HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standard set by U.S. Environmental Protection Agency California Air Resources Board. Perfor the first scheduled maintenance is very impor tant. It compensates for the initial wear that occurs during the break-in period Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 20 describe parts of the motorcycle, grouped ac cording to location. Find the section you want on this page, then tum to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The sub- sequent pages give detailed procedures. If you don't know the source of the trouble, go to section 21 TROUBLESHOOTING. CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM COOLING SYSTEM | _ALTERNATOR/STARTER CLUTCH ENGINE | CYLINDER HEAD/VALVE CYLINDER/PISTON CRANKSHAFT/TRANSMISSION / COWLING/MUFFLER/REAR FENDER FRONT WHEEL/SUSPENSION/ ‘STE! CHASSIS HYDRAULIC BRAKE BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/INSTRUMENTS/SWITCHES ELECTRICAL WIRING DIAGRAM1. GENERAL INFORMATION GENERAL SAFETY ww SERVICE RULES m1 MODEL IDENTIFICATION 12 SPECIFICATIONS 13 TORQUE VALUES 15 TOOLS VW CABLE & HARNESS ROUTING 19 EMISSION CONTROL SYSTEMS 1414 EMISSION CONTROL INFORMATION LABELS (U.S.A. only) GENERAL SAFETY oo Ifthe engine must be running (odo some work, make sure the ‘area is well-ventilaied. Never run the engine in a cloved area. The exhaust contains poisonous carbon monoxide gas that can ‘cause loss of consciousness and may lead to death. | wvarnovs) ‘Gasoline is exremety flammable and s explosive unde certain conditions. Work in a well ventilated area with the engine opped. Do not smoke or allow flamer or sparks in you? working are 7 where gaotine Is sired. om Inhaled asbestos fibers have been found to cause respiratory seas and cancer. Never use an air hove oF dry brush wo cleen ‘rake assembles, Use an OSHA-approved vaca cleuner oF ‘lwerate method approved by OSHA designed to minimize ‘the hazard caused 05 etrorne asbestos ters, SERVICE RULES ‘The battery aives off explosive eases; keep sparks, flames and cigarettes aveay, Provide adequaie ventilation when charging. + The battery contains sulfuric acid (electotyte). Contact with shin oF eves may cause severe burns. Wear protective clothing and a face shield. = U electrolyte gets on your skin, flush with water, — If electrolyte gets in your eyes, flash with water for at least 15 minutes and cail « physician. = If wrallowed, drink large quantities of water or mie ‘and follow with mil of magnesia or vegetable ol and alta phy, + Used engine oll may case skin cancer if repeatedly left in contact with the skin for protonged periods. Although this is unlikely unless you handle used oll on @ daily basis, 1 is still advisable to thoroughly wath your ‘hands with soap and water as soon as possible after hand ing used oil 1. Use genuine HONDA or HONDA-recommanded ports and lubricants or thelr equivalent, Perts thet do not meet HONDA’S ‘design specifications may damage the motorcycle. 2, Use the special tools designed for this product. ‘only metrie tools whon . Install new gaskets, O-rings, cot ‘When tightening a geri torque diagonally, unies ue rvicing thie motoreyele. Metric bolts, nuts, and screws are not interchangeable with Enalist fasteners, The use of incorrect tools and fasteners may dama F pins, lock plates, ete. whan re ‘of bolts oF nuts, begin with the larger-diameter of inner bolts frst, and tighten to the specified particular sequence is specified. Ctean ports in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly Atter reassembly, check all parts for proper installation and operation. wotorcyele, smbting.GENERAL INFORMATION MODEL IDENTIFICATION \ } (2) FRAME SERIAL NUMBER “The frame serial number 's stemped on the riant side of the steering head, ENGINE SERIAL NUMER The engine serial number is stamped on the lower right tide of the roar cylinder. | Xe, The vehicle identification number (VINI is on the right side of the frame pipe. (3) CARSURETOR IDENTIFICATION NUMBER retor body (righ (6) COLOR LABEL ‘The colbr label is atteched to the right frame tube under {tho coat. When ordoring a color coded part, always apecify Its designated color code. 1-2 ?GENERAL INFORMATION SS). $NA SEN ERAL INFORMATION SPECIFICATIONS ® 8 | DIMENSIONS | Overall longth Overall width Seat height Ground clearance Dry woight Curb weight SPECIFICATIONS 2,205 mm (89.2 in) 865 mm (34.1 in) 1.265 mm (498 in} 1,508 mm (59.3 in} 850 mm (33, 225 mm (8.9 in 181 kg (399.0 bp 201 kg (443.1 Ib) FRAME Type Front suspension, traval eer suspension, travel “4 Seri double cradle Telescopic fork, 200 mm {7.9 in) Swing arm/Shock absorber, 187 mm (7.4-in) Front tire size 80/90—21 548 Rear tie size 130180-17 68S i Cold tite | Upto 90kg | Frent_| 29 psi 2.00 kg/em?, 200 Pal Pressures | (200 Ibs) load Fea | 29 psi (2.00 ko/em?, 200 kPa} Upto vehicle | Front | 29 psi (2.00 ko/em?, 200 kPa) i [capacity toad Rear | 29 pei (2.00 kg/em?, 200 kPa) Front br Hydraulic dise Rear brake | Intornal expanding shoes Fue! capacity V8 liters (4.8 US gal. 4.0 Imp gal) Ful reserve capacity 2.9 liters (0.77 US gel, 0.64 Imp gel) Caster angle 2B° Trail 108 mm (4.3 in) » ®. Fork lag oil capacity 549 cm? (185.7 US oz, 18.3 Imp oz) ENGINE Type Water cooled 4-stroxe Cylinder arrangement 2 cylincers, 52°V Bore and stioke 75.0 x 86.0 mm (2.95 x 2.60 in) Displacement 883.2 cm? (36.59 cu in) Compression ratio 9.201 Valve tain Silent, multitink chain drive and OHC with rocker aims Oil capacity 2.8 It (2.96 US qt, 2.46 Imo at) after disessembly 2.2 lit (2.02 US qt, 1.94 Imp q’) after draining Lubrication system Forced pressure and wet sump Air fitration | Paper fiter Cylinder compression, 117 kPo (12.0 kg/em?, 171 pil Intake velve Opens 10° (BTDC) | 40° (ABDC) Exhaust valve Ovene: 40° (BEDC) | & | mn lire Closes 10° (ATDC) Valve clearance {cold} inteke 0.15 mm (0.006 in) ‘exhaust (0.20 mm 40.008 in) Engine dry weight 59.5 ko (131.17 Ib) "®@ »®@ 1-3GENERAL INFORMATION <_>: California model TEM SPECIFICATIONS ‘CARBURETOR | Type Piston valve, dual carburetor 1.0. number YOFHA Main jot FRONT: #120 REAR: #120 Pilot serew opening 2-1/2 tuns out Flost level 7 ro (0.28 in) Idle speed 1,300 = 100 rpm DRIVE TRAIN | Chatch Wot, mult plate Transmission S-speed constant mesh 1.888 (68/36) | 21133 a6) 2871 (36/14) Gear ratio 4.777 492/18) | Gear ratio th 1/380 126/21) | Gear ratio iV 1.425 (27/24 Gear ratio 0.961 (26/26) Goer shift pattern Left foot operated return aystem, 1-N-2-3-4-6 ELECTRICAL | Ignition pe-co1 Ignition timing itil 10° BTDC ot idlo | Full vance | 30° BTDC at 4,500 rom Atemator AG GENERATOR 0.31 kw/5,000 rpm Battery capacity 12V 12AH | Spark plug NOK NO. | Standard DPRSEA—8 X2aErR_U9 For cold climate ea DPR7EA—9 X226PR-UB For extended high Genes Et, speed driving Spark plua gap 0.80.8 mm (0.031—0.036 in) Fuse Main 30A Sub 10Ax3 150 Sterting system Electrical stoter Heactight 12V 6OI56W Position vant 12vaw Tum signal ight 12v 21W Stop & talight 12 21/5 Meter lights 12V 1.7W x3 Indicater light Neutral 12v 3.4 High beam 1av 1.9 “Tum signal \2v sav warning | 12V 3.4 ™ ™ ™ moe TORQUE VALUES GENERAL INFORMATION ENGINE vrew ary | READ roRQuE Nm tam em) | REMARKS Oi panna ch Gy B0aa oo sere Souths | a tata to Engine oll drain bolt Be 14 35 (3.6, 25) iri 1] 2 fouio.7 rust cup }r] fonz0 Valve using sce tock nut a} 77 BBS In Apelyal Dam stepper ive pec bo exh |i tue oo ecg agent Priva ake sour magi bak er | so moes) | Casber Ol puto even posta ot i] 's eine euch ook ra + | a 120 130, 9) hutch ter lot ot i| tonon Olipmrs pe (7 me) a) 3 jonon term) eee lla Basin Faye bt i] oa 120180,98) | Lafehond oven! ts po Starter otc to bolt o] 8 50,93.0,22) | Appiptacang eget ern nee cover bl a] wore, Spel oon Caratetholie termtony = | 8 | wes.in (Sir nat 2] 8 aestn trmoty | a |g otto Cyinderheed = Worms | 8 |e s2(48 35) Gros | a |e mest term at 2] 8 Bast temo | 2 fe wouen Cam epoch bt ae (Lo Best Cam chan tensioner mountngtot | 4 |g torre.n Connecting rod toning ow rat fs sa 25) toning spre +] 6 torn pov yen Tin hao ome +) ore.) Poni Mose eee Crarkeaea hos cap i | a 1stis.1 | Apply Most gece Gonrehit epi oun pin + | [% west Sarr mor eb 2| 6 joan Dike oot 2| ion Cyincorvunttak —(10x1938mm)| 2 | a8 so (40 20) toxin | 8 | 10 0.28) txirnm | 2] 'e 528,18) Crmtene counter xssmn) | | 8 tana xasmm | 13] 8 tans stator coket bot 3] aus Thermos etch [eens Jo rata, 59) FRAME rem ary | TRAD | roRauE Nm iam, ei | AeMARKS ic cover zy] 6 08,8 tower conlng 2] 6s ‘ora son tar 2| 8 jonon fe leeds t| oc jone.n Echos! pe potetor 2] os iahan chote er if 6 one. 1-5GENERAL INFORMATION FRAME ven carry | GRREAD T ronaue nm om. ib) | EMARKS [8 : ear axle nut a? 95 (9.5, 69) Spot woruien — sese 27 Sningnmionin petra 1 Mo4ti.9, 801 | eaticckng pried | cin Bs 20) 2) "s nani i| 3 2a2 10 Exhest pe fr nt t] 8) | Ber2 | cnn Mutter ming bat ron +] 8 | dowoan tee i] | Geese | wh cone prea bt toner) | 1 |‘ as, 33) tet 2] 8 229,20 Tu sgn! ty ot 2] 68 229,20 Hanatar upper hae a] os eae. 10) Dove des ¢| 8 40 140,20 | Aeoiva Front heal hab cover 3 | he tess nn Frnt se i | wesen | fe hdr foes} 16 ‘anaes Fn oer eet bet 2| 5 Boo. Fomiegonci att pean a] os 2920 ower mh ts aoa, 20) Fork tube cap tat 2| 3 asin Gwan pta ok wa ‘one. Se coe esc nate Sosza — |[ Yarns w ‘Steering stem nut 1 24 100 (10.0, 72) stot Stern pushed i. Driven sored ua 3] ie talaarsa, | Apply ot Sick siete lower moune ek av isaieer | | 14 e108, 40) | Abn lockng agent Shrek seca oping ok ut i| 90 1.0, 28 Shock seaber mounting bl tieuienen | 2 | 10 45148, 391 | seoctng Shack sm toning arm rut Pa] a 108 ft0 70 Shock incaeonoe am nat 1| ta a5 18847 | Satoching Steck intuit i} to esiesan | Sartctng Bid vate 2| 's se ost, a Cate’ bot i| 8 2) 27.20 Brace hve fhe i | 1 35 38 21 Brat oct ma tefoite 19 ft. 12 Cato’ bracket bl 2) 's 229,20 Brace hove bot i | 38 (38,28 ator pot bo 1 | mesin | Si stand pot mt i |v io 40,20 pekesteds i| te to 40, 20 ica eset bn wee e720 Roar sep hdr bacet mel |e 55133, 20) Feo foo i} ooa ei8san Lt foot peg. [sales 6516.8, 47) __ fF -APpY locking egent Tora specicaora ated above forthe most impo ighterg pat. Ie pelican sot ated low te wa soarteber ‘STANDARD TORQUE VALUES ToRGUE Tonave ne Nem (kg-m, ft-ib) ie -m (kgm, ft-tb) Tie bot and mt 62,083, 47 | Samesew 39,048, 9 Sin balt and nut 010.9 ren pee noo at 2ia2te | oonwerorat nore 808.7 {Orn bok and nt Sessa) | Sm tone balan nut waiiae Tamm bot and nut 8615540) | 1Ommnge bl nt fo 40,2 1-6| GENERAL INFORMATION OND speci | 1 ] REFER TO | oeseneriow ‘Took Mua eremare roo | maween rarer Of mer wrest oran-pus7eT00 2 Ot presere toe 71082000000} Enivalet Commerity 2 Ot preenre gage tachment | G7e10-a2s0000 | Hevtaisin UA 2 Vove carance sustng wrencn | 07908Ke90000 | Valve dat wrench orsos-kesor0o | 3 } Neowum guage 740s 0080000 | Ven guye st hovreca | | | “oonoe 3 Compression tage | 07208 0010000 3 | Guten contr Poker 97828-KE10000 | Chch ene hldr o7H¢B0010008 ; Salve pide rome ON) 970042000001 | Valve qe omer o7a04—2000000 ® (U.S.A enys ° ete ple eae EI oraesze20001 | vave gue wumer orgee-ze2000 } USA ow ° Valve guide driver sttechment (IN) | 07943—MF50100 | ‘ive guide chives stchrant EX) | 07043 -M80200 ° Sear rove oe 72983710001 | Wot avtaie wm USA en nonee oreas—s7tote0 " — bearing remover set 07836~3710800 | =v ang wae G7ret 0010201 | Remover weight “teeing ever uscenent roman nnso%00 " Fort sel ever reer —easotoo 8 Fook ve ver ethene 7047 -xrootoo 8 Seung eon oscar Srote_syror00 | 3 ies eon | 07083=MAo0000 | Aqustale vewing remover | 07730-A01G00A 3 Steng tan avr oreaa—4scotd | Sterne stm diver orese_weoeco) | 3 ‘nth GN Hea ° Noodle bearing driver 07048KA6o000 4 Diver shat o7040—Miooro0 % | Sup vg lar orete250001 $7 The tools morked "=" are new For tha modelGENERAL INFORMATION COMMON REFER TO DESCRIPTION TOOL NUMBER ALTERNATE TOOL NUMBER oe Wrench, 10 x12 mmm | 07709-9090200 | Eauivotont Commercial a Spanner C, 58x 6.1 mm 0701-0020300 J available in U.S.A 4 Float level gouge 107401 0010000, 4 Lack rut wrench, 17 % 27 mm 077180020300, 7 Extention ber 07718-0020500 | Equivalert commercially avalos in US. 713,18 Gear holler 0724-0010100 Not available in U.S.A. 7 Fsor puller 077330020001 8 Fiyntree holder 07725-0040000, 8 ‘Valve guide driver. 5.6 mm (Ni | 077420010100 8 uice driver, 8.6 mm (Ex) | 077420010200 | Valve guide driver (07942~6570100 8 Vaive spring compressor 077570010000 8 Drive 97749-00100 14,13,94 Attachment, 42 x 47 mm (077480010300 1Wiaa sa ‘Aviactenont, 82 x 58 mm 07745-01030 u 20 mm (977450040500 u Plot, 22 mm 977490041000 u Biot, 25 mm 077480040800, u Bearing remover shate 07749-0080100 _ f Equivatert commercially 13,14 Bearing remover head, 1 men 1077460080400 [lavatabiain U.S.A 13 ‘Aviachment, 32.35 mn | 977480010100 13,14 Filo, 18 mm 07948.-0040300, 13 Lock nut wrench, 30 x 32 mm 0718-0020400 | Equivatert comrnerciaty 13 Bearing remover head, 17 mm 0746-0060800 [I avatabin in U.S. 4 Fin spanner 89201-KAd—811 14 Fin epannae 39202—KAs—a11 1 ‘Atiachreert, 37 x 40 men 07748-01020, 14 Flot, 17 mm 07748-0040400 uw Attachment, 24 x 28 men, 07746-01070 14 TESTER: Digital mutt-taster (KOWAY | 074110020000 ocxs—anm—s2— | 16,17, 18, 19 003 (U.S.A. erty) ‘circut wstor (SANWA) or 073080020000 16,17, 18, 19 Circuit tastor [KOWA) TH-5H 16,17, 18, 19 Honds battery tester O7GMJ—cor0co9 ie Cato batory charger Mci01212 USA. only 16 VALVE SEAT CUTTER DESCRIPTION TOOL NUMBER REFER TO SECTION Cutter holder IN 6.6 mm (077810010101 EX 6.6 mm 07810010201 Float cutter IN. 28 mm (92°) (07780-0012100 EX 36 mm (32°) (077800012300 Interior cutter IN. 3O mm (60°) (077800014000 Seat cutter EX 37.5 mm |60°) IN 27.6 mm |46°), EX 36 mm (45°) (077800014100 (077800010200, 077800010400 | 9Oo ° nw ® ome CABLE AND HARNESS ROUTING ‘Note the following when routing cables and wire harnesses, © A loose wire, harness or cable can be e safety hazard. Aftor ‘clamping, check each wire to be sure. © Do not squeeze wires against the weld or ond of ite clamp when a weld-on clamp is used. © Secure wires and wire hameeses to the frame with their ro: ‘spective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses, 1 Route harness cossive slack, ‘50 they are not pulled taut or have no ex- © Protect wires and hamesses with electrical tape or tubes If they contact a sharp 0% ‘surface thoroughly befor © Do not use wires or harnesses with broken insulator Repair by wrapping them with protective tape or replace them. © Route wire hamesses to avoid sharp edges or comers, © Also avoid the projected ends of bolts and screws. © Keop wire harnesses away fiom the exhaust pipes and ccther hot parts. 