service Haaaua! + For recommended spark plug and specified spark pus gem refer to section 1 {Specifications}Maintenance \Using the spark plug wrench, hand tighten the spark plug unt its seated, then tighten it to the specified torque: Terque: 9 Nim (0.9 kgm, 7 fetb) When the spark phig wrench (O7KMA—MRBO200)} is used Hand tighten the epetk plug unt itis seated, using the epark plug wrench. “Tum the iidex piste 10 align tho staring ina ofthe tightening, am Install the handle onto the spark plug wrench, ‘When a new spark plug is used (the sealing washer is not com. reseed), tighten the plug fromthe starting nto the” market the index plate ‘When the spark plugs reuse (the sealing washer c compressed), tighten the plug from the stars Ine to the” &” mark of the index plate. CAUTION INDEX PLATE (5} SPARK PLUG WRENCHMaintenance Valve Clearance | NOTE eae ~ = seat coming (page 22) 7 Inspect and adjust valve clawance while the engine is cold (below 35°C/95°F), | Cylinder Head Cover Removal Front Cylinder Remove the lower faring nage 2-4) Remove the upper and lower radiator mounting bolts and move the raditoes forward. Remove the folowing: = tual tank (page 2-5). = air olganer ease (page 6-4 — ar cleaner case bese. - — heat protector, Ee front spark plug caps. = tront cylinder head cover bots = front ovinder head cover. caution _~ + Cover the radiator fine to prevent therm from Gamaging whee | servicing. \ | Be earefud not to damage the Front fends Rear Cylinder Remove the folowing: — fol tank [page 2:51 = rear oylnder head cover bolts ~ roar cylinder nead cover Inspection oe ermave the tining hole ep ‘Turn the crankshaft clockwise and alga the “T” mark (ham: T2, — roar: TI) on the starter clutch cover with the index mark on theright ccankease cover i mounmne aor (UPPER RADIATOR | (Bi Mounting B07 16) MOUNTING a (4) MOUNTING B07 (6) LOWER RADIATOR {) REAR CYLINDER HEAD COVERMaintonance ‘Wren the 098 mark ch the righ sides ofthe cam shafis are fac lng up, the piston of the following cylinder is at TOC (Top, Dead Canter en the compression stroke. Front (72): No. 4 ovindor Rear (7): No. 4 eyfander Whine SE mi ate icin dis HETolono Oia {ToC the corpresion she Front (72): No, 2 eyinder Relation between the timing mark and edge marks [Tiringmax |” Sigemane | Aewn ar ToG one |_campresion sucke | Facog Net ovinder n {ee Roca oH eerie [Facing dowe No.3 oviindar Fee Na 4 oyinder a | Facing ve Seyiinas Facing down No. 2 evlinder. (1) EDGE MARK ‘Make sure thatthe piston is et TDC on she Gompitsion siTOko, Measure the valve clearance by inserting the fester gauge batween the rocker arm and adjustment shim, Valve cloarance: Intake valve: 012—0:18 mm (0,005--0.007 in} Exhaust valve: 0.21— Shim Removal ‘Make sure that the piston ie at TOC on the compréion aGke. Proce teh shop tavelsin the spark plughote and eam gear case hole {and place the magnet near the shim to prevent the shim from faling, ‘Move the rocket arm inward by pushing i. CAUTION the valve clearance is too small tha sham may jump out ‘when moving tho rocker arm. Nore “f hold the moved rocker aan, fle eonvenient to use the snap ring piers (07914 —6870100), Fermove tho shim with ¢ tweezers. (61 ROCKER ARM. (7) CAMSHAFT HOLDER (a sana 3 valve stem [i CAMSHAFT HOLDER (2) Shiv (@) ROCKER aia 3-8Maintenance Shim Selection NOTE 7 Sinty-ive shims are avaliable in thickness intervals oF ©. sm. The thinn 100mm sad tha thick 1g00mm Clean the shim with a clean shop tevrel IMoasure the shim thickness with # micrometer and record ic “select the chim needed to bring tre valve clearance within specification, use the following formule: metd = new shim thckness recorded vaive clearance a ‘specified valve cleorence ‘le shim thickness Example: FReecorded valve clearance = 0.20 mm () ‘Specified valve clearence = 0.18 mm (e) i id shim thieknass = 2.200 men {d) 2 = 0.20 O45 + 2.200 a= 225 Naw stim titckness = 2.250 mm Note + the require thiokness of the new stim is more than 2.600 imam, the valve seats probable heavily ex-boned. Reface the ent, recheck vale clearance and reselect the shim. Shim Installation ~ Mee sure that the piston is at TDC on the compiession stroke, ‘Apply molybdenum disulfide oto the shim and rece arm sinpes | Place the shop tawelsin the spark plughole and cemgeor case hole tnd place the magnet nest the valve to prevent the shim from feling. ‘Move the rocker am inward by pushing i. Nove = = To held the moved roakar aim, tis carvorient 10 uso the ‘snaa ring pliers (078146670100), ~ "inca ie Sim wih te twee. low ce (2) CAMSHAFT (3) SHIM ay TWeezeRs oy icroMerER, (2) shat 2 ROCKER ARIE ~ eAMaintenance Carefully slide the rocker aon back te the eriginal position. Make sure that the shim contacting surface of the rocker arr is positioned in the center of the shim and the.shim le completaly seated CAUTION a [= Be corotutnet to bound tho hiem out when sing the rocker “Turn the crankshatt clockwise several tines Recheck the valve clearence ie Apply Honda bond A or equivalent to the gasket groove in the eylinder head cover Install the cover gasket witn the “IN” mark facing toward the i- ‘ake side, (ROCKER ARI (i) COVER GASKET 1) “iN” MARK M (2) SH I VALVE RETAINER (2 CYUNDER HEAD COVER Install the ovinder head cover with the “IN mark facing toward the intake sige. Install the cover bole washers with the "UP" mark fecing Un install the cover bolts and tighten them. “Torque: 10 Nem (1.0 kg-m, 7 feb) Install the removed pars in the reverse ender of removal (1) COVER BOET WaSHER ‘Ny Carburetor Synchronization Nore {+ Roter i section 2 of Common Service Manual for carburetor synchronization procedure. i + Synchronize the carburetor with the engine at nermal oper: ating temperature, transmission in neutral and motoreyele ‘supported upright | Disconnect the vacuum tube from the Na 3 cylinder intake manifold, apply vacuum to the ao fuel valve and pinch the tube with at. Remove the pluge from the No.1, 2 and 4 cylinder intoke manifold ‘a install he vacuurn gauge adantor, 3-10Maintenance ‘Connect the vacuum gauge adaptor tothe aute fue! vale vacuur tube joint of the No. 3eylinder intake manifold ‘Adjust tho cerburetor synchronization by turing the synchroniza- ‘ion adjusting seraw. Drive Chain Wm |= Naver inspect or adjust the eve chain wi LL muning. Face the motoreyale on its side stand and shift the transmission trxo nena Check slack in the deve chain lower run mizway betwean the — sprockets Slack: 15~25 rom (5/8—1 io} ‘Agjust the chain clack a6 folowe: teosen the bearing holler pinch bol. “lurnthe axl bearing lar withthe pin spanner proved in thetol it unt the comecs dive chain slack is obtained, Nore [+ Yo wase the adjustment, raise the rear whael with an optional stand enessum the whselin the came direction a the bear L__hoider rotation (1) ORIVE CHAIN (2) BEARING HOLDER PINCH BOLT 3} PIN SPANNER 3-11Maintenance ‘After adjustment, check the chain wear label. f the red zone on the label reaches the outside deameter of tha driven sprocket, replace the drive chain with anew one, ‘Replacement chain: AK GBS25SM4 - Nore . + Because the endless type drive chain is used, the ewingarm must be removed to replace the drive chain. Tighten the bearing holder pinch bot. “Torque! BS Nem (5.5 kgm, 40 feb] Side Stand CCheck:the side stand rubber for wea, Replace the rubber if wear extends to the wear matk Check the side stand operation, ‘The side stand should lower easly to ite fret stop, then lock after moving farther forward 19 suppart the motorcycle asthe r= ber touches the ground, When the motorayeto i lifted upright, the etend should automat cally move the frst position, and raxact when kicked up. Hr the side stand does not move freely, csassdtle Romove the return pring at the retracted position. Femave the plvot bolt and remove the side stand assembly from the frame et Check the folowing parts for wear or damage 7 = inside ofthe pivot end pivot coll. = pivot dust seals. Lubricate the plot area with cleen grease and reassemble the side + Make sure thatthe dust seal spriagis not ‘stall tho side stand, ‘Side stand bracket bok: 36 Nim (3.5 kg-m, 25 ft) Recheck the eide stand operation. # By (3) DaIVEN SPROCKET POSITION, (2) Finst STOP () RETRACTED POSITION ae cy Ve (4) SIDE STAND HUBBER 11) RETURN SPRING Ae BSF 2 waster Le oe sre NS 8 DUST SEAL YS) PIVOT COLLAR, 3-124. Lubrication System ‘Service Information 41 Oil Cooler Removalinstatiation 43 “Toubleshooting 41 OW Pump Removaliinstallation 44 Lubrication Systorn Diagram 42 Oil Pump DisassemblyiAsserbly 46 Service Information + The service procedures inthis sacticn can be performed with the engine ot tain. + When removing and instaling she oll pum use care not to allow dust ordi to enter the engine. + IF any portion of the ol pump is wom beyond the zpecifid service kits, replace the ol purnp as an assembly, 1 Atzr the of pump has been installed, check that there are no of leaks and thet of pressure is corect. | Troubleshooting | | (Oi Lovet Low Low 08 Pressure + Olleonsurtation Pressure rai! vals suck open. Exernat ol este Cloggee oS ecreen + Wen piston ring or ncocrecs piston ring installation + Of puna wom or dameged, Wor valve guide or seal. + Item ll leak | + incorrect of being used, | Oi Contamination 2 Lowel evel + From coolant mixing with ol = Faulty wator pump mechanical eal High OU Pressure Faulty head gasket. 1+ Prosowe rele valve suck dosed. Water leat in eanieoase, Plugged oi fie, gallery or metering erfce - * incormet off being used, No Oil Proseure + Oillevel 20 low. Seized Engine | + Oi pump drive chain or drive sprocke: broken, + Necrlow of pressure + Ol pump damaged (pump shat. + toma! el lees. Clogged al orfasipaszage (i leakage insice the engine + Use of el not recommenLubrication System Lubrication System Diagram (2) CONNECTING ROD O1L JET (@) OL. COOLER (7) on FiereR (6) OIL PRESSURE @) GL PUMP: RELIEF VALVE (6) OL STRAINERLubrication System Requisite Service + Lower fecing ramovalinetallation (page 2. {Engine el draining Wacation: page 3-3, step: section 2 of tho Common Service Mania) Procedure oy Remarks Removal Order Tistalicton isn the reverse arder of removal. (0) | Oi caoter bot 5 (2) | Otcooler jaar 13) | Oxing } 2 14) | Tube LzOil Pump Removal/Installation Lubrication System (j= Q=us 4-4rE Lubrication System [> Remove the dive sprocket bat before removing ths of pump ncunna bolts 7 Eerie she of pump civ sprocket batt with care as itis castad wit thead locking agent L = = - a Requisite Service Engine ol desining (lncaten: page 3-3, stop section 2 af the Common Service Manual. + Et pring renovation (age 24 Lae i craps: rmovaialeton (ages -4 an 9-6 1 eabtoeraue yom faye 270) 1 Bett ene cover emovelinsatition ge © Frowdre Ler Tai 7 Removal order Installation is in the reverse order of removal. cn | Orpen 2 fh | olen | nore | rey tigen me bots Rist set he ol pan in corest pester (21 | Pressure rb vave + | Rote [Regn te evtout a the stopper wath he pe (3) | on seainerng in | nore | ott theo seiner aging the bss nthe sane wih EE | the slit on the oll strainer. (61 | Ot preo-roa 2 i (3) | Give bo A i | oteeeo-eng th | nore tore te ive aprecket bt before emvng 8 ot i pump moun ta 121 | of pum bot 3 {3 | oppump esvemby 1 | note Whining the pnp assem gn te 9 ee patna wth te cee nthe eo pip het a ren ee nung safe Deosomby coe Pape + £0) | bows pe 2 (11) | Oil otifice/O-ing wa NOTE i ifthe office ts remaved, check it for clogging before ren stallation. 4-5Lubrication System Oil Pump Disassembly/Assembly cereLubrication System Se nore _ __ Fr Gate mart wi arng save and Sot with cen angie a befo ater Aequisite Service 1 Ol pump remvalintaaon page 4) Procedure Tay Reval Dissremy Order 1 Tami hte voce art of dsssembhy «0 | Ot pump boy bot 3 12 | Coster pu cover i {3 | Bowel pm 2 fa) | Cooler ute tar 17 | nore : | Ital he cut rotor with Re punch mark acing coke amp over ¢51 | cooler ter ote 1 (6) | Dive pin i 17 | trust waster ha 18) | tpn boay 14 (3: | Dower ia 2 1) | Fou pump oar coer + | wore st te tr otr wi punch mark fasng Fes + pump cover, (7) | Feed pump terror 1 (12) | Dee in 1 {13} | Of pump shote 1 | nore vt With he bse ating the cover ater eur sie (1 | Fen puna cover 1 tt | Coner pn t {16} | Spring retioer 1 (17) | Spring } 4 ti) | Patoe Ja 9) | Cotte pin a [1201] Of emer ioerO-ing Low | | i 4-7—_—_—— 5. Cooling System Service Information $1 Water Pump Disassembly/Assembly 55 Troubleshooting 5-1 Radiator Removal/nstallation 56 System Flow Pattern 5.2 _ Radiator Disessembly/Assembly 58 Coolant Draining 53 |__| Thermostat Removaliinstaliation 54 | Service Information Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engi fs under pressure may cause serius scalding. + Radiator coolant ic txle. Keep it away trom eyes, mouth, skin end clothes. Ii any coolant gets in your eyes, nse them with water and consult a dostor immediately. — Heany-goclant is swallowed, induce vomiting, gargle and consul a physician immesiatly. — Hany enolant gets on your skin or clothes, rinse thoroughly with plenty of water <_ KEEP OUT OF REACH OF CHILOREN. } ‘Acid coolant atthe reserve tank. Oo not remove the rator cap except to refi er drain the syste [all coaling aystem service can be made with the engine in the treme ‘Avoid sping cavient on painted surfaces. — fa ‘after servicing the system, check fr leaks wih a cooling system tester Rfer to section 16 for fan mater switeh and thermo sense: inspections. ~ froubleshooting Engine Termporarure Teo High + Faulty radiator cap. + Insufficient cectant 1 Peecoges blocked In radiator, hoses, 0: water jacket 2 alrin syscem. Faulty water pump. “Thermostar stuck closed, i Faulty temaerature gauge oF therme sencor = + Fauky cooling fen moter. + Faulty fen motor switch + Fan shround installed improperly [Engine Temperature Too Low + Faulty temperature gauge or gauge sensor + Thermostat stuck open. = + Faulty cooling fan motor switch (see seoton 18 Coolant Leaks + Faulty pump mechanical sel is 2 Deterorated O-ings. 1 Fauity radiator ap. + Damaged or deteriorated aesket + Loose hose connection oF ama + Damaged er deterocates hoses,Cooling System System Flow Pattern n) SIPHON TUBE (2) RESERVE TANK (2) WATER PUMP 5-2Cooling System Coolant Draining "The radiator eap i under high pressure and radiator coolant ould spurt out, reeuting in scalde on your hands ote. Ifthe ‘apis romoved while the radiator is hot. Wait until the radia- | tor coais down and temove the 639, remcve the side faring and the lower fating (bages 2-9 and 2-4) Remove the raciator cz. Remove the erin bolt (on which 2 copper washer attached) from the water pump and drain the cookant. “move the two drain Bolts from the ylinder and dean the coolant. 5-3Cooling System Thermostat Removal/installation Requisite Service + Fuel tenk removalinstaliation [page 2-5h + Lower faring remevalinstalation (page 2-4. + Cosiant raining (page 5-3 : + Coolant refi ection 5 of the Common Service Manual. Pracedure Tew Remarks | Romaval Order installation isn the reverse ordor of removal (1) | Bandiwater hose 2g | NOTE | + Loosen the hose band. (2) | Thermostat cover bolt 2 | (2) | Thermostat cover i (4) | Owing | (6) | Thormostat joa (@) | Thermo sensor connects: 1 (9) | Theme sensor = | nore | 1 At reassembly, apply a sealing agent tothe threads. {9} { Thermosta: housing bolt 13} | Oring iCooling System Water Pump Disassembly/Assembly ~~ — oe = nore : Before remaving the water pump place an a pan under the engine to cate Requisite Service + Lower faking removalinstalaion Ioage 2-4 + Goolans eraining (page 5-3) + Coolant rel isection 5 of the Commen Service Manuf. Focdve Lawl Tamar Removal Grr Tpasiadonis We ove eof enc iy recent fen |S Toosen the bond and plot the waters 42) | So 2. | NOTE |S Beto removing bls tnosen the ump cover boi (3 | wer mu assenbiy | 1 | ore | 7 ps lnsatatenalgn the punp sat lt wht of pu hate 12) | Housing cover ot 2 \ 18 | Cover [i \ 18 | Garg [2 | | |G) | Dowloin ; | i | Wo fare | + | caution + Avoid further disassembly | 5-5Cooling System Radiator Removal/Instaliation 5-6CAUTION 7” Protect the radiator fina by attaching a piece of adhesive tape oF equivalent and removel not to break the fins. | «Take care not to damage the front fender. — Requisite Service + Lower fating romovalinstaiaion (pege 2-4). 2 Coolant draining (page 5:3). Cooling System 1 Scone efi eecton of the Common Service Msn Leis Procedure ow] Remarks Removal rdor [ istaon 1s tne svar of removal «9 | Upper racitor hose 1 | (2) | Radiator bresther tubs: 1 |) | Fenmotor eaanectoian motor switch con- fectee nm (a) | Lower raiser hese 1 {5} | Upper reiator bok 2 | nore "pemove the two bl, pu the upper tat toe Sywhee! soe and dicannes: athe upper cowecton ofthe reitor mou (6) | Lomb rcttor bce 2 | nore Remove the two bok, pul the lower rato othe nah ee and ciscannect athe unper connection of the radetor mount. (7) | Uppertower rasstor mm | note i + Remove as an assembly.Cooling System Radiator Disassembly/AssemblyCooling System ‘CAUTION 7 Protest the radiator fins by attaching a piece of adhesive tape or equivalent and removefiastall the radiator with care not 0 Break the fins. NOTE i Set the fen motor wire in the fan shround clamp properly 10 avd interference between the fan and the c Requisite Service + Radiator removalinstallation (page Procedure oy Remarks Disassembly Order T ‘Reser is in the reverse order of isassemby a | Radiator gte joa (2) | Fight raciator hose 1 13) | Left radiotor 1 (4 | Fan motor switch 1 | Nore + Ax installation, poly sealant to the threads. caumion + Danot oversighten the fan motor switch or the radiator | | may be demaged. (6) | Fan motorbott 3 | Nove + On eessembly, tighten the ground wire together with she upper bot. (6) | Fan motor assernbly 1 | nore + Disconnect the connector and the wire from the clamp | Nur 1 4) | Cooling fan 1 | Nove ‘When teaszemtling, sigh the fan motor shaft and the cutout in the fan blade, (9) | Fan motornut (90) | Fan moror Nove Install te fan motor on the fan shroud with the water I drain hole facing down. 5-9—_——— 6. Fuel System Service Information 6-1 Carburetor Removal/instaliation 68 Troubleshooting 62 Carburetor Separation 6-10 Fuel Tank Disassembly/Assembly 63 Carburetor Combination 6-12 Fuel Valve Disassembly/Assembly 6-4 Carburetor DisassemblyiAssembly 6-14 Air Cleaner Removal/installation 66 Service Information ‘Gasolvie ls exremely flaramable and ls explosive under certain conditions, Wark ina well vendlated area. Smoking oF lowing ‘amoe or spars in the work area or where gasoline Is stored can cause fre or exolosion. cauTion [> Bending or twisting the control cables wil impar smooth operation and could cause te eablos to atiok er bind, resuting in loss of vehicle contol + Be sure to remove the diaphragms before cleaning air and fue! passages with compressed ai The diaphragms might be damaged. NTE [+ rine shies tobe sarod error thon one nonin Gai os Bowls. Fuse the oe bowls ay cae Soaaede | resulting herd staring cr poor reat. j Carburetor cisassembly is not requlre for servicing the vacuum piston end the lost chamber eter to section 2 for fuel tank removal and instalation, When disassembling fuel system pers, note the locations of she O-rings. Replace therm with new anes on reassembly Befove disassembling the carburetor, place the suftable container under the carburetor dzsin bok, ther locsen the batt and drain ‘the carburetor. + Attor removing the carburetor, wrep the intake port of the engine with a shop towel or cover it with niece oft foreign material from dopping into the engine = “+ Carburetor number ls aot that cowespands to the eylincer number, 1 0 prevent anyFuel System a —_—__ ‘Troubleshooting Engine Won't Start + No fuel z0 carburetors = fuel steiner clogged fuel tube clogged faulty fuel voive = flost level misadlusted — fel tank cap breather hale clogoed + Too much fuel gatting tothe engine — air cleaner clogged — flooded carburetors + ake alr eae + Fuol conaminatodieteriorated + Slow circuit or bystarter crcut clogged Ignition mattunction Engine Stalls, Hard to Start, Rough ling + Fue line restricted + Ignition matfunetion + Fuel mire too feantich + Fuol comaminated/deteriorted + take aie teak + Iole spéid misadjusted + Pilot screw misadjusted + Siow circuit or bystarter circuit clogged + Float level misadjusted + Fuel tank breather tube clogged ‘Afrerburnon Deceleration Lean moc in slow eieuit Backing oF Mistiring During Acceleration + Ignition system fautty + Fual miuretoo lean Poor Performance (driveabifty) and Poor Fuel Economy + Fuel system clogged + Ignition mattunetion ean Mixture + Fuel ets clogged + Float valve faulty Float love too lew Fuel line restictod Carburetor sé vent hole (or tube) logged Inzake air leak ‘Vacuum piston feuly ‘Throwte vaive Faulty Fich Mixture + Bystarer valve in ON positian + Flat valve faulty Fiat level 00 high Airjet clogged ‘Alc Cleaner element contarrinsted Flooded earburotore| Fuel System Fuel Tank Disassembly/Assembly r = ee er = ‘Gasofne b ovemel fananable ands explosive under cova conckions, Werk a wallvenilaed aoa. Smoichs or atewing |” flames or sparks in the work orea or where gasoline is stored can catise a fire or explosion. Requisite Service + Fuel ani removalinstallstion ipoge 2-5 # Procedure Tow Femerks Disassombyy Order “Roserbly is Inthe reverse order of disassembly. fa) | Bolvtank cap a (2) | Fuel valve boit 3 13) | Oning 1 | nore e Wien acsembing the fuel tank, eke care nat 1 get te (O-ing caught or pinched in the pers. (4) | Puol valve assembly 1 (5) | Beeather tube joint Ja (8) | Foo! tank La 6-3Fuel System Fuel Valve Disassembly/Assembly @ 12) | Otapnragm ever 18) | Spring 16) | Disphragen 7) | Set pate 18) | Fuel vane body “+ Gataline sara ammo ands exposve undr conan condone Work ina wal vented wen, Sincing or aonina flames or spats fate work aon or whey gasolnel stored ca mae re oer Requisite Service + Fon tak dsassomblyaserbly page &2) Poceaire Ley oo Dissserbiy Order “cenbly bi the rover oder of Abas tn | Rue va lever 5 2 | Fast tee : €2) | Diaphragrn cover exon 2 | note + On assembly tighten the seras equallyFuel System MEMOFuel System Air Cleaner Removal/Installation 6-6 SEE eee eee seRequisite Service ‘ust tank removalinetaliation page 2-5), Remarks ‘Air cleaner case cover Sub ai cleaner ibe Fuel tank drain tube ‘ir cleaner element Sub alr cleaner element instalation fs inthe reverse order of removalCarburetor Removal/Installation Fuel SystemFuel System "Gasoline is extemely flammable and is explosive under certain condttons. Work in a well vniiaed area, Smoking or allowing flames or sparks in the work area or where gasoline is stored can eause a fre or explosion. NOTE "Afterremoving the carbureter, cover the engine take port with 2 chop towel or tape to prevent foreign materials from entering the engine through the port. Requisite Service + Ait cleaner removaifinstallation (page 6-6) EEE Procedure Oty ‘Remarks le | | Rene mee 3 |e Pee oe piles i Glee ialFuel System Carburetor Separation #3 CARBURETOR #1 CARBURETOR () THRUST WASHER — (®) PLASTIC SPRING WASHER () PLASTIC THRUST WASRER ©) corTeR Pin 6-10Fuel System > Gasoline is extremely flammable and ls explosive under certain conditions. Werk in e well ventilated eres. Smoking or allowing flames of spare inthe work area or where gasoline is stored can cause fie or explosion, Requisite Service + Caraureter removal ipage 6-81 Procedure ‘Separation order 1) | Airchember screw (2) | Lock plate 18) | Air chamber/sir cleaner duct 1) | Dowel pin (6) | Sreckot screw (6) | Carburetor eat ecron | (2) | By-staner tink | te) | Throttle ine 19) | By-starer am + Remove from the No 2 and No. 9 carburetor. Nore + Disconnect from the Na, 2 and Ne. 2 carburetors. NOTE = Loosen the screws. Note + Loosen the synchronizing serews, NOTE + Note and record the jsnt pine installation dzection, 6-11Fuel System Carburetor Combination 2 4 CARBURETOR > : one, comer an tts (a) THRUST WASHER — (8) PLASTIC SPRING WASHER (©) PLASTIC THRUST WASHER (>) COTTER piv #1 CARBURETORFuel System Requisite Service + Carburetor instalation (page 6-8) ‘CAUTION Altar Sesembiing the carbureror check the throw tink and the bystarte ink for smooth operation 1 after assembling the carburetor, move the bystartar ink ever to “CLOSED” position and be sure that the byscarter valve is not pulled by the bystarter rod cia. Procedure oy Femarks ‘Combination Order cy | Bystarter Enk a | nore + Refer to the drawing forthe combination of the washer. (2) | Throtle ink 1 15) | Sub ci cleaner tube 2 (@) | Arbon tube 4 (5) | Fuel tube i (6) | By-starter arm 2 | nore 1 Set the claw of the by-starter rod and arm on the by= Starter velve securely (71 | Carburetor set sorew 2 | CAUTION | + Take care not to demage the fuel joint pipe O-rings. (8) | #13 #2-4 thaust spring 2 12) | Bracket screw 2 (101 | Dowel pie a (11 | Airchamber 1 (02 J Leck piare 4 (93) | Air chambor soreer 8Fuel System Carburetor Disassembly/Assembly 6-14Fuel System (Gasofne is extromaly flammable and is explosive under certain conditions. Workin @ well vendleted area, Smoking or allowing | "ames or sparks in the work area or where gasoline fs stored can cause & fie or explosion. NOTE . 7 The serve procedure is for the Na 2 carburetor on this pose Pa 1 The procedures of the flo. 1 3, end 4 are the same as the No 2 1 The vacutm chamber anc float chamber can te serviced with the carburetor assembly {The pilot screws ace ftorypro-cet and should not be removed unless the ca bureors are overhauled, Tun each at sew in dng coehly count the numberof tums Defoe Irseate ight, Make anote of thi to use af a reference when renetalng the Filet screws fnew pilot screwe are installed, tum pet serewe out tothe ntl opening fooge +O) Requisite Service + Carburetor removlinstatation page 68. Frovesure Low | Remarks ‘Disassembly Order TTT carly ein tho reverse Order of css Freet Chambor (9 | Sew 2 {2} | Froat chamber cover 1 13) | Oxing 1 (4) | Freat pin 1 (5) | Frost i | (6) | Freat valve i | (71 | Vane eoae 1 (3) | washer 1 (0) | Fiter i 420) | ain je 1 (0 | Necete jet note 1 152) | Siow it 7 52) | Pot serowrspring un 38) | WasherO=ing mw 115) | Thwortiecabie neler i ‘Vacuum Paton | | «961 | Vacuum enambor cover soon |g | wore |e petal with eae nas ta pinch the laa | 67) | Vacuum enaroer cover 5 } ‘381 | Spreng 1 #29) | Vacuum piston 1 {20)| Jot needle hocer 2 | sore | “urn coumterlockwise while pushing the held font 421 | Spring Joa b | 122i} Jer naesie Lo ie 6-15 47. Engine Removal/installation Service Information 7-1 Engine installation T4 Engine Removal 72 Service Information '© A floor jack or other adjustable support Is required to suppor and meneuver the engine, ee GALTON ic iia [po not eokup he motjcle wang tw ofan : + To protect the engine, place @ rubber board or equivalent on the floor before remavingfnstaling the engine. {Place a Jack under he engine and supper the motoreyele sacurey. Remove and Inste the engine with care not to damoge the ‘ame, enging, cables, and the hemesces. — + When remevingfinetaling te engine, tape the frre to protest. “The follwing comaonents can be serviced withthe engine installed in the fr ‘itarnator (Section 14) = opines head (Section) elutes Secton 8) gearshite inkage (Section 8} i = all pump ‘Section 4) = starter motor ‘Section 16) = water pump iSeetion 6) + The folowing components require engine removal for service: = connecting rd (Section 10) = crankshaft (Section 10) ~ piston (Seeton 8! “= tranemission (Section 10),Engine Removal/installation Engine Removal 15), @ veEngine Removal/installation CAUTION 7 Place a jack under the engine and support the motaraycle seourely {Tum the ignition switch OFF before disconnecting the sable from the battery negative {—} temminal {When placing the jck under the engine, rake eare not to set the jack against the of fier. Requisite Service + Tako care not to pinch the wire hamesces, | Nore : oe + When the clutch lock net, primary drive qear bol. and the flywheel bok are removes acer removing the engine loosen them Engine a drsining flocstion: page 3-3, step: section 2 of the Common Service Manual Ful tank removal (page 2-5). + Ratiator removal fpage 5-6 in advance te case removal. + Exhaust pine removal (page 2 + Coolant draining ipage 5S). + Carburetor removal (page 6-8). + Lnasen the crve chain (page 3h Procedure a Pameike 0 ‘connector ented fea (2) | Pulse generator wise connector . G) | Neutral switch wire connector 1 | nore + Disconnect the which fs imograted with the oll pressure switcb. 2) | Spark plug cap 4 (6} | Stazter moxor cable 1 (© | Gearsritespincia ire bot 7 7) | Gearshift spine joint 5 1 (@) | Chnch cable | Nore + Loooen the lower adjuster lock mut and remove. (2) | Speedamezer gear box } 4 | Nove Remove the mounting bolt 120) | Drive sprocker cover 4 11) | Deve sprocket 1} Nore mave the sprocket and remows the crive chat 112) | Heat protector boa £83} | Ol pipe jot bott 4 104) | Lower radiator stay 1 105) | Oi pipe Bott 2 1 1 1 {1} | Rear lower engine mounting ut | (37) | “adkrtng bast lock re Bl ae 178} | — mowreng exfusting sl | nore ~ 1 2am countorleckoice together with he mounting bo) ad remove | 193) | Rear upper ott ek nex 1 {20)| — mounting bot fa (21) | —-edjusting bot: 1 NOTE 4 | ‘Loosen unt the Bol end snot axing nse the | frame, (221) Left mounting bolicober | an | note | "Pent bot mst be rtenes together withthe rasiator | bredket (23)| Ratt mounting totieoar 22 | {24)| Engine wosembiy P| wore | Lower the engine straight, then rice the fame. 7-3Engine Removal/installation Engine Installation @ am Qrae » & 40.140, 29) 8516.5, 40) 1138) ¢ ; 2AY pal { v2 a2) 2a (23) |e ica) Sinn tr oan GunmcAse SprCOLAR Soecoun Serco QD vo2n | ete 8) 8D sow0.291 voy BD 88005,40 a, Note + The Bolt must be Ughtened together with the radiator bracket Check forthe correct position,~ TT Place a jack under the engine and support the motorcycle Securely. Take eare not to damage the frame, engine, etc. Engine Removal/instaltation — ‘CAUTION . | + Tako eare not to pinch the cable and wires. | + When placing the jack under the engine, take care not to set the jack against the oi fter. | 1 Loasely tighten the all mounting bolts and cheok te cee thatthe engine I placed in corect position. Tighten the mounting bots |___fiese that are tightened together with the adjusting bats (pace 7-6 a Requisite Service Exhaust pipe installation (page 2-101 + Radistor installation (oage 5 Couyeeretstaten amo 6-2. : ‘paar 2 «ieee actor Sof the Common Senice Ma = EE Feces wy emai nn Installation Order 12 | Rearlower erie mouning soaring ok | 1 | NOTE | |v nser the mounting botinto the adsating bo | i them. and oghton them togete: 13) | — asier bat ook ne 1 18) | = mounting at 1 | (5) | Rearunper eng 1 | nore i : 1 Dovey ten, (0) | = mduning bot Jv for i | | bowsly taht the Gok fiat ohen the eng bot ! seimuh ae goee ano ett oer 1 | ~ tek nt 1 (8 | lat mouning bliin an | NOTE 1 fhe rarward bal iter em of with “Th forward bot mur be ghtned tegetor ith the radar bacte, Laonsly Sghen to ches the covet {alotion peeion 12) | Font maomtingbotnter nore Tra the clin oper pesions 10) | Oipipe po 1 | Lower eto stay wore Intl he dive chain on te ive soroctet 612) | oi pipe jon bok wore + Intestock the iter arm with the liter rod (G9) | Heat protector (94) | Drive spractet 105) | Drive sprockat cover 6) | Ciuteh cabie (07) | Speedometer gear nox Nore : \ Engage withthe drive sprocket bol (osge 10-2) (18) | Gearshift spindle join 1 (19) | Gearshite spindle jeint bolt 1 | NOTE + Insel the punch mark on the arm aligned with the mark fon the spindle (page 10-2} | (20}) Starter moter cable (211 | Spork plug cap (22}|| Puse generator wire connector 23)| Atieretor wie connector (243 | Neutra! switch wite connector Q 7-5” Bigind Mounting Bolt lnetalation’ ~ Engine Removallinstallation {Rear Upper Mounting Bott] ‘Set the adjusting bolt over the mounting Bolt and engage trem, Push the mounting battimo the place shown in the drawing 2s full, at it goes Tighten the mounting halt and the adjusting Bott By using @ hex wrench, TORQUE: 11 Nim (1:1 kg-m, 8 feb) Install tbe lock rut. Hold the adjueting belt and tightan the lock nut by using the lock nut wrench. TORQUE: 55 Nem (5.5 kgym, 40 fab) TOCK NUT WRENCH ‘o7unta.e70200 (ear Lower Mounting Bott) Sat the adjusting b Push the mounting bolt i 2s ft goos. to te place shown in the drawing 22 ful () ADJUSTING BOLT I (2) MOUNTING BOLTEngine Removal/instaltation “Tighten the mourting bott and the adjusting bot by using a hex synch. TORQUE: 11 Nem (1A kgm, € feb) Insta the lock nut. Hod the mounting balt and tighten the lack aut by using the lock nut wrench. TORQUE: 55 Nim (5.5 kgm, 40 flo) o7HMAMR70200 Tighten the mounting nut on the other side TORQUE: 40 Wm (4.0 kgm, 28 fb) (2) Hex OmENCH (1 LOOK NUT WRENCH 7-7Serviee information ‘Troubleshooting Camshaft/Cam Gear Case Removal Cylinder Head Removal/installation Service Information 8. a4 82 83 Cylinder Head/Valves Cylinder Head Disassembly/Assembly 8-6 ‘Camshaft, Cam Gear Case Installation 8-€. Cam Gear Case Installation 8-10 Camshaft Installation an 1+ ‘The oyinder head, camshatt, andthe cara gear case can be serviced withthe enine mounted on the frame. {Ifthe ont or rear eamahartie removed, be sure to eneck the valve tiring on the cthe: cytinde from which the shaft isnot amaved, ‘then reinstall the removed shaft. + When servicing the eylinder head, note and record the shim numbers an locations so that they can be set in their eriginal position. + When assemnbing the: arm shaft end the eamehatt. ler head, epoly molybdenum clsulfide rezee the siding surfaces ofthe valve stem, rocker arm, rocker + Be-sure that the No.1 eylinde is atthe top deue! center of the compression strcke when the TT markis aligned vith the alignment rere ort clutch cover (cutout) and the eamahaftedge markis toward up Le aligned withthe site ine co the camshaft holder Each mer should be positioned as shown in the drawing, «The erankchett should rotate clockwise and the camshaft counterclockwise viewed from the olutch cover side {The evlnders shouldbe arranged as shown inthe drawing, (1) LEFT SIDE. GLO iwc (3) CYLINDER ARRANGEMENT tai camsart Fozpen % a (6) CAMSHAFT x i _ ©) q co swnen Eure cover > CRANKSHAFT) ~ + Besure hat she No.4 oyinder is atthe top dad center ofthe comoression stroke when the T2 marks aligned withthe afgrmenc mark on tha clutch caver leutoutl and the eamebattadge marks towar6 up 2 aligned with ve serene on the camshstt holder Each merk should be positioned as shawn in the drawing Troubleshooting (gal) CAMSHAFT HOLDER 5 OW Ne %acaushary 5 sae 6 (8) cc or stanren Gtutcu cover ‘The oylinder head troubles can be cetected by the cylinder compression and the abnormal engine noise Cylinder Compression Too Low Valve ~ Misadsted vaive clearance = Seized or bent valve = Damaged valve soring + Cylinder esd Leads from the cybnder head = Distorted or cracked cyinder nese Grinder Compression Too High «Carbon deposits on the piston and in the combustion chamber = Abnormal Noise * Misasfustos valve clearance + Seized valve or damaged valve soring + Damaged or worn eamshe" holder and camshaft + Damaged or worn rocker etm + Damaged o: worn cam gear 8-1Camshaft/Cam Gear Case Removal Cylinder Head/VaivesCylinder Head/Valves NOTE e Service on the front side ie described on this page, Perform the rear side service in the same manner | | 1 Take care not to drop any ar into the helo in the cam gear case. | 1) The cam goar ease fe stamped with the front and ear LD. marks. Do not confuse the front and rear gear cases when the Both | are removed. : «When removing the carnshatt hokers, be sure thatthe eamghatt of one cylinder is at ths tap dead center ofthe cexpression _sroke. Loosen the holder baits onthe ide ofthe other cylinéer {which cameheftis et the top dead center ofthe exhaust stroke} | ‘equally in 2 oF 3stops, then loosen the remaining holder bolt fn the sarne mance. Remove the holders gs stzight es possibie. | Each camshaft is stersped with the LD. mer F forthe front cylinder and R for the rear eyinde, Also each earshafts marked vith IN o° EX respectivy Requisite Service Radiator removal (p93e 6-6) + Carburetor ramovat (page 6-8) 2 Water pipe + Spark plug removal i Procedure ay Remarks: ‘I = | Removal Order i «| Carburetor insulstor 2 | {2 | Cylinder head cover botvwasher aa | (3) | Gyinder head cover es | (| Gasket i | ; (5) | Camspate holder bolt 16 | Nove | ‘+ Check that the camshaft of one eyfinder is a the top ead center ofthe compression stroke. + Loose the holder bolts a the side of the other eylinder which eamehatt ie atthe top dead certer of the exhaust srroke in 20” 3 steps equaly, then laosen the remaining holder bots. (6) | Oi'pipe stopper plate } 2 7) | Oilpipe 1 {3} | Camshatt cesembiy 2 | Nove + Check for the cam gear and cive gear aagagernont (2) | Cam noider owe! in 2 | Nove: + The cam holder dowel pins must not necessarily removed, 100) | Comshatt hokior 4 | nove | | + Check the marke on the camshat: hele and erase either | front () or rear (RI mark (0 | Camshaft 2 | nove | + Remove by eligning the cam lobe with the long ine in the comm holder 12) | Cam gear ease set ost a | Nore + Wath copner washer. 1131 | Cam gear ease mcunting bolt 4 | nore | 1 With conical washer Lacsen in 2 or 3 steps equelly 114) | Com goar case 1 | Nore | + Do net eontuse the front and rest when both ara 105) | Dowe! pin (Senet i2Cylinder Head/Valves Cylinder Head Removal/instaltation Age gee 8-4Cylinder Head/Valves |_ wore Sense on the fom Side is described on this page Fororm the oar edo sence in he sane Manner. When removingjnataling the front engine mounting bot, be sure to protect the ol pan by actaching it with 2 sutablo wood board and sunpart the engine with a jack to pravent load on the bolt CAUTION a Apply engine of to the threads and the seating face of tha evinder head bolt. Requisite Service Operations related tothe front cylinder Radiator removalinstalation (psge 6-6). Operations road to the both. cylinder: Camshaft holdefearn gear case removal (oage 8-2) ‘Exhaust pipe removal instalation (page 2-10), Carburetor removalinstellation toege 6-21 ‘Thermostat removalfinstallation (page 5-4) scooter ersning (page 5-3) 2 Engine mounting batt removal Procodur Removal Order : instalation ln the raverse ovr of removal. tay | Cylinder head bold 8 x 84mm 4 | nore | + Loosenrightan the conical washer attached special bite together with the Gmm bots in 2 or 3 steps eaux (2) | Cylinder head bots 6x 62mm (3) | Cylinder head assembly 1 4) | Gacket Nore 1 Insel with the "UP" mark facing Up « L181 { Dowel pin 2‘Cylinder Head/Valves Cylinder Head Disassembly/Assembly Bo nat remove bxcest onrepacement. | i 92) o 8-6| Cylinder Head/Vaives = GAUTION [Before sonicing the oyinde heed, nate und veoord te chim Gickneds and combination with the valve'to Installed the shims in thelr original position. + Do not compress the valve springs more than necessary 1) Note the location of each part and reinezall them in their original poston. 