24 In their grooves property. © After clamping. check each harness to be certain that it ie ‘ot interfering with any moving or sliding parts. ‘© Wire harnesses routed a long the handlebar should not be pulled tout, have excessive slack, be pinched, or interfere with adjacont or surrounding perts in all steering positions. not twisted © After routing, check that the wire hornesoos a ‘or kinked ® Do not bend or twist control cables. Damaged controt ‘cables will not operate smoothly and may stick or bind. GENERAL INFORMATION OL’ X on O x eo a eK. xX eo E (0: CORRECT x: INCORRECT 1GenenaLimrormanion (2) CLUTCH CABLE (1) THAQTTLE CABLES ( ) (8) STOP & TAILLIGHT WIRE (7) ALTERNATOR WIRE CONNECTOR aS (11) COLUNIT (FRONT) (10) C4 UNIT (REAR 1-10GENERAL INFORMATION (1) MAIN WIRE HARNESS 1-11GENERAL INFORMATION CALIFORNIA MODEL ONLYGENERAL INFORMATION ———————r_-_ ys EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency and California Air Resourcos Bosrd (CARB) require manufacturers to certify thot their motorcycies comply with applicable exhaust emissions standards during thelr useful life, when operated and maintained According to the instructions provided, and that motoreyeles built after January 1, 1983 comply with applicable noise emis: sion standards for one year of 6,000 km (3,730 miles) after the time of sale to the uitimate purchaser, whon operated ond maintained according to the instructions provided. Compliance with the terms of the Distributor’s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the omissions system warranty in effect, SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic Honda Motor Co.,Ltd carbons, iizos loon carburter sottings as well as other systerns, to reduce carbon monoxide and hydro CRANKCASE EMISSION CONTROL SYSTEM. The engine is equipped with a closed crankcase system to prevent discherging crankcase emissions into the atmosphere Blow-by gas is ratuned to the combustion chamber through the air cleaner and the carburetor. (2) DRAIN PLUG. - note + Do not serew the cap in when making this check, (3) LOWER LEVEL 5 WV the olf level ie below the lower level mark on the dipstick, fil to the upper level mark with the recommended oi (see below! ENGINE OIL CHANGE NOTE + Change the engine oil with the engine warm and the motor- Coycte on its side stand to assure complete and rapid drain ing. 3 Remove the oil filler cop/dipstick and drain boit With the engine stop switch OFF, stort the starter motor for a phalanges ceil fl aiychg ” Y ss (1) DRAIN BOLT nore [ore ‘iV BRAIN BO TORQUE: 35 Nom (3.5 hem. 26 8) Fill the crankcase with the correct quantity of the recommenc- } aa Y on capaci: 0 (2.90 US at, 2.46 hop at afer nntorbiy (2) SEALING WasHen 2.4 lit (2.84 US qt, 2.11 Imp qt) at ol filter and oll change 2.2 lt (2.32 US at, 1.94 Imp at) after draining RECOMMENDED Oil: Honda 4-stroke oil or equivalent AP! service classification: SE or SF VISCOSITY: SAE 20W—50/10W—40 Install the oil filer capicepstick. ‘Start the engine and let it idle for @ few minutes. Stop the engine and wait a few minutes, then check that the oil level ist the upper level mark with the motorcycle upright. Check that there are no oll leaks. — a *LUBRICATION ENGINE OIL FILTER REPLACEMENT Drain the engine oil (page 2-3). a + Do not replace the oll filter when the exhaust pipe Is hot. Remove the cil filter with a filter wrench. Tool: Oil fiter wrench, 07HAA—PJ70100 ‘Apply cil to a now cil fiter O-ring and instal @ nevr ol fiter. Tighten the oil fiter with a fitter wranch, TORQUE: 10 Nem (1.0 kg-m, 7 feb) Fill the engine with recommended oi (page 2-3), OIL PRESSURE CHECK NOTE + After warm up the engine, check the oll pressure, Remove the lower cowling (page 12-3) Remove the drive sprocket cover (nage 5-8) Remove the oll pressure switch screw and disconnect the oil pressure switch wirs. Remove the oil pressure switch and connect an oil pressure ‘gauge to the pressure switch hele, Check the oil level Start the engine. Chock the oll pr ro at 8,000 rpm. ‘STANDARD OIL PRESSURE: 190588 kPa (5.06.0 kglem?, 7185 psi Stop the engine. Apply sealant to the pressure switch threads and install It. TORQUE: 12 Nem (1.2 kg-m, 9 ft-lb} Connect the cil proseute ewitch wire ‘Start the engine and check the oil pressure warning light goes fone or two seconds, TOOL: Oil pressure gauge 07508 -3000000 Attachmont 075104220100 fr equivalent commercially avaliable in U.S.A, NOTE + Route the oil proseure ewitch wire properly (pege 1-11). 2-4 en a (1) O1L FILTER \>> ~ OIL PUMP PRESSURE RELIEF VALVE REMOVAL Separate the crankcase (Section 11), Remove the attaching bolts end the pressure reiet vaive from the of pump. fr (3), PRESSURE RELIEF VALVE PRESSURE RELIEF VALVE DISASSEMBLY (1) SNAP FING Remove the snap ring using the snap sing pliers (07914— 3230001) and disassemble the raial valve PRESSURE RELIEF VALVE INSPECTION (2) B0Dy Check the spring. O-ring and valve tor wear or damage. 1) O-RING (Check the bocy for cogging or damage. “SO OY Chose alt of the remaining parts Assemble the parts in the reverse order of dinassembiy. (4) Spring = (5) SNAP RING. OIL PUMP REMOVAL Temporary loosen the three socket headed bolts when disas- ‘sembing the of pume. Remove the of pump by removing the ttvee bolts Remove the dowel pins and O-ringsLUBRICATION LUBRICATION (1) O1L STRAINER Romove the oll strainer and oil pipe from the oll pump. \ (2) OIL PIPE Chock the O-rings and cil seal for demoge. cay on’ Seat Rou ‘lean the oi! strainer and cil pipe with non-flammable or high sh point solvent. (3) RINGS | OIL PUMP DISASSEMBLY 41) BoLTS } Disassemble the of pump by removing the three socket = headed boits.. Clean disassembled parts with non-flammable or high flash OIL PUMP INSPECTION a {Install the outer rotor and inner rotor to the pump body, ‘Measure the pump body clearance. SERVICE LIMIT: 0.35 mm (0.074 in)LUBRICATION ‘Temporarily install tho pump shaft to the pump body. (1) QUTER ROTOR (2) DRIVE SHAFT ‘SERVICE LIMIT: 0.20 mm (0.008 in) (3) INNER ROTOR, ” Remove the oll pump shaft from the ell pump. | Measure the pump end clearance ‘SERVICE LIMIT: 0.10 mm (0.004 in} | ol PUMP AssemeLy (1) punp aoov \4) PRESSURE RELIEF VALVE BODY (2) ouTER ROTOR ot eae (9) WASHER 0G “pain (31 SPRING. (10) INNER ene’, oD 26 4 (9) DRIVE PIN g = te) pump shat 0 (7) OL. STRAINER 27LUBRICATION Install the outer rotor to the cil pump body with the punch ‘mark facing the cover. (1) OUTER ROTOR Instell the inner roter. Install the drive pin and washer to the oil pump shaft. Install the oll pump shaft to the oll pump body, aligning the dive pin with the groove of the inner rotor. Install the dowel pin and anew gasket to the oil pump body. Install the of pump cover to the pump body. Install the O-rings, oil seal, oil strainer and oil pipe to the oll |1) Gil STRAINER’ pump. i CAUTION + Install the O-rings to the oil pipe with the lapered sides facing ‘out as shown, or the engine willbe dortaced. (2) PUNCH MARK 9) OlL PUMP COVER) (1) O1L PUMP BOLTS: co (2) O-RING (3) O1L PPELUBRICATION OIL PUMP INSTALLATION Install the dowel pins and new O-rings. Install the oil pump as an assembly. PRESSURE RELIEF VALVE INSTALLATION Install the pressure rele! valve to the oll pump. Assemble the o iKease (Section 11). (70. RINGS/DOWEL FIN: agLUBRICATION LUBRICATION POINTS Use general purpose grease when not specified here, ‘Apply oll 0: grease to the other slicing surfaces and cebles not shown hore CONTROL CABLE LUBRICATION Periodically disconnect the throttle and clutch cables at their upper ends. Clean the eable end mount in the throttle ‘and clutch lever, then ail the cable ends and reinstall Ha cable begins to bind, it must be replaced. San (2) THROTTLE CABLE ENDS 1) BRAKE AND CLUTCH LEVER PIVOTS sas (12) STEERING HEAD BEARINGS, DUST SEALSIRACES. , NQ ‘. (11) WHEEL BEARINGS DUST SEALS Sm |9) BRAKE PEDAL (10) SPEEDOMETER GEAR (3) SWINGARM BEARINGS! a (8) SIDE STAND, DUST SEAL Pivor Apply @ paste grease with 40% or more molybdenum dislufide to the SPECIAL LUBLICANT ] mark compo: NOTE ‘Some source of MoS: paste groaee with 40% or mors mo ybdenum ere: + Molykote® Gen Paste manufactured by Dow Corning, U.S.A. + Honda Moly 45 (U.S.A. only) + Rocol ASP manufactured by Rocol Limited, UX. Rocol Paste monufectured by Sumico Lubricant, Japan. Any other manufacture’s paste grease equivalent f0 the ‘above may leo be used. a (4) DRIVE CHAIN /SEAR Olly (sae x20 \on woo / BUST SEALS (5) BRAKE CAM! ANCHOR (6) WHEEL BEARINGS! DUST SEALS, ‘SPECIAL LUBLICAN 7) SHOCK ARM AND SHOCK LINK) BUSHINGS/COLLARS/DUST SEALS 2-103. MAINTENANCE SERVICE INFORMATION 31 MAINTENANCE SCHEDULE 33 DRIVE CHAIN 31 DRIVE CHAIN SLIDER 312 FUEL LINE 34 BATTERY 3-12 FUEL STRAINER SCREEN: 34 BRAKE FLUID 313 E ‘THROTTLE OPERATION 34 BRAKE SHOE/PAD WEAR 313 CARBURETOR CHOKE 36 BRAKE SYSTEM 313 AIR CLEANER 35 BRAKE LIGHT SWITCH 314 (CRANKCASE BREATHER: 36 HEADLIGHT AIM. 314 ‘SPARK PLUGS: 36 (CLUTCH SYSTEM 3-15 VALVE CLEARANCE 37 ‘SIDE STAND 315 ‘CARBURETOR SYNCHRONIZATION 38 SUSPENSION 316 ‘CARBURETOR IDLE SPEED 39 SPARK ARRESTER (U.S.A. only) 3-16 RADIATOR COOLANT 3-9 NUTS, BOLTS, FASTENERS 317 COOLING SYSTEM 39 WHEELS/TIRES 317 CYLINDER COMPRESSION 3-10 STEERING HEAD BEARINGS 318 EVAPORATIVE EMISSION CONTROL ‘SYSTEM (California model onty) 3-10 SERVICE INFORMATION GENERAL ae Seis Efe yetienn See oume 2-4 SPECIFICATIONS: ‘Spark plugs — aaa : For old nate orn7ens | xzzemnus Fer gna igh opened venoevs | _xz7emnve Spark plug gap 0.80.9 me (0.031 —0.035 ind bref niece ome oe reo ex cameo tae pend Ssoom tose Cylinder compression, 1,177 & 98 kPa (12.0 # 1.0kglem®, 171 + 14 psi) 2=6 mm (1/16~ 1/4 in) Both carburetor within 40 mm (1.6 in) Hg of each other 2030 mmm (3/8—1-1/8 in) 10~20 mm (3/8314 in) 35~45 mm {1-3/8~1-3/4 in) 3 mm (1/8 io) ipper wear service init 5 mm (3/16 in) 3-1MAINTENANCE Tires eee et Tire sizo Cold tie pressures |_Un to 90 ko (200 tbs! load Front Fear 8090-21 548 28 si (2.00 kgicm?, 200 kPa} 130/80- 17 66S | 29 psi (2.00 kgiem?, 200 kPe)_| Up 10 vehicle capacity load| 29 psi (2.00 kgiom?, 200 KPal 29 psi (2.00 kgiem?, 200 kPa) ‘Minimum thread depth 1.5 mm (0.06 in} 2.0 mm (0.08 in) TORQUE VALUES: TOOLS sea ail Soe Osc o7ree-cooanMAINTENANCE MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Qwner’s Manual at 1ch scheduled maintenance period. |: Inspect and clean, Adjust, Lubricate, or Replace if necessary. Ri Replaco C: Clean L: Lubriceto (Tem note | x100km | 10 | 64 | 128 | 192] 256 | 320 | 384 to page ee: ee ae eee * | FUEL STRAINER SCREEN. c clic c c c | 34 = CRANKCASE BREATHER NOTE 3 jc c c c c c 36 2 |_| spank Luc CO =| = | VALVE CLEARANCE 1 1 1 Tilers onl g ENGINE Oil R a a | 23 3 |_[enaine ow Ficrer a ® R a | 24 HBR ae is ts [a nas MS V's | CARBURETOR-IDLE SPEED 1 | 1 1 1 1 39 ome ere Pee ee eee CONTROL SYSTEM dil i i eG 3 | Taraxe ru Bia a BRAKE SHOE/PAD WEAR 313 a * | BRAKE LIGHT SWITCH o14 2 CLUTCH SYSTEM. 315 % (= | suspension ‘316 & + | SPARK ARRESTER 316 2 (= | NUTS, BOLTS, FASTENERS: 317 ‘Should be serviced by an euthoriced Honda qualified. ** In the interest of safety, we recommend the NOTES: 1. At higher odometer ree ‘unless the owner has proper tools and service data and is mechanically ‘tems be serviced only by an authorized Honda dealer. 1, repeat at the frequency interval established hi ‘Service more frequently when riding in unusually wet or dusty area Service more frequently when riding in rain or at full throttle. California type only. Service more frequently when riding OFF-ROAD. - U.S.A. only. Roplace every 2 yoars, or at indicated odometer interval, whichever comes first. Replacement requires mechani cel ski 3-3MAINTENANCE FUEL LINE (Check the fuel ine and vacuum line, and raplace any parts which show detoriorstion, damage or leakega. (1) FUEL LINE] FUEL STRAINER SCREEN ‘Tura the fuel vaive OFF. Remove the fusl cup, O-ring and strainer scr gasoline into a suitable container + Gasoline is exiremely flammable and is explosive under certain conditions. + Do not smoke or allow flames or sparks near the equipment while draining fuel and drain the Wash the fuel cup and straine: screen in clean non-flammable or high flesh point solvent. Roinstall the strainer screen Reinstal the fuel cup, making sure @ new Finger tighten the cup, then torque it ing isin place. TORQUE: 4 Nem [0.4 kg-m, 2.9 fib) ‘Aftor instaling, turn the fuel valve ON and check that there are 1o fuel leaks. THROTTLE OPERATION Chock for emoath throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables end replace them if they are deterio: rated, kinked or damaged. Lubricate the throttle cables, if throttle operation isnot peoen Ea It) Lock NUT Measure throttle grip free play at the throttle grip flange. INCREASE PLAY FREE PLAY: 2—6 mm |1/16—1/4 in) i Minor adjustments are made with the upper throttle cable ad- (3) DECREASE PLAY| juster ‘Adjust the {ree play by loosening the lock nut and turn the ac luster. re Thon the look rt (4) AosusTER 3-433 Major adjustments ore made with the lower adjuster ‘Adjust the free play by loosening the lock nut and turning the ‘adjusting nut, Tighten the lock nut Recheck throttle operation. Replace any damaged parts, it (2, LOCK NUT CARBURETOR CHOKE Check that the choke lever moves smoothly, Lubricate the choke cable, if the operation ie not smooth. Loosen the choke valve nut and remove the choke valve from the carburetor ull the choke lever on the handlebars all the way back to the fully ON position and check for smooth operation of the choke lover There should bo no free play. Check the vaive seat on the choke valve for damage. Reinstall the choke vavie in the reverse order of removal AIR CLEANER Remove the lett side cover Remove the sir cleanor cover screws and element cover MAINTENANCE 2) CHOKE VALVE. : vg femme 2! ARCLEANER ELEMENT COVERMAINTENANCE Remove the sloment Replace the clement in accordance with the maintenance schedule. Also, replace the element any time it is excessively dinty or demaged. Install the air cleaner element. Install the parts in the reverse order of removal CRANKCASE BREATHER Release tho drain tube of tho air cleaner case to empty any de- posits. If any deposits are visiblo in the traneparent parte of the drain ‘tube, remove the plug from the air cleaner ces drain tubes to cempty them, Install the drain phag Note a + Service more frequently when ridden in ain or at Al thot Gitta tl or if the deposit level can be seen in the tansperent | (1) DRAIN TOBES 2) DRAIN PLUG port of tho daly tubo — 6 (1) PLUG GaP 2) SIDE ELECTRODE SPARK PLUGS 0.8-0.8 mm (0.031 —0.035 in} Disconnect the spark plug cap and remove the spark plug. Visually inspect the spark plug. Discard it ifthe insulator is cracked oF chi (3) CENTER ides ELECTRODE Measure the spark plug gap with a wite-type feslor gouge. ‘Adjust the gap by bending the side electrode careful. ‘SPARK PLUG GAP: 0.80.9 mm (0.031-0.035 = | | RECOMMENDED SPARK PLUGS: = NGK, ND Standard OPREEAS | X24EPRUO For cold elimate | Ticacumete | opn7ea.s | x22epRU ‘ For extended high Boe pprsea-s | x27ePR.UG ‘Make sure the sealing washer is in good condition Install the spark plug, tighten it by hané, then use a spark plug wrench for the final tantening, TORQUE: 14 Nom (1.4 kg-m, 10 #16) 3-6.__@ 2 2 MAINTENANCE VALVE CLEARANCE NOTE + Inapect and adjust valve clearance while the engine is cold (below 35°C/95°F1, Remove the fuel tank (page 4-3). Remove the radiator mounting bolts and the radiator (page 5: 8) Remove the crankcase hole cap and timing hole cap. Remove the vaive adjusting covers from the cylinder head cov For the inapection and adjustment of the front cylinder head valve clearance, rotate the flywheel counterclockwise to align the “FT” mark with the index notch on the left crankcase ‘Make sure the piston is at TOC (Top Dead Center) on the cor pression stroke. FRONT CYLINDER HEAD Inepect the clearance of all three valves by inserting a feeler gauge between the adjusting screw and the valve, VALVE CLEARANC! Intake: 0.15 mm (0.006 in) Exhoust: 0.20 mm (0.008 in) Adjust by loosening the lock nut and tuming the adjusting screw until there iso slight drag on the fooler gouge. Hold the adjusting screw and tighten the lock nut. TORQUE: 23 Nom (2.3 ko-m. 17 ftb) Toows: Valve clearance adjusting wrench 07908 —KE90000 or valve adjust wrench (07908 KE90100 Wrench, 10 12 mm (077080030200 Apply oil to the nut and screw thresd. REAR CYLINDER HEAD NOTE + Aftor the inspection and adjustment of the front cylinder head valve clearance, rotate the flywhee! counterclockwise to align the “AT” mark with the index natch on the left crankcase cover to inpsect and adjust the rear cylinde valve clearance. Make sure the piston is et TDC (Top Dead Conter) on the compression stroke. Rear cylinder valve inspection and adjustment Jame way as front evlinder valve cl (1) TIMING HOLE CAP) TH INDEX MARK] = aCMAINTENANCE Check the O-rings of the valve adjusting covers INJEX! for damage and replace if necessary. q ¥ Install the front and rear valve adjusting covers. ‘Apply MoS2 paste grease (page 2-10) to the timing and crank- cease hole caps. Install and tighten them. ‘TORQUE: Timing hole cap: 10 N-m (1.0 kg-m, 7 fetb) Crankshaft hole cap: 15 Nem (1.5 kgm, 11 fetb) CARBURETOR SYNCHRONIZATION NoTE + Perform this maintenance with the engine at normal operet ng temperature. Remove the fuel tank (page 4:3). Me ci ve the fuel tank on the frame. snect the fuel line 10 the fuel tank, Remove the plug from the front cylinder head intake ports and the fuel vacuum tube from the rear cylinder head intake ports. Install the vecaurn gauge adaptors as shown, Connect ty yacuun groan prow Werm uo the engine and adjust the idle speed with the throttle stop screw. IDLE SPEED: 1,300 +100 rpm ‘Check that the difference in vacuum readings between the cy! Inders is 40 mm Hg oF less. Synchronize to the specification by turning the eynchronizo- tion adjusting screw. Recheck the idle speed and synchronization. Disconnect the gauge adaptors and install the plug and ‘vacuum tube. ToL: Vacuum gauge 074040030000 or ‘vacuum gauge sot M9378 —021 — XXXXX 3-8MAINTENANCE