1 When instaling the valve springs, install wth the narrower col pitch side towaré the combustion chamber | | ee Snows the rocker arm shoft plug except when it ia roplaced as i as the tapered threads, When the rocker arm shaft | plug fs eplacedapply sealing agent zo the threads and install Nore [+ Sending onthe font bank le desorbed on ts page Performs rea bank ] Requisite Service + Cynder head removalinetalation (nage 8 ~ Procedure ~~ Tray, Remarks i [] Bisssceribiy Order i = T Reser ie te reso order of csassery «1 | Shien @ | NOE | © Note the locaton and thickness of thesis. (2) | Rocker rm shalt a | Note + | 2 The rocker ar shaft can be easy removed by pressing the spring with the two rocker arms and moving whe ‘Shaft ward, When inetaling the rocker arm shat, align ‘the groowa in she rooker arm shafts with the recess groove of the camshaft helder bos. (3) | Rocker am @ | nore \ | + Check for missing spring. (a) | Toews sping 4 15) | Valve coer 6 (6) | Vale retainer e tr | Outer series a | nore 1 etal them withthe narow pitch en facing down. 63 | torr sina | s (8) | Outer ering sot 8 | NOTE tat | Inne: sping set 3 |» sexa tush, There should bene stip bebwean he sori sat. oy | Stem sea s ti | Vetwe Wax 8 + [3 | ate ide 2 | I>: te st —Cylinder Head/Vaives Camshaft, Cam Gear Case Installation ven aa) Nore: + The front cylinder service is described on this page. Perform tre rear oylinder service in the sare manne + heck that the shim ia instefed on each valve retainer securely. Take care nat tocrop any part inte the le inthe eam gear case + When instaling the cam shaft holders, check that the camshaft of one cylinder fe atthe top dea center of the compression stroke Loacoly tighten the holder bolts en the sige ofthe other cylinder which camshaftis the top dead conter ofthe exhaust stroke in 2 or 2 steps equally, then tighten the remaining nolderbetts (page 11. +The camshatt a marked with for front eyinder and Roc rar cylinder. Ech camshafts also marked with IN or EX respective ly (page 8-1, eee Requisite Service + Radiator inscaiation inage 5-6 + Corburotor installation ipege 6-6), + Water pipe inetallation. + Spark pug instalation, 8-8Cylinder Head/Valves Procedure: Low | Remarks 1 trstaaion Grr ' | 4 | Bowel pom 2 | nore push the dove! pn fly and instal 12} | Cam gear case 1 NOTE [TSS me tng for Fo tonto Ror et ar Sri acetal wt eset bl installation le towaid tho carburetor age B20) «31 | Com gear cose maunting belt a | note | esely ght, check for proper engapument of he se- | Sena gear ant ine crckahatt ing peer end puch the | cam gear case as much as it goes. 14) | Cam gee cave set ba 1 | wore With copper washer Laasaly tohten, ‘Toft the cenrgeer mounting bate ofthe dowel in hue fst ther the vrmaining mouring bots diagonal | “Fgtan the set bo (page 810 «a1 | camsner 2 | Nore real by aligning tho cam abe wh the long tae the { cam bole, \ (6) | Camanate holder 4 | note check the mark onthe carat hlder and ssserbie : sh the eamahat acsoringly. (7) | cartahet nederdel in 8 {8} | Comat assembly 2 | nore : check the timing mak on he tae dutch, | Check te engagorent ot the eam gear and the ive fea and neal by signing te edge mark wth she | Serbs neon the hale 2) | 0% pipe 1 (10 | Gi spo stopaer ae 2 tr | Cemahet hoider bot ts | sore 2 Cheek that te carshat of one eyes ea the tp Gene entero the compression stoke acaey heen | the relocr bots on the ice of the other vind which | Conant ic atthe top dead Geter of Ue exhaust suoke fr 2or 8 sto equal thon Stan the orang oder bolts The outa ons ofthe carat her | Sots lghanad on he yb hes ae the sores | bore | nay! casket + [nore | 2 ign the in marc wit the mark on the cove and attach Sy esing the recommended adesha oper page 30). 113) | cytinder nese cover 1a | wore rsa with the IN mek owd the caureor | «10 | cinder head cover washelote a [hore ‘= instal the washer with the “UP” mark toward out, | 1) | Carrer naltor 2_,| hore | | ste with the "CARE" mark toward the earburtar and | [teu matt owe ue | 8-9Cylinder Head/Valves “Cam Gear Case Installation (9), MARK (F OF FI NOTE i | (2) FRONT siog >The cam gear case is marked with F er Ron the flange, Install the gear caso marked F on the front cylinder and the case marked R on the rear cylinder. + When the identification matk is not cit, the goar casa can be identified by the sub gear of the secord gear. With the sub gear toward you! — fortront eyincer: the sub gears off to the left side trom ‘the main gear. — for rear cylinder: the sub gear is off tothe ight side from the main gear. (3) REAR SIDE (4) SECOND GEAR Push the gear ease dowel pins fully Into the eylinder hess. NOTE .. z +The second gear and the crankshaft timing gear donat_ ‘engage properly when the dowel pine are net pushed into the full [Check the ID, mark on the geer case and install the case on the designate cylinder head Check for the proper engagement of the timing geat and the seconds gear nthe following procedures. < Lighy move te this goar back an fren with he geareaze j (@) CRANKSHarT—e( |) ~ lighty used own. The engagement is correct te ange TIMING GEAR Of the gear case is pushed by the timing gear and raised off ‘he cylinder nead slighty. Pomave the guor cage and reinetol it if necessary. > Tighte the four gear case mounting bolts fully with your Ti) GEAR CASE MOUNTING BOLT fingers. Install an¢ loosely tighten the gear case eet batt and er washer. No? ‘When tightening the set bolt, take the gear ese threade and the bolt th TTighte® the goar case mounting bolts of the dowel pin side to the specified torque, ‘TORQUE: 36 Nem (3.6 kg-m, 26 Fuld) Then zighten the remsining mounting bots. Tiohte the gear ose set bok mm TORQUE: 12 Nem (1,2 kg-m, 9 ft) ae an eatenCylinder Head/Vaives Camshaft Installation (1) TIMING HOLE CAP Remove the lower fairing [page 2-4) Remove the timing hole cap. When bath font and reer evlindore are deaesombed: womnann Hoen cautio 1 ~ ee ee NG eeice mane 7 nett the camenate with he aga arrow the pe SS Fight crankease cover. | x he ‘Apply molyodennum disulfide solvent to the siding surface of the camshaft, camshaft holder, and the rocker acm, E> S SA J wee pee Refer to she marks on the camshaft holders and the cylinder heed and note each camshaft holder instelletion position, | CAUTION ~The camshaft holders make up the ol passage. Be sure | FE =~ ‘to instal them in the correct postions as instructed with | 2) CAMSHAFT HOLDERS the marke. i ‘Check the ID, marks of each bank’s camshaft and essemble ‘the camshafts with the reapective eamshatt holders LD. MARKS: FRR: Rear bank FR: Front ben IN: intake EX: Exfiaust (3) CAMSHAFT 1.0. MARK 1 8-11” Align the Gam lebe with the long hote i Cylinder Head/Vaives land inzert the camshaft into the camshatt holder. cauTION + Apply molybdeum disulfide solution to the eam lobe, ‘camshaft, and the camshaft holder journal and insert ‘the camshaft with oare not to damage thers Roa: bank side installation] Rotate the crankshaft clockwise and align the starter dutch T1 mark {eoribe ine} with the cutout falignment mark) in the rigat erankoase cover. {The No. cylinder should be st the top ddoad center of the compression stroke.) — oe CAUTION, + Be sure to install the camshaft holder of the No.3 | corlinder first, as It is at the top dead conter of the ex- | hhaust stroke Install the assembled intake side and exhaust side camshaft hholdars on the cylinder hess wrth the comehatt edge macs facing up end aligned with the scribe line on the howers. —, CAUTION + Be sure each shim ic installed property | + Check for proper engagement of the eam gear and the | camshaft side driven gear, and install with care not to | let the edge morks out of the alignment with the scribe | Jinos. | + Do not strike to install the camshaft holder | ‘Set the oll pipe end the pipe plete between the camshaft holders end loosely tighten a the camahaft holder bolts. caurion + Before foosely tightening the camshaft holder bolts, be ‘sure that the bolt holes atthe cylinder head comers align with the recess holes for fixing the rocker arm shatts. + After confirming the alignment of the recess holes and ‘the bolt holes, insert a mm pin into the holes to: the rear bank side installation. + Do not remove the seating pig. (1) CAMSHAFT HOLDER aR (2) CAMSHAFT (3) LONG HOLE (1) RooKER ARN a Je SHAFT y‘Tighten the eight No.¢ side camshaft holder baits (Iand EX sidec) until the eamehatt holdars closely set on the cylinder ead. ‘CAUTION 7 The camshafts on tho No.3 eylindar are so close that they get “overlapped”. Tighten the eight holder bolts (No.8 side only) in 2 or 3 steps equal + Tighten the stepped bolts at the comers of the cylinder head. Rocheek that the both camshsft edge marks align with the € fines on the camshaft holders. Tighten al the camshaft holder belts in 2 or 3 steps diagonally. TORQUE: 12 Nam (1.2 kgm, 8 fb) CAUTION + The No.1 cylinders atthe top dead conter of the com preselon stroke, Tighten the No.3 eyindar’s camshaft holder Bolts frst until the No.3 camshatt holders lose ly sot on-the evlinder head, then tighten the remaining bolts in 2 oF 8 steps eaually Cylinder Head/Vaives | on HoLoER “BRS = ong EE @ epee Mane SE (4) No.9 CAMSHAFT HOLDERS [ Tay Bout After the installation, slowly turn the crankshaft 2 or 3 revo- lutions clackwise and adjust the shims to fit. Valve clearance adjustment: see page 3-7. eee {Front bank side instattaion! - ‘Turn the efankshaft clockwise and align the starter clutch Tt ‘mark (scribe Hine) with the cutout alignment ara ine right crankease cover, Be sure thatthe camshaft edge mark facing lup ane aligning with the serine ine on the carnshatt holder ‘it not, align By turning the crankshaft on emore clockwise revolution. (The No. cylinder hould ba at the top dead center cof the compressian stroke.) — ‘Turn the Srankshaft further 90 degress clockwise and align the starter clutch T2 mack (scribe fine] with the cutout (align ment mark) in the right erankease cover. Bo sure thatthe camshaft adge mark is facing up and aligning . wit the seribe ne on the carmstiaf: hlder. (The No.4 cylinder should bo at the top dead center of the compression stroke.) ‘Now install the camshaft in the follwoing procedures, Set the oll pipe and the pipe plate between the camshaft elders ead tighten al the carnshett holder bolts. cAuTION oa + Before loosely tightening the camshatthaldor bolts, be |] sure that the bolt holes atthe evlinder head comers aign | with the rocass holes for fixing the rocker arm shafts before loosely tightening the camshaft hokder bots. Do not remove the sealing plug. (3) STARTER CLUTCH COVER (it ROCKER ARM (2) PLUS (00 NoT FEMOVE.! (a) ROCKER ARM SHAFT (2) 80LT (STEPPED! 8-13Cylinder Head/Valves Tighten the eight camshaft holder bolts af both No.2 eyiinder camehafts IN and EX sides) until the camshaft holders closs- ly set on the cylinder head.as did on the rear bank side. CAUTION _ Bo eure each shim is installed proper | + check for propar engagement of the cam gear and the ‘camshaft side driven gear, and instal with care not to ler the edge marks out of the alignment with the scribe + Do not strike to install the camshatt holder. ‘Tighton the all bolts including the camshaft holder bots Of the No. evlinder side is 2 or 3 steps. TORQUE: 12 Nm (1.2 kgn, 8 felb) CAUTION + No.4 cylinder is at the top dead center of the compres lon stroke. Bo sura to tighten the No.2 cylinder’s earn- ‘shaft holder bolts frst until the camshaft holders closely set on the oyinder head, then tighten the remaining bots in 2 or & steps equal Velve clearance ecjuetment: see page 3-7 Head cover installation: see page 3-10. Apply the molybdenum disulfide solution to tha timing hole cep O-ring and install the cap. WHER tne Font cle ie dicasserbiea] Remove the ear evlinde: head cover anc check that the No.1 cylinder is at the top dead center of the comprescion ctroke Gage 8-7) “Turn the crankchaft 90 degress clockwise from the timing rar ‘Tt pasition and align the sterter clutch T2 mark (zeribe line) ‘with the cutaut (alignment mark) in the right erankease cover. (The No.4 cylinder should be at the top dead center of the com. pression stroke.) Now install the front camshaft9. Clutch Service Information 7 9-1 _ Clutch Removal 9-4 ‘Troubleshooting 9-1 Clutch Installation 9-6 Right Crankcase Cover aoe Removallinstailation 9-2 ~ Service Information + Clutch masintenance can be done with the engine in the frame. 1 Giean any gasket off the crankcase cover-orankcase mating surface. Bo not damage the coverscase mating surface. Bs + Never allow fereign materials to get into the engine. 2 inthe ttansmiscion caquire servicing, remove the engine ond separate the crankcase (Section 10). Troubleshooting Most of the.clutch malfunction resit from the improper clutch free play. Check the etch fre play ane adjust, it necessary, before disassembling the clutch Hee - Clutch is Stepery When Accelerating ctchte Hartt Disengageorthe torre Moves wis CI) FFo0 small cit lever fe8 play the Chath Disengoged. + Worn clutch die _t Exoessive citeh lever tree play + Deteriorated aiophragm spring Bone sutzh plato 1 Excessive engine oll Loose clutch iock rut Excessive engine oll or excoscive oil viscosity Cluten eable not routed properly ‘Clutch Operation is not Stabilized! + Wom eluteh outer groove Gesr ic Hare to Engage. 2 + Clutch misadiusted a Clutch Lever is Heavy. = Poor clutch cable cperetion due to damage ornust Damaged olutch lifter mechanism Damaged clutch litte plate bearing Clutch cable nat routes properly Bont clutch lifter armRight Crankcase Cover Removal/Installation Requisite Service Engine oll draining (crain boit location: page 8-8, step: section 2 of the Common Service Manat + Lower faiting removaliinstaliation (pege 2-1. Procedure Removal Order Installation Is in the raverse order of removal. Right crankeage cover bolt Flight crenkeave cover 2) | Gasket 4) | Dowel pin 9-2Clutch Clutch fock Nut Removal Straighten the locking tabs of the lock nut with care not te damage the main shaft is NOTE + With engine mounted: move the chit lover to the 6th speed, operate the reat brake, and loosan the lock nut. ‘With engine dismounted: mavs the shift ever zo the 6th speed, hold the drive sprecket with a universal holder, | ‘and loosen the lock nut. Loosen the feck nut by using the lock nut wrens ees nine: sa SSak Mur waeHch, 26 x30 mm 07716-0020200 Sirension gaa ore 9020800Clutch Clutch RemovalClutch Installation \ iS \ pe es 00 a3) 18) | inseatl with the ariven 3 3-6 kot mark fecing in,Clutch NOTE 7 Tighten the elvich center lock nut a follows. Move the ahift lever tothe 8th speed, operate the rear brake, ang tighten the clutch center lock nut. | Wien the engine alemounted from the frame, move the shift love to the 6th speed and bold the dive sprecket with a universal holder or equivalent. + Tighten the all pump driven oprocket belt with the elds assembly intalled. Apply the thread locking agent to the belt 5.5 to 7.5 mm from the tin 7 | + The ise contact surface of the two clutch end discs_are different in material (black). Do not interchange them. | + ingtall the Htor rod with the long iron ends toward lett. | Requisite Service + Right crankcase installation (page 9-2), Starter elutch installation (page 17-4). = : Procedure oy Remarks Removal Order (1) Cluten outer quige 1 {2)| Mf pump erive chain/sprocket " {3)] Oil pump driven sprocket 1 | nove 8 + Install witha seribe line on the goar toward in and tighten with @ bole {4)| On pump driven sprocket bolt 3 (6}] Clutoh outer 1 | nore + Engege with the drive sprocket and inctal {@)] Clutch center A 1 | NOTE + Take care not to damage the main shaft spline (7i| Thrust washer 1 | ()] One-way clutch assembly i | Not + Coat the eprag roller ang inner with clean engine off and assemble with the clutch center B with the roller lange toward the cease cover (9)] Cluteh conter & 1 | 1101} Clute ise 10 | Note + Contact surface of the both end plates is black. Cost the | iece with eelen engine ail and asembie with th clutch | sates alternately. 1110} church plate 8 J112}] Threst watcher 1 }103)| Pressure plate 2 [14] Disphrogm spring 3. | NoTe + Install with the projected side toward out. (m3) spring eet piste a 1 | ote + Set the thrust washer on the stepped portion st the bot rom of the set plate {page 9-8), | (76)| Lock washer + | nore + Install with the OUTSIDE mare facing out (17)] Leck nur 1 | caution’ + Check that the érive sprocket and the clutch outer are properly engaged, then bend the lacking tabs with care rot to damage the threads. (18)] Litter rod 1 | nore "+ Inetal with the long iron ence towerd lett. Apply molybde- rum disulfide grease to the Jett end. Alignment with the liter eam: see page 10-2 (39)] Uner guige 1 | note | + Assemble with the lifter plete bearing (20)| titter platerbearing 1 (21)| Snap ring 1Clutch (Clutch Disphragii Spring Installation ‘When inetalling the clutch, inst the three ciaphragm springe ‘on the pressure plate with the projected side toward the tock rut, then assemble with the spring set plate. ‘Be sure that the thrust washer is eecurely set on the stepped section.st the bottom of the set plate, ae CAUTION Replace the three diaphragm springs as set. | + Note thatthe thrust washers ati the soiract posi tion of the sat plate. Otherwise, the diaphragm spring | and the locke nut cannot be set propery | + Coatthe thrust washer with clean engine oft ease in | staltation, Clutch Lock Nut Installation ‘Aevemble the clutch ipage 8-6) Piemesstess NOTE With engine mounted: mave the shif lever to the 6th Saeed, operate che rear brake, and tighten the clute lock aut With engine dismounted: Move the shift lever tothe 6th sspged, hold the drive sprocket with a universat ho'Ger fF equivalent, and tighten the clutch fock nut Tighten" look nut by using the tock nut wren, = LOCK NUT WRENCH, 26 x 30mm 077160020203 = EXTENSION BAR 07716.0020800 Bent the locking tabs ofthe lock nut NOTE + Take care net to damage the main shaft (1) THRUST WASHER mn (2) SPRING SET PLATE \ (4) PRESSURE PALTE (3) DIAPHRAGM SPRING (1) LOCK NUT WaENGH 7 (2) EXTENSION BAR———_—$—_—_—— 10. Gearshift Linkage |) Service Information 70-1 Gearshift Linkage, Shift Drum | Troubleshooting 10-4 Removal 10-4 | Drive Sprocket Cover Gearshift Linkage, Shift Drum In- |_ Removal/instalation 10.2 Stallation 108 Service Information «The geacshitelinkage including the shift drum, shitt fork, and the shift fork shaft] ean be serviced with the engine mounted fon the frame + Take cata not to let dust, dit, and any ether foreign materials enter the engine 1 Separate the erankcase when che transmission service is requied. Troubleshooting Gear Skips Qut of Engagement. ‘Worn gear dog Bent shift shaft Damaged stopper a Bent or damaged shift forks worn shit drum groove - Gear ic Hard to Engage + Bent shift fork + Domaged shift drum cam groove + ant gear shit spindle claw 10-1Gearshift Linkage Drive Sprocket Cover Removal/InstallationGoarshift Linkage Requisite Service + Lower faiting removeliinstltation (page 2-4, Procedure ary Remarks Removal Order 11) | Clutch cable holder i (2) | Clutch cable 7 | woTe + Disconnect from the titer arm. (3) | Speedometer gear box belt (@) | Speedemeter gear box 1 | Note | Romove the gear box. (8) | Dveeprocket cover bat ‘ (8) | Dive smrcket cower ‘ 7) | Bowel pin {2 [7 Tnstallation Order | cy. Dowel nn la |B) Deve stocker cove 7 | nore | Cadence ee ace . i Tedlerreaoyongaing hr olestne ane dos. Ar . shy mlyodonur die eae ete he fod ena | ta] vee sprocket cover bot ‘ Ua | Speedomrar pe box OT | wore | | te obncet we gear tox de jn io he set bot | (3) | Speedometer gear box bolt 2 NOTE | Nofmtal wih oor notte esonnect te it 12) cuch cate _ ot [nore / | Eecenndt othe tram Fer] elton cable hater 11 | note | | + install by aligning the hole with the stopper pin 10-3Gearshift Linkage Gearshift Linkage, Shift Drum Removal - 10-4| note mounted on the frame. | atonnoctag the soctng system host, e service Lower falring remavel page 2-8) 1 Drive sprocket cover remevel (psge 10-2). 