CARBURETOR IDLE SPEED NOTE + Inspect and adjust idle speed after all other engine ments ere within specications. + The engine must be warm for accurate adjustment. Ton minutes of stop-and-co riding is sufficient ‘Warm up the engine, shift to NEUTRAL, and place the motor: oyele on its side stand, ‘Turn the throttle stop serow ax required to obtain the specified Idle speed. IDLE SPEED: 1,300 +100 rpm RADIATOR COOLANT Remove the left side cover (page 12-41. Check the coolant level of the reserve tank with the engine running at normal operating temperature, ‘The level should be between the “UPPER” and "LOWER" Jovol lines, If necessary, remove the reserve tank cap and fill tho tank up to the UPPER level ine with 80/50 mixture of distiled water ‘and antifresze. Reinstall the cap and left side cover. COOLING SYSTEM Check the radiator cores for clogging and radiator fins for bending Straighten bent fins and collapsed core tubes, Remove insects, mud ot any obstruction with compressed sit or low-pressure water. Replace the ra 20% of the radiating surtace. Ficted over more then Inspect the water hoses for cracks or deterioration, and ra- place if necessary. Check the all hos clamps te be seeure, (1) THROTTLE STOP SCREW)MAINTENANCE CYLINDER COMPRESSION Warm up the engine. Stop the engine and remove the spark plug. Connect © compression gaug Tur the engine stop switch OFF. (Open the throttle grip fully. Crank the engine with the starter ‘motor until the gaugo stops rising Check the gauge reading NOTE + Check the there Is no leakage at the gauge connection COMPRESSION: 117 = 98 kPa (12.0 £ 1.0 kg/em*, 171+ 14 psi) TOOL: Compression gauge 07308—0010000 Low compression can be caused by: + Improper valve clearance adjustment + Valve loako + Leaking cylinder head gasket + Worn piston rings or cylinder High compression can be caused by: + Carbon deposits in the combustion chamber or on the piston head. EVAPORATIVE EMISSION CONTROL SYSTEM (Califomia model only) Check the system hoses for damage, deterioration, kinking clogging oF loose connections. Check the charcoal canister for eracks or damage. Refer to the vacuum hose routing diagram label for hose con- nections. (1) CHARCOAL CANISTER U 3-10Cen a MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION + Never inspect or adjust the drive chain while the engine ts run ing. ‘Turn the ignition switch off, place the motorcycle on its side ‘stand and shift the transmission into neutral. Check slack in the drive chain lower run midway between the sprod SLACK: 35-45 mm (1-3/8 1-3/4 in) DRIVE CHAIN ADJUSTMENT Loosen the axle nut. Loosen both lock nuts and turn both adjusting nuts ny. cauTiON + Be sure the same index mark on the edjusier are aligned with the rear edge of the swing arm hole on both side. Tighten both lock nuts Tighten the rear axle nut TORQUE: 95 Nem (9.5 kg-m, 69 f41b) Check the chain woar label. If the red zone on the label aligns with the arrow of the chain adjuster after the chain hae been adjusted, the chain must be replaced DRIVE AND DRIVEN SPROCKET rockot teeth for exces ive wear or damage. ‘CAUTION + Never install @ new drive cahin on worn sprockets or @ worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly. & (2) ARROW. (1) DAMAGE REPLACE (2) NORMAL ‘S000 _ (2) WoRN REPLACE 3-11MAINTENANCE DRIVE CHAIN INSPECTION Clean the drive chain with a non-flammable or high flash point solvent that well not damage the O-rings and wipe dry. cauTION + Do not use steam cleaners high pressure washers or aerovol ‘chain lubricants ax these will damage the O-rings. + Do not use commercial erosol chain lubricanis, They conten ‘solvents which could damage the O-rings. Ingpoct the drive chain and O-rings for wear or damego. Replace the chain if itis excessively worn or damage. Lubricate the drive chain with SAE #80 or #90 gear cil DRIVE CHAIN SLIDER Check the of 5 for wear oF damage. Replace the drive chain slider if the thickness exceeds the ser vice limit SERVICE LIMIT: 3 mm (1/8 in) caution + Uf the chain slider becomes excessively worn, the chain will wear against the swingarm CHAIN SLIPPER Inspect the chain slipper and replace it if the depth of the chain ‘groove exceeds the service limit. ‘SERVICE LIMIT: 5 mm (3/16 in} BATTERY Remove the right side cover and inspect the battery fluid level. ‘When the fluid level ie near the lower level, add distilled water to the upper lavel line a8 follows: Remove the battery (page 16-3). Pulllthe battery out, and remove the filler caps and add disild ‘water to the upper level line. ae +The battery elecroyte contains wpa ald Protect your ees, skin and clothing. Uf electrolyte gets in your eyes, flush them thoroughly wich ater and get promo’ mediealatienion. Foinetall the filer cape and the battory. CAUTION + Add oniy distilled water. Tap waier will shorten the service Wife Of the basery. (3) LUBRICATE (Hy SAE #80 or SAE #00 GEAR OIL 3 mm (1/8 in) (2) LOWER LEVEL)o—2 > MAINTENANCE a AINTENANCE BRAKE FLUID Check the front brake fluid reservorr level IF the level neare the lower leve! mark, remove the cover and ‘laphragm. Fill the reservoir with DOT 3 or 4 brake fluid only. Check the entire eystem for leaks, if the level is low. CAUTION + Be careful not to let dust or water into the system when Filing the reservoir, + Avoid spilling brake fluid on pointed surfaces or tnstruemnt Tenses, as severe damage can result + Do not remove the cover until the handlebar has been turned so ‘that the reservoir is leve + Do not mis different types of fluid, as they are not compatible itt each other Refer to section 15 for brake bleeding procedures. BRAKE SHOE/PAD WEAR BRAKE SHOE INSPECTION Replace the brake shoes if the arrowr on the brake indicator plate aligns with the reference mark A" on full application of the rear brake pedal BRAKE PAD WEAR Inspect the pads visually trom the direction indicated by the ‘arrow mark curing all regular service intervals to determine pad If cither pad wears to the wear lines, both pads must be ro- placed, CAUTION + Always replace the brake pads in pairs to assure even de pres Make sure there are no fluid leaks. Check the brake hose and fittings for deterioration or cracks, BRAKE SYSTEM BRAKE PEDAL HEIGHT To adjust: Loosen the lock nut and adjust the pedal helght by turning the stopper bolt. Tighten the lock nut, Aglust the brake pedal free play (nage 3-14) 1) LOCK NUT i (2) STOPPER BOLT 3-13MAINTENANCE BRAKE PEDAL FREE PLAY NOTE + Adjust the brake pedal free play after adjusting the brake pedal he Measure the brake pedal tr play. FREE PLAY: 20-30 mem (3/4—1-1/8 in) 1 adjuetment ie necessary, tur the rear brake adjusting nut BRAKE LIGHT SWITCH nore +The front brake light switch does not require adjustment. Adjust the brake light switch go that the brake light wil light when the brake pedal is depressed and the brake begins en: gegement Hold the switch body and turn the adjusting nut as required. cAUTION + Do noi turn the switch body, The wires may be damaged. HEADLIGHT AIM Note + These adjustments can be done without removing the front cowling Adjust the headlight vertically by turning the vertical adjusting ‘Turn the adjusting screw clockwise to dizect the beam down Adjust horizontally by turning the horizontal adjusting screw ‘Turn the adjusting screw clockwise to direct the beam toward the left side of the rider \ Ter Ug NOTE 7 Adjust the headlight beam 96 specified by local laws and regulations, + An improperly adjusted headlight may blind oncoming drivers, ‘or it may fail to light the road for a safe distance. 3-14MAINTENANCE CLUTCH SYSTEM FREE PLAY: 10-20 mm (3/8—3/4 in) 10-20 mm (3/8—3'4 in} Minor adjustments are made with the upper adjuster. ll the lever cover back, loosen the lock nut end turn the ed BRINN juster to obtain the spectfied free play. Tighten the lock nut and inetal the caver. Check elutch operation, Mejor adjustments are made wi he lovrer adjuster. Loosen the lock nut and turn the adjusting rut to obtain the specified free play, Tighten the lock nurt and chack the clutch operation. SIDE STAND ‘Check the spring for damage or lose of tension, Check the side stand assembly for freedom of movernont, Lubricate the pivot bolt and he side stand pivot area if neces sary. Tighten the pivot nut. [1) PIVOT BOLT TORQUE: 40 N-m (4.0 kg-m, 29 ft1b)MAINTENANCE Check the side stand ignition cut-off system: ~ Sit astride the motorcycle and raise the side stand, — Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeezed, Move the side stand fully down, = The engine should stop as the side stand is lowered. If there is a problem with the system, check the side stand ‘witch leaetion 17) SUSPENSION FRONT ‘Check the action of the front suspension by compressing the fork several times. Check the entire fork assembly for signs of leaks or damage. Replace any components which are unrepairable. Tighten all nuts and bolts to the specified torque value (pages 1-8 and 1-6). + Do not ride a vehicle with Jaulty suspension. Loose, worn or ariaged suspension parts may affect stability and rider con- trol, REAR Check the action of the rear susper pressing the rear end several times. ‘Check the entire suspension assembly, to be sure itis securely ‘mounted and not damaged or distorted. Jon components by com Tighten all nuts and bolts to the specified torque value (pages 15 and 1-6), SPARK ARRESTER (U.S.A. only) Remove the muffler bolts and washers, ‘Start the engine and increase rpm's to biow carbon out of the exhaust pipe while momentary creating exhaust system back pressure by blocking the end of the muffier with a shop towel Repeat unttl carbon stops coming out. + Do.not perform this operation while the exhaust pipe is hot. ‘+ Perform this operation in a well ventilated area, free from fire hurd, + Use adequate eye protection. (1) BOLTS WASHERS. 3-16m ® MAINTENANCE ——_—. SS ——S a_i nance After cleaning the sperk arrester, install the washer and bolt. NUTS, BOLTS, FASTENERS Tighten the bolts, nuts and fasteners at the intervals shown the Maintenance Schedule (page 3-3) ‘Check that all chassis nurs and bolts are tightened to theit specified torque velues (pages 1-5 and 6). Check all cotter pins and safety clips. WHEELS/TIRES TIRE PRESSURE Nore Tire prassure should be checked wt thet ‘are COLD. Font fear Tie ze 9019921 548 [90/80— 17 638 Cade [Up s0xe 2a 2 pressures |(200 tbs) load| (2.00, 200) | (2.00, 200) Epateen® [Up to vehicle 20, 29 = capecity ead | (2.00, 2001 | 12.00. 200) Chock the tires for eute, imbedded nails, or other sherp ob- sects. Check the front and rear wheels for ruenass (Sections 13 and 14). Measure the tread depth at the canter of the tires Replace the tres if the tread depth ri ite MINIIUM TREAD DEPTH: Front: 1.5 mm (0.06 in} Rear: 2.0 mm (0.08 in} ches the foliowing lim- Tighten the wheel epokoe periodically. More frequent inspec: tion is necessary whan riding aifsroad TORQUE front/rear): 3.8 N-m {0.38 kgm, 2.7 feb) Too: SPANNER € 5.8 x 6.1mm 977010020300 Equivalent ‘commercial available in U.S.A.MAINTENANCE STEERING HEAD BEARINGS 3K that the control cables do not interfere with handle bar rotation. tho front wheal off the ground, Check that the handlebar moves fr ly from side to side. If the vertical movement, 3-18FUEL SYSTEM 27 Nem (2.7 kgm, 20 ft1b) 404, FUEL SYSTEM EO ‘SERVICE INFORMATION 41 CARBURETOR SEPARATION) ‘TROUBLESHOOTING ae | COMBINATION ae iceagranik 43 CARBURETOR INSTALLATION 416 FuEEVALVE a4 PILOTSCREW 417 RINGLEARER case: 4.7 PILOTSCREW ADJUSTMENT 448 CARBURETOR REMOVAL Panco Tae aoe EN aie CARBURETOR DISASSEMBLY: 48 PURGE CONTROL VALVE INSPECTION E CARBURETOR ASSEMBLY 412 (California model) 4.20 SERVICE INFORMATION = * Gasoline is extremely arnmabie and ty explosive under certain conditions, Work ina wel ventilated area. Do not imoke ov allow Flames ar sparks in the work area or where gasoline is stored. Rofer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments, ¢ When disassembling fuel eyeter perie, note the locations of the O-rings; replace them with new ones on reassembly. © Tho caburetor float chambers have drain screws that can be loosened to drain residual gasuline. CAUTION + Do not bend or twist control cables. Dartaged control cables will no! operate smoothly and may siick or bind, NOTE * vehicles to be stored for more than one month, drain the float bows. Fuel left in the float bowls may eause clogged jeta, resulting in herd starting oF poor drivecbilty. SPECIFICATIONS Fuel capacity Fuel reserve capacity 18 liters (4.8 US gal, 4.0 Imp gal) 2.9 Iters (0.77 US gal, 0.64 Imp gal) <_>:California model Throtve valve di, Throttle grip roe play $34) x Indentification No. = \VDFHA Float lovel iz Tmm (0.3 in) Main jot FRONT #120 REAR #120 "Siow jet #38 | late speed 4,900 = 100 rpm 2-6 mm (1/16—14 in) Pilot screw initial opening Vacuum difference between cylinders 2-1/2 turns out 40 mm (1.8 in} Hg mex. TORQUE VALUES Fuel tank mounting bolt Fuel valve lock nut Fuel cup TOOL Common, Float level gauge VacuumvPrassure pump Vacuum pump 20 feb) 40 Nom (4.0 kg-m, 29 Feb) 4 Nem 10.4 kg-m, 2.9 fb) (07401 0010000 A9I7X-OAT-XXXXX oF ST-AH-260-MC7 ST-AH-255-MC7 (U.S.A, only) ee hh 41FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start + No fusl in tenk + No fusl to carburetor ~ Fuel fiter/strainer clogged — Fuel line clogged — Float valve stuck — Float level miseojusted Fuel tank broether tube clogged — Fuel auto value matfunction + Too much fuel getting to the engine Air cleaner colaged — Flooded carburetor + No spark at plug ignition system matfunction) + Intake air leak + Fuel conteminstedideteriorated + Slow circuit clogged Lean mixture + Fuel jet clogged + Float valve fauity + Float leval too low + Fup line restricted + Corburotor air vent tubo clogged + Intake aie leak + Fuel auto valve malfunction Vacuum picton faulty + Throttia valve faulty Rich mixture. + Choke valve in ON position + Flogt vaive faulty Float level too high + Airjet clogged + Ai cleaner element contaminated + Flooded carburetor Engine stalls, hard to start, rough idling Fuel line restricted + Ignition system malfunction + Fue! mixture too lean/tigh + Fuel contaminatadidateriorated + Intake air leak + Idle speed misadjusted + Fuel auto valve malfunction + Plot screw misadiusted + Slow circuit-clogged + FLoat level misedjusted ‘+ Fuel tenk breather tube clogged + Purge control valve faulty ICalifocria model only) + Hoses of the emission control system faulty [California model only) ‘Afterbumn when engine braking is used + Air cut-off valve Faulty + Loan mixture in slow circuit + Hoses of the emission control system faulty (Colifornia model only Backfiring of misfiiing during acceleration + Ignition systom malfunction + Fuel mixture too lean Poor performance (driveability) and poor fual oconomy ‘+ Fuel system clogged + Ignition system malfunction + Damaged/mieconneetod omigsion centro! system hoses (California mode! oniy) 42FUEL SYSTEM FUEL TANK REMOVAL + Keep gasoline away from flames or sparks. Wipe up spilied gasoline at once. (1) SEAT \ Remove the side covers (page 12-4) end side cowling (page 12.2) Remove the two bolts and seat. Tuin the fuel valve OFF and disconnect the fuel tube and vacuum tubes. Disconnect the fue! tank cap vent tube (California model only) Remove the fuel tank mounting bolt and fuel tank. Check that fuel flows out of the fuel valve freely flow is restricted, clean the fuel strainer screen (page 3-4) INSTALLATION Install the fuel tank and tighten the mounting bolt TORQUE: 27 N-m (2.7 kg-m, 20 feb) Connect the fuel tube and vacuum tubes. Install the seat with the two bolts, Install the side covers (pego 12-4) and side cowling (page 12-2). Connect the fuel tank cap vent tube (California model only) et) FUEL TANK CAP we VENT TUBE {After assembling, meke ure there are no fuel leaks. (2) FUEL TANK. (3) MOUNTING Bout (1) FUEL TANK CAP (2) CALIFORNIA MODEL: .7 keen, ,/| Ent (3) FueL FILTER = An VENT ey 10 Nem (4,0 kgm, 28 feb) DIAPHRAGM (4) TO CARBURETOR ° (5 STRAINER et ‘SCREEN (9) TO REAR CYLINDER (6) SPRING 4 Nem (0.4 kg-m, 2.8 feb) 4-3FUEL SYSTEM. FUEL VALVE INSPECTION Install the vacuum pump to the vacuum tubs of the fuel valve Apply @ vacuum to the diaphragm with the vacuum pump and be sure the gasoline flows smoothly. “The fuel valve is operating normally if fuel flaws out of the fuel ‘tube when vacuum is epplied and if fuel siops flowing out when the vacuum pump is disconnected. If the fuel valve does not operate normally; ~ Inepoet the fuel velve for clogging and clean the velve. — Replace tha diaphragm if fuel flows cut without app! NOTE + Place a clean fuel container under the {uel tubs. DISASSEMBLY Remove the fuel tank (page 4-3) Remove the diaphragm cover with the four screws. Romove the spring and spacer. (Check the spring for damage. ‘Check the diaphragm for pin noles or other damage. Roplace necessary. oh vacuuM TUBE (2) FUEL TUBE (2) SPACER r | 3) vacuum (1) DIAPHRAGM. 