1 Cluteh removal ipage 9-4 Procedure Removal Order | Gearshift Linkage | 0] Gearshift epindie joint boltigearstitt spindle | i, | jaime i (2)] Gearshift linkage cover batt (@)] Goarenitt linkage cover | (4)| Dowsl pin ‘6)| Gasket Gi] Gear shite spindierepring ‘The water pump mounting belts must be removed to service the gearshift linkage. However, Gearshift Linkage [e_Bemowefnaa the chchsecemby arse ot anc emevetnta he sh ok fk sas ard shift dum. + Water pump removal (page 5-5 + Oil pan removal ipage 4-4). Remarks wore Nore + Do nat remove the spring except on replacerment. ul out etraight with care not to damage the dust sel ——$_ $< | [7 the onte fork, site fork shat, and tho shift drum ean be removed, inctlles, andlor disassembled with the engine | itcanbe crviced without | ero | 1) Te wane : Oo Saas so : i ; vest teens then og mere conn rb yt Tose ee a | unnecessarily. } (741] Spacer_cottar -| 1 3] Saas | 3 (13) Suh im 1 | note | 1 | Sram ets ems wane tees wh | nore [81 onrnats cram | jt ct + PUI our to the left side 10-5| Gearshift Linkage Gearshift Linkage, Shift Drum Installation a8. a J fam | / \ Se NF Sen Se ae V Fe 11.2, 9} 7 G 2 \o" G at 7 && ee eee So { na)Gearshift Linkage NOTE > When instaling the water pump, check the watar pump shaft and oll pum Requisite Service (oll pen instalation (page 4-4). Drive sprocket cover instalation (page 10-2), Water pump installation (page 5-5). shett connection Clutch instalation (pace 9-61 Lower faring installation (page 2-4) re Tew] fone Removal Order T Saroee (| SH gumeotea tn Bh] Sa toe 3 | nore SPREE an at ea ce ear ata ani Peotirtrbaeeieinen onty bon | omemeh edie urs Sex a bose Hea (31| Shift fork shaft 1 | nore is | Steet anton ein «| tropee wacent 7 Gouri Untoge : «| Shivam so 1 | nore [Sot he ae dum sn on the shit um | te eum onan — | oa) eaten SARTT bering ait rum pn wh nab | ae eee | (7}| Shift drum center bolt 1] (| Soo i 1] Bit tm er te ; th| pacer cour : - ose serait as secoamssndiarar seis pepsin rere antenatal Boia teonte cetene: Remorse oahe, 12) rae water 1 [13] Gee pera ater assem a \ Ar inte nats Pace be Soc yor | Pasa ah‘ asoembles Bee on te st Som 10} box 2| 73) Se cote ilies | Ps tee i (t3| Goon aoeteantne va | sore 30 cust 1 | 30} Gove pn 4 (20) Gene iexage cove 1 | sore - | iets telcos es eae sai (21)] Gearshift linkage cover batt 5 22) Gaara sede frets cine ee on > | ore ~ 10-711. Crankshaft/Piston/Transmission Service Information 11-1. Countershaft Disassembly/Assembly 11-6 Trouble shooting 41-1 Piston Disassembly/Assembly 118 Crankcase Separation 11-2 Bearing Selection 11-10 Shift Fork Installation 14-4 Crankease Assembly 14-12 Mainshatt Disassembly/Assembly 115 Service Information Bere noe a foo en Gute we eg gene vray 119 ‘When there is smoke from the crankease breather pine, it might indicate broken or seized piston ring. Troubleshooting Cylinder Compression fs Too Low, oF Engine ie Hard to =. Goar ts Hard to Engage. Stor +" Chtch is misadjsted (excessive tee play + Blown out eylinder head gasket = Bent shih tor + Wom, stuck, or broken piston ting 2 "Bent shift fork shote Worn or dmages eylinder or pieton 2 Damagod goer stutt spindle + Bent valve, or bent anc ceterorated valve seat_ 1 Damaged shift rum guide groove Cyinder Compression f» Too High, or Engine Overheats + Damogod shift drum guide pin oF Kooks Gear Slips Out of Enegement. Carbon deposits on the cylinder head ancior piston + Worn ger dowel Piston Sounds. + Bent shif fork shett + "Wer evlinder, piston, and/or piston rina + Damaged shit drum stopper + Wom piston pin hoe ang piston Bin + Worn shir dram guide 2 Worn connecting rod smell end 2 Ween obit fork groove of gest Smokes trorn Butter ‘Abnormal Engine Noise *""Wom, stuck, oF broken piston ting > Worn connecting ro large end bezting + Weak valve stem seal _ + Bent connecting rod + Worn crankshaft main bearing + Worn transmission gearCrankshaft/Piston/Transmission Crankcase Separation (2) UPPER CRANKCASE SIDE: So - (1) LOWER. (CRANKCASE SIDE 1 a9 3)Crankshaft/Piston/Transmission Selact and ood match with the crankshaft main Journal (pege 11-101 Select and replace the connecting rod bearing by using the selection table to make ite good match with the crankshaft {page 11-101. [Note the looation of each part to reinstall them in their original position. ‘The gear shift inkage such as the shift fork and fork shaft can be removed after separating the crankshatt. If the erankcase cannot be ceparted by lighting tapping on the upper case. check whether the crankcase halves are til tightened with a bolt ‘bearing By using the celection table to make it Requisite Service Cylinder heed removal {page 6-4) Gearanvtt linkage removal (pege 710-4) Oi! pure removal (peas 4 Alternator removal (cage 15-8) Engine remavel (page 7-2) Primary drive gear moval (page Water pump removal Ipage 5-5) Starter moter removal (page 17-7). it fier removal. 41, Procedure ay Tenens Removal Order Upper Case Side (2) | Mainshafe bearing set plate 1 (2) | 6 fam bolt 5 LwoTE () | 8 mm bot TAI] voosen se ntti eiseroce pater 2 o 9 steps 10 mm bolt 1 Lower Case Side 6 mm bot 7 bore 8 mm bolt 10) - ‘Loosen the bot in evaseroas pattom 2 or 9 steps Lower erankoae 1 | Note 7 2 Set the ctankoase with the upper case coward dow, || Ut the lower case 20 separate the upper and lower halves. (2) | Dowel sin 3 | (2) | Teanertesion assembly | 150) | Mainshate bearing 1 | (11) | Bering cap stop pin 1 (12) | Countersheft cit 96a 1 (33) | Countersnert bearing 3 (14) | Thust washer 1 (1) | Bearing stopper ring ~ -) 4 (16) | Connecting rod bearing cap nut 8 (17) | Bearing cap 4 | wore 1 Do not remove the conneeting rod cans with force but pall therm out straight. Remove the bearing 118) | Crankshate 1 | Nore Phemove with care not to damage the crankshaft | jour 119) | side main bearing 4 | wore Remove from the upper anc lower cases and record the Installation location (201 | Center main bearing 21) | Connecting rodlpiston | nore Remove tothe eylinder head side, Fiston removal | Ingtallanon: page 17-8 11-3Crankshaft/Piston/Transmission Shift Fork Installation “TB: top an sliding surfece. | \ l Requisite Service + crenkase scorn page 112 nae Tow eos [eect cree a (2) | Conter shite fork (3)_| Right shite fork + Install on the shift fork sheft with each mark (R,C. and |) toware the chien, on | tar | 1 iCrankshait/Piston/Transmission _ Mainshaft Disassembly/Assembly ae a 8 o “weblpbdoer ‘a seakine: 208 Tih + pont caon CO Dp Swe Sling surtce. Requisite Service TT + crankcase separation (page 11-21. c Procedure Femerke | ‘Assembly is in the reverse order of disassembly. lo 1 (2) | 2 eer (13) i (3) | Trrust washer 1 (a) | M6 gear (227) 1 {5) | Spline busting 1 |. | 16) | Thrust wosnefsnop sng 1" | ty | saan gear 2277207) 1 (8) | Snap rinartarast washer w | | eh | as bssting + |] G0) | Me gear a7: fea | [any | tirest washer 14 L421 | Msinsnate wi gear 47H taCrankshaft/Piston/Transmission Countershaft Disassembly/Assemly 90) (9) 8) va an \ PG 900 0®Crankstiatt/Piston/Transmission Requisite Service + Crankease separation (page1?-2) Procedure *Eomarks Disassombiy Order (1)] | Thmust washer (2) Ct gear 417) (3)| Needle bearing (a)|Theust washer {8)] C5 gear (337) (6)| snap singithrust washer (7) C8 gear (367) (a) | Spine bushing (a}| Lock washer (101| Spline washer (in| C4 gear 357 112)| Spline bushing (18)| Thrust wesker/snap ring (14)| C8 gear (257) 48) Snap ringithrust washer 16)! “C2 gear (287) 1171] €2 gear Bushingithrust washer (18)| Countershaft A “Assembly is in the reverse order of disassembly. | nore : + When assombly, insert the tang of the washer into | the lock washer greave securely. 11-7Crankshaft/Piston/Transmission Piston Disassembly/Assembly FRONT SIDE: mask | TOP RING SECOND RING ; 11-8Crankshaft/Piston/Transmission CAUTION, 7 Take eave not to damage the pistons. 1 ~ | + Glassity and store the parts for each cylinder. _ 1 number of arty Hsted inthe table indicates the numbers that are shown inthe erawing, {Before assembling the piston pin with the connecting rod, apply molybdenum disulfide oll to the siding surfaces. | 1 Select the appropriate connecting rod andor bearings by using the selection table to make a good match. Also select the connecting rods of the most appropriate weight by using the table (page 11-10), Requisite Service + Crankease separation (page 11-21. Fy Romarks ] Procedure Disassembly Order “Rasembiy ie in the reverse order of disassembly. 1 | (1 | Front connecting rod bearing a | Note + Note the color codes of the connecting rod bearing | fend the connecting rod cap and store, | (2) | Reer connecting rod beating a | wore + Note the eoler codes of the connecting rod bearing {and the connaating rod eap and store, (2) | Piston pin ctip 4 | NOTE . + Do not lose. (a) | pedomn pin 1 | (3) | Front piston assembly NOTE {51 | eae piston assembly + Do nat remove the piston ring except on replacement. ‘Assembly Order = (8) | Roar piston assembly 1 | nom = Check the eonneeting rod LD. mark. Insta! with the IN mark toward the carturetor and the cornecting rod | cil jot port toward the other side. 15) | Front piston assembiy a | Nove | | + Check the conneering roe LD. mark. install with the IN mark and the connecting rod oil jet port towerd the corburetor (a) | Picton pin (3) | Piston pin clip a (@) } Rear connecting rod bearing 1 | ore - = Install with the off passage hole aligned with the con | necting rod hele. 1) | Front connecting rod bearing i | wore + Connecting rod bearing selection: see page 17-10.Crankshaft/Piston/Transmission Bearing Selection Main Bearing Record the erankease LD. code. Nore : {Aor B atamped on the No.4 journal ofthe upper eran taseis the .D. code ofthe jounal, The code letters, fom loft to right, Indicate each journst LD. respectivaly. Refer to the drawing to the Fight ecard the crankshatt main journal 0.0. code for measure the main journai 0.D.). NOTE [> Vor stampee on the crank weight is the main journal | 0.0. code. (Refer to the drawing to theight.) | Determine the bearing I.D. code by referring to the case 1.0, ‘code and the main journal code. ‘Male journo! 0.3. gage t 2 [23 886—30.0ozmm|30.002—30.01Ore| o-1800~s 1012 |1,4012-1. 1615 a | [1) CRANKSHAFT | rm rol Ms Lt te | Bg! | 3.000 —73 608 © eto! }33.008--39.01 re Fri2segm2ggen|| —&¢Sreent oe | 8 4 (Brown): 1.498—1.502 mm (0.0590-0.0591 in} E (Groen): 1.494 —1.498 mm (0.0528 0.0590 in) C {Yeow}: 1.490—1.404 mm (0.0587—0.0588 in} Thickness of the boaring metel car be identitied by the color code. Connecting Rod Bearing Record the connecting rod |.D. code number, It} COLOR CODE NOTE _ 1 or 2 stamped on the connesting rod is the conneating LD. code number. (Reler to the drawing to the right.) i += ~~ coNNecTING ROD (2) 10, CODE 11-10iF ecaed the crank pin O.D. code number (or measure the erank poh - nove “Ror Batamped on the rank waight « tha erank pin 0.0, ood. | refer t0 the drawing to the rahi.) sgeloct the appropriate bearing metal by refering to the crank ‘ang the connacting r06|.D. code number. gin0.0. code letter ote “There are two types of the connecting rod bearings: ene forthe front evinder Imarked with the one LD. paint) and the other fer tne rear cylinder (marked with the two LD. paints). Do not confuse. Ganrciing 8 18. Pe 9209) : few | is c eat e-g[a|z2eez maton | S| tow | gab | oe | SIA iessooce ttt | com | te | en | (dy [8 fae (Sc|o/2090¢—-20002m) 8 | teen, | | tteonn, | Pople | ss | Sc | mes | | (2) FOR REAR CVLINDER 11} FOR FRONT CYLINDER (3) BEARING METALS Selective boating metal: 2 (Brown) (Brown, Brownk: 1.494- 1.898 mm (0.0588 -0.0590 In) 8 iGreen) (Green, Green): 1.480- 1.484 mm (0.0587 6.0588 in) Welow) (Yellow, Yellow): 1.488. 1.480 mm (0.0585 -0.0587 in) Connecting Rod Weight Selection The connecting rods are stamped with the mark A, B, or © which indicates the weight of the rad. When replacing the conniecting r0d, reter to the selection ts — ble and select the connecting 706 of the appropriate weight [ Wieight code of | Weight code of | Weight code of |] os the connecting | the fermaining con- | the now connect rod whieh iste | geting roc on the | Ing foe bbe replaced | same erark pin e oF iz ABoc c Aor a Bore fs 8 = A Bore Aas a oe a & 5 AB oe (2) WEIGHT CODE, 11-11Crankshaft/Piston/Transmission Crankcase Assembly GENS + Apaly tothe outer mating suraces = a2 w2,10 Te) 1200.2.) CONNECTING ROD BEARING > MAIN BEARING LOWER CRANKCASE ‘SIDE BOLTS Ay _@ b aa . 5 dy qeee®j) BB at UPPER CRANKCASE SIDE BOLTS 11-12: E Crankshaft/Piston/Transmission CAUTION, 7 Select and replace the main bearing by using the selection table to make it a good match with the crankshaft main fournal (page 11-10). Select and replace the connecting rod bearing by (oage 11-10). + Clean the crankcase mating surfaces and apply the sealant to the outer mating surface of the erankease halves with ccare not to get the sealant on and around the main bearing. Assemble the crankcase halves. + Assomble the crankease halves with the upper case toward down. If the upper and lower onses are not assembled properly, chock the transmission assembly for proper instalation. 1g the selection table to make ita good match with the crankshaft Requisite Service Atternator installation (page 15-8]. + Starter motor installation (page 17-7) {it pump installation jnage 4, + Gearshift linkeae installstion (page 10-6) + Primary drive geer installetion (page 1 + Starter clutch installation (page 17-4). + Cluten installation Spage 8-6) = + Gwlinder head installation (pegs 8-4). + Water pump installation (page 6-5). + Engine installation {page 7-4), + Oil fitter installation, + Engine ot fling. + Coolens filing Procedure: ow Rem | Assembly Order | Lower Case Side | (1) | Connecting recipision Install fram the eylindes head side. | (2) | Center main bearing (3) | Side main bearing [4 | Cranksnafe 1 | No ||» Take care not to damage the journa (5) | Bearing cap 4 (6) | Cap rot 8 (2) | Beasing stopper cing 1 (8) | Bearing cap ston pin (9) | Thrust washer et (10) | Countershatt besing i 11) | Countershate ot seat 1 | 182) | Mainehatt bearing a | (13) | Needle beeting oa ee i 2 nce Sy vore et 129 | Metts eins : (17) | Lower erenkcase 1 | Nore + Apply aaslant to the mating surfaces wlth care nor 40 ‘set # on and around the main bearing, (98) | 6 mm bok ray, (19) | @ mm belt to-]| + Tighten the bolt in 2 crisscross pattern 2 or 3 steps. | + Tighten at the lower side fist, then reise the engine | to tiahten a: the upper side Upper Case Side (20) | 6mm bolt S—pNoTe 21) | 8 mm bok 3] + Tiomen the vot in e crisseross pattem 2 oF 9 steps. 22) | 10 mm bot is 11-13Service Information 124 Troubleshooting 424 Left Handlebar Disassembly/Assembly 12-2 Right Handlebar Disassembly/Assembly 12-4 Front Wheel Disassombly/Assembly 12-8 Service Information | _ 12. Front Wheel/Suspension/Steering Fork Removalfinstallation Fork Disassembly Fork Assembly Steering Stem Removal Front Whee! Removal/instaltation 12-6 Steering Stem Installation 12-40 1242 12.43 1244 12.6 Refer f0 the section 74 for brake system information. Troubleshooting Hard Stapring + Steering head bearing adjustment nut too tight + Fauly ateoring head bearings + Damaged steering stem races : + Inguffleient tre proseure + Foutty te Steers to One Side oF Does Not Track Stratght ~ Bent fork Bent front axle: whee! installed incorrectly Faulty stesring head bearings Bent frame Worn whee! bearing Worn swingarm pivot Front Whee! Wobbling + Bent rim + Worn front whee! bearings Sect + Faulty tie + Unbalanced tee and wheel |_ Riding on damaged rime impairs cafe operation of the vehicle. When cervicing the front wheel, support the motareycle secure! ‘When instelling the front wheel, note the. normal rotating érestion. Tubelege tice temoval, repair, and remounting procedures are covered In the Section 16 of the Common Service Manual, When remounting the tire, note the nosmal rotating direction. + Refer to the section 18 for fight, meter and switch information, Wheel Turns Hore + Faulty whee! besring + Brake drag ipage 14-1) + Bent fron axle Soft Suspension + Weak fork spring Inaufficient fivid in fork Low flu fevel In fork + Low tire pressure Hard Suspension + incorrect fuid + Gent Fork tubes + Cloggee fork fluid passege + High tre pressure Front Suspension Noisy + Insufficient fluid In fork + Loose fork fasteners with 2 jack or other support under the engine. 12-1Front Wheel/Suspension/Steering Left Handlebar Disassembly/Assembly 12-2Front Wheel/Suspension/Steering Procedure emanks iseembly Order 7 (1) | Clutch switch wire 2 | Disconnect from the switch terminals. {2} | Ctutch fever noider bolt 2 (@) | Clutch lever holderybrackes uw" () | Attaching screw 2 (6) | Lefe hangiebar switch 1 (6) | Left handiabar weightiattacting screw = | 1/1 7) | Left hadtebar gio | {@) | Handlebar holder pinch boit 2 | Leasen the bolts. {6) | Left handlebar pinch bolt 4 (70) | Left handlebar a | wore + Spread the sit slightly and push the handlsbar out. Handlebar holder removal order Installation i in the reverse order of removal {a}. | Lower fore pinch bolt 1 | Loosen the bok. (bi | Upper fork pinch bolt 7, | Loosen the bolt. Remove the wire bands. {ol | Left handlebar holder a | nor: ~ + Remove the front whee! (page 12-6) and lower the fork ‘Assembly Order T (70) | Left pondlebar 1 (9) | Left handleber pinch bott 1 | (a) | Handtener holder pinch bolt 2. | NOTE {Align the loesting pln on the holder with the groove in | the fork top bridge, and tighten the upper bolt first. (7) | Left handlebar grip 1 (6) | Loft hadiebar weightratracting soreve an | NOTE { | + Apply locking agent to the screw thread. (5) | Loft handiebar switch 1 | NoTE | + Align the locating pin with the hole In the handlebar. [4] | Attaching scrow 2. | wore + Tighten the Font serow first. [1 | Clutch lever hotderforackot an | wore + Install the holder with the “UP” mark facing up. (2) | Cluteh lever holder belt iss Nore Tighten the upper bolt first. 2) | clutch switch wire 2_| Connect to the switch terminals. 12-3Front Wheel/Suspension/Steering Right Handlebar Disassembly/Assembly ° vo Cesu020 8) SQ en20 _ 12a) Front Wheel/Suspension/Steering Cc Procedure ow] Remarks | Disassembly Order 1 = «11 | Front broke swrten wice 2| Disconnect from the switch terminal | {21 | Master evinerhoiger bok 2 {31 | Master eyinder heer i | (2) | Brake master oynder essembiy + | caution Peap the master oyiner uprish (5) | Throite housing serew 2 (ei | Throte gn 1 | Disconnect he trate exble (71 | Engine sop switch +. | Remove the serows. {ai | Rlgne handcbar weightiottaching ecw | 1/9 | {9} | Handisbar botser pen bolt 2) | Loosen the bots. 10} | Aight handlebar pinch bol 1 (ith | Right hanstebar 1 | Note | Spread the sit slightly and puch the hendieber out. | 1 ianaibar nelder removal order instalation is in tho Teverbe order of removal | | tay | tower tore pinen tote 1 | Loosen the bole | 18 | Upper toe gine ae 1 | teen th Eo Remove the brake nase bane, | | GG) | Cok nenstebar holder i | Nore MOjemove the front whee! {pege 12-6) and lower the : fort ! Resembiy Order | cay | Righe nanctesar 1 {70} | Righe hancebsr pinch bok : (8) | Henciepar hoicer pinch bolt 2. | nore ichn the locating pin on the holder with the groove | fn he for top bite, and tighten tha upper bake ist (6) | Thott ofp 1 | Connect the trate eabies. {5} | Throtte Rousing serew 2 | NOTE reign the mating surface withthe punch mark onthe fhondiobar and tightan the front screw fest. 17) | Ensine stop awiteh 1 | nore P figmen the front attaching serew the | 141] brake master evtinder assembly 1 (8) | Mactor evinder nator + | note | re iptal with the “UP mark facing Up. (2) | Master yinder bol 2 | note 2 Rign the end of the holder with the punch mark on the handlebar end tighten the upper bolt first, | (19 | Fron: bee switch wire Gonnect tthe en terminaFront Wheel/Suspension/Steering Front Whee} Removal/Instaltation a © oP 27,20 ei in Vay : a | \ LARALIFront Wheel/Suspension/Steering | A contaminated brake dise or pad reduces stopping power, Discard contaminated pads and clean a contaminated dise ‘with a bigh quay brake degreasing agen: | + Inhaled asbestos fiers have been found to cause respiratory disease and cancer. Never use an ait hose or dry brush [wo ctloan brake assembles. NOTE i + Install the front wheel with the arrow mark (stamped onthe right side} facing 2 the normal rotating direction, Do not depress the brake lever whan the caliper ie removed, or it willbe cifficult ro refit the disc betiveen the breke pads Requisite Service “+ Raige the whool off the ground by placing a jack or other support under the engine. Frosedie Tes Remarks Removal Order 7 ae ee (1) | Caliper mounting bolt 4 (2) | Front caliper assembly 2 | caution = Do not hang the caliper by the brake hose. (3)_| Right axte pinch ote 2 | Loosen the batts @)_ | Axle bolt i (6) | Lefeaxie pinch bolt 2 | Loosen che bots (i | Axleshatt 1 (7) | Front wheel assembly 1 | Disassembly/assembly (page 12-8) (Bi_| Side cottar 2 Installation Order ae (8) | Side coke - 2. | note + Right side collar fs longer than the left side collar. + Apply grease to the cust seal line before instalin, (7) | Front wheel assombly 1 16) | Axe shate 1 | nore + Apply thin coat of grease, 14) | Axle bot 1 (5) | Left axle pinch bolt 2 43) | Right axle pinch belt 2 | Nove + Yighton after tightening the axle bolt 12) | Front catiper assembly 2 | caution = Be caroful not to éamage the pads. 11_| Catiper mounting bot 4Front Wheel/Suspension/Steering Front Wheel Disassembly/Assembly 12-8Front Wheel/Suspension/Steering | aA contaminated brake diac or pad reduoos stopping power, Discard contaminated pads and clean a contminated disc ‘with @ high quallty brake degreasing agent. NOTE “The lef and Aight brake discs should be Installed on the original side unless they are fenlaced. 1 When temounting the tie onto the wheel, face the arrow marks on the wheel and tire to the same directien. Do not ado mare than 60 g (2.1 oz} of the whsel belarice weight. : 1 Always replace wheel bearings a5 9 set Requisite Service Front wheel removalfnstellation [ Procedure ‘emarks Disassembly Order “Assembly isin the reverse order of dissesembly. Int | Dust seat 2 (2) | Broke aise bolt 2 (3) | Brake cise 2 (a) | Right whee! bearing (G004ULI 1 (6) | Distance ootlar 1 + | At installation, drive @ new left bearing Into the hub frst, (6) | \eft wheel bearing {8004LU1 then drive @ new sight besring NOTE + At installation, 4200 the srrow mark to the same direc- ton as the arrow mark on the wheel 7 | Fron 1 12-9Front Wheel/Suspension/Steering Fork Removal/instaltation ‘ToP BRIDGE RSS \ ae yak e ; Lo 2 /é 4 as f iy < sS NS /Front Wheel/Suspension/Steering anor NOTE = 7” When the fork le to be disassembled, set the preload adjuster to the “soltest™ position, loosen the upaer fork pinch bolt and loosen the fork bolt but do not remove ie yet <_After assembling the for, tighten the fork bolt which is tempera tightened before tightening the unpar fork pinch bot 1 Requisite Service eee a + Front wheel removal/nstallation (page 12-6 Frovedire Romance Removal Order (a) | Front fender mounting bolt 4 12) | Front fonder : | {8) | Handlebar older pinch bol 2 Loosen the bos | 12) | Unpes fork pinch bole 5 Goosen the bot | {6} | Lower fork pinch bot 3 (6) | Wire bane 2 | | + On the right fork, remove the brake hose band. ] (7) | Handiebor sssemoty + | Lower the fork par wy end remove from te fork CAUTION 2 Oa the right side, Keep the master cytnderuriht. 1®) | Stopper rng 1 (8)_| Fare assembly 1_| bisassemby (psge 124121 Installation Order (21 | Fork assembly ; te) | Stopper ring + | Support the fork and instal into the groove securely. {7} | Handlebar assembiy + | NOTE | + Install onto the fark and raise the fork through the top bridge, aligning tne locating pln of the hanclabar holder with the tap bridge groove. Lower fork pinch bolt Upp fork pinch bot i | ondlebor older pinch bot Wire bone front ander Front fender mounting botFront Wheel/Suspension/Steering Fork Disassembly ray 8) a7) a | tp t NOTE freee (er <= 13), 8) ee Sa Set te prevond aijuster we tha “soRte™” posiion bears loosening the fork bolt : Requisite Service + Fork removalinstataion ipage 12-10). Procedure Tow omar 7 Disassembly Order | «1) | Stopper rng 1 £2) | Fender bracket 1 £2) | Fork bot 1 Remove from the fork tbe | (a) | Stopper sear + | Nore Drain te fork ol from the fork tube ang piston cod af | fer removing { (8) | Fork bot 1 | Hold the predoed adjuster end cemove the fork bot as shown. (8) | Ong 4 | | Spring cost 1 | te) | Spacer 1 | | (9) | Spring seat 1 1 (10) | Fork soning + (11) | Socket bot waeher 1 (12; | Fork piston assembly 1) | caution £'Do nt remove the adjuster trom the fork piston. 113) | O19 tock piece 1 (14) | Dust sea: 1 {18} | Stopper rine 1 116) | Fone ube 1 17; | Ot sea 1 118) | Backup rng + (19) | Sider bushing 1 (20) | Fork be bushing + | caution | Do not remave the bushing unless i replced | ~ 12-12Front Wheel/Suspension/Steering Fork Assembly 9) 20 12.0, 13}, (re), | Procedura ‘Assembly Ordar (11 | Eork tube bushing (2) | Stier bus 1) | Fork tube 8) | 01 eck piece (5) | Fork piston (6) | Sealing wesher/socker bolt (7) | Backup sing 1B) | Of seat 19) | Stonver sing 79} | Dust seat 131 | Fork spring | 22) | Spring seat (13) | Space: (4) | Spring sear (15) | O-ring (18) | Fork bott (17) | Stopper ceat 118) | Fork bott (79) | Fender bracket (201 | Stopper ring Inetal onto the fork tt Install onto the ene of the fore piston. note ‘Apply locking agent te the bot threads. Use the fork seal diver (07847—KASO100) and attach- ren: (0787 —KF00T00) Nove + Pour fork oil to the specified level before instliing the spring foage 1-11), NOTE Install with the tapered end fscing down, Instat onto the adjuster. Screw inte the fork tubs. but do not tighten vet. caution + Be careful nat to cross-threae.Front Wheel/Suspension/Steering Steering Stem Removal ‘Straighten tho lock wesher tabs.Front Wheel/Suspension/Steering RSSeEe SoHE Sete eee HSER SESE Sete ee Note T Replace the steering bearing and races as a set. + Do not reuse the lock washer. Requisite Service + Front wheel removal (page 12-6) + Fork removal [page 12-10), Procedure Toy Removal Order | (2) | Brake hose clamp Ja (3) | Steering stem nut cep {oa (5) | Top bridge } oa | Sacra (12) | Steering stem 1 | (3 | Seeks (07846 -KM90500) and bese (07946—KM906001. 12-15Front Wheel/Suspension/Steering Steering Stem Installation Bend down the two tabs ino the adjustment nut grooves and bend up two tabs Into the lock nut grooves. = ea} we “Ne no KS 140 (14.0, 101)| Seer | S&S Ee Pf =n Pi\ | Kae? i: Se ; (e | 4 eS S SY 12-16NOTE ‘Check the steering bearing preload efter nsteling Requisite Service + Fork installation toage 12-10) Front Wheel/Suspension/Steering 1 Front wheel intaiton gage 12-6 Proce Tew oo Tastalation Order 11) | Upper bearing outer coe 1 Luce she diver attachment B (07248-—-KM90200), driver {2} | Lower beating outer ace 3 ST] eesembiy sate o70e0~K4290300), bearing remover € {o7946-kM90500) ane bece (07S45~—Kur0600) C3) | Lower dust set 1 {41 | Lower beeing ner rase 4+ | se the stom ativer attachment (07HMD—MR70100) an Inver diver © (OTPAEOD80T00; (5) | Lower beating 1 {61 | Stoonng ster : £2) | poe beerng 1 {2) | Upper booting fone ace ; (2) | Upper duct sea! fai 110) | Steering bearing odlustment nut | 1. | se the steering stom socket (07HMD—MR70%00) 1) | Loci washer | 1 | Bend down the two tbs int the adlesmment nut groowes 1) | Looe nx | 1 | Mana tighten atgn the groover with te lock washer tata ane bend up te abe int the orooven 139) | Top bree 1 {94} | Steering far rut + | Note TTomporaily instal the fron forke and tighten the at 11 | steering stor nut eap 1 138) | Hem + | conect he hor wee 1) | Bre pose oleme 1 | 12-1713. Rear Wheel/Suspension 43-1 Shock Absorber, Service Informati inkage Removal! Siang qa.1_ ‘Installation 138 Rear Wheel, Driven Sprocket Removal’ eee eeeatetatie 132 installation 13-2 7 : Shock Linkage Disassembly/ Bearing Holder Removaliinstaliation 13.4 _ NOC ea | Bearing Holder, Axle Disassembly} os i ay 43.6 Swingarm Removel/instaltation 13.16 Swingarm Disassembly/Assembly 13-18 Service Information + ‘The shock absorber contains nitrogen under high pressure. Do not alow fire or heat near the shock absorber. 1 Bofore disposal of the chock absorber, release the nitrogen (Step: seciton 19 of the Common Service Manual; Dring point: page 1-11). - +_ Riding 8n damaged rime impalrs safe operation of the vehicle. + Tubeless tire removal, par, and remaunting procedures ere covered in the section 16 of the Common Service Menus! When remounting the tte, note the normal rotating direction. + Rafer to the section 14 for brake system information. + Use only genuine Honds replacement bolts and nuts fer all suspension pivot and mounting points Troubleshooting Rear Wheel Webiting Hard Suspension oase wheel nut + Bent damper rod Bent rim + Damaged swingarm pivot bearings Loose bearing holaer Damaged shock absorber bushing Damaged axle bearingle] Faulty swingarm plvat bearings) Loose ahock linkage/ewingarm fastenerts Faulty te Unbalanced tie and whee! e i Incorrect suspension adjustment Faulty shock fnkaga bearings Insufficient lubrication of suspension pivots Damages mount bushing Foor Suspension Noise Soft Suspension + Loose fasteners + Weak spring + Incorrect suspension sdjustment + Faulty damper unit + Oil leakage from damper unit‘Rear Whool/Suspension Rear Wheel, Driven Sprocket Removal/Installation 120 (12.0, 87) ‘Align the pins with the holes. 13-2Rear Wheel/Suspension Requisite Service + aise the roar wheel off the ground and support the maroreyce, Procedure oy Remarks Removal Order aa a1) | Center capicotter pin wn (2) | Wheel rut 1 13) | Shim 1 (2) | Center look spacer 1 (5) | Fear wheel 1 Driven Sprocket Removal Order Installation ie in the reverse order of removal. (a) | Driven sprocket nut 6 NOTE + Loosen the dive chain before removing (oage 3-71) (o} | Driven sprocket installation Order 5) | Rear wheet 1 | note + Align the holes with the drive pine of the oxle 14) | Center lock spacer 1 @) | Shim 1 2) | Whee! nut 1 ! ()_| Coxter pinveantar cap 13-3Rear Wheel/Suspension Bearing Holder Removal/Installation C870Rear Wheel/Suspension with a high quality brake degreasing agent. 10 clean brake assemblies. Nore * A contaminated brake dise or pad reduces stopping power. Dizeard contaminated pads end clean a contaminated dise Inhaled asbestos fibers have been found to cause respicatory disease and cancer. Never use an air hose or dry brush Do nat depress the brake pedal when t aliper is vernoved, or i'willbe dificult to refit the dsc between the brake pads, + Support the removed caliper with #piece of wire.so that it does not hang by the brake hose. De not twist the brake hose Requisite Service + Roat whee! romovaliinsteliation (page 13-2) + Loosen the drive chain (page 3-11), (a) | Thrust washer 13) | Spring washer (2) | Lock nut (1) | Ase bolt Procedure ~_ [ew Renae Remaval Order on | Aste bot 1 | nore "Tap out the bolt tothe lft se with & plastic hammer ume if to be tenlaces 12) | Lock nus 1 | Loosen after unstated £3) | String waener 1 14) | Thrst washer 1 18) | Brake caper mounting bolt 2 (61 | Broke coter 1 | caurion + Do not hang by the brake hose. (2) | Axtofrate dsc assemby 1 | Pui out to ae righ sce we eng tho ceiver Range Disassembly (page 18-6 «21 | beivestonge 1 | Remove tom the eve chan {91 | Srap rng 1 | 0) | Cater backer : (111 | Bearing olde pinch bok 1 | Futy oosen 112) | Bearing holder 1 | Putout of she swingarm r Disassembly (page 19-0) Instat Order | 112) | Bearing noise 1 | 111) | Bearing noid inch bot 1 | Loosely instal 110) | Caliper bracket 1 | (3) | Snap rng 1 (7) | Asarrako dae assembly 1 | Install from the sight side white hong the divan Henge 18) | Deven tange 1 | Instat the aeive cain, then instal aligning the epnes | 16) | Brateealper 1 | CAUTION i + "Be coreul not to damoge the brake pad 15) | Brake caliper mouncing bot =| | Note | + Install with the dished side facing in Use a new nut and stake it atte tightening Install # new bolt from the left side while aligning the splines wnen itis replaced, NOTE + Aaghust the drive chain slack after inetaling the rear wheel (page 3-11). 13-5Rear Wheol/Suspension Bearing Holder, Axle Disassembly/Assembly XH Doses.en 1501.8, 11) a ei 4 art i ee ‘Wheel side ——— i ic} = a am allele Teh ded ; WK AO) 00 | am NOTE + Replace the axle bearings as 0 set Requisite Service + Bearing holder removal/intallation (page 13-4) Procedure — —| oy Remarks {| Bearing Holder Disassembly Order ‘Assembiy is in the reverse order of disassembly. ay | Colter 1 | (2) | Outer dust seal 2 | (3) | Bearing set ving | 2 (4) | Lett bearing (6908LU) eee Lee ()_| Right needle bearing | 1 | Repiecement ipage 13-7) (8) | Inner dust seat : {0 | ‘Axle Disassembly Order ‘Assembly isin the reverse order of disassembly. (2) | Brake disc botwnut ang (0) | Brake dise 1 | Note | + At easembly, install with the “MIN, TH. 8 mm" mark tacing toward the whee! {0} | Drive pinypia bolt 4ia | NOTE | + Carefully remove as the thiead locking agent is used,Rear Wheel/Suspension Axle Needle Bearing Replacement Press the needle beating out of the bearing holder. Driver 077490010000 Attachment, 42.47 mm 077460010300, Pilot, 40 min 077480040900 Grease the new needle bearing and press it into the bearing holder until it bottoms. 1077490010000 (07746-01050 Drv Attachment, 62 x 68 mm (1) ORIVER i (2) ATTACHMENT (1) DaIVER ‘ | (2) ATTACHMENT. i i | | 13-7| Rear WheelSuspension Shock Absorber, Linkage Removal/installation 13-8Cc Procedure oy co 1 Removal Oraer Tiwtolation isin thor reverse order of Tewoval aay | Holger band 2 | Loon the band screws (2) | Shock sbeorbor roserveir 1 | Remove from the Bracket. |G) | Shock absorber upper mounting bolt + | Removal (o2ge 121 | (4) | Schock link-to-trame bolt 1 15) | shock abcorber lower mounting bolt + | 16) | Shock arm-toswingarm bot : | 17) | Shock inkago assem 1 | Remove trough the space between the exheust pipes Dieassembly(eage 13-14) (0) | Shock absorber sesembiy + | Bisassembty Ipage 13-12) 121 | Upper mounting cole i Rear Wheel/Suspension 5 ‘Do not service the shock absorber and linkage wile the exhaust sysstem is hot. aequisite Service + Seat cowling removaliinstalition tpage 2-2) 13-9Rear Wheel/Suspension Rear Suspension Bolt Removal Raise the reer wheel off the ground and support the motorcycie securely. Remove the seat cowing. Romove the shock link-to frame bok. se Note +" Lesan the aut fret then remove the bok for easy] | moval a Remove the shock absorber upper mounting bolt while ' 1) UPPER MOUNTING BOLT ; ‘supporting the rear wheel by hend. | 1ck absorber lower mounting nut. | Gy sHock AgsoRaeR | further by hand and remove the shock abeorbar [= Be careful not to damage the exhaust pipe walle] | L_sewicing. 4 It I I Sy DY dori! Brower mduvrne Sout _\ | Remove the screw and the lower portion of the drive chain [ ~~ ay SHOCK ae TO-SWINGARM BOLT slider from the swing Remove the shock ar 13-104 Rear Wheel/Suspension Rear Suspension Bolt Installation - Insta! the shock absorber with the drain tube forward and. temporarily install the upper mounting bel. Install the shock tinkage assembly, and install and tighten the chock arm-to-swingazm Salt Torque: 45 Nm (4.5 ke-m, 33 fetb) Install the drive cheln slider and screw. Torque: 4.Nim (0.4 kgm, 2.9 fet} ‘While holding the shock absorber, romove the upper mounting bolt. Raice the rear wheel and install the check absorber lower mounting Dott Torque: a5 tm (4.5 kgm, $3 fb) Install the shock link-to-rem bolt. Torque! 48 thm (4.5 kgm, 39 felb) While supporting the rear wheel, install the shock sbeorber Upper mounting bolt and tighter It Torque: 45 Nem (4.5 kg:m, 33 fetb) (1) UPPER MOUNTING BOLT (3) DRIVE CHAIN SLIDER oo | | Pe | oy A \ & | - Pa i Lowen MOUNTING SLT, TaTSHOEK LINK-TO FRAME) (2) UPPER MOUNTINGRear Wheel/Suspension Shock Absorber Disassembly/Assembly = ae he shock absorber contains nitrogen under high pressure, Do noi allow fire or heat near tha chock absorber |__ point: page 4-11, NOTE = | 7 Before disposal of the shock absorber, release the nitrogen (Step: eection 19 of the Common Service Manual; Diling Requisite Service + Shock absorver, linkage removalfineteiation (13-6) * Loosen the spring pre-load adjuste: lock nut and adjuster nut fully for easy disassembly, When the edjuster nat slow” senad, adjust the spring installed length ane tighten she log = - Procedure ew Remarks Disassembly Order (| Drain tube 1 (2) | Stopper ring 1 (3) | Lower spring coat Poa 1 i (4) | Spring | (5)_| Damper unit [Assembly is in the reveras order of clesssemibly. | Removalfinetallation (page 13-13)Rear Wheel/Suspension stopper Ring Removal/installation Install the chock absorber compressor and attachment on the ghoek absorber as show. ‘Shock absorber compressor. O7GME~-0010000, ‘Attachmant (079891310000 ‘Tum the camprassor handle anc slowly comprese the spring ‘until the stopper ring can be removed. Remove the stopper zing Install the stopper ring in the reverse order of removal THT SHOCK ABSORGER COMPRESSOR Shock Absorber Disposal Procedure eel Center punch the center of the pressure tank cap to merk the diiling point. ‘Wrap the prescure tank inside @ plastic bes. ‘Suppor the presaure tank in 2 vige es shown, ‘Through the open end of the bog, insert a drill motor with 8 sharp 2—3 mmm (5/64—1/8 in} dil bit "Do not use @ dull Gil bit which could cause a build-up cof excessive heat and pressure inside the damper, eat ing to explosion and severe personal Injury. +The shook absorber contains nitrogen gas and oli under | high pressure. Do net del the damper caso pressure tank body, or you may dill into the ell chamber; oll escaping under high pressure may cause serious personal injury protection to avoid getting metal shav- yes when the gas pressure is released. The Hold tne bag around the dl motor and briofly run the eri mo: tor Inside the bag; this will inflate the beg with sir from the_ motor and hip keep the bag from getting caugtn in the bit when yeu start Remove the joint hase from the damper (1) PLASTIC BAG a WP (2) PRESSURE TANK CAP 73-13Rear Wheel/Suspension Shock Linkage Disassembly/Assembly Requisite Service + Shock absorber, linkage removalfinstliation (13-8) |Sexmen tfeeaen oes le + At assembly, note the installation direction af the | shock arm, shock lnk and bor (4) | Dust sea! 6 (6) | Shock tink needle beating J 2 (6}_| Shock arm needie bearing 3 Shock Linkage Bearing Replacoment Pity DRIVER * y Aeee are ee ee =a Pe atew cenkty —_O7CMD-rat100 wore ee i a | + Donnot remove the shock absorber ower moun bushigg, 13-14Rear Wheel/Suspension Aemove the needie bearings from the shock link with the fc T(ULNEEDLE BEARING (2) SUDING WEIGHT Foenng toate, ' \ es - etiee \ = i | \ Bootng ramove 07936-3710300 | Fomover ange 79383710100 zy Sina welsh Gr7a1oot0201 ch ! Y ( AAG (A) BEARING REMOVER 18) REMOVER HANDLE | sectalation : ‘Aeply molybdenum cisulfide grease to @ new needle bearing . 7d press the bearing inte the sheet: link unti it Battoms, = 7 See Driver 077490010900 Attachment, 24x 28mm 07746--0010700 Pot, 17 mks 07748—0040200 es (9) ATTACHMENT: Shek tink pivot iy DAIVER Fi Aaviy molybdenum disuse grease to # new needle bearing Sha prose the Soaring into he shoek err Unt he etachment bonome = Driver 07749—-9010000 — Attachment, 24x 26mm 07746-01070 Pilot, 17 earn (0746-0040400 i 7 =e (3) PLOT swingarr pv Taye Siete rng ooo os eee | Bleoue ~ 7 | Bears) Driver 07749—0010000 M2) ATTACHMENT! - i Reathment, 26.26 mm 977480010700 Pion oyras_aosose0Rear Wheel/Suspension Swingarm Removal/Installation ‘6 80 (8.0, 88) ess 13-16Réar Wheel/Suspension CAUTION, (5 Suppor the removed caliper with a pisce of wire 90 that ft Goes not hang from the brake hose. De not twist the brake hose. NO’ 7 Bo nat depress the padel when the caliper is removed, of F willbe difficult to refit the diac between the brake pads. Requisite Service + lear whee, driven sprocket removalinstallation (page 13-2! 1 Shock absorber, linkege removaliinstaliation {page 18-8) {i Procedure “Tee T Ramarke bel Femoval Order | ia) | Bearing holder inch botehess clame | 1/3 12 | Deve show cover bout in {31 | Brive ebsin cover +! | Remove tne brake hose from the clam. (4) | Rear brake caliper | (5) | Pivot nut a] (6) | Aajunt bot look nut 1 | on | acjost aor [1 | boosen by suming the svat bolt counterclockwise with | [1 een wens (8) | Pot box 1 {9} | Swingormiétive chin | HE | Seserivanensy nae 18-18 | 10) | Lote pivot citar 2 installation Oréer {8} | Swingarm chein |) | Asiust note {8} | Pret nut i | (6) | Aust aot lock owe (@) | Rawr brake caiber | (2) | Drive ehain cover borin an | 1)| Bearing noider pincn oleae clamp | w/t | NOTE | + After installing, adjust the ¢rive chain slack {nage l l 317.