4-4FUEL SYSTEM SYSTEM Remove the fuel strainer eup, O-ring and streiner screen, Clean the fuel strainer screen. Loosen the lock nut, and remove the fuel valve from the fuel tank. Remove the fuel filter and O-ring, Clean the fuel titer. ASSEMBY Install the fuel fiter and a new O-ring to the fuel va Install the fuel valve to tho fuel tank. ‘TORQUE: 40 Nem (4.0 kg-m, 29 feb) Install the strainer screen. Instell a new O-ring to the strainer cup, and install the strainer cup onto the fuel valve, TORQUE: 4.0 Nem (0.4 kgm, 2.9 Felb)FUEL SYSTEM Instal the spacer to the fuel valve. NOTE + Align the pine of the epacer with the holes of the fuel valve, Install the spring and diaphragm cover. ‘Tighten the four screws of the diaphragm cover securely. Install the fuel tank (page 4-3). ‘Make sure there are no fuel jan? " (2) SPACERAIR CLEANER CASE ei system (3) cb! UNIT_12) Mounting BOLTS) a. 4 @ Fett Rise the ‘ear wheel off the ground by placing « box or vt ‘ REMOVAL worketand under the engine cauTION + Do not jack up the engine by puting the jack under the vil fi ter. Flomove the battary (nage 16-2) (3) STARTER Romove the starter reley switen, 2 RELAY switcH! Romove the roar fonda anc inner fender (page 12-5). Remove the rear wheel (page 14-3), Remove the air cleaner ca: mounting bolt on right side, Remove the CDI unit from the ak cleaner case, Ramove tho air cleaner case mounting bolts on upper side, Loosen the insulator band and sir duct band screws end (1) al Ue femove the air duct. Pull the ai cleener case backward. FUEL SYSTEMFUEL SYSTEM Nore * Correct routing, see page 1-9. + When inotalling the sir cuet band, apply oil to the inside of (2) AIR DUCT BAND |SEE NOTE) the tube band, (3) AIR CLEANER CASE (1) AiR DUCT (5) INSULATOR (4) ELEMENT CARBURETOR REMOVAL (2) Cloke CABLES Remove the fuel tank (page 4-3) Remove the air duct (page 4-71. Loosen the drain sorewe end drain tho fuel into a containor. + Keep gasoline away from flames or sparks. Wipe up spilied ‘gasoline at once. Disconnect the throttle cabi Disconnect the right and leit side choke cables. Loosen the insulator band screws. Pull the carburetors upward and ewey from the engine, CARBURETOR DISASSEMBLY ininsuuaton NOTE + Tho disassembly of the carburetor can be done without separating the carouretors. Remove the insulator from the carburetor, loosening the Remove the fual tube 7 Mae eschew 48np Cub) re FUEL SYSTEM VACUUM CHAMBER Remove the four screws and vacuum chamber cover. Remove the spring, diaphragm and vacuum piston. Inspect the vacuum piston for wear, nicks, scratches or other damage, Make sure the piston moves up end down freely in the char ber. Push the jot needle holder in and umn it in 60 degrees counter- clockwise, Then remove the needle holder, spring and jet needle trom the piston. Inepect the neadle for excossive w other damage, Inspect the diaphragm for damage or pin holes. Inepect the vacuum piston for woar or damage. Fat the ti bonding or fi ©) ‘ (1) ScREWs (2) VACUUM CHAMBER COVER] (1) SPRING (2) DIAPHRAGM @)y E (ny igrON 2) parrnacm Bebe te) vouoen De ~ (5) JeT NEEDLE Me (a serve 4-9FUEL SYSTEM FUEL SYSTEM FLOAT CHAMBER, FLOAT AND JETS 1) FLOAT CHAMBER Remove the four serews and float chamber. Ramove the float pin, float and float valve (1) FLOAT VALVE (2) FLOAT PIN Check the float vaive and valve seat for scratches, clogging or damage. {Inspect the operation of the float valve, (2) VALVE SEAT Remove the main jet, nesdle jet holder, slow jet, valve seat and (2) NEEDLE JET HOLDER, titer. Check each part for wear or damage, Blow all jets open with compressed air. Coan all jote with non-flammable or high flash point solvent. (3) VALVE SEATIFILTER 4-10FUEL SYSTEM Inspect the float valve seat and fiter for grooves, nicks or de posits: Clean the filter with low-comprassod air. NoTE +_Do not use high-pressure air, AIR CUT-OFF VALVE Remove the two screws and air cut-off valve cover. Remove the spring, diephregm and O-ring. Check the diaphragm for pin h 18 oF other damage. Replace if necessary. Seperate the carburetors (page 4-14). Blow all passages open with comproseed air before installing the jots and valves. (1) VALVE SEAT (3) WasHer (2) FILTER, (Ty AIR CUT-OFF VALVE COVER (2) SCREWS (1) DIAPHRAGMFUEL SYSTEM CARBURETOR ASSEMBLY we TuRust 1) VACUUM SPRING CHAMBER Over S {or HOLDER c (10 bapHnacn (21 PHOT SCREW (sean caseane (6) JET NEEDLE (11) SPRING QF . (9) O-RING Aw (6) 1APHRAGM (Sqta a & ‘NS tage, Me. Z eo \ PY FD S pr @ BS mS , S ri x (12) AIR CUT- ~ i OFF valve it Ps ington NE aves wBy x (17 valve Wa) NeeDLe ver eS SEAT HOLDER (18) stow ser (18) FLOae (15) MAIN JET CHAMBER AIR CUT-OFF VALVE (1) DIAPHRAGM (2) SPRING Install the diaphragm, spring, O-ting and air cut-ott valve cover ‘to the carburetor body. NOTE + Install the Orring with ike flat aide toward tho carburetor body, Tightan the screws secursly. VALVE COVER, FLOAT CHAMBER, FLOAT AND JETS (1) SLOW Jer) MAIN JET 5; NeeDLe instal the valve seat, slow jet, needle jot holder and main fet. Nt (4) VALVE SEAT 4-12FUEL SYSTEM HS system Install the float with the float valve toward the carburetor body {end install the flost arm pin through the body and float. (1) FLOAT vaive 2) PIN FLOAT LEVEL Measure the float level with the float tang just contacting the float valve. FLOAT LEVEL: 7 mm (0.3 in) TooL: Float level gauge 074010010000 Adjust the flost leval by carefully bending the float tang. Apply thin ol to the O-ring. (1) FLOAT CHAMBER (2) screws. Install the float chamber and tighten the screws securely. the correct position. VACUUM CHAMBER ae Install the jet needle, spring and needle holder to the vacuum eae piston. Push the jet ns le holder in and turn it in 60 degrees clock- (2) HOLDER wise, (3) SPRING 4-13FUEL SYSTEM Install the vacuum chamber with the tab of the diaphragm sligned with the groove of the carburetor and with the vacuum piston held up 10 almost full open so that the diaphragm is not pinched by the chamber cover: Install she chamber cover with the spring, aligning its cavity ‘with the hoie in the earburotor, and eacure with at least tivo, ‘screws on diagonal before releasing the vacuum piston, Install the remaining serows NOTE + Do not pinch the diaphragm with the chamber cover. Install the fuel tube to the carburetors as shown. Install the insulator to the carburetor and tighton tho eerow eo. (1) INSULATOR curaly (2) SCREW! CARBURETOR SEPARATION/ 1) screw COMBINATION g SEPARATION Loosen the synchronization adjusting serevr. Soparate the carburetors by temoving two attaching screws. (2) SYNCHRONIZATION ADJUSTING SCREWFUEL SYSTEM ny THRUST ‘Toke care not to lose the thrust spring and synchronization ad SPRING justing spring, (2) SYNCHRONIZATION SPRING COMBINATION (1) ADJUSTING SCREW ia Lecsen the synchronization adjusting screw until there is no tension. Install the thrust spring between the throttle links, ‘Assemble tho carburoters with the two attaching screws. Install the synchronization spring.FUEL SYSTEM Inepect throttle operation as described below: * Open the throttle slightly by rotating the throttle valve, ‘Then relsase the throttle. Make sure that there Is no drag when opening and closing the throttle, Jum the throttle stop screw to align the left side carburetor ‘throttle valve with the edge of the by-pass hole. ‘Aign the right side carburetor throttle velve with the by-pass hole edge by tuning the synchronization adjusting sere Moke sure the throttie returns smoothly. (1) SYNCHRONIZATION ADJUSTING SCREW (21 BY-PASS HOLE CARBURETOR INSTALLATION |2) CHOKE CABLES ps Install the carburetor in the reverse order of romovel NoTE * Route the throttle cables properiy pages 1-0 through 4-12) Ferform the following inspections and adjustments, + Throtte operation page 3-4), + Idle speed ipage 3-9), + Choke cable operation (page 3:5}. + Corburetor synchronization page 3-8) 4-16FUEL SYSTEM (1) PILOT SCREW PLUG. PILOT SCREW REMOVAL Note * The pilot screws are factory pre-set and should not be re- ‘moved unless the carburetors ara overhauled + Tho pilot screw plugs are factory installed to prevent plat Screw misadjustment. Do not remove the plugs unless the pilot screws are being removed, + Cover all openings with tape to keep metal particles out when the plugs are dried, Conter punch the pilot screw plug to center the drill point Drill through the plug with © 4 mm (5/32 in) dil bit. Actach a Gril stop to the bit 3 mm (1/8 in) from the ond to prevent dil ing into the plot screw, ‘CAUTION + Be careful not to drill into the pilot screw. * Ifyou replace the pilot serew in one carburetor, you must re lace the pilot screw in the oiher carburetor for proper piloi serew adjusimont (page 4-18), Force a self-tapping 4 mm serew (H/C 069999, P/N 93903— 36410) into the drilled plug and continue turning the sorevr- driver until the plug rotates with the screw. Pull on the screw head with pliers to remave the plug. Use compressed air to clean the pilot screw area and remove metal shavings. om Use appropriate eve protection Turn each pilot screw in and carafully count the number of turns until it soats lightly. Make a note of this to use as a re ‘ence when reinstalling the pilot crows. CAUTION + Damage . the pilot seat will occur ifthe pilot serew is ighoned against the sea, Romove the pilot screws and inspect them. Replace them if they are wom or damaged. 4-17FUEL SYSTEM INSTALLATION Install the pilot screws and return them to their original position as noted during removal Porform pilot screw acjutment if naw pilot screws are installed. NOTE + Do not install new plugs in the pilot screw holes until after ‘sho adjustment has been mado, + if you replace the pilot screw In one cerburetor, you must replace the pilot screw in the other cerburetor for proper allot serow adjustment. (1) PILOT SCREW PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE (U.S.A. ONLY) NoTE + The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced. + Use a tachometer with graduations of 50 rpm or smaler that will accurately indieate a 60 rpm change. 1, Turn each pilot serew clockwise unti it s2ats lightly, then back it out to the specification given This is an intal setting prior to the final pilot screw adjustment, INITIAL OPENING: 2-1/2 tums out CAUTION + Damage 10 the pilot serew seat will oceur if the pilot screw is tightened against the seat 2, Warm up tho engine to operating temperature Stop and go driving for 10 minutes is sufficient. 3. Attach © techometer according to the menufacturer’s inetructions. 4, Adjust the idle speed with the throttle stop screw. 5, Turn each pilet screw 1/2 turns cut from the initial setting. 6. the engine speed increases by 50 rpm or more, turn ‘each pilot screw out by 1/2 turns until engine speed crops. by 50 rpm or less, 7. Adjust the idle speed with the throttle stop screw 8. Turn the No, 1 carburetor left side) pilot screw In until the engine speed drops 60 pm. 9, Turn the No. 1 carburetor pilot screw 1 turn out from the position obtained in step 8. 10, Adjust the idle speed with the throttie stop scrow. 11, Perform steps 8, 9 and 10 for the No. 2 carburetor pilot screw. 12, Drive new pilet screw plugs into the pilot ecrew bores with a7 mm valve guide driver (P/N 079428230000). When fully seated the plug surfaces will be recessed 1 41) Plus.FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT (U.S.A. ONLY) When the vehicle is to be operated continuously above 2,000 ‘meters (6,500 feet), the carburators must be readjusted as de- scribed below to improve driveability and decrease exhaust (1) PLOT SCREW Remove the each pilot screw plug. (Page 4-17). ‘Warm up the engine to normal operating temperature: ‘Stop and go driving for 10 minutes is stficient ‘Turn the pilot screw clockwise 1/2 turn, Adjust the idle speed to the specification, with the throttle stop screw, IDLE SPEED: 1,200 100 rpm Nore + These adjustments must be made at high altitude to oneure proper high altitude operation, (1) VEHICLE EMISSION CONTROL INFORMATION LABEL Drive new pilot screw plugs into the pilot screw bores. (Page 4-18). Attach the Vehicle Emission Control Informetion Update label 48 shown, See SL #132 for information on obtaining the lobe. re ‘YENICLE EMISSION CONTROL INFORMATION UPDATE NOTE HONDA MTOR C0, LID. PES EC ily Fo IMPROVE EMisSION EDUTRGL PERFORMANSE + Do not attach the label to any part that can be moved from the vehicle, WHEN OPcATED AT MH ALTITUDE. ALTITUDE PERFORMANCE ADILSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER, * Operation at an attitude lower than 1,500 meters (5,600 feet) with the carburetors adjusted for high altwues may cause the engine 10 ile roughly and stall When tho vehicle is to be operated countinuously below 1,500 meters (5,000 feet); turn each plot screw counterclock wieo 1/2 turns toits original position and adjust the idle speed to the specification Drive new pilot screw plugs into the pilot sorew bores. (Page 4.18) ‘Be sure to do these adjustments at low altitude with the engine ‘at normal operating temperature, 4-19FUEL SYSTEM PURGE CONTROL VALVE INSPECTION (California model) NoTE The purge contrel valve should be inspected if hot restart ie sitficutt Check all fuel tank, Purge Control Valve |PCV) and chacoal filter hoses to be sure they are not kinked and are securely con- nected. Replace any hooe that shows signe of damoge or dete tioration. NOTE The PCV Is located above the breather separator. Remove the fue! tank (page 4-3). Disconnect the PCV hoses from their connections and remove (5) the PCV from its mount, Refer to the routing labelon theinside |TO. of tho loft side cover. CHARCOAL, CANISTER. ito Uf CARBURETOR BODY tomatoe GERUNTNGDS 48 rah O48 0) 10, om [oo ee) spats heconceursar aye ona oan So (4) TO CARBURETOR BODY SPECIFIED VACUUM: 250 mm (9.8 in) Ho ‘The specified vacuum should be maintained. Roplace the PCV if vacuum is not maintained Vacuum/Pressure pump A937X-041.XXXXX or ee ers Remove the vacuum pump and connect it tothe vecuum hose thot goes to the eerburetor body. Apply the specified vacuum t0 the PCV. ‘SPECIFIED VACUUM: 250 mm (9.8 in) He The specified vacuum should be maintainec. Roplace the PCV if vacuum is net maintained. TooL: Vacuurn/Pressure pump A937X.041-20000% or Vacuum pump ST-AH-260-MC7 (U.S.A. only) 4-20FUEL SYSTEM Connect a pressure pump to & mm (0.91 in) LD. hose that goes 10 the chacoal canister. While appiving the specified Vacuum to the PCV hose that goes to the carburetor body, ump air through the canister hose. Air should flows through the PCV and out the hose that goes te the carburetor body. Replace the PCY if air dass not flow out. (1) VACUUM PUMP CAUTION To prevent damage 10 the purge control valve, do not use high- pressure air sources. Use a hand operated alr pump only. Toot: (2) PRESSURE PUMP Vacuuum/Pressure pump ADI 7X-041-XXKKX oF faciuim pump ST-AH-260.MC7 Proseure pump ST-AH-255-MC7 (U.S.A. only) Remeve the pumps, install the PCY into its mount, route end feconnect the hoses according to tho routing label. 