+ Rear Wheel/Suspension Pivot Bolt Installation oe Screw the adjust bolt in the left pivot by hand. ‘Apply thin coat of greaze to the pivet bolt end ingert the bott fi the pivot ‘Align the hex. head of the pivot bolt with the hex hole in the ‘adjust bolt and push the pivot bott in fuy. TightéA the adjust bolt by turning the pivet bolt with the hex. Torque: 15 Nm (1.5 kgm, 11 fel Loosely install zhe pivot nut. Install the eds nots lock nus and tighten it while holding the pivat belt to prevent the adlust bolt from turning Torque: 80 Nim (8.0 kg-m, 38 fo) - ar 7 ~ Pivot adjust wrench 07908~a690001 Tighten the pivot aut. Torque: 95 Nem (8.5 kgem, 69 feb See aa (2) PIVOT Boxy (2) PIVOT BOLT, ADJUST BOLT (1) PivoT ADJUST WRENCH 13-18Swingarm Disassembly/Assembly Rear Wheel/Suspension Requisite Service _wp + Swingarm Removallinstallation (nage 12-16) [ Procedure ow | Remarks, Disassembly Order (1) | Deive enain slider (2) | Catiper brackestoott @) | Torque linkibote (4) | Right dust seal {) | Snap ring (6) | Right pivot bali bearing (7) | Lett aust seat Left pivo: noedie bearing Replacement (page 13-20) Replacement {page 13-20) ‘Rasembly iy in the Feverse order of Gisassernaly 13-19’ Rear Wheel/Suspension Pivot Bearing Replacement Romoval Remove the snap ring Remove the ball bearing from the right swingarm pivot. am Bearing remover set 07936—3770007, Drive the needle bearing out of the loft swingarm pivet. Nacdle bearing remover Driver shatt Inctaiation Analy molybdenum disulfide grease to « new needle bearing Carefully press tne nescle bearing into the loft swingarm pivot 4 mm [0.16 in] from the edge of the swingarm, measuring witi the vornier caliper. a Driver Atcachment, 87 x 40 mm Pilot. 28 mm o7tMc—n1870700 07946—MJ00100 07749-0010000 (07746--0010200 (07746—0041100 Drive ball beatings into the right swingarm pivot one by one ‘with the marked side facing out untl they bortorn. ay Driver Attachment, 37 x 40 mm Pies, 20 mm Ingtall the ena ring 97743-00100 07746-0010200 077460040500 ~ Td SHAFT (2) NEEDLE BEARING REMOVER, (1) ATTACAMENT 4g (2) DRIVER ty arracumens PSService Information 14. Brake System Service Information 14-1 Front Brake Caliper Disassenbiy! Troubleshooting 141 Assembly aa lena aac saz Rae Master Cynder Diseemi/ Rear Brake Pad Replacement 443 - pear Brake Caliper Disassembly! Front Master Cylinder Disassembly/ Assembly 14-10 Assembly 14-4 Rear Brake Pedal Removaliinstallation 14-12 | yA contaminated brake disc or pad reduces stopping power. Discard contaminated pads and cleen @ contaminated dise with a high quaity brake degreasing agent, + Inhaled asbestos fibers have been faund to cause respirarory disease and cancer. Never use gn air hose or dry brush to clean brake assemblies, = Spilled brake tluid will severely damage instrument lenses.end painted surfaces. It is alzo harmful to some rubber parts. Be very careful whenever you remave the reservolccap: make sure the front reservoir is horizontal frst. Never alow contaminants (dirt, water, etc.) to gat into en oper reservoir. ‘Once the hydraulic system has bsen opened, of #f the brakes fee! spongy, the system must be ble. ‘Always use tresh DOT 4 brake fd from «Seale contater when servicing the system. Do not mix ciferent types ff Tuid as they may not be compatible. ‘Always check brake operation belore riding the mororeycl. Troubleshooting Brake Lever/Pedal Soft or Sponay Brake LoveciPedol Hare +i bubbles in the hydraulic system + Cloggeditesticted brake system + Leaking tnvsraulc system Stiskingiwor ealper piston + Contaminated brake pes + Caliper not sling properly + Worn caliper piston seal + Cloggedtreswieted tule passage + Worn master sylinger platen cups + Worn caliper piston sea) + Wom brake pedisise + Stiokinghwom master evinaer piston + Contamigated ealiner + Bent brake leveripedal + Calizer not siding propedy + Low brake fais lavel Brake Drag + Clcgsed fuid pessage Contaminated brake padiies + Warpedisetormed brake oi Iaisalignec wee! = Stiskingiworn ealiner piston = = S Badly worn broke padiaiss : + Warpediestormes brake Gise + Contaminated master cyinger + Caliper not sing propeny Gloggediestricter fiuié passage Stiekingiwor caine: piston Bent brake leveripeds! 14-1 fiBrake System Front Brake Pad Replacement Fen = * A contaminated brake disc or pad reduces swapping power. Discard contaminated pad and clan @ contamicated tise with a high quality brake degreasing agent. | 7 Inhaled asbestos fibers have been found 10 cause respiratory disease and cancer. Naver use an air hose or dry | brush to clean brake assemblies. + Aor roplacoment, operate the brake lever to seat the caper pistone agains the pads NOTE + The’brake pads can be replaced without disconnecting the hyeraulic syetom- + Roplace tho brake pedis as a set 7 : +_Apply a thin coat of grease onto 2he pad pin and pat plug thyeads so as notte rust te Prosecure Femenks Removal Order [instanton fe the reverse order of removal (1) | Dust cover (23 | Pad pin plug {3} | Pad pin (8) | Pas sorng 1 | Nove + At installation, align the tabs with the caliper grooves at | | shown. (5) | Psa 2 | note | i + Push the sistonallhe wey into provide clearance for new | ! | pags po ‘JBrake System rear Brake Pad Replacement seer ronaminaied brake dice oF bad Tedusce HOphING power DiscarE contarinaie bads Gh clean # consamicatec Gise with a high quality broke degreasing age. + Tenatey cebestoe bese have buen found te cause respiratory disease and cancer, Never wee en sir hose or dry brush to clean brake essemblies. + Aier replacement. eperate the brake lover to seat the caliper pistons apainst the pads = . = == Nore eee [> The bre pads tan be repacea witar dacomseteng We mrad BATON 1 replace the brake pads 6 & 3et i |_| Aoply a thin coat oF grease cota the pad pin and psd plug tntoads so es pos to 7st = Se [ Preceaure Tent ] Removal Order 41) | Pad pin plug | i Loosen the pad pin after removing the plug. ea fal Pad pin | 7 | Locesty instal! while auching me pads in slightly (11 | Pad pin plug, | _1._[ Tighten the pad pin before instaling the plus.Brake System Front Master Cylinder Disassembly/Assembly 3513.5, 25) 14-4Brake System "Check the brake system by applying the brake after the air bleeding, i AUTION, se Avoid eplling fuid on painted, plastic, & rubber parts, Place @ rag over these pars whenever the eyetem ] serviced. a 1 |. hen remoing the oil bok, cover the end of the brake hose to prevent contamination. Do not alow the foreign P| meteral to enter the system. | ||, Batt alo he tos fh cups etm ine and be crn he epg fem seated nthe groove NOTE _ |_| [Use only BOT # brake tid om 2 sted Cortina : i ] Requisite Service + Front orake fluid érsiningiak bleeding - Procedure = _ 7 Remarks | Disszeembly Order ‘Assembly fs in the reverse order of disassembly. || ()] Brake of botc 1 | | 2)] Brake hose : 2 | nove | { : + De net twist the hoses. | 1 | (| Seating washer 3 {| 141] Master eviinder assert + | Disconnect the brake ewitch wires and remove the holder. | | ti] Reservoir hose | | (6)] Reservoir assemoty 1 | 0] Broke switeh | (6)| Brake lever pivot bolt 1 | 18)| Brake lever assersiy i (10)| Rubber cam fa (11)| Snap ring 1 (32)] Reservoir nese joint 1 } 1 [118] Oning i {|112}] Fiston boot 1 [fai] snap ring 1 | Use the snap sing piers (07914.-329000%). | caution : ‘At installation, be certain the snap ring is firmly seates i in the groove in the master cylinder body. 1 }16)] saster piston assembly 1 | note c i | + De nor remave the piston cups from the piston (171 Spring > | Note f | at instalaion, inst with he mall ea end feing roweré | ples the primary cur. 14-5 — =Front Brake Caliper Disassembly/Assembly - ee D : 0-Fing, sesl and seating washerBrake System fen ‘Dsicard contaminated pads and clean a Sontamicated disc with @ high quality brake degreasing agent. ~ __| Skea sytem by sppvne te ba rth o Deed. |— CAUTION ee |__[-_ Spilled brake fad wi semege panied. laste, or rubber pars NOTE + De not remove the Bleed vaive unless Rie replaced, * Requis Service + Front brake fluid drining/air biseding e Procedure: Tow Ty Femerce Disassembly Order T “Ascembly Is in the reverse order of disassembly. {1)] Brake of Botvhose in | NOTE + Do not twist the hose, + At installation, install the hose with the joint pipe facing toward the fork (21| Seating washer 2 Gi] Pad” 2 | Removailinstaliation ipage 74-2) {4)| Calizer mounting bolt | 2 | NoTE | + Loosen the torx Bolte before removing the mounting | batts. {51| Brake caliper assembly Joa 18)/ Torx bolt 4 | wore = + At instellation, tighten efter installing the caliper ‘mounting Bots CAUTION al Caliper pieton targe diameter! (@)| Cativer piston (eral dismere + Mark the piatan to ensure that they are reinstalled in| | | their orginal postions. t {2)| Dust see) 4 | caution (20) Fistor. seal 4_| + Be careful not to damage the caliper eylindersBrake System Rear Master Cylinder Disassembly/Assembly 51 Bien aeBrake System |. ‘Cheok the brake system by applying the brake aftor the air bleeding. i CAUTION | Pa en ORE TORE OTANI TE Ras a TR NTE] tone. 1 lot ng ue of bok ever the endo he brake hase 9 prevent cntaminion, De net alow the fosgn ‘material to enter the system. | 5 [BERTUSIIS EL 2c neo cera i sot te | ore * : [Use only BOT 4 brave tld Wom « soled conan ; ] | Requisite Service | + on broke Hid daring Boesng Procedure Ter | Remarks 1 Disassembly Order ign caer ‘ «| pte of beunose ha {2)| Sealing washer eee 1] Reset hose rvcrow i | | ta] Ona ‘ 13] Rie eyncer mounting bt 2 | Loosen he bt (6h Gomera ; | Soint pin 1] {2 Most ovideresemy 1 (remove rm ha oh te rae fo) peaaoee 1 | RRS G7 te fos me (10) Roser boot i (3) Baer vee 1 | sete ane ing stars 07814228000) trai poo oo Ha 13] Faar stn esentiy Jo from aa "Bi | [+ De net remove the piston cups from the piston. | TE [eva song aise TAseeniy cer Seen - | «1a| Sore 1 : (13) Master piston assembly 1 : (33) Pooh ' {03} Seay sn 1 tJ eaunon | SAT in snap ng fy eae nt ove 4 ee ntutcrtnir boty. 109] Raabe boot ay | Post 1 | nore (| Mast: eyinde scat, | (a gener 1 | iam te mara etngee mounting ot tt Ineaing (3 | One Iai 1 Bet nose vse Jah | | (2) Sealing washer 2 { ct) Seake of bothose Lain Le fet the jot agains the mater ene boss. eeBrake System Rear Brake Caliper Disassembly/Assembly ®D « oving, seat and seating washer ” © \ Qaes aBrake System — ‘Dsicord contaminated pads and clean @ contamicated dise with a high quality Brake degreasing event + Check she brake system by applying the brake after the air bleeding. CAUTION [+ Spilled brake fivid wil damage painted, plastic, or rubber parts. NOTE 7 _Do rot remove the bleed valve urless J replaced | Requisite Service - + Rea: brake thie draining bleeding He Procedure | arty | “Remarks | Dizsssombiy Order T Tasenbiy sn ihe terse order of Guassembiy- (1)] Broke of wmose in | caurion 2 Do not twist the hose. Note + Remove the hose by loosening the joint nut wile ' hiding the hose eur. 121] Sealiig washer 1 {8)| Caliper mounting Bott 2 | NoTE + Loosen the pad pin before removing. (@)| Pad {2 | Removalfinstaliation page 14-31 | (| Caller sssembly 1 | Separate the bracket from the caliper. 18) Poe retainer 1 | note | | + At instelition, note the installation direction. | (7), Pad rerainer hoa | {81| Pivot boot 1 {9)] Pivot pin bolt 1 | Nore (701 Pivot pin boti 1 | + De not remove the plvor pin bot: unless i is replaced. (311 Caliper piston 2 | cauTion | + Mark the piston to ensure that they are reinstalled in | their original positions. | I (12)| Dust seat 2 | caurion | | (3 Piston seal 2 _|+ Be careful not to damage the caliper oylinders. o 14-11Brake System Rear Brake Pedal Removal/Installation i yy co ieee \\ LeT.2 es \ nore Stee [The pedet height can be adlusted by turang the pe cagulindey push ro pt Procedure Remarks. - Homoval Order Teee- oa ectadeon ass Fovemne Se SEL 14-1215. Charging System/Alternator Service Information 15-1 Charging System inspection 155 ‘system Location 15-2 _ Regulator/Rectifier Inspection 15-6 Troubleshooting 15-3 Alternator Inspection 187 || Battery Removal/instellation 15-4 Alternator Removall/installation 158 Hl Service Information oo battery gives off exalosive gases; keep sparks, flames, and cigarettes away. Provide adequate ventilation when charging or ueing the battery in an enclosed space. + The battery contains sulfuric acid (electrolyte). Contact With skin or eyes may cause severe burns. Wear protective clothing and a face shicld. If electrolyte gets on your skin, lush with water | = iteloctretyte gets in your eves, lush with water for at loast 15 minutes and call a physician immediately. lacrroyte iz poisonous. f swallowed, drink large quantias of water ar miicand follow with mik of magnesie or vegetable | cil and call a physician iis JUT OF REACH. OF CHILDREN. | + Aiwaye tum off the ignition switen before disearnecting any electtcal component. CAUTION |. [Serres componens maybe dampers or connecor are comes of bonmared whe te ton switch is ON and current is present. | + For extended storage, remove the battery, cive ita ful charge, and store i in s cool, dry place. + For batery remaining in # stored moxorovete, disconnect the negative barry cable from the battery tecrinel Nove” sonance (ree bariery rust be replaced when ie feaches the end of ts service Me. ] ‘CAUTION The battery cape should nat be removed. Attempting to remove the sealing caps from the eels may damage the battery. + Battery can be damages if overcharged or underchorged, oF If lott to discharge far ieng periods. These came conditions contribute to shortening the “fe span’” of the battery. Even under normal use, the performance of battery deteriorates after 23 years, + Batzary voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventusly die out. For this reazon, the charging eystem is offen suspected to be the problem. Battery avercharge often results irom problems in the battery Itself, which may appear 20 be an avercharge symptom. If ane of the battery cells s shorted and | battery voltage does not increase, the regulator/recttir cupplies exons voltage to the bettery. Under these conditions, | the elaciroiyze level goes aown cui + Before troubleshooting the chatging system, chesk for proper use and maintenance of the battery. Check i the battery |s frequently under heavy load, such as having the headiight anc talight ON for fong periods of time without riding the +The battery wil self-discharge when the motorcycle isnot in use. For this reason, charge the battery every two weeks 1 prevent sulfstion trom forming + Filing a new battery with electrolyte will produce some voltage. bur In order to achleve its maximum performance, alweys charge the bettery. Also, the Datzery He is lengthened when ie i initilcherged. + When checking the charging system, slways follow the steps in the toublestiooting flow chenipage 15-3) + For battery testing/eharging, refer to section 22 ef the Common Service Marl. + For charging system location, see page 15-2. 15-1Charging System/Alternator ‘ ee eee a eee System Location () IGNITION swiTcH (2) Maw FUSE. (9) BATTERY (5) ALTERNATOR ma ey (3) ALTERNATOR i | a 7 | (4) REGULATOR/RECTIFIER =e C ' 1 ~ 152Charging System/Alternator Troubleshooting pattery Overcharging + Faulty regulatoriectitier attery Undercharging NOTE, + In orde to obtain accurate test readings when charging system, the battery must be fully charged and in good condi tion. See Common Service Manual section 22 for chegk the, [ease the botery carentieakage ampere iaak | __Incovect | est oge 15-5) Saar + Shortel wire harness corect + Feiynntion etch | ly repsarettir * - - Corie cara [[apeat ae ausied vohge tape TE) SPE open srmin re ones + Pooriy"eonnectes connectors Not Charging Cheok the volteges ofthe requistorrectiev bate | _ABnoume! Tery charging line and ground line (oege 18-5) pw a 7 Normai ‘Check the alternator (cherging coll) resistance # | ___Abnarmal {the regulatorirestifier connestor (pege, 15-6), a Atormal Hormel | t Notmat ery edrnectd ater + Fauity alternator Check the regulatovractilier unit nepection (page 18-6) I + Fauity requlstarie 15-3 aCharging System/Alternator Battery Removal/Inatallation caunion, [Eten the ignition switch otf. Requisite Service + Seat cowiing semovaliinstalation (page 2-2) Procedure oy Remake 1 ‘Removal Order Installation is i the reverse order of removal (1) | Battery folder band (2) | Negative |~) eabie 1 | Remove the bok anc disconnect the cable. | (3) | Positive (+) cabie 1 | note + At instalation, connect the positive (+) cable frst, ‘apply grease and caver the terminal : (a)_| Baxery i sper 15-4Charging System Inspection Leak Test Homove the seat cowling (page 2-2) ‘Turn the ignition switch off, and disconnect the negative {—) cable from the battery. Connect the arimeter {+ | probe to the negative (—) cable and the ammeter {—) prabe ta the battery negative {—) terminsl ‘With the jgnition switch off, check for current leakege. — Note 7 When measuring current using a tester, get to 2 high range, and then bring the range down to an appropriate level. Current flow larger than the range selected may ‘blow out the fuse in the tester, + While meesuring current, do net turn tha ignition on, Aaudden sutge of currant may blow out the fuse in the tester, Specified curcent leakage: 1 mA 1 current lea ‘ult is Holy Locate the shortby disconnecting connections one by one and ‘measuring the curent jp exceeds the suecified velue, @ shorted cir- Regulated Voltage/Ampere Inspection NOTE + Before performing this test, be sure that the battery fully charges sna that the voltage between its terminals, is greater then 12.8 V. ‘Start the engine and weer it up to operating temperature, then ‘um the ignition ewiten OFF. Remove the seat cowling (nage 2-2). | Connect the multtester between the battery terminals, Digital muitivester o7a11—0020000 = + Ifthe engine must be running to do some work, make sure the aroa is well-ventilated. Never run the engine in | |, an enclosed area, + The exhaust contains poisonous carbon monoxide gas that may causo loss of consciousness and lead to death, Disconnect the etarter eley switch connector and remove the main ‘une, Reconnect the connector securaly. Charging System/Alternator me & (G) STARTER RELAY SWITCH (2) BATTERY NEGATIVE CABLE (1) BATTERY NEGATIVE TERMINAL B (2) MAIN FUSED 15-5Charging System/Alternator Connect the ammeter botween the main fuso terminals. CAUTION ammeter Start the engine and incresee the engine speed gradually Regulated voltage: 13. Regulated current: 0-9 A/5,000 min itp) Regulator/Rectifier Inspection Wire Harness Inspection Remove thé seat cowfing (page 2-2). Disconn ‘Measure the following betwoen connecter tarminals of the wire = Be enceful not to short any tester probes. = Although the current could be measured when the | femmeter is conneoted between the battery positive terminal and positive eable, a suddon surge of current 10 the startor motor could damage the ammeter. + Always turn the gaition switch off when connecting and cizoonnecting the ammeter. Disconneeting the ammotor for wios when eurrent Is flowing may damage the 15.5 V/5,000 min“ (pai) the 6P (white) connecter fromthe reguistoxtectitien land check it for loose or corroded terminals, (1) STARTER RELAY SwiTCH! Tams [Satie Red/white (+; Battery voltage Hee React ne _| end sound | shod vee, Ground fine | Groen and ground | Continuity exist. ss "i ‘Charging coi | Yellow and yellow | 0.1—1.0 of Pee Se (20°C /68°F) lf the charging coil line reading is ou of spectticaion, check ‘the alternator (page 15-7),Charging System/Alternator Unit Inspection “Tho circuits on tha wice hamess cide are normal and thore ore rho loose connections at the connector, inspect the regula: toc/rectfer unit by measuring the resistance betwean the tor- rinals NoTe ~ Yau" ge false readings If the probes touch your fingers. the specified multitestors. Using other equipment may not allow you to obtain the cortect results. This is ‘due ta the characteristic of semiconductors, which have different resistance values depending on the applied vokage. Specified multitester | = 074110020000 (kKOWA Digits! type) | = 073080020001 (SANWA Analogue type) ~ TH—BH (KOWA Analogue type} (1) REGULATORIRECTIFER CONNECTOR + Soloct the following range: i 'SANWA: ka KOWA: x Toa + An old battory stored in the mutitester could cause ‘naceurete readings. Check the battery ifthe multitester rosgisters incorrect. + When using the KOWA muhitester, remember that all rescings should be multiplied by 100, | 1Ce the regulator/octiior unit ifthe resistance valua be- ‘wo0n the.terminals is abnarmal Denes] he T fe T veto | vetow | vetow | croen © axond He Rediwhite reeefeciertit a-eeete aetael Yetow [aS =10e aor Soo 90-00 |For 2004 Retow | a5 10K [pox—so0e fetow [95 10¢ | soe 0c [BOR soo fosen | 1x20 [O.5= 10K | 05 10K | GS-10 Alternator Inspection {Nore - Remove the seat cowling Ipoge 2-2). Disconnect the slternator SP (white) connector. Measure the resistance between tha yolow wire terminals and heck for no continuity between each terminal and ground. ‘Standard: 0.11.0 9 (20°C/68°R) = Replace the stator if the resistance is out of specification oF if there ic continuity between any yellow wie terminal anc ‘round,Charging System/Alternator Altemator Removal/installation | | rot 85 (6.5, 61) A es 5 note ~ ar - : ~~ [>The engine il wil epi out when che fot crankcase cover is removed. Place a clean oil pan under the engine to cetch ; ‘the ail and add the recommended oil to the specified level after insealing the cover | Requisite Service : + Lower foiting romovalinstaliaton (page 2-4) Procedure Ory Remarks an Removal Ordor Installation i inthe reverse or der of removal. | | 9 | atternator ire connector a 1 | Disconnect the connactor. {2} | Lafe erankease cover bolt cra (G) | Lett erankease cover 12) | Wee clamor 18) | Flywheel bottwasner Hold the tlyerhes! with the universal holder | {07725~0030000) znd remove the bot. 161 | Fiywhoet 1. | Use the rotor puller (07733 00200011. 