4-21COOLING SYSTEM 5-05. COOLING SYSTEM ‘SERVICE INFORMATION 5-1 THERMOSENSOR 55 TROUBLESHOOTING 5-1 THERMOSTATIC SWITCH 5-5 SYSTEM TESTING 5-2 RADIATOR 5-6 COOLANT REPLACEMENT 5-3 WATER PUMP 58 THERMOSTAT 5-3 RESERVE TANK 5-10 SERVICE INFORMATION com Do not remove the radiator cap when the engine (s hot. The coolant is under pressure and severe scalding could result. The engine ‘must be coo! before servicing the cooling system. Use only cistiled water and ethylene glycol in the cooling system, A 60/50 mixture is recommended for maximum corre sion protection. Do not use slechol based ertifroeze, ‘© Add coolant at the reserve tank. Do not remove the radiator cap except to refill or cool. © All cooling systom service ean be dono with the engine in the frome. Avoid spilling coolant on painted surtaces. © After sorvicing the system, check for leaks with a cooling system tester. the eystom when the system is SPECIFICATIONS: Tew ~ Radiator cap viet pressure Freesing pont ycrometer tes SPECIFICATIONS 88— 127 4Pa (0.91.3 kofem®, 13-18 pall ‘55% Distled water + 45% ethylene gyeck: A290 25°F) 50% Distlod water + 50% ethylene gycck:~37°C _|-34°F) 45% Distiled water + 85% ethylene Gycol: ~44.5°C |-a8°F) ‘Coolant capacity “Tota system 1.75 liters 11.85 US gt, 1.54 inp at) Thermostat ;Bagine to opon: 80° v0 649C (176° to 163°F) Valve lift: Minimum of & im at 95°C (0.3 in at 203°) UUnpressurized: 107.7°C (26°F) Cap on, proseurzeci 126.6°C (268°) ating point (with 50/50 mixivre “Thermosensor ‘emperatu 50°C (122°) 0° (176°F) 120°C (2 resistance 169.90 3199 tet ‘Thermostatic swith Cores into action: 98° to 102%C [208° to 216°F) ‘Stops: below 93°—97°C (199° —207°F) TORQUE VALUES ‘Thermostatic switch Gearsnift pedal TROUBLESHOOTING 18 Nem (1.8 kg-m, 12 Feld) 1ONem (1.0 ka-m, 7 fFlb| Engine temperatura too high + Faulty temperature geuge or geuge sensor + Thermostat stuck closed + Faulty radiator cep + Insufficient coolant or cootant level too low + Passages blocked in radiator, hoses or water jecket + Cooling fan motor does nat turn Broken or loose sub fuse, Faulty fan motor Faulty thermostatic switch = Poorly contact or open circuit in harness + Faulty water pump Engine tomperature too low + Fouity temperature gauge or gauge sensor. + Thermostat stuck open Coolant leaks * Faulty pump mechanical seal Detoriorated O-rings SSS 5-1COOLING SYSTEM COOLING SYSTEM SYSTEM TESTING COOLANT MIXTURE Test the coolant mixture with an antifreeze tester. For maximum cortosion pratection, a §0/50% solution of eth- Ylene qlyco! and cistiled water is recommended, RADIATOR CAP INSPECTION Remove the right side cowling [page 12-2), Remove tho radiator cap. ie sure the engine is co! before removing the cap. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if it's relief pressure is too high or t00 low. It must hold the specified pressure for atleast six sec onds. NOTE + Before installing the cap on the tester, wet the se faces with wotor RADIATOR CAP RELIEF PRESSURE: ‘88127 kPa (0.91.3 kolem?, 13-18 psi) (1) RADIATOR CAP TESTER SYSTEM PRESSURE TEST ___ (1) RADIATOR CAP TESTER Remove the right side cowiing (page 12-2) and radiator cep. Prassurize the radiator, engine and hoses, and check for leaks. CAUTION “Excessive pressure can damage the radiaror, Do noi exceed 125 KPa (1.25 kg/emt, 18 psi) Repair or replace components if the aystem will not held tho specified preseure for at least six seconds. &2COOLING SYSTEM —2]AN_OOOLING SYSTEM COOLANT REPLACEMENT oI + The engine must be coo! defore servicing the content replace ‘ment, or severe scalding may result, Remove the lower cowling (page 12-3). Remove the radiator cap (page 5-2). Drain the coolant trom the system by removing the drain bot (on the water pump cover, Install the drain bolt, Frill the system with 50/50 mixture of distiled water and othy|- ene glycol Bleed air from tha caoling systom. + Apply side stand and shitt the transmission into neutral + Stert the engine and snap the throttle grip, 3—4 times at 4,000—6,000 rpm. Then add coolant up to the radiator filer neck, + Roinetall the radiator cep. + Check the level of coolant in the reserve tank and illo the Correct level if the level is low. Instell the lower cowlings (page 12-3) THERMOSTAT REMOVAL Remove the fuel tank (page 4-2). Drain the coolant. Disconnect the switch connectors, Remove the thermostat housing cover by disconnecting the water hoses and rerroving the housing cover mounting bolts. CT THERMOSTAT HOUSING Cover) (1) DRAIN BOLT. (1) RADIATOR FILLER NECK 3) WATER HOSES!COOLING SYSTEM. Remove the thermostat from the housing. INSPECTION Inspect the thermostat visually for damage. ‘Suspend the thermostst in heated water to check its opera: tion NOTE + If the thermostat or thermometer touches the pen, you'll get 2 false roading, Replace thermostat if tho valve stays open st room tempers: ture, oF if it respones at temperatures other than those spec! fed Data: Starts to open | 80° to 84°C (176 -183°F] Vatve tirt, [8 mm (0.3 in) minimum when heated to 95°C (203°F) for five minutes INSTALLATION Install the thermostat into the housing Install a new O-ring to the housing cover and install the hous- ing cover om the housing, Tighten the thermostat housing cover mounting bolts Cannect the water hoses to the housing cover.COOLING SYSTEM THERMOSENSOR REMOVAL Drain the coolant (page 5-3) Disconnect the wire from the thermasensor Remove the thermosensor. ‘Suspend the tharmosensor in 60/50 mixture of distilod water ‘and ethyiene glycol Heat the weter gracually and meesute the resistence. NOTE + Ifthe thormesonsor toushes the pen, you'll get a Felee read ing, Dat Temperature (PCI°F) | 60/122 | 80/176 | 120/248 Rasistance (a isas | si9 | 161 INSTALLATION ‘Apoly sealant to the threads of the thermosensor and tighten the thermosensor to the thermostat housing, NOTE + Do not apply sealant to the area 2-3 mm from the end of the threads of the sensor. Connect the thermosensor wire to the thermosenzor Fil the cooling system (page 5-3) THERMOSTATIC SWITCH The thermostatic switch senses the temperature of the radia tor coolant. The fan motor comes on at 98° 102°C (208° 21°F) and stons at below 93° 97°C (189° 2079}, amen nga eee ‘ HU Ire tne mer doee fxs esi io HTT) ters rom the thermostatic switch ang imp the connecters iil Cw fab | eran If te fan motor movas with the ignition switch “ON”, the thecmostatic switch is faulty. INSPECTION Remove the thermostatic ewitch and suspend it in 60/60 mix: {ute of distilled water and ethylene alycal Hoat the ccolent gradually and check the thermostatic switeh for continuity at 98°— 102°C (2089 216°F), oo! the heared coolant gradually and chack the thermostatic witch for no continuity at 98°—87°C (199° —207°F, Apply sealant to the switch thread and inctall it. TORQUE: 18 N-m (1.8 kg-m, 13 feb)COOLING SYSTEM COOLING SYSTEM RADIATOR Tip oveR FLOW TUBE (Sy BREATHER TUBE REMOVAL Diain the coolant (pege 6:3). Remove the side cowling (page 12-2) Remove the fue tank (page 4-9). Remove the following components from the right radiator. = Thermostatic switch and thetmesensor connectors (page 55) = Water hoses = Breather tube Overflow tubo — Air cleaner Disconnect the fan motor connector, Remove the radiator shroud bolts and radiator shroud from the (1) SHROUD radiator. BOLTS (2) SHROUD} Romove the radiator mounting bolts and radiator. 11) RADIATOR Remove the leit radiator in the same orcer as the right ravietor / H removalCOOLING system —._SOOLInG system DISASSEMBLY (1) Bouts (2) FAN MOTOR SHOULD Femove tho fon motor shroud mounting bolts, end remove the ‘fan moto: shroud and fan motor at an aesombiy. Fie tno nt ad fen, (0) Nur $ t the fan moter mounting nuts and fan moter from the (1) FAN MOTOR nurs j motor shroud. 4 BLY. C2ach part for damage the fen to the fan mozor shaft, aligning the boss of the Iwith the groovo of the fan. ble the remaining components in the reverse order of soombly.COOLING SYSTEM COOLING SYSTEM WATER PUMP MECHANICAL SEAL INSPECTION Remove the lower cowling (page 12-3) Inspact the teltele Nole for signs of mechanical seal coolent Pree on? erToM OF THe WATER PUMP ay ee 6 REMOVAL, i WE 2) Drive sprocker Coven] Drain the engine oil (page 2-3). ie Remova the gearshift retaining belt and gearshift pedal Remove the 1wo mounting bolts and drive sprocket cover. (3) 80LT Drain the coolant (page 5-3), Disconnect the water hoves from the water pump cover and water pump. Remove the water pump mounting bolts end water pump Remove the dowel pine end O-ring. Remove the water pump.en rr ” COOLING SYSTEM INSTALLATION Install a new O-ring en tho water pump. Install the water pump, aligning the boss of the oil pump shaft with the groove of the water pump shat (3) O-RING Inetall the dowel pine and a new O-1ing to the water pump. Install the water pump cover onte tha water pump. (3) WATER PUMP COVER Tighten the water pumip mounting baits with the wire clamp. Tighten the drain bolt with the sealing washer Connect the water hoses to the water pump and water pump. ‘cover, and install end tighten the water pipe clamps. Fill the radiator with coolant (page 6-3) Fil the engine with the recommended engine cil (nage 2-2). Check the cooling system for leakage, (8) DRAIN BOLT? SEALING WASHER the drive sprocket cover and gearshift pedal, ToRQu Goorshift pedal: 10 Nem (1.0 kgm, 7 ft) Install the lower cowling (nage 12:3). 5-9COOLING SYSTEM COOLING SYSTEM RESERVE TANK z (1) MOUNTING BOLT REMOVAL (2) TUBES, Romove the starter motor (page 18-3) Remove the reserve tank mounting bolt. Disconnect the overflow tube (black) and breathor tube (rod) tank. Remove the reserve tank INSTALLATION Intall the reserve tank in the reverse order of removalENGINE REMOVAL/INSTALLATION 27 Nem (2.7 kg-m, 20 ft-4b} 22 Nom (2.2 kg-m, 16 ft-lb)6. ENGINE REMOVAL/INSTALLATION | SERVICE INFORMATION 6-1 ENGINE INSTALLATION 6-2 ENGINE REMOVAL 6-2 SERVICE INFORMATION GENERAL CAUTION + Do not jack up the motorcycle by putting the jack under the oil filter. @ During removal and installation, support the frame with suitable stay. Oil pump Section 2 Cylinder head Section 9 Crankshaft/Transmission Section 11 SPECIFICATIONS Engine dry weight 59.5 kg (131.17 Ib) Oil capacity 2.2 lit (2.32 US qt, 1.94 Imp qt) after draining 2.8 lit (2.96 US qt, 2.46 Imp qt) after disassembly TORQUE VALUES Swingarm/engine pivot nut 110 Nem (11.0 kg-m, 80 ft-lb) Engine mounting nut (upper/lower} 85 Nem (5.5 kg-m, 40 ft-lb) Engine bracket nut 27, N-m (2.7 kg-m, 20 ft-tb} Gearshift pedal bolt 10.N-m (1.0 kg-m, 7 ft-lb}ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL ; areca seapcrus Do not jack up the motorevete by putting the jack under the ott filer CAP. Drain the oil from the engine (page 2-9). Drain the coolant from the system (page 5-3). Remove the following components: Side and lower cowlings (page 12-3) — Fuel tank (page 4:3). = Air duct (page 4-7) and carburetor (page 4-8) Drive eprecket cover (page 5-8) and drive sprocket, = Water hoses from the water pump and cylinder. = Alternetor end neutral ewitch wirs connectors {page 8.2) ‘Spark plug cape from the spark plugs. — Resaive tank mounting bolts and reserve tank by swing reward (page 5-10). — Front ignition coil with the stay (oege 17-5) ~ Canister and PCV (California model) (4) WATER HOSES WIIDRIVE SEAOCRET « Cooling fan ipage 5-7) — Exhaust pipe (page 12-4). = Sterter motor (page 18-3}. Water hoses and breather tube from the cylinder head. = Clutch eabie. ‘Support the freme and remove the engine bracket mounting bolts and engine mounting bolts. ‘Swring the front eylinder upward, and remove the engi left side. tothe NOTE + Do not damage the radiator fins. ENGINE INSTALLATION NoTE + Inzertall the engine pivot bolt and engine bracket boits (rom the lot sido + Install the lower engine mounting botts with the collar. + Install the upper engine mounting bolt with the cowbng stey. etter mms singers 6-2ENGINE REMOVAL/INSTALLATION Install tho engine from the lett side, NoTE + Do not damage the radiator fine, Insert the engine pivot bolt through the ewingarm end the engine from the let side, and install the nut; but do not tighten, it yet: Install the engine brackets. cowling stay, engine bracket bolts ‘end engine mounting bolts. Install and tighten each nut. ‘TORQUE: ‘Swingarm engine pivot nut 110 Nem (1.0 kg-m, 80 feb) Engine mounting ute (upper/lower 59 Nem (5.5 kg-m, 40 ft-lb) Engine bracket nuts: 27 Nem (2.7 kg-m, 20 feb) Install the drive sprocket with its marked side facing our. Install the fixing plate end tighten the bolts securaly Install the water hoses securely with the clamps. Inetall the following components: = Front ignition coils with the stay. = Spark plug caps. Canietor and PCV (Californie model) STTSWINGAPN ENGINE PIVOT 80CTENGINE REMOVAL/INSTALLATION Install the water hoses and breather tube to the cylinder heed ‘with the elmaps. Inotall the following components: = Alternator (page 16-8) and neutral switch connectors, = Clutch cable, = Cooling fan tpage 5-7) — Exhaust pipe (page 12-4). — Starter motor (page 18-6), = Carburetor (page 4-16) end air duct (page 4:8), NOTE = When inatalling the air duct band, apply oll to tho inside of the tube band. — Reserve tank (page 5-10) = Drive sprocket cover (page 5-9) Fuol tank (page 4-3) = Side and lower cowiings (page 12-3) Route oll wire harnesses and cables properiy (page 1-9 through 1-13), Perform the following inspections and adjustments: Engine of (page 2-3) Cooling sysiem {page 5-3) Throttle grip ‘ree play {page 3-4) Drive chain’ Ipage 3-11) Rear brake pedal free play (page 9-14) Clutch lever {roe play (page 3-15) Check all electrical equipment.CLUTCH/GEARSHIFT LINKAGE 10 Nem 90 N-m (9.0 kg-m, 65 ftb) , 0° + ‘@ io © ie Le 23 N-m (2.3 kg-m, 17 ft-lb)7. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 7-1 PRIMARY DRIVE GEAR 79 | TROUBLESHOOTING 7-2 CLUTCH INSTALLATION mW RIGHT CRANKCASE COVER REMOVAL 7-3 RIGHT CRANKCASE COVER CHUNTCHEROUAL 7-4 INSTALLATION 7413 GEARSHIFT LINKAGE 738 SERVICE INFORMATION GENERAL © This coction covers the removal and installation of the clutch, gearshift linkage and primary drive geer. All these operations ‘can be done with the engine installed in tho framo. ‘© Coat new clutch aises with clean engine ol before reassembly, & SPECIFICATIONS mn) ‘STANDARD ] SERVICE LIMIT Spring free length 39.0 (1,64) [| s7.411.47 ‘Spring preloedilength 26.2~24.2/26.28 ka/mm (87.76 53.95/1,033 Ib/in) Dise thickness T 2,923.08 (0.115-0.121) 2,60 (0.102) Clutch Wise were 0.20 (0.0121 21,891 22.016 (0 8658 —0.8668) 22,09 (0.870) ower gues LD enone { (dl 0. 31,969-37.075 (1.2682 —1,2569) 31,96 (1.259) Outer 10. 32,000 ~32,025 (1.2598 1.2608) 32.10 (1.264) Olt pump dive sprocket LD. 32.000—32.025 (1.2598 1.2608) 32.10 (1.264) Meinshaft 0.0, et clutch outer cue 21 967-21 980 (0.8648 ~0 9654) 21.92 (0.00) TORQUE VALUES Drum stopper plate mounting bolt 12.Nem 11.2 kg-m, 9 fo) Frimary ceva gear mounting bolt 90 Nim [9.0 kg-m, BB fib) Oil pump crivon sprocket belt 15 Nem (1.5 kgem, 11 ft) Clutch lock nut 130 Nem (13.0 kg-m, 04 Fe1b) Clutch after pace bolt 10 Nem 1.0 gem. 7 ftb) Gearehift podal bole 10 Nem (1.0 kgem, 7 feb} Oil pass pipe bo. (8 mm) 28 Norn (2.3 4g-m, 17 feb} Crankcase cover bolt 12 Nem (1.2 kgem, 9 feb) TooLs Special Clutch center holder 07823—-KE10000 or 07HGB-O01000A (U.S.A. only! orrenon Lock mut wrench, 17x 27 mm 07716-0020300 Extention ber 077160020500: Gear holdor 0724—co10100-1 Net evalabe in U.S.A, 7-1CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch lever free pley. Clutch slipe when accelerating + No tree play Discs worn Springs weal Clutch will not disengage + Too much free play Plates warped Motoreyele creeps with clutch disengaged ‘00 much tree play Plates warped Excessive lever pressure Clutch cable kinked, damaged er dirty Lifter machanism damaged + Chitch outer slots rough Dirty clutch cableCLUTCHIGEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL iT Cran Po SUTCH CASTE 3). ind efter (pege 12-4). Drain the engine cil (p Remove the exhaust pipe Remove the oil pipe bolt and sealing weshers, Remove the right crankease cover mounting bolts end discon- ‘ect the clutch cable from the clutch lifter arm, Remove the right crankcese cover, Remove the gasket and dowel pins. Romove the oil orifice. RIGHT CRANKCASE COVER INSPECTION Remove the clutch lifter piece, clutch lifter arm shaft and spring from the riant crankcase cover. Check the clutch lifter piece and clutch lifter orm chaft for damage or excessive scratches, Check the spring for damage. ass 7-3CLUTCH/GEARSHIFT LINKAGE Check the nesdle bearings for wear, damage or loose ft, wiv necotr eearmcs: Check the eil seal for damage. a PN i Yi CLUTCH REMOVAL Remove the clutch bolts, lifter plate and springs Unstake the chrich lock nut with a dil or grind NOTE 8 not te Install the clutch center holder and remove the clutch lock nut. TooL Clutch center holder 07923—KE10000 or ‘07HGB-0010008 (U.S.A. oniyi Lock nut wrench, 17x27 mm 07716-0020300 Extention bar 077160020500 [Not available in U.S.A. Romove the washer, clutch certer, plates, discs and pressure plate as an assembly.CLUTCH/GEARSHIFT LINKAGE Remove the thrust washer and clutch outer. Remove the oil pump driven spracket bolt, driven spracket, oil pump drive chain and oil pump drive sprocket. Remove the clutch outer guide from the mainshaft. INSPECTION (1) BEARING Check the bearing lifter plate for damage. Tui the bearing Inner race with your finger The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the clutch Iter plate Replace the bearing or lifter plate with a new one if necessary. (2) CLUTCH LIFTER PLATECLUTCH/GEARSHIFT LINKAGE ‘Measure the spring free length. ‘SERVICE LIMIT: 37.4 mm (1.47 in) Replace the clutch discs if they show signs of scoring o ls: coloration. ‘Measure the thickness of the disc A and B. SERVICE LIMIT: 2.60 mm (0.102 in) NOTE Replace the discs and platos as a set if any one is beyond the service limit Check the plete warpage on the surface of the thickness gauge. ‘SERVICE LIMIT: 0.90 mm (0.012 in} Check the clutch center for nicks of indentations made by tho clutch plates. 