17} | Stator mounting bot | | [a1 | stator viFEEEEEEEEE-EceeececeeeSSeeeeee SSeeeoee eee eee cece eee Ree _ 16. Ignition System {Service information 16-1 Pulse Generator Inspection 16-6 System Location 16-2 _Ingion Timing 167 | Troubleshooting 16-3 Pulse Generator Ignition System Inspection eee neon aaneeean id Ignition Coil Inspection 186 Service Information «Tho digital raneleorze ignton system uses an elecicaly conta ignition timing system, No adjustments can be Irate tothe Ignition timing. cone eres ale made by identvng the evnder wise spe rng i ncorec. | eet coches oc denagesl eropped, Alsi te comectoriseconnectea wher curentls own, the excessive Tene may domage the ue. Always turnoff te inion switch Before sencaing. «RISB Ipvldon system soften seltee to poor connected aonnoctrs. Chock those 1 Ae ee tawny ts aseccetely charges Using the staner motor ih a weak bl Sfanting speed as well 2s ro spark atthe apork plugs. Genes rte oy the carest het range, Uning spark lug with an incorrect het renge can damage the engin. Refer teenies 2 ef the Comon Service Manual «eee Zot Rich and engina stop etch inspection, Gheckfor continuity ofthe continuity chart of the Wing Di: Fe te tS oteconeet ane ignitor ane engine sepe swith connectors onthe ight conactor bracket page 1-24) See check ther 16-1System System Location = aeana nen (2) ENGINE STOP SwiTCH (3) FRONT SPARK PLUGS (4) REAR SPARK PLUGS (8), MAIN FUSE (7) SPARK UNIT (27) BATTERY 14) SUB FUSE _ (18) MAIN FUSE i = (931 ENGINE STOP” (16) IGNITION SwITCHt iv 6 ak SWITCH ne oe 112) IGNITION Con. ;6 \ | wis 1 1 : \ et od | | white Le] Lee | LUT TT (20) SPARK UNIT (aOke © (19) PULSE GENERATORS f ee — (18) TACHOMETER faeIgnition System Troubleshooting + Before roubleshooting, check that n2 spark jumps at the spark plug using @ known good! spark plug (to ensure that the plug does not cause the problem). # Fioreover, check for proper spark plug aap and loose spaik plug wire as well as forieakage of the ignition col secondary ccurtent caused by moisture. = tt no spark jumpe st ene part of the ignition system, exchenge the ignition coll with the ather good ene and perform the spark test. If good sparks jump, the exchanges Ignition cai is faulty. + Astor peak veltage inspection. frst measure the primery cal voltage of the Ignition coll. I the cltage is abnormal, chad ‘cach item in numerical ordr in the “*Probaale Causa” column dexeribed on the Troubleshaoting chart “fptia! voltage” of the ignition primary col fs the voltage measured with the ignition switch ON and engine stop switch ‘at RUN (when the engine is not eranking with the starter moter), No Spark At All Plugs Unusual condition Probable cause (Check in numerical order) Tpnition coll | No intial voltage with the nition | 1. Fauity engine stop switch. primary Switch ON. and engine stop | 2. Open crcuitin BIW wire between the ignition coil and engine ston voltage ‘switch at RUN. sewiteh, {Other electrical components are| 3, Loose or poor connection of the ignition coil arimary wire terminal formal.) fF open circult in primary coll 4, Faulty spark unit, when the intial vot | tunis connectors eisconnected. .geis normal with the spark} Tnitat vottage is normal, but it) 1. incorrect peak voltage adaptor connections. rope by 24 velte while erank-| 2. Battery is undercherged. (Velage drops laraely when the engine ing the engine. ie started.) 3, No valtage at BINW wire of the spark unit EP white connector, 91 loose or poorly connected spark unit connector. 14, Poor connection er open citeule in G wire of the spark unit OP white connector \ 5, Loose or poor eonnestion, er open sitcultin ¥/Bu or BulY wire be- ‘pveen the ighition col! and sperk unit 66. Short clurcult in the ignition primary coll. 7. Foulty pulse genorater. (Measure the peak voltage.t 8. Fouity spark unit (wher above No. 1—7 are normal. \ iniviat voltage fs normal, but no| 1. Incorrect peak voltage adaptor connections. peak voltage exists while crank-| 2. Fculty peok volage adater. Ing the engine, 2, Feulty spark unit (when above No. 1 and 2 sre normal Initial valtage is normal, but 1. The mubitester impedance I t90 low. Voltage Is lower than the sten-} 2. Cranking spaced ic too slow. (Bettery is undercharged. 2rd value 8. The sample timing ofthe tester and measure nuise were not sy0- chronizes, (System fs normal if measured voltages over the sten-| ard voltege at least once.) 4, Faulty spark unit when above No, 1—S ere normal. | {ntl voltage and peak voltage | 1. Faulty spark plug oF leaking igri ‘are normal, but ne spark jumps | 2. Faulty ignition coll mn eal secondary current ampere. | at plug | Plse Peak voltage is lower than the| 1. The muttitester impedance is too low. generator | standerd value. 2. Cronking speed is toc-slow. (Battery is uncarcharged.). 3. The smple timing of the tester and measured pulse were not syn-) chronizes, |System is normalif measured voltage is over the stan) dard voltage at least once.) [ 4. Faulty pulse generator (when above No. 1—3 are normal No peak voltage. 1. Faulty peak voltage adaptor | Faulty pulee generator. 16-3Ignition System Ignition System inspection (1) DIGITAL MULTITESTER NOTE f é + ifno spark jumps at al plugs, check all sonnections for | loose or poor contact before measuring each peek | voltage. | +The reading differs depending on the muttierster input Jmpedanes. Use only genuine cigital mutierster or com ‘mercially avalable muititester with the inpitimpadance | higher then 10 MQIDCV. ‘Connect the peak voltage adaptor to the digit ey (2) PEAK VOLTAGE ADAPTOR Poak voltage adaptor 07HGJ.-0020100 eee Digital multiester 074110020000, Janition Coil Primary Voltage Inspection ignition Coil Primary Voltage Inspection NoTE + Cheok aj! system connections before this Inspection Poor connected connectors can cause incorrect readings. + Make sure tht al oyinder compressions are portal and check that the 5 Sera i oe finde: Place the motorcycle onits side stand and shift the transmis. sion into neutral. = Remove the seat sowling (page 2-2) anc the lower fairing (page (iv GOOD KNOWN SPARK PLUG 24) Disconnect’all spark plug caps from the spark plugs. Leave the epark pluge intalod in all eynder heads, install good known spark plugs into the spark plug ceps end ground them to the engine NOTE +The peak voltage must bo meesured under the normel ‘oylinder compressions and with the ignition seconsry Grout closed, Conneot the Beak Valiage adaptor probes between the primary ‘ignition col terminal and ground withthe connector connected. Connection: Front ignition colt: BurY terminal (+) and ground Rear ignition coi: Y/Bu torminal (+) and ground (—} ‘Turn the ignition ewiteh ON end engine stop switch to RUN, position, and measure the initial voltage, ‘Tho battery voltage chould be registered.Ignition System —_—_— ‘Meacure the ignition ec primary peak voltage while cranking the engine with the starter motor. Connection: Be Front ignition coil: BulY torminal (+) and ground (| Rear ignition coil: WB terminal (+1 and ground (—) Peak voltage: 140 V rainlmurn T_T “To avoid possible electrical shock during veltage mess: urements, do not touch the tester probe metal pars. NOTE + Ag long as the measured votage exead the specified | value, the system fs normal, | Pulse Generator Peak Voltage Inspection Note = +The peak vokage must be mozcured with all spar pleas Instaliad inthe eylinder heads and under nonel evindsr Remove the seal cowling (page 2-2). Disconnect the spark unit 4P biack connector. Connect the peak voltage adaptor probes to the pulse gener- ator wire terminals of the wire harness side connector. Connection: = ‘Pulse generator 1: WIY terminal (+) and Y terminal (=) Pulse generator 2: WIBu terminal (+) and Bu terminal ( ‘Measure the pulse generator peak voltage while cranking the engine with the starter-motor. ~ Peak voltage: 1.8V minimum fl + Teavoid possible electreal shock during voltage meas urements, do not touch the tester probe metal pars. 11 the peak voltabe is abnormal, disconnect the pulse genere~ 101 4P block connector on the fight connector bracket (page 4-28), Connect the peak voltage adaptor probes to the pulse gener stor wire terminels Connection: Pulse generator 1: WHY terminal (+) and ¥ term alee generator 2: W/Bu terminal (+) and Bu terminal (=) Measure the pulse generetor peak v engine withthe starter motor. ye while crankingIgnition System If the peak voltage measured atthe epatk unit is abnormal end ‘the one measured at the pulse generator wire connectors nor- ‘ai, the wire hamees has an open circuit or iosee eonnetion.- NoTE ‘As long as the measured voltage exced the spacifiec value, the system le normal. i 4 \ Ignition Coil Inspection (SV GNTION con Remove the seat cowting {pane 2-2) and the lower firing (pave 2a, Disconnect the primary wire connectors and meesure the primary coltyesistance between the terminals, Standard: 2.5 — 3.59 (20°C/68°r1 Flomove thé spark plug caps from the plugs and measure the” [~ (i) SPARK PLUG Wines secondary call rosistance between the spark plug caps. Standard: 14 — 25 k9 (20°C/68°F) It the resistance is out of range, remove the ignition col, re move the spark plug witas fiom the ignition col and measure the secondary colt resietance, ‘Standard: 11 — 44 2 (20°C/68°F) Pulse Generator Inspection Note rr pus Ge + tis not necessary to remove the puise generator to make this Inspection. Remove the lower fairing (page 2-4) Disconnect the puise generator wire connector on the right connector bracket (page 1-24). ‘Measure the pulse generator coll resistance betiveen the WiY and Y wire vermines and between the Was and Bu wire ter- 480 — 560 9 (20°C/68°F)Ignition Timing NOTE +The spark unit eyetem is Factory pre-sex and cannot be _36justed. Igrtion timing inspection procedures are given {fo inspect the funtion of the spark unit components. + Gonect the timing lignt to the other sper plug wire it | you see that the ignition timing fs Incorrect, and you right be able to eee the timing ts correct. Warm up the engine to operating temperature, [+ the engine must be running to de some work, make |) sure the area fs well-ventilated, Never run the engine | wan enclosed +The exhaust contains poisonous carbon monoxide gas that may cause lose of consciousness and lead to death. | Ss aaaaineeeee ae SS Romove the lower faring (page 2-2) Remove the timing hele cap from the right crankcase cover. Connectthe tirna Tight to the No. 1 eylinder spark plug wire ‘The timing is correct if the "F” mark of the "T1"” mark aide aligns with the index mark at isle. Idle speed: 1,200 min Mp} Increase the engine speed and check the “F"" mark begins 10 move to the left side. Apply molybdenum disulfide of to the O-ring and timing hole ‘cap threads, and instal the timing hole cap. Torque: 18 Nem (1.8 ka-m, 12 fet) \ a ae “TIMING INSPECTION HOLE ~ 16-7Ignition System Pulse Generator Removal/Installation Hit e nia - ee Sa + Rowte the pluse generator wires above te wire gui 2 se egg pa Requisite Service + Fight erankease cover removaVinstatiaton (page 6-2) Rossa "Teel cape - Removal Order | Installation isin the reverse order of removal (| Wire connectoe | Disconnect the connecter. (2)| Oil presoue switch terminal serew (3) | Neutral ewiteh wire connecter | Disconnect the connector. 14) | Wire grommet (5) | Pulse generator mounting bolt (©) | Pluse generator 16-8Ignition Timing NOTE 7 The spark unk systems factory pre-ser and cannot be ‘tose. lgnion timing laspection procedures are giver qo inapact the funton of the spark unit components + Goneet the Sing light to the other sper pug wire it You see that the ignition timing is incorrect, and you ‘Right be able to eee the timing is cores ‘Warm up the engine to operating temperature. + the engine must be running to de some work, make ‘sure the area is well-ventilated. Never run the engine in én enclosed are + The oxhaust contains poisonous carbon monoxide gas") that may cause lose of consciousness and lead to death. | (page 2-2). Romove th Remove the timing hele cap from the right crankease cover. Connect the timina Tight te the No. 1 eylindsr spark plug wite ‘The timing fe correct if the "F” mark of the "771" mark oide aligns with the index mark et idle. Idle speed: 1,00 min~Mrpm) Increase the engine speed and check the “F*” mark begins 10 move to the left side. Apply molybdenum disulfide of to the O-ring and timing hole cap threads, and inetall the timing hole cap. Torque: 18 Nem (1.8 kam, 1 feb) inition System 16-717. Electric Starter/Starter Clutch Service Information 77-1 Starter Clutch Disassem- ‘System Location 17-2. Ply/Assembly 17-6 ‘Troubleshooting 47.3. Statter Moter Removalinstaliation 17-7 Stater Motor Disassem- — bly/Assembly 178 Starter Clutch, Primary Drive Gear Removal/installation 174 Service Information = Always turn the ignition switch OFF betare gervicing the starter motor. The motor could suddenly start, causing ser us injury. + A week battery may be unable to turn the starter motor_quiskly enough, or supply adequate ignition current ifthe edtrent iz alowed to flow to the etacer mator to in it while the engine is not cranking Over, the starter motor may be damaged. + For the following component in epections, refar zo the following pages: f ‘manual (System Location} the parts locations, see page 17-2 of this ‘Guich ewitch diode _| Section 24 of the Common Service Manual Starter motor ‘Section 24 of the Comon Service Menusl | Clutch switch Section 25 of the Common Service Manual | [Neutral ewitet Section 25 of the Common Sarvice Manus | | lonition.switen ‘Check for continuity on the continulty char of the Wiring Diagram, page 19-1 Disconnect the switen connector on, the right connector bracket (page 1-24) and check i 17-1Electric Starter/Starter Clutch System Location (21 STARTER SWITCH (2) IGNITION switcH fe (0) cluTeH swircH (4) STARTER FELAY SWITCH (5) MAIN FUSE _ (BATTERY 75 ar (12) IGNITION swatcH ean’ (16) STARTER RELAY SWITCH oe PY re tke AY, wel R | Peet 2 (17) STARTER i. | a MOTOR 0 (gue P a rent m6 Tal ao (15) main Fuse DY 1A 30.8 | 8 Bier Low vm L 1 (13) STARTER SWITCH (9) NEUTRAL ar worcator LP tga (20) NEUTRAL SWITCH (sy CLUTCH “DIODE 17-2Electric Starter/Starter Clutch Troubleshooting — cn a [+ Cheek fora blown main af sub fuse before servicing. | <_Moie ert Bator fly eared ang go eon ee Starter Motor Wil Hot Turn. : 2 ‘With the ignition switch “ON” and enginc sop | [Connect the starter motor (+) terminal wo the | ‘switch at “RUN”, check for a “elick’” sound torn starter relay swith. NO CLICK [ Disconnect starter relay witch connecter, ane | chezk the relay call ground wire - conminumry rolay switch connector ae VOLTAGE MEASURED ABNORMAL Sterter Motor Turns Slowly + Low specific grevity in Bartery (or Dead battery) Poorly connected battery teminal cable Poorly connected starter motor cable Faulty starter motor Poorly conected battery ground cable ‘Connect the starter reiay switch connector, Measure the starter relay voltage at the starter Gheek the starter relay operation }— CLICS——+ battery positive terminal -_- {Because a large amount of current flows, donot tse thin wires) | --p Starter motor turns Starter mater ove net turn i 1 1 + Loose or discon- + Faulty sterter moter nected wire or cable Faulty starter relay switch NO CONTINUITY+ Foulty neutral ewiten FaURry citer ewiteh Faulty starter switch Loose or poor contanct at connector ‘Open circuit in wire hares. Fauty ignition ewiteh Brokgn starter switch wire Loose or poor contet et connector Over circuit in wire hamess, NNO VOLTAGE» Laose.or poor contact at starter velay switch ‘Fou steit@ relay ewitch ‘Starter Motor Turns, but Engine Does Not Turn + Starter motor is runnign backwards ~ Brushes assembled Improperly — Case acsembied improperly minals connected improperly stertet clutch 2 gear or redvetion goer Starter Motor Relay “clicks”, but Engine Does Not Turn Over + Excessive reduction gear friction Crankshaft does not turn due to engine problems 17-3 ——Electric Sterter/Starter Clutch = Starter Clutch/Primary Drive Gear Removal/Installation Remove through the recessec Portion of the eluteh outer. = At instllaton, align the wide groove ‘with the wide tooth,Electric Starter/Starter Clutch Requisite Service + Right crankease cover removai/installation (page 9-21 “Remarks Proceoure [ew Removal Order i 111 | Pulse gonerator mounting bolt 2 121 | Stare ide geerfshaf vw {51 | Primary chive gear Doe 18; | Storer chnen 1 «51 spacer 2 {81 | Primary erive gear 1 Installation isthe reverse order of removs Remove the pulse generators. Use the gear holder (00724007010) as shown, Disescombly/asserbly (page 17-6 NoTe + Remove the clutch through the recessed portion of the cluteh outer. + At installation, align the wide groove with the wide tooth of the crenkshatt 17-5 4“Electric Starter/Starter Clutch Starter Clutch Disassembly/Assembly a y A ‘ lad | ia | Qee.w a ‘ Requisite Service + Starter clutch removatfinetallation {page 17-4) ce (| Starr deven pear 1 2 At installeton instal he gear into the clutch while rum- ing i clockwio (2) | Needte bestng (3) | Chetoh eaver boi 4a) | Cutch cover Note + At instalation, align the hole with tho locating pin (5) | Rolie (8) | Plunger (7) | Spine (8) | Starter olan booy \ & . ty : Procedure Oty fc a eee | Removal Order ‘Assembly is in the reverse order of disassembly. NOTEStarter Motor Removai/installation Electric Starter/Starter Clutch With the ignition awiteh OFF, remove the negative cable from the battery bofore servicing the starter motor. Requisite Service + Lower fairing removaliinstaliation (gage 2-4) {41 | Starter motor/O-ring Proveduee oy Remarks Removal Order Installation is in the raverse order of removal (11 | tower raciator mounting bott 2 | note + Remove the belts and move the lower radiator forwerd, | ‘CAUTION | + Cover necator fst proven them om damage when | servicing, (2) ) Stacter motor cable 1 | Disconnect tne eabie \ Note i + Install the rubber cep securely after Instaling (3) | Starter motar mounting bolt 2 "i Disascembiy/assemsly Ipage 17-8) 17-7Electric Starter/Starter Clutch Starter Motor Disassembly/Assembly L 7 . IAAI __. see a = a 7 yee 7 Ee “| i orice cal ‘| 17-818. Lights/Meters/Switches Service Information 7@-1 Turn Signal Light Bulb System Location 18-2 Repaleement ee Ol Pressure Switch napecdon —-—«—18.g_‘Henllht Bulb Replacement ee tic Ignition Switch Fan Motor Switch Inspection 18 eee valfinstallation 187 Coolant Tempereure Gauge instruments, Heodignt Unit Inspection 18-4 Removal/installa: 18-8 Headlight Relay Inspection 18-5 Service Information Ce ‘Be sure to let it cool down bofore servicing. from the burner. Wear protective clothing, gloves and eye protection ‘Aihalogon headlight bulb becomes very hot white the headlight is ON, and remain het for a whle after itis turned OFF. Use a hast elament to heat watericoolant mixture for thermosensor inspection. Keep all flammable materials away + Note the follwing when replacing the halogen headlight butb. a 'WWeat clean gloves while replacing the bulb, Do not put finger prints on the hesdlight bulb, as they may create hot spote.en the bull end cause it to break. — Ifyou touch the bulb with your bare hends, clean it with o cloth mistened with alcohol to prevent its early flisre = Be sure to install the cust caver after replacing the bulb. + Gheck the battery condition before performing any inspection that requires proper battery voltage, * Avcontinty tect oan be made with the switches installed on the motorcycle. 18-1Lights/Meters/Switches System Location (3) IGNITION swircH (2) InsTRUMENTS (4) FRONT BRAKE LIGHT SWITCH o (1) LEFT HANDLEBAR 7 switcH (131 FAN MOTOR SwiTcH / 7 (8) RIGHT HANDLEBAR, / SWITCH (py THERMOSENSOR (7) HEADUGAT HIGH BEAM RELAY ©) CLUTCH DIODE (9) BRAKETAILLIGHT OF CONNECTORS 12) ow pressure swirce S77 (11) NEUTRAL ewiTcH \ pean (10) TURN SIGNAL RELAY 18-21 Lights/Meters/Switches Oil Pressure Switch Inspection (1) OIL PRESSURE WARNING LIGHT Remove the lower fairing (pege 2. Hf the oll pressure warning Eight does not come on with the ignition switch turned ON: 1. Disconnect the oll pressure switch wire from the ‘switch and ground it. 2. Turn the ignalion switch ON and check thet the off pressure warning Fight comes on, = If tre light comes on, the eil pressure switch is faulty. Replace the switch, Ifthe light dogs not comes on, the bulb is bown oF wire harness has an open circult. Check tram. If the oil pressure waming light stays on while the engine i= running. 4h Check the engine of favel and adé the recemmended cil ifthe lavel is low. i 2, Disconnect the oll pressure switch wire from the ‘ewiteh and chack that the ell pressure warning ght does not come on with the ignition switeh tured oN. = ifthe tight comes an, the wice hanes between the light and ewiteh le shorted te the around, = Ifthe light does not come on, measure the oll pres: ‘ure, If tho pressure is normal, replace the oll pres~ ‘sure switch, Fan Motor Switch Inspection NOTE + Perform this inspection while the engine Is cold “Tar the ignition switeh OFF. Remove the lower toting (page 2-4), FF the fan motor does not stop: 1. Disconnect the fan moter switch connector from, the cawiteh and tur the ignition switel ON, if = I the starter motor does not star, the fan motor ‘switeh is faulty. Replace the ewitch, — FF te far motor stars, tho wire between the motor tend switch is shorted to the ground. ' GLFAN MOTOR SWITCH CONNECTOR 18-3Lights/Meters/Switches If the fan motor does not start 1. Disconnect the fan metor ewitch connestor from cho switch and ground it with a jumper wit. 2. Turn the ignition ewiteh ON, and eheok the fen moter. — ff the motor turns, the fan moter switeh is faulty or switch connecter is loose ar poorly connected, — Ifthe motor does not turn, check for voltage be- tween the connector end Ground. © ifthe battery voltage exists, the fon motor is faulty, © If novoltage, the wire harness hae an open circu, When installing a new fan motor switch, apply sealant to he ‘threads ond tighten it to the specified toraue Torque: 18 Nem (1.8 kg-m, 18 Fb) ‘Connect the fanmotor switch connector. Instal the lower fairing (page 2-4) N Coolant Temperature Gauge Inspection Remove the lower fairing ipage 2-4) and the fuel tank inage. 25). Disconnect the thermosencor wire connector from the sen: sor and ground it with a jumper wire, ‘Turn the ignition switch ON end check the coolant tempera ture gauge, Disconnect the tharmasaricor wire fram the ground immediately when the gauge needie moves july 0H. ‘CAUTION * Do not ground the thermotonor wire longer trhan 5 se- onds to prevent damage to the gauge. {the needle does not move to H, chack the wire harness be tween the switcn ané gouge, W the wire harness is normal, replace the coclant tomperavure ‘gauge. ‘natal the removed parts in the reverse order of removal. 18-4Lights/Meters/Switches Headlight Relay Inspection High Beam Relay Remove the lowar fairing (page 2-4). Turn the ignition switch ON : “Turn the dimmer snitch to “HI” and check fore “click” sound from the high beam realy. = Ifthe relay click, measure the voltage between the B1/R wire (+) and ground with the fanition ewiteh ON. 2't the battery voltage exists, repiace the relay + If no voltage, check the wire harness, = I the relay dows not click, messure the voltage between the BuMW {+1 ond G (=] wice terminals at the relay con- “The Battery voltage should be segistered when the head- light switch is turned to “Hand the dimmer ewiteh is ined to ft the battery voltage exists, replace the reley. {Hing voltage, chesk the wize harness, lighting switeh and Wimmer switch. Low Beam Relay Remove the upper fating (pace 2-2. “Turn the ignition switch ON end the headlight switch 70 ‘Tum the dimer SwitcR to “LO” gnieeheak Tore "erck” from the high bearn relay. 5 the reley clicks, measure the voltage between the BUR, (+) and ground with the ignition ewiten ON. if the battery voltage eixsts, replace the relay. + tfno voltege, chick the wire harmess = Ifthe relay does not click, measure the valtage between the WiGu (+) and G (—) wire terminals at the relay cor= nectar. ‘The Battery voltage should be registered when the he light switch ie turned 10H" and the cimmer ewiteh is tumad to "LO". + Ifthe battery voltage exists, renlace the reley. Ife voltage,check the wire harness, lighting switch and cimmer switch. Turn Signal Light Bulb Replacement Remove the screw and the tuin signal fight from the case. Remove the bulb socket from the light by turning ft counter. clockwise Remove the bulb from the socket by pushing fin and turning it counterclockwise Install the new bulb in the reverse order of removal. NOTE [eal + Align the tab of the turn sign! ight with the hole in the ‘case propery. SARE A [om Screw: (2) HOLE is) SOCKET (Tas or euB, 14) LigaLights/Meters/Switches Headlight Bulb Replacement ‘halogen headlight bulb becomes very hot while the headlight is ON, and romain hot for a while after iis earned! ‘OFF. Be sure to let it cool down before servicing, [[iryou touch the bub with your bare hands, clean with a cloth motstened with alcohol to prevent early failure. Requisite Service + Upper faring cemovaliinstaition page 2-21 + Instrumonte removalfinetalation (page 18-8) Procedure oy Remarks (2) | Headtight connector (2) | Rubber cep 1 | nove | install cap securely with the "TOP" mark facing up. (31 | Headight bu (4 | Headlight unit mounting sorew (6) | Position ligne socker (1 { Position ght bulb Removal Order | Tnatellaion is in the reverse order of removal | 18-6s/Meters/Switches Ignition Switch Removal/Installation : a NOTE _ Hi 7 Rowe the ignition switch wire hamess prozerly (see page 1-21). ae | Procedure ary ‘Removal Order Instalistionis in the reverse order of removel (11 Ignition ewiten wire connector 4} Disconnact at right connector bracket pene 1-74}, (2) | Ignition switch mounting bolt 2 ) | Ignition switch 1 ee = 18-7Lights/Meters/Switches Instruments, Headlight Unit Removal/InstallationNOTE [7 tastuments can he removed with the upper fering installed. 1 the ight one left mounting brackets are dferent, When replacing the bracket, instal the headlight aim adjusting seraws {in the marked locations as shown, Requisite Service + Upper fairing removaVinstallation (psge 2-2) Lights/Meters/Switches (ai | Heastight pivot holder screw (| Heaatigne Procedure ay | Remarks Instrument Removal Order | installetion is in the reverse order of removal, (1 | Speedometer cable 1| (2) | Instrument mounting bolt 2 | {1 | Instrument wire connector 3. | Digeonnect the connectors. 14} | Instrument unit 1 Hndlight Removat Order Tnstalietion is In the reverse order of cemoval {a} | Oi coole: mounting bolt 1 (b} | Hoag wire connector 2. | Disconneet the connectors. fe | Heads sty mounsirg bl 2 {@) | Headlight mounting screw 3 Headlight Disassembly Ordor ‘Assembly is in the reverse order of disassembly. (e) | Hosatignt aim adjusting screw 2 Wh | Headlight aim edjusting epring/nut a | Remove the scraw ond open the holder cover.oo09- 8a -zoe00 weibeig Buin “EL |on302- mre -610020. Technical Feature Cylinder Head 20-1 Newly Designed Spark Plug 20-2 | Shim Direct Push Mechanism With 1 se 202 Cylinder Head (5) SPARK PLUG “The new design dats not require the racer atm which i positioned th the rocker atm shaft and the thrust spring, the camshaft whieh is located on the same shatt as the valve giem, and the vaive lifter. This achieves a larger valve cismoter fand higher valve lift emount for the newly designed eylinder head. The part supporting the valve lifter is not required, because 2 mechanism directly pushes the shin and the nevily Geskiged speciat spark plug (detaile are described en the next pegel is used. The resulting compact oylinder head vielde a higher performance. Compares with conventiona’ mocels, the inste tion position of the new engine can be shifted further toward the front. Thus, the new design contributes to an improved fotation performance, ckiving safety end foad balance of the front and rear wheels by shiing load to the front wheels, and simultaneously decreasing he requleed whee! base. 20-1Technical Feature Shim Direct Push Mechanism With Rocker Arm (4) CAMSHAFT See (2) ROCKER ARM SHAFT Pee ee (1) THRUST SPRING 16) SHIM ‘The new design is » compact cylinder head, using @ shim direct push mechanism with rocker arm for easler maintenance, without any valve liter In conventional desians, the direct push type shim is located inside the valvefiter. Therafore, the valve lifter including the ‘camshaft must be removed/installed when the shim is replaced, The new direct ahim push mechanism used in the VFR4OO4A. ‘acitates easier maintenance then with the valve adjuster method, however, without requiring any valve adjuster. The deereacod ‘operating mass Thanks to the reduced weight ofthe rocker arm, the decreased operating mass results in better valve perfor mance during high speed, as well as in enhanced durabilty and reliabilty. Newly Designed Spark Plug [Conventionat Typel [Scrow Diamater: 8 ment (11) SPARK PULG The newly designed degiceted spark plugs (diemeve:: 8 mim) maintain @ balanced combustion and use a vaive with larger diameter. Greater charging efficiency and higher gae epeed are attained, resulting in @ better acceieration response, 20-2a ee 21. Troubleshooting Engine Does Not Start or is Hard Poor Performance at High Speed 213 area 24-1 Boor Handling 21-4 Engine Lacks Power 24-2 Poor Performance at Low and Idle Speeds 24-3 Engine Does Not Start or is Hard to Start Posse Cause Not Reaching Carkuyretor ts Cioggad fuel tube or fust strainer + Sticking float valve Resching Carburetor + Clogged fue! tank Breather + Disconnected of Faulty ute fuel valve vacuum tube 1. Check fuel flow te carbu —— Weak or No Spork + Faulty spark plugs Fouled spark plugs Fauley spark unit Broken or shorted spark pluo wires Broken or shorted ignition cot Faulty ignition switch Faulty pulee generator Faulty engine stop switch ‘Loose or disconnected ignition system wires 2. Pertolin a spark test Good Spark 3. Fest eylinder compression Low Compression e+ Improper valve clearance (shim too thick! Valve stuck open ‘Worn cylinder and piston rings Damaged ovlinder head gasket Seized valve Improper valve timing Improper valve ond saat contact Compression Normal : Y 4, Start by following normal ——— Engine Starts But Stops > Improper chock operation procedure + Carburetor incorrectly adjusted + Intake pipe leaking Engine Does Not Fire pee 1 Impraper ignition timing (Faulty | spark unit or pulse generator} + Fuel contaminated ' 5. Romeve and inepect epark plug — Wet Plug > Carburetor flooded + Choke closed + Throttle vaive open + Air cleaner diry‘Troubleshooting Engine Lacks Power 1. Raise wheels off ground and spin by hand Whee! Spine Freely 2. Cheek tire pressure Pressure Normal 3. Accelerate rapidly from low to ‘second 7 Engine Speed Increases Chitch is Released 4, Accelerate Lightiy Engine Spood increases 5. Check ignition timing Correct 6. Check vaive clearence Corcece 7. Test ylinder compression Normal 8. Check Gatburetor for clogging Not Clogged 8. Remove spark plug Not Fouled or Discolored + 10 .Check cil lovel and condition Correct Y 11, Remove cylinder head cover and inspect kubrication Valve Train Lubricated Property Wheets Oe Nat Sain Freely ————~-e Pressure Low ————-—e+ Engine Speed Not Changed When —~es Clutch is Reloased 7 Engine Speed Does Not Increase ——=+ Teo Low ———_____+- Ciogged ——-———— Fouled ot Disealored Valve T:aln Net Lubricateg ————r+ Properly : Possible Cause Broke dragging Worn or damaged axle beatings ‘Axle beating needs lubrication Drive chain too tight Axle cut excessively tight Faulty the valve Fauky cluteh lifter system Woen dutch disciplete Werped clutch ciscipiae Weak church spring Carburetor choke closed Clogged air cleaner Restricted fual flow Clogged mutiar Pinched fue! tank breather Faulty spark unit + Faulty pulse generator proper vaive adjustment Worn valve seat Valve stuck open \Wotn oylindar end piston rings Leaking head gasket Improper vatve tening Selzed valve Improper valve and seat contanct Carbureter not serviced frequently enough Plugs not serviced frequently enough Spark plugs ate incorrect heat rang Oil fevel too high Git level to0 tow Contaminated ait Cloggee off passage Clogged ei! contl orifice Contaminated oil Faulty of! pump \ 27-212, Check for engine overheating Overheating =~». Not Overheating ' 1, Accolerate of run at high Engine Knocks ———— e+ speed z Engine Does Not Knock Poor Performance at Low and Idle Speeds Troubleshooting _————}— rie scoting Possible Cause CCootant leve! iow Fan motor not working eulty fan motor switch) Thermostat stuck closed Excessive carbon build-up in com bustion chamber Use of paor quality fue! Clutch slipping een fuel mixture Worn piston and eytinder Wrong type of fuel Excessive carbon build-up in com bustion chaminer Ignition timing too edvanced (Faulty spark unit) Lean fuol mixture Possible Cause 1. Check inition ting ane Incorrect + improves valve clearence hyarautetappet eonaion + improper ignition timing —Fauty spark unit conece = Fauty pulse generator 2. cnet carburetor lt stow ingatect~—~———_--e tee Fu Systm Seton 8) of the ecustment 7 Common Service Mena : Conees 3 Check for taking intake pine Leaking——-=—__ues Looe insulator clase + Damaged inulaor No teak ' : 4, Perot spark test Weak or intomiten: Spark—————+ Faulty, carbon or wet touled spark ples Good Spark + Faulty span une + Faulty ignition coi + Broken or shorted sparkplug wes + Faulty engine step sth + Faulty pulse gonertor + Foust ignition switch Loose or dlssonnacted ignition eys- tom wires z 21-3 |‘Troubleshooting Poor Performance at High Speed Possible Cause Improper ignition timing — Faulty spark unit 1. Check ignition timing and Incorrect ~——————-~u—_s improper valve clesrance hydraulic teppet condition : Correct 2, Disconnect fuel tube at car Fuel Flow Restricted e+ buretor a Fusl Flows Freely . Ramave carburetor and check tor clogged Jers Crogged Not Clogged * 4, Check valve timing Coneet, Weak 5. Cheol valve spring Not Weakened Poor Handling + creck ice pressure * Cleen ~ Faulty pulse generator Fuel tank empty ‘Clogged fuet fine Clogged fuel cas vent hole ‘Clogged fuel va've Fautly fl valve Clogged fuel fiter Incorrect» Cam sprocket net installed prozecly Faulty spring Possible Cause 1. steering 1s nee yy nnn ___sioom Sescrin fit adiustment nut too 2. If olthor whee! ie wobbling 3. If the motoreycte pulls to one side ight Damaged steering head bearings “em Excessive wheel bearing play Bent rim Improperly installed wheel hub ‘Swingarm pivot bearing excessive- ly worn Bent frame Swingarm pivot adjusting bott too tight + Faulty shook absorber Incorrect drive chain adjustment Front and rear wheels not aligned Bent fork legs Best swingarm Bent frameBir Cleaner Removaliinstallation Alternator inspection... Remavaiinstalation Battery Remvai/Installation Bearing Holder Removal/intatation Holder, Axle Fassdneelbiesianitatl a Selaction Brake System . Cable & Harness Routing. Cam Gear Case Installation Camehatt inetallstion Camshaft, Cam Gear Gove instalation Camshait/Cam Ge Carburerar Combination ..eneemeeom Dissssombly/Assembiy Removalinstallation ‘Soparation| ‘Synchronization wn Charging SycemvAkernator lespaction sn. 7 Clutch a lngtalation Removal « Coolant Draining ‘Tempereture Gouge Inspection Cooling System... Countershatt DisassembiiAssombi Crankease Assembly. 7 ‘Separation Crankshafe/Piston/Transmission Cylinser HeadrValves «.. Head «. Cylinder Head Disassembiy/Assembly Removailinetallation Delve Chal ree ‘Sprocket Cover Remo Electric Starter/Starter Clutch Engine Remavaliinseaiation Installation Removal « Exhaust Pipe Rernovellinataiation Fan Motor Switen inspection . Fork Assembly a Disassembly 7 Removal/instatation -. Frame/Soay Panels/Exhaust System Front WheelSuspension/staoring Front Srake Caliper Disassombly/Assembly Pad Replacement Front ttzeter Cylinder Disasserbiyiasseraly Front Wheel Disassembly/Assembly .w Remevatiinstal . Foot System’ Fuel Tank Disascembiv/acsembly Femovallinstabation sane Fuel Valve Disassernbiy/Assemibly Gearshift Linkage enn ‘Gearshift Linkage, Shift Orom Installation Removal iti titat General information vn o Case Removal ca 22. Index Safety a ‘ ce Headlight Bule Replacement 12868 Relay inspection .. 188 Ignition Syst0m seer ie Call inspection i" 168 Switen Removal/inssalistion wer System Inspection .. i oe TEM Tien 187 Instruments, Headlight Unit Removall installation Lett Handleber Disassembly/Assombly Lignts/Meters/Switehes wre Lower Fairing Removaliastalation Lubrication System .... Lubrication & Seal Points ‘System Dagcam .. ‘sinhattDiasserbi Assembly Maintenance». ‘Schedule Mosel Identification Muffler Removaliinetaistion| : Newly Dasigned Spark Plag.vnnnnnn 011 Cooler Remova¥instalation Pressure Switch Inspection (oi! Pump Disasoembly/Aecembiy Removallinszallation sans Piston Disaesembly/AssemBly on Pulse Generator inspection Femavallinsallation . Radiator Dissssembly/Aesombly Removal/installetion Rear WheeliSuspension ... Rear Brake Celiper DisasoembiyiAssemoly Pad Replacement a Pedal Hemovailinstllation eer Master Cylinger DisassemblyiAssemibly Wheel, Driven Sprocket Removal! Installation, Reguistor/Recttier inspection =. : Right Crankease Cover Removal/installation Handlebar Dissssembly/Assombly «. ‘Seat Cowling Removal/instaliation Service Access Guide . Service Information Brake System... ‘Charging System/Aleernatar Ciutehs Cooling System =n Cranksnefe/Piston/Teansmission «. Cylinder Head valves «. 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