2-6CLUTCH/GEARSHIFT LINKAGE Shock the spring seat and judder sing fr distorton, wear or 44) Spina SEAT Abi ad alee lamage. ‘ GED ensts em it ncesan cp OC Check the slots in the clutch outer for nicke or indontations made by clutch discs, (1) stor \ Check the oll pump drive sprocket for damage Measure the 1.D. of the clutch outer and I,D. of the oll pump thive sprocket SERVICE LIMITS: Clutch outer 1.0. 32.10 mm (1.264 in) i ll pump drive sprocket 1.D.: 32.10 mm (1.264 in) Measure the I.D. and 0.D. of the cluteh outer guide, SERVICE LIMITS: 1D. 22.09 mm (0.870 in) 0.D.: 31.98 mm (1.259 in) Moacure the mainehaft 0.0. at the clutch outer guido, SERVICE LIMIT: 21.92 mm (0.863 in}CLUTCH/GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL Remove the right crankcase cover (page 7:3). Remove the clutch (pogo 7-4) Remove the gearshift pedal (page 5-8) Remove the bol's, oli pipe anc oil pipe stay. Remove the gearshift spindle. Romove the drum stopper arm attaching bolt, washer, drum stopper arm and spring, Remove the drum stopper plate belt and drum stopper plete, Romove the dowel pin, INSPECTION (1) SPINDLE Chack the gaarshitt spindle for bending or damage. (Check the return spring for damage. (2) SPRINGSil CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the dowel pin to shift drum. Install the spring, drum stopper arm and washer, and tighten the drum stopper arm bolt. install the drum stopper plate, aligning the hole of the stopper plate with the dowel pin. Apply locking agent to the threads of the stopper plate mount- Ing bolt and tighten it to the specified torque. TORQUE: 12 N-m (1.2 kg-m, 9 ft-lb) Install the gearshift spindle, aligning the return spring ends with the gearshift spindle return pin, Install the oil pipe stay and tighten two the bolts. Install the oil pipe with a new O-ring onto the oil pipe stay and tighten the bolt Install the gearshift pedal (page 5-9) TORQUE: 10 N-m (1.0 kg-m, 7 ft-tb) (3) O-RING PRIMARY DRIVE GEAR REMOVAL fismove the right crankcase cover (page 7-3). Remove the clutch lifter plate, clutch center, clutch plates and dutch discs (page 7-4), Remove the pulse generator mounting bolts and pulse generators. | Remove the pulse generator wire grommet from the groove in the right crankcase. 7-9CLUTCH/GEARSHIFT LINKAGE Install the gear holder as shown. y . a 11) GEAR HOLDER 12) PRIMARY DRIVE GEAR Remove the primary dri ‘mounting dott, puleo generator fotor and primary drive gear from the crankshatt Remove the gear holder. 07724-0010100 Not available in U.S.A. INSTALLATION Install the primary orive gear with the “OUT” mark facing out. Install the pulse generator roter. NOTE + ‘The primary drive gear and pulse generator rotor will only {80 on in one position bacause of the extra wide aligning spline. ‘Temporerily install the clutch outer and install the gear holder 18 shown, ton the primary drive g torque. 3 mounting bolts te the specified TORQUE: 90 Nem (9.0 kg-m, 65 ft1b) TooL: Goar holder 07724--0010100 ‘Not available in U.S.A. Remove the gear holder. Install the pulse generator wire clamp and pulse gor and tighten the pulse generator mounting bolts. Set the grommet into the groove in the right crankcase. Install the clutch (page 7-11). 7-10CLUTCH/GEARSHIFT LINKAGE Wri CLUTCH OUTER GUIDE J) pp rcronnanese CLUTCH INSTALLATION Apply MoS2 paste grease (page 2-10) to the outside of the dlutch outer guide. Install the clutch outer guide onto the mainshaft Rail the ail pump drive chain aver the oil pump drive sprocket and oil pump driven sprocket with the ‘‘IN'' mark on the driven Sprocket facing inside. Install the oll pump drive sprocket onto the clutch outer guide and install the oil pump driven sprocket onto the ol! pump shatt. (2) “IN” MARK Apply a locking agent to the threads of the oil pump driven A 1, sprocket bolt and tighten it with the washer to the specified : a torque. . \ a rs) TORQUE: 15 Nem (1.5 kg-m, 11 ft-tb} Install the clutch outer onto the oil pump drive sprocket, align: ing the bosses of the sprocket with the grooves of the clutch outer. Install the thrust washerCLUTCH/GEARSHIFT LINKAGE install the spring seat, judder spring and clutch disc B onto the clutch center. NOTE + Note the proper positions for the spring seat, judder spring and disc B as shown at right. a EATS a (3) PRESSURE Install the clutch disc A, clutch plates and pressure plate onto PLATE the clutch center, then install them into the clutch outer as an assembly, NOTE + Stack the discs and plates alternately as shown. * Coat new clutch discs with clean engine oil Install the lock washer onto the mainshaft Hold the clutch center with the clutch center holder, and tight en the lock nut to the specified torque. TORQUE: 130 N-m (13.0 kg-m, 94 ft-lb) TOOLS: Clutch center holder 07923 —KE10000 or 07HGB—001000A (U.S.A, only) Lock nut wrench, 17x 27mm 07716—0020300 Extention bar 07716—0020500 Not available in U.S.A. ‘Stake the lock nut with the center punch. Install the clutch springs. lifter plate and bolts. nen een (1) BOLTS: Wa CLUTCH LIFTER PLATE Tighten the bolts in a crissctoss pattern in 2-3 steps. a4 TORQUE: 10 N-m (1.0 kg-m, 7 ft-lb) Install the bearing into the lifter plate. 7-12CLUTCH/GEARSHIFT LINKAGE Install a new O-ring to the ail orifice. K ( iy O-RING NG Install the oil orifice with its smaller hole facing out , es IRS RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gasket. Apply grease to the dust seal and needle bearings. Install the spring, clutch lifter arm shaft and clutch lifter piece to the right crankcase cover. f (3) DUST (4) SPRING SEAL Tighten the right crankcase cover mounting bolts in a crisscross pattern in 2-3 steps and install the clutch cable holder and oil pipe holder at the same time. TORQUE: 12 N-m (1.2 kg-m, 9 ft-Ib) Connect the clutch cable to the clutch lifter arm. Tighten the oil pipe bolt with the sealing washer and a new lock wash TORQUE: 23 N+m (2.3 kg-m, 17 ft-lb) (2) OIL PIPE BOLT/SEALING , WASHERS. Install the exhaust pipe and muffler (page 12-4). Fill the crankcase with engine oil (page 2-3) Adjust the clutch lever free play (page 3-15) (3) RIGHT CRANKCASE COVERALTERNATOR/STARTER CLUTCH 30 Nem (3.0 ko-m, 22 ftb) 8-08. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 8-1 FLYWHEEL INSTALLATION 85 © | LEFTCRANKCASE COVER REMOVAL 8.2 _LEFT CRANKCASE COVER FLYWHEEL REMOVAL gz NS TARA TION oe STARTER CLUTCH 33 SERVICE INFORMATION GENERAL # This socton covers the removal and Installation of the atemater and starter cltch, ‘© Those operation can be dene with tho engine inoaled inthe fame, ‘For alternator inspection, refer to section 16 SPECIFICATION mm tind TEM STANDARD SERVICE LIMIT Starter driven gear 0.0. ‘57. 749— 57.768 (2.2736-2.2743) 57.60 (2.288) TORQUE VALUES Flywheel bolt 130 Nem (13.0 ko-m, 94 feb) Left hand thee Starter chitch torx bots 30 Nem (3.0 g-m, 22 F18) Apply locking agent TooLs common Rotor pullor 07733~0020001 or 078333290001 (U.S.A. only) Fywhoel holder 07725 0040000 or equivalent commercially ovate in U.S.A. Torx it 077030010100 or equivalant commercially avaiable in U.S.A, Ld fe 8-1ALTERNATORISTARTER CLUTCH LEFT CRANKCASE COVER REMOVAL ae \ Romove the lower cowling (page 12-3). Remove the seat and disconnect the alternator 3P connector. Romove the drive sprocket cover (page 5-81 Remove the lett crankcase cover bolts and left crankcase Remove the dowel pins and gasket. STATOR REMOVAL, jy BQut (2) WIRE CLAMP Romove the belt sttaching the wire clamp. Remove the stator bolts and stator. FLYWHEEL REMOVAL Hold the tivwhee! with the fywhee! holder Remove the leftthand throad flywheel belt and wesher. TooL: Flywheel holder 077280040000 ‘r equivalent commercially available in U.S.A. NoTE +The flywheel bolt has left-hand threa 82ALTERNATOR/STARTER CLUTCH Romove the starter idle gear and shaft, Remove the flywheel with the starter driven goat using the rotor puller Toot: Rotor puller 07733—0020001 ‘of 079333290001 (U.S.A. only) Femove the sterter drive gear and shaft. Femove the needle bearing and cam chain tensioner set plate. Remove the woodrut! key. STARTER CLUTCH Inspect the starter clutch by tuming the starter driven goar Th driven gear should tun counterclockwise freely ‘and should not turn clockwise; # not, replace the starter lutch, (3) STARTER CLUTCH! DISASSEMBLY (1) BOLTS: tho sterter clutch is feuity, remove the Socket bolts using a ZA torx bit. Remove the starter clutch outer, aneway clutch and washer, 077030010100ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH INSPECTION Meapure the 0.0. of the boss of the starter driven gear. SERVICE LIMIT: 57.60 mm (2.268 in) Inspect the eneway clutch for woar or damage and replace if necessary. ASSEMBLY (1) ONEWAY CLUTCH Install the oneway olutch onte the starter clutch outer with the fiange side facing inside (2) FLANGE SIDE Apply a locking agent te the torx bolt thresde and tighten the bolte TORQUE: 30 Nem (3.0 kg-m, 22 feb) (1) Botts 8-4ALTERNATOR/STARTER CLUTCH Install the washor into the flywheo! FLYWHEEL INSTALLATION Clean the crankshaft Install the cam chain tensioner set plate Install the needie bearing orto the crankshaft. {Install the woodruff Key Into the groove in the crenkshatt, Install the starter deive gear with Install the drive gear shart. 1 "OUT" mark facing out Install the fyweel, aligning the woodruff key on the crankshaft with the flywheel keyway Isto the startor idle goer ond shaft Hold the flywheel with the flywhee! holder, in ‘and flywheo! bolt and tighten the bolt. TORQUE: 130 Nem (13.0 kg-m, 94 feb) NOTE + The flywheel bolt has left-hand threads. LEFT CRANKCASE COVER INSTALLATION (1) Bot STATOR INSTALLATION Install the Intall tho at crankcase cover Install the wire ciamp and tighten it with the bolt as shown. ‘and tighten it with the four bolts, tor Wire grommet into the groove of the laft (4) BOLTS: (1) WASHERALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER INSTALLATION iy DOWEL FINS Install the dowel pins and a new gasket. Inetall the laft cranekease caver and tighten the left crankcase ‘cover bolts with the slternator (1) BOLT NOTE + Apply Connect the alternator SP connecter and install the seat. Install the drive sprocket cover (page 5-9). Install the lower cowiing (page 12-3). 8-6CYLINDER HEAD/VALVE 10 N-m (1,0 kg-m, 7 ft-b) i ‘ =D 10 Nem (1.0 kg-m, 7 ft-lb) 23 Nem (2.3 kg-m, 17 ft-lb) 9-0ft-lb) 9. CYLINDER HEAD/VALVE SERVICE INFORMATION TROUBLESHOOTING ‘CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL VALVE SEAT INSPECTION/ REFACING VALVE GUIDE REPLACEMENT ‘CYLINDER HEAD COVER REMOVAL 9-1 9-2 9-3 9-4 9-8 9-10 9-11 CYLINDER HEAD ASSEMBLY ‘CYLINDER HEAD INSTALLATION (CAMSHAFT INSTALLATION CYLINDER HEAD COVER INSTALLATION 9-14 9-15 9-16 9-19 SERVICE INFORMATION GENERAL # To service the cylinder head, the engine must be removed from the frame; you can service the cylinder head cover, rocker arm, camshaft, cam chain and cam chain tensioner without removing the engine. ‘© Camshaft lubricating oll is fed through an oil pass pipe. Be sure the hales in the oil pass pipe bolts are nat clogged. © During assembly apply MoS: paste grease (page 2-10) to the camshaft holders, camshaft journals of the cylinder head, rocker arm shafts, rocker arm slipper faces and valve stems to provide initial lubrication, SPECIFICATIONS Unit: mm tin) 'TEM STANDARD: SERVICE LIMIT Compression pressure 1177 + 98 kPa eieae (12.0 = 1.0 kgicm?, 171 + 14 psi) Camshaft Cam lobe height IN "38.189 (1.5035) 38.17 (1.503) | Ex 38.213 (1.5044) 38.19 (1.504) Journal 0.0. 21.959—21.980 (0.8645—0.8654) | 21.95 (0.864) Runout 0.030 (0.0012) 0.05 (0.002) Oil clearance 0,050—0.111 (0.0020—0.0044} 0.13 (0.005) Rocker arm Rocker arm 1.D. 2 INFEX 12,000— 12.018 (0.4724—0,.4731) 12.03 (0.474) ppeoal ea olen a8 11.966— 11.984 (0.4711-0.4718) | 11,96 (0.471) Valves and af Valve stem 0.D. LIN 5.475—5.490 (0.2156—0,.2161) 5.45 (0.215) velve guides EX 6.555—6.570 (0.2580—0,2587) 8.55 (0.258) Ive guide 1.D. IN §.600—5.520 (0.2165—0.2173) 5.56 (0,219) _ Ex 6.600—6.620 (0.2598—0.2606) 6.65 (0.262) Stem-to-guide IN 0.010—0.045 (0.0004 —0.0018) 0.10 (0.004) clearance [ex a 0,035 —0,050 (0.0014—0.0020) 0.11 (0.004) A Valve seat width 0.91.1 (0,035—0.043) 1.5 (0.06) Valve springs Free length OUTER IN 42.14 (1.659) 40.44 (1.692) EX 42.83 (1,686) 41.43 (1.619) INNER | IN 38.11 (1,500) 36.41 (1.433) iy EX 38.81 (1,528) 37.11 41.461) Cylinder head warpage — 9.10 (0,004) 9-1CYLINDER HEAD/VALVE TORQUE VALUES Cylinder head cover mounting bott Camshaft holder mounting bolt (8 mm) rut (8 mm) bolt (8. men) Cylinder head mounting nut (10 mm) bolt (8 mm| nut (8 mm) bolt (6 mm) Cam sprocket bott ‘Cam chain tensioner mounting bolt Gil pase pipe dott {7 mm) (8mm) TOOLS Specia Valve guido reamer (IN) Valve quide reamer (EX) Valve guide driver attachment (IN) Valve guide driver attachment (EX) Common Valve guide ctiver, 5.5 mm (IN) Valve guide criver, 6.6 mm (EX) Valve spring compressor Valve seat cuttor Cutter holder IN 5.6 mm EX 6.6 mm IN 28 mm (32°) EX 35 mm (329) Ioverior cuttor IN 30 mm (60°) EX 37.5 mm (00°) IN 27.5 mm (45°) EX 35 mm (45°) TROUBLESHOOTING Flat cuttor Seat cutter Engine top-end problems are usually performans 10 Nem {1,0 kg-m, 7 fe1b) 29 Nem (2.3 kg-m, 17 Fel 23 Nem (2.3 kg-m, 17 feb) 40 Nem (1.0 kgm, 7 Feld) 48 Nem (4.8 kg-m, 35 ftlb) 23 Nem (2.3 kg-m, 17 felb) 23 Nem (2.9 kg-m, 17 fel) 10 Nem |1.0 kg-m. 7 ft-lb) 23 Nem (2.3 kg-m, 17 feo) 40 Nem [1.0 kgm, 7 flo) 10 Nem [1-0 kg-m, 7 ft-lb 23 Nem [2.3 kgm, 17 felb) (07984— 2000001 97984—ZE20001 07943 MF50100 07943—mF50200 077420010100 077420010200 or 079426570100 (07767 0010000 o 079673280001 077810010101 077810010201 (077800012100 (077800012300 (077800014000 07780—0014100 (077800010200 (07800010400 elated and can usually be diagnosed by a compression test. Engine noises can usually be traced to the top-end with a sounding rod or stethoscope. Uneven oF low compression + Valves ~ Incorrect valve adjusiment Burned or bent valves = Incorrect valve timing = Broken vaive spring + Cylinder head Leaking or damaged head gasket = Watped or cracked cylinder head + Cylinder end piston (Rotor to Section 10) High compression Excessive noise + Incorrect valve adjustment + Sticking valve or broken valve spring + Damaged or worn rocker arm or camshaft + Loose or worn cam chain Worn or damaged cam chain tensionor + Worn cam sprocket teeth Poor + Compression too low + Excessive carbon built-up on piston crown er combus- tion chamberCYLINDER HEAD/VALVE ee eee NE CYLINDER HEAD COVER REMOVAL (n Eas vSroReHaou Diain the coolant {page 5-3), Fiemove the fuel tank (page 4-3). Remove the carburetor (page 4-8) Remove the fan motor and fan motor shroud as an assembly. Hang it from the handlebars using a string not to be damaged. “flamove the spark plug cap from the spark plug. i flmove the bolt and ignition coil stay from the frame. Wig mn (2) SPARK PLUG CAP. flamove the frame bridge mounting bolts and frame bridge. Disconnect the cylinder head cover breather tube at the cylin- der head cover. Hiemove the bolts and water pipes from both the cylinder (1) BOLTS/WATER PIPES (2) CYLINDER HEAD] heads. Remove the cylinder head cover mounting bolts, rubber Washer covers, rubber washers and cylinder head coversCYLINDER HEAD/VALVE CAM CHAIN INSPECTION 7.0 mm Measure the height of the cam chain tensioner projection as ania shown. Replace the com chain with a new one i the projection exceeds 7.0 mm (0.28 in). ‘To replace the cam chain, drain the oll from the engine and remove the fellowing parts: FRONT CYLINDER HEAD | | Lett orenkes Front camshaft Flywheel \ ee (2) CAM CHAIN TENSIONER CAMSHAFT REMOVAL (INDEX MARKS Remove the cylinder head cover (page 9-3). Remove the timing hole cap and erarksheft hole cap from the left erankeoss cover ‘Align the “FT mark (rear: “RT” mark) on the flywheel with ‘the notch on the left crankcase cover by turning the crankshatt counterclockwise, Make sure the piston is at TDC (TOP DEAD CENTER) on the compression stroke. It the piston is not at TDC, turn the crankshaft 360° counter- clockwise, and re-slign the mark with the notch. Ramove the camshaft holder mounting bolts and nut, oil pas- sage and camshaft holders. ee, (2) CAMSHAFT HOLDERS Remove the dowel pins. (1) DOWEL PINS 9-4CYLINDE: Pull the cam chain tensioner wedge A straight up wl wedge 8 down, Secure the wedge A with a 2 mm pin as shown, holding (1) WEDGE B Remove the cam sprocket bolt, rotate the crankshaft counter- clockwise one turn (360°) and remove the other cam sprocket bolt. NOTE * Be careful not to let the cam sprocket bolts fall into the crankcase, Remove the cam sprocket from the camshaft flange. Hang the cam chain on the camshaft behind the camshaft flange and remove the cam sprocket while lifting up the cam- shaft. Attach a piece of wire to the cam chain to prevent it from being dropped into the crankcase. INSPECTION ‘Cylinder head Inspect the camshaft holder and cylinder head journal surfaces for scoring or evidence of insufficient lubrication. AD/VALVECYLINDER HEAD/VALVE Camshaft runout Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial indicator. SERVICE LIMIT: 0.05 mm (0,002 in} Using a micrometer, measure the height of each cam lobe. SERVICE LIMITS: IN: 38.17 mm {1.503 in) EX: 38.19 mm {1.504 in) ‘Check the camshaft journals for wear or damage. Measure the 0.D. of each journal SERVICE LIMIT: 21.90 mm (0.862 in) Camshaft bearing oil clearance Wipe any oil from the journals. Lay a strip of plastigauge lengthwise on the top of each camshaft journal, NOTE + Avold placing plastigauge over the oil hole in the camshatt. Install the camshaft holders and tighten the mounting bolts and nut in a crisscross pattern in 2—3 steps. NOTE + Do not rotate the camshaft when using plas TORQUES: & mm bolt: 23 Nem (2.3 kg-m, 17 ft-tb) & mm nut: 23 Nem (2.3 kg-m, 17 ft-tb) 6 mm bolt: 10 Nem (1.0 kg-m, 7 ft-lb) 9-6CYLINDER HEAD/VALVE flemove the carnshatt holder and measure the width of each Hlestigouge. The widest thickness determines the oil clear nce SERVICE LIMIT: 0.13 mm (0.005 in) When th service mit is exceeded, replace the camshaft and facheck the oil clearance. fvplece the cylinder head and camshatt holder if the clearance sillexceods the servi CAMSHAFT HOLDER/ROCKER ARM SHAFT/ ROCKER ARM flamove the rocker arm sha‘ts by tapping the holder and the ‘ocker arme with a soft hammer. Remove the rocker arms and wave washers from tho shits, Inspect the rocker arm shafts and rocker arms for wear or damage. Chock the rocker arms for clogged ol holes. Meosure the 0.D. of each racker arm shatt, SERVICE LIMIT: IN/EX: 11. mm (0.471 in} Measure the 1.D. of each rocker arm. SERVICE LIMIT: 12.03 mm (0.474 in} (1) PLASTIGAUGE (1) ROCKER ARMS (2) ROCKER ARM SHAFTS (1) ROCKER ARMS. |2) ROCKER ARM, SHAFTS (9) WAVE WASHERS 9-7CYLINDER HEAD/VALVE eSes>4__«oSme*w’_l CYLINDER HEAD REMOVAL SEALING WASHERS! Remove the ongine from the frame {page 6-2). 3 LOCK WASHER. cylinder head cover ipage 9-3) ae emshatt holder (page 9-4) Remove the camshait (page 9-4), f Remove the oil pess pipe bolts, sealing washer, lock washer, cil paze pipe holder mounting bol: and cil pass pipe. Remove the cem chsin tensioner mouting bolts and washers from the cylinder head and cylindor. Loosen the 6 mm bolt. 8 mm bolts, 8 mn nut and 10 mm rista! weshers in a criss-cross pattern in 2 oF 3 steps. Remove the bolts and nuts. Remove the cylinder head, Remove the gasket, dowel pins and cam chain guide from the cylinder. (2) CHAIN GUIDE, 9-8CYLINDER HEAD/VALVE DISASSEMBLY/INSPECTION Remove the valve spring cottore, retainers, springs, spring ‘seats, valve stem seals and valves using Valve Spring Cor pressor, TooL: Valve spring compressor 07787-00100 CAUTION * To prevent loss of tension, do not compress the valve springs ‘more than necessary io remove the cotters. NOTE + Mark ell parts during disassembly so they ean be replaced in their original locations. Gylinder head Gean the cylinder head surfaces off any gasket material CAUTION. + Avoid damaging the mating surfaces of the cylinder head. Check the spark plug hole and valve reas for cracks. Check the cylinder head for warpage with the straight edge ‘ang thickness gauge. [SERVICE LIMIT: 0.10 mmm (0.004 in| Valve eprings Measure the free length of the inner and outer valve eprings SERVICE LIMITS: INNER (IN): 36.41 mm (1.433 in) (EX): 37.11 mm (1.461 OUTER (IN): 40.44 mm (1.592 in} (EX): 41.13 mm (1.619 in) Replace the springs as a set if any ere shorter than the service limits Valvo stom-to-guide clearance, Inspect each valve for bending, burning, scratehos or eb rormal stem wear. Check velve movement in the guide, and meacure and record each valve stem 0.0. ‘SERVICE LIMITS: IN: 5.45 mm (0.215 in| EX: 6.55 mm (0.258 in| (1) VALVE SPRING COMPRESSOR,CYLINDER HEAD/VALVE ‘Meacure and record each valve guide I.D. SERVICE LIMITS: IN: 5.56 mm (0.219 in) EX: 6.65 mm (0.262 in) ‘Subtract each valve etem 0.0. from the corresponding guide 11D. ta obtain the stem to guide clearance. SERVICE LIMITS: IN: 0.10 mm (0.004 in) EX: 0.11 mm (0.004 in) IF the stem:-to-guide clearance exceeds the service limits, de- termine if @ new guide with standard dimensions would bring the clearance within tolerance. H so, replace any guides ‘85 neceesary and roam 10 Ft IN; 07384—2000001 or 07384—2000006 7.8.8. only EX: 07984—ZE20001 or 07984 —ZE2000C NOTE Te ie important that the ream: always be rotated in the same direction when it is inserted or removed. If the stam-to-guide clearance exceeds the service limits vith new guides, also, replace the valves. NOTE Reface the valve epete whenever the valve guides are ro placed, VALVE GUIDE REPLACEMENT Chill the velve guides in the freezor section of a refrigerator for ‘about an hour. Heat the cylinder head to 180~ 140°C {275—200°F} with o hot plate or oven. Do not heat the cylinder head beyond 150°C (30°F) Use tempereturs indicator stics, available from welding supply ‘stores, to be sure the cylinder head is heated to the proper ‘temperature. + To avoid burns, wear heavy gloves when handling the heated eplinder head. CAUTION + Do not wse @ torch to het the eylinder head or it may cause warping ‘Support the cylinder head and drive out the old guides from the ‘combustion chamber side of the cylinder heac. NOTE + Aveid demaging to the eylinder heed. (1) INSIDE MICRO METER, (1) VALYE GUIDE DRIVER, nia le 9-10CYLINDER HEAD/VALVE pects: ta (1) VALVE GUIDE DRIVER Valve guide driver ‘ ft 077420010100 EX: 07742—0010200 Make note of the valve guide projection height following below, then drive in new guides from camshaft side of the cyl inder head. TOOLS: Valve guide driver Boe 5.5 mm (IN): 07742—0010100 ~-. mA 6.6 mm (EX): 07742—0010200 or L2G AN Bere teases 07942— 6570100 (U.S.A. 3 i only) Attachment 6.5 mm (IN): 07943—MF50100 6.6 mm (EX): 07943~—MF50200 (1) VALVE GUIDE (2) VALVE PROJECTION HEIGHT VALVE PROJECTION HEIGHT: IN: 19.5 + 0.1 mm (0.77 = 0.004 in) EX: 18.5 + 0.1 mm (0.71 + 0.004 in} Ream new valve guides after installation. + Use cutting oil an the reamer during this operation, + It ls important that the reamer always be rotated in the same direction when it is inserted or removed. Clean the head thoroughly after reaming the valve guides. TOOLS: Valve guide reamer IN: 07984—2000001 or o7e64—20p0000 5014.4. only EX: 07984—ZE20001 or 07984—ZE2000C VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust valves thoroughly to remove corban deposits. Apply a light coating of Prussian Blue to each valve seat. Lap tach valve and seat using a rubber hose or other hand-lapping tool.CYLINDER HEAD/VALVE Remove and inspect each velve. ‘CAUTION © Te valve cannot be ground. Ifthe valve face is burned or badly worn or fit contacis the seat uneventy, replace the valve. Ingpect the width of each valve seat as shown. STANDARD: _ 0.9-1.1 mm (0.030.043 in) ‘SEAVICE LIMIT: 1.5 mm (0.06 in) I the oeet ie too wide, too narrow or has low spots, the st ‘must be ground: VALVE SEAT CUTTERS Honda Valve Seat Cutters, grinder or equivalent velve seat refacing equipment are recommended to corract a worn valve seat, NOTE Follow the VALVE SEAT REFACING Use a 45 degree cutter to remove ny roughness oF rreqular- {es fiom the seat, NOTE + Refece the seat with @ 45 dogroe cutter when a valve guide is roplacee. Use 2 22 degree cutter to remove the top 1/4 of the existing valve seat materi 9-12 45° |) SEAT CUTTER iC Lj : (2) FLAT CUTTER |9) INTERIOR CUTTER (1) ROUGHNESS/IRREGULARITIES 45° (2) VALVE SEAT (1) OLD SEAT WIDTHCYLINDER HEAD/VALVE Use 2 60 degree cutter to remove the bottom 1/4 of the okt Seat. Remove the cutter and inspect the area you havo fefeced. Install 2 48 degree finish cutter and cut the seat to the proper Width, Make sure that all pitting and irregularities are removed, Refinish if nocossary. ‘Apply a thin coating of Prussian Biue to the valve seat, Press ‘the valve through the valve guide and onto the seat to make & ear patter. NoTe +The locetion of the valve seat in very important for goed sealing lation to the vaive face is the contact area ie too high on the valve, the seat must be lowered using a 32 degree flat cutter. It the contact area is too low on the valve, the feised using a 60 degtee inner cutter, must be (1) OLD SEAT WIDTH 60° 0.91.1. mm (0.035 0.042 in) (1) CONTACT TOO HIGH ° . (2) OLD SEAT WIDTH 2 (1) CONTACT Too Low (2) OLD SEAT “\WwinTH 9-13CYLINDER HEAD/VALVE Refinish the seat to the specifications, using @ 48 degree finish TTT After cutting the seat, apply lapping compound to the valve face, and lop the valve using light pressure After lapping, wash all residual compound off the cylinder head and valve. NOTE Dao not allow lapping compound to enter the guides, CYLINDER HEAD ASSEMBLY ‘SM ay VALVE 2) STEM SEAL | (4) RETAINER A (3) OUTER Recension cs = wag, (7) SPRING (6) INNER SEAT SPRING (5) COTTERS Install the valve springs and retainers. NOTE Install the velve epringe with their narrower pitches facing to the eylindar head + Replace the stem seals with new ones if they were re: moved, ‘+ Install the valves into the valves guides while turning them slowly, $0 the stem seales are not damaged. FACING TO CYLINDER HEAD. Compress the springs and instal he valve cote. (a) vaive SAME, CoMPRESSOR CAUTION + To prevent loss of tension, do not compress the valve springs more than necessery (0 install the valve cotter TooL: Valve pring comprossor 077570010000 9-14CYLINDER HEAD/VALVE he valve stems gently with a soft hammer ta firmly seat otters. ft | Stpport the cylinder head above the work bench surface to prevent possible valve demaa: JNDER HEAD INSTALLATION te Gam chain guide into the cylinder. ‘that the cam chain guide bosses are set in the yooves of cylinde ban the cylinder head surface of any gaskat material sll the dowel pins and a new head ‘natal the cylinder head Install the 10 mm ruts/washers, 8 mm nut, 8 mm bolts and 6 _tmbolt and tighton them in a crissoroze petiorn in 2-3 stops “Bshown, 48 Nom (4.8 ko-m, 36 feb) Bmm bolt: 23 N-m (2.3 kg-m, 17 felb) Bmm nut: 23 Nem (2.3 ke-m, 17 feb) ‘6mm bolt: 10 Nem (1.0 ko-m, 7 feb) fistall the cam chain tensioner int the cylinder head and tight- “ithe mounting bolts with new sealing washors, TORQUE: 10.Nem (1.0 kg-m, 7 feb)CYLINDER HEAD/VALVE Check the oil pass pipe b bending, ‘and oil pass pipe for clogging or Install the oil pass pipe, new saaling washers, new lock wash ft, oll pass pipe bolts and ol pass pipe hoider bolt. Tighten the oll pass pipe bolts and cll pase pipe holder bolt 10 the specified toreuas. TORQUES: il pass pipe bolt (7 mm): 10 Nem [1.0 kg-m, 7 fb) Oil pass pipe bolt (8 mm): 23 Nem (2.3 kg-m, 17 ft} Instell the cemehatt (pege 9-16) Inetell the camsha‘t holders (page 9-19) Install the cylinder head cover Ipage 9-19). Install the ongine in the frame [page 6-2), CAMSHAFT INSTALLATION Apply MoS2 paste grease (page 2-10) to the rocker arm shaft. Install the rocker aims, ;ocker arm shafts and wave washers to ‘the camehatt holdors NOTE + Install the wave washers in the original position. Position the grooves in the ende of the rocker arm shafts verti cally, aligning the bolt holes in the holder wrth the holes in the shatts ‘Apply MoS: grease {page 2-10) to the rocker arm slipper faces. “a TH Olt PASS PIPE BOLTS: SEALING WASHERS (2) SEALING WASHER LOCK WASHERIEOLT] (1) WAVE WASHERS. =P, (2) ARM (EX) b oh SS 14) SHAFT (IN| (3) SHAFT (EX) (6) ARMS (IN) SH Mos (1) GROVES: 9-16CYLINDER HEAD/VALVE a ER HEAD IVALVE Nore (1) CAMSHAFT IDENTIFICATION MARKS + IF both the front and rear camshafts were removed, start ‘the installation with front cylinder es described below. if Ene opea eh / ‘RY: Rear cylinder camshatt FRONT CYLINDER NOTE It the rear cylinder has not been serviced, ramove the rear cylinder head cover and check the rear cylinder camshaft position as follows: Remove the timing hole cap, turn the crankshaft counter lockwise and align the “RT” merk on the flywheel with ‘the index merk on the right eranksese cover, then check the Identification mark on the camshaft fiange. 1 the ““R’ mark on the camshaft flange faces up, turn the cranckshaft counter clockwise 488° (1-1/3 tuins| and begin installation of the front camshaft. Wthe “RY mark faces down (cannot be seen}, turn the crankshaft counter clockwie 128° (1/3 ture) and begin installation, (7) INDEX MARKS 3 with the index merk on Align the "FT" mark on the flywhs the right crankcese cover, (3) “FT” MARK. Lubricate the camshaft journal surfaces of the clyinder head with molybdenum disulfide grease, (1) CAMSHAFT Install the camshaft on the cylinder head through the eam chain and install the cam sprocket on the camshaft with the timing marks {indox lines) facing the outside. Place the camshaft on its correct position with the “F' merk on the flange facing up. Align the timing marks (index lines) on the cam sprocket with the top of the cylinder head and place tho cam chain on the sprocket. Install the car sprocket on the camshaft flange and rachock thet the timing marks (index lines) align with the top af the cyl: Inder head. (1) BOLT Align the cam sprocket bolt holes in the cam sprocket and sy ‘camshaft, install and tighten the cam sprocket bolt, TORQUE: 23 Nem (2.3 kg-m, 17 feb) ‘Tuin the crankshaft counterclockwise 360° and install the ther sprocket ott. After instaling the front evlinder camsha‘t turn the crankshafi ‘counterclockwise 92° (approximately 1-2/3 tumns) and align the “RT” mark with the index mark on the timing holo, then in stall the rear cylinder camshaft using the same procedure a¢ ee for the front cylinder. y EeCYLINDER HEAD/VALVE REAR CYLINDER (1) INDEX MARKS, NOTE + If the front ovlinder was not serviced, remove the front cyl Inder head cover and cheok the front cylinder camshaft po- sition as follows: Remove the timing Nole cap, tuin the crankshaft counter Clockwise and align the “FT" mark on the flywheel with the index mark on the right eankease cover. then check the identification mark on the camshaft flange, If the ““F*" merk on the camshaft flango faces up, turn the ‘crankshaft counter clockwise 232° (approximately 2/3 ‘tums) and begin installation of the rear camshaft. 3) (2) "RT? MARK. Ti the “F” mark faces down {cannot be seen), tum the ‘crankshaft counter clockwise 592° (approximately 1-2/3 tuins) and begin instellation, Make sure that the ""RT” mark on the tlywhes!eligns with the index mark on the right crankease cover. Place the camshaft on its correct position with the "A!" mark on the flange facing up and install the cam sprocket in the ‘seme procedure as for the front cylinder. Remove the 2 mm pin, holding the cam chain tensioner wedae (1) WEDGE A A NOTE + Be careful not to let the 2 mm pin fall into the cranks + Do not forget to ramove the 2 mm pin before installing the cylinder head cover Install the dowel pins into the cylinder head. 9-18CYLINDER HEAD/VALVE Install the holders, oll guide plato, 8 mm bolts, & mm nut and 6 (1) OW GUIDE PLATE ‘im bolts, CAUTION + Note the direction of the camshaft holder end, nstaltit with the Slat surfece on the holder facing in Tighten the camshaft holder mounting belts and nut in e Gisscross pattern in 2~3 steps as shown, TORQUE: 8 mm bolt: 23 Nem (2.3 kg-m, 17 fib) 8 mm nut: 23 Nem (2.3 kg-m, 17 ft-lb) {6 mm bolt: 10 Nem (1.0 kg-m, 8 feb) Filthe oil pockots in tho head with ol so thet the cam lobes are ‘submerged, Adjust the valve clearance (page 3-7). CYLINDER HEAD COVER INSTALLATION (0) gasxer N Clean the gesket ond apply sealant to the gasket groove of the cylinder head cover. Install the cylinder head cover, rubber washer, washer covers (1) BOLTS, And cylinder head cover bolts. Tighten the cylinder head mounting bolts to the specifiod ‘orque. TORQUE: 10 Nem (1.0 kg-m, 7 fb) Check tho O-ring for woar or damage. histall me rear water pipe with a new O-ring and tighten the botCYLINDER HEAD/VALVE Inetell the frame bridge and tighten the frame bridge mounting bolts with the ground cable. TH) BREATHER TUBE es Connect the cylinder head cover breather tube, Install the ignition colt stay and tighten the bolt. Connect the spark plug caps to the spark plugs. Install the fan motor and fan motor shroud as an assembly and tighten the boits with the ground cable. Install the following parts. = Carburetor (page 4-16). — Fuel tenk (page 4-3). 9-20CYLINDER/PISTON 10-010. CYLINDER/PISTON GENERAL # This eoction covers ‘om the frame SPECIFICATIONS SERVICE INFORMATION 10-1 PISTON RING INSTALLATION 10-5 TROUBLESHOOTING 10-1 PISTON INSTALLATION 10-5 CYLINDER REMOVAL 10-2 CYLINDER INSTALLATION 10-6 PISTON REMOVAL 10-3 SERVI ICE INFORMATION vice of the cylinder and piston. These procedures can only be performed with the engina removed crn tn) ew STANDARD SERVICE LT 6 76.000~76.015 2.9628-2.9889 76.17 2.969) Worpage aos top i 0.1010.008) Teper = 0.05 0.02) out of sound J as 0.05 0.092) Fietoningtorng | TOP 0.615~0.086 (0.0006-0.0078 | 0.100.004) spncie Clearance SECOND 0.015—0.045 (0.0006—0.0018) 0.10 (0.004) Fin ord 09 TOP 019-030 (0.004-0.012) 0.60 (0.020) SECOND: 0. 90 (0.004-0.012) | 0,500, 020) [on | 0.20-0.7010.000-0.028 | 0.900.035) Piston 0.0, 74.965— 74.980 (2.9514—2.9524) 74.84 (2.948) Piston pin bore 18.002 18.008 (0.7087-0.7090) | 18.06 10.711) Connecting rod small end 1.0. 18,016 18.034 (0.7093—-0.7100) 18.09 (0.712) Piston pin 0.D. i _17.894— 18.000 (0,7084—0.7087) | _17.80 (0.701) Pistoro-iston pln cewrance 0.092--0.014 (0.0001-0.0608) | 0.25 10.010) Cylinger-to-piston clearance 0,010 0.080 (0.0004 0.0020) Sy 13) | Kee eta 0.018-0.040 1.0008-0.0018) | 0.2910.0111 TROUBLESHOOT NG {on oF uneven compression + Worn cylinder or piston rings. * Leaking head gasket * Incorrect velve timing, Excessive smoke * Worn cylinder and piston ri + Improporly installed piston rings, + Damaged piston or eylindar. Overheating * Excessive carbon deposits on piston or combustion chamber. + Feulty water pump. Piston noice + Worn cylinder and piston + Excessive carbon deposits. sh 10-1CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder heads (Refer to Section 91. amove the gaskets and dowel pins and the cam chain guides. Remove the cylinder. Romove the gaskets and dowel pins. CYLINDER INSPECTION Inspect the eylinder walls for scratches and weer. Measure and record the eylinderI.D. at three levels in both an X and Y axis. Take the maximum reading to determine the oy! Incer wear. SERVICE LIMIT: 75.17 mm (2.959 in) Coleuilate the oylinder for taper at three levels in an X and Y axis. Take the maximum reading to determine the taper SERVICE LIMIT: 0.08 mm (0.002 ind Calculate the cylinder for out-of-round at three levals in an X and V axis. Take the maximum reading to determine the cut- of-round, SERVICE LIMIT: 0.05 mm (0.002 in} ‘The cylinder must be rebored and oversize piston fitted if the service limite aro exceeded. The following oversize piston are available: (0.26 mm (0.010 in) and 0.50 mm (0.020 In) “The cylinder must be reberad go that the clearance to an over- size piston is 0,010--0,050 mm (0.0004—0.0020 in} 10-2 (1), GASKET (4) MIDDLE (5) 80TTOMCYLINDER/PISTON CYLINDER WARPAGE INSPECTION “Oban the cylinder gasket surface. Inspect the cyincers for transver warpage across the top. Nessure warpage using a straight edge and fesler gauge in “the directions shown, "SERVICE LIMIT: 0.10 mm (0.004 in} PISTON REMOVAL ‘Poo 9 shop towel into the crankcase and remove the piston tin clos. Note Bo not lt the cips fal into the crankcase, Pish the piston pin out and remove the piston. PISTON/PISTON RING INSPECTION Alerove the piston rings end mark them to indicate the correct, “syinder end piston position for reassembly. Wepeet he piston for cracks or other cammage anc the rng _gjoves for excessive vrear or carbon built-up. NOTE ¥ Bo not damage the piston rings when removing them. Measure the piston 0.0. NoTE * Tale measurements 10 mm (0.4 in) from the bottom, and {99° to the piston pin hole. “SERVICE LIMIT: 74,04 mm (2.946 fn ‘Gaovlawe the piston-to-cylinder cleerance by subtracting the piston 0.0. from the cylinder I.D. Ipage 10-2) SERVICE LIMIT: 0.32 mm (0.013 in) 10-3CYLINDER/PISTON Measure the piston ring-to-groove clearance. SERVICE LIMITS: Top: 0.10 mm (0.004 in} Second: 0.10 mm (0.004 in} Measure the top and second piston ting end gaps: using a pis: ton, push the ring into the cylinder squarely and make the mea- surament. SERVICE LIMITS: Top/Second: 0.60 mm (0.020 in} oi: (0.90 mm (0.038 inj Measure each piston pin bors. SERVICE LIMIT: 18.05 mm (0.711 in) Measure oach piston pin 0.0. SERVICE LIMIT: 17.80 mm (0.701 ind Caleulate the piston pin to piston clearance, [SERVICE LIMIT: 0.25 mm (0.010 in} Measure the .D. of the connecting rod smal end SERVICE LIMIT: 18.09 mm (0.712 in) Calculate the piston pin to connecting rod clearance SERVICE LIMIT: 0.29 mm (0.011 in} Refer to section 11 for connecting rod raplacemont, 10-4CYLINDER/PISTON PISTON RING INSTALLATION Clean the piston dom: ring lands, and skirts. nore inser the outside surface of the ng into th propor ng ‘groove and roll it around in the groove to make sure that the fing hae a froe fit around the piston’s circumference. Carefully install the piston rings onto the piston with the merk- ings facing up. nore * Be careful not to damage the piston and piston rings during essembly. Stogger the ‘ing end gaps 180° apart from each other as shown, + 11) Tor ANG = }- — EZ2=— 2) SeconD RING + Toinstall the oil rng, install the spacer first, then install tho pores (4) SIDE RAIL S15) SPACER! (3) OL, Aiter installing the rings, check that they rotate freely without RING re (6) SIDE RAIL PISTON INSTALLATION Place a stiop towel into the crankcese. Cea the red small end with molybdenum disulfide grease. [ (2) PISTON PIN CLIP Assemble the piston and cemecting rod with the piston and ‘ew piston pin clips as shown, NOTE * Inatall the pistons with the “IN'" marks on the intake valve side + Be sure to Install the pistons in their original positions as noted during romovel. ‘Aftar installing the piston pin clipe, make sure thet they are Seated properly and the end gaps are not aligned with the cut-out in the piston. + Do not let the piston pin clips fall into the crankcase, 10-5CYLINDER/PISTON CYLINDER INSTALLATION Install the dowel pins and new gaskers. Coat the cylinders, piston rings/grooves and pistons with of. Slide the cylinders over the pistons whi piston rings with your fingers, compressing the NOTE + Be careful not to damage the piston rings during assembly. + When the cylinder is halfway over the pieton, route tha cam, chain through the cylinder Install the cam chan guides. NOTE ‘Align the guide bosses with the grooves in the cylinders. + Make sure that the and of the guide is inserted into place in the crankcase. Install the dowel pins. Install new gasket Ingtall the eylinder heads (page 9-15). 10-6 (1) GASKET (1) GASKET] (3) DOREEERS (2) CAM CHAIN GUIDE]CRANKSHAFT/TRANSMISSION 11-011. CRANKSHAFT/TRANSMISSION | SERVICE INFORMATION 144 TROUBLESHOOTING W2 CRANKCASE SEPARATION 11.3 CRANKSHAFT/CONNECTING ROD REMOVAL 11-4 CRANKPIN BEARING 115 MAIN BEARING WT CONNECTING ROD/CRANKSHAFT INSTALLATION 11-9 ‘TRANSMISSION REMOVAL 11-10 (CRANKCASE BEARING REPLACEMENT 11-12 ‘TRANSMISSION INSTALLATION 11-14 CRANKCASE ASSEMBLY 11-15 SERVICE INFORMATION GENERAL © To service the connecting rods, crankshaft and transmission, the erankoase must be separated. © All bearing inserts ere select fitted and ate identified by color coda. Select replacement bearings from the code tables. After installing naw bearings, recheck them with plastigauge to verify ol ck and crankpine during essembly. ® Apply molybdenum disulfide grease to the main journal * To service the connecting rods, crankshaft and transmission, the angine must be removed from the frame (page 6-2) and the crankcasoe must bo soparcted © Gefore separating the crankcase, the fallowing parts must be removed. + Flywheel (Section 8) Starter motor {Section 18) + Wetor pump (Section 5} + Cylinder heed (Section 9) + Cylinder/piston (Section 10) : + Glutch/gearshit: inkage (Section 7) SPECIFICATIONS oe Tew STANDARD SERVICE Una hstotat, | Etbocting sed i aed se deranca 0198=020 (0.002~0.008) | 0.4010.016) premaction soe Crankpin oll clearance "0,028 0.062 (0,001 1—0.0020) 0,07 (0.003) Tain our i 0.026-0.041 0.0010-0.0016) | 0.06 16.002) [Crankshaft runout ‘oe =_— 0.05 10.002) ee a 24,000~-24-001 10.8448~0.9457) | 24.04"0.047) 'Ma. M6, C2, 63 | 98.000~28.021 (1.1024 1.1098) |} "38-04 (1.108) | Gear banking OD. [er 20.959~28.980 (0,9433-0.9481) | 24.94 (0.862) [wa we,c2,c3 | 27.950=27.98001.1007=1.016) | 27.94 1-100 | Gear bushing 1. [ct 20,016 20.087 (0.7880.-0.7888) | 20.08 0.780) [wa e2.c3 26.000 26.021 (0.0049 0.0861) | 26.04 0.886) Ma, C2. 3 0.008-0.0470.0002-0.019) | 0.06 2002) Capes on | MAP MECI 0.020-0.082 0.0008 -0.0024) | 0.10 0008 [-Mairsheft 0.0. |W busting 74.050 24,080 0.9826~0.9838) | 24.80 0.880) Countorehatt OB. | Ct bushing 18.980—19,899 (0.78660.7871) | 19.82 0.784 (62, c9 bushings | 24,960—24.96070.9826~0.9898) | 2480 0.8801 Backlash ist __ | 0.089-0.170 (6.0035-0.0067) | 0.24 10,009) 2nd, Sr ih, Sth | 0.068 0.196 (0.0027--0.0084) | 0.18 0.007) Shik Yok) | Caw wisknees 5.99-6,00 0.288-0236 | 5.63 (0299 forse’ right and lft hi foi 1 7a.000—-13.0180.5118--0.5128) | 1304 0.61a Shaft 0.0. 12.966— 12.984 |0.6106—0.5112) 12.90 (0.508) [Shit cum 0.0 et the let side aura 12.966 12.084 (0.6496~0.5500) | 13.90 0.5471 11-1CRANKSHAFT/TRANSMISSION TORQUE VALUES Connecting rod 94 N-m (3.4 kgm, 25 feb) Bearing set plate 10 Nem (1.0 kg-m, 7 ft-lb) Apoly locking agent. TOOLS Special Bearing remover set 07938--3710001 Not ovailablo in U.S.A remover handle 079383710100 — bearing remover set 07938 -3710600, remover sliding weight 077410010201 or remover weight 07936-3710200 Bering driver attachment ‘07HMF—MM90400 Common Driver (077490010000 Actachment, 42 x 47 mm 07748 0010300 Attachment, §2 x 55 mm (077480010400 Pilot, 20 mm 077480040500 Pilot, 22 mm (077460041000 Pilot, 25 mm 077460040600 TROUBLESHOOTING Excessive noise + Crankshaft = Worn main bearing Worn crankpin bearing Worn rod smell end — Worn erankpin bearing Hard to shit + Shift forks bent + Shift fork shaft bent + Shift spindle claw bent + Shift drum cam grooves damaged + Shift fork guide pin damaged ‘Tranemission jumps out of gear + Gear dogs worn + Shift shaft bent + Shift forke bone 11-2CRANKSHAFT/TRANSMISSION INKCASE SEPARATION ‘the engine from the frame (Saction 6) to the servica information (pege 11-1) for the parts thet De removed betore the separating the crankcase. the bolt and bearing aot plate. the rear cam chain and cam chain drive sprockot, the bolt and cam chain tonsioner set pl v€ the front cam chain from the crankshaft. the neutral switch wite and oil pressure switch (1) NEUTRALTOIL PRESSURE | by removing the nut and bolt with the clamp, SWITCH WIRE the 8mm bolts and 6 mm bolts from the left crank Hiomove the boits in a crisscross pattern in 2—3 steps. {Loosen the 6 mm bolts frst, then tho 8 mm bolts. BV9 the bolts in @ crisscross pattem in 2—3 steps. in the 8 mm bolts first, then the 8 men bolts,CRANKSHAFT/TRANSMISSION Place the left side crankcase down and separate the right (1) RIGHT CRANKCASE crankcase from the left crankcase witle prying the crankcase halves ae shown and topping the casos at severe! locations ‘with a soft hammer. CAUTION + Do not damage the cronk imaiing surfaces with prying. Remove the dowel pins. Clean the crankcase mating aurfecee thoroughly. (3) PRYING POINT (2) LEFT CRANKCASE CRANKSHAFT/CONNECTING ROD REMOVAL Remove the crankshaft from the left crankcase. (1) CRANKSHAFT CRANKSHAFT SIDE CLEARANCE INSPECTION Check the connecting rod side clearances. SERVICE LIMIT: 0.49 mm (0.016 in) If either side clearance exceeds the service limit, replace the connecting rod and recheck. {fis stil beyond the limit, replace the crankshaft. Inspect the crankshaft for rough spots or damage. CONNECTING ROD DISASSEMBLY CAUTION + Do not interchange the crankpin bearings. They must be in ‘stalled in their original pasitions or the correct bearing oil clear- ‘ance may not be obtained causing engine damage. Remove the bearing cap nuts and bearing caps. 11-4CRANKSHAFT/TRANSMISSION a _SRANKSHAFT/TRANSMISSION Mark the disassembled connocting rode and beating ceps to 1) CONNECTING ROD rsure reinstallation in their criginal positions (2) BEARING CAP CRANKSHAFT RUNOUT INSPECTION Support the crankshaft contor a8 shown and set a diel indica {or on the center main bearing journal. Rotate the crankshaft ‘wo revolutions and read the runout. SERVICE LIMIT: 0.05 mm (0.002 ini NOTE * The crenkshaft cannot be repaired. Replace it the journals Dr erankpins are burnt, erackod, or if the runout is beyond the service limit CRANKPIN BEARING 11) PLASTIGAUGE OIL CLEARANCE INSPECTION Inspect tha crankpin bearings for unusual wear oF damage. Wipe oll ol off the crankpin bearings and erenkpins.. Puta pieca of plastigauge on each crenkpin, Nore + Do not put the plastig instal the bearing caps and connecting rods to the correct grankpins and tighten the bearing cap nuts to the specified torcue. TORQUE: 34 Nem (9.4 kgm, 25 fr) Note * Donot rotate the crankshaft end connecting rods during in- stallation.CRANKSHAFT/TRANSMISSION Remove the bearing caps and connecting rods end measure the width of the compressed plastigauge on each crankpin. SERVICE LIMIT: 0.07 mm (0.003 in) If the rod bearing clearance Is beyond tolerance, select re- placement bearings. BEARING SELECTION ‘The connecting rod I.D. cade number (1 oF 2) atampod on oach connecting rod identifies its inside diameter. (1) CONNECTNG ROD 1.0. CODE NUMBER ‘The code letter (A or 8) stomped on the crankshaft counter (1) CRANK PIN 0.0. CODE LETTER |) weight identifies the outside diametor of ite crankpin. Gress references the crankpin end connecting rod codes to ‘elect the correct replacement besring, ‘CONNECTING ROD 1.9. CODE No [mene 43.000- |43.008— 43,008 mm |43.016 mm (1.6920 (1.6932 1.0935 in} 39 582— 39.890 mm Al it. 741— pone Black (1| COLOR CODES jcrankewn 0.0. |_| 1.5744 ind CODE Letter | | "730.074 |g | 39-982 mm 5/29.282mm) sack | the [1.5241 int | BEARING THICKNESS ‘ Blue: 1.495—1.499 mm Black: 1.491—1.495 mm Blown: 1.487—1.491 mm 11-6MAIN BEARING OIL CLEARANCE INSPECTION 12 main journal visually for unusual wear. il off the main journal, and mescure and note the 0, of the main journal. Measure the I.D. of the main journal beering. Calculate the cloarance between the main journal and main bearing. SERVICE LIMIT: 0.06 mm {0.002 in} CRANKCASE SELECTION Hote the main journal 0.0, code number or meesure the main jour 0.0. crankcase main bearing 1., code number (A or B) ped on each crankcase identifies its inside diameter, CRANKSHAFT/TRANSMISSION ([(1) WAIN JOURNAL 0.0. CODE NUNIGER im (9 CRANKCASE LD. CODE NUMBER,CRANKSHAFT/TRANSMISSION Cioss references the main journal and erankcase codes to do. termine the replacement bearing. MAIN JOURNAL 1 2 0.0. CODE \44,992— | 44.984 | ee 45.000 mm | 44,992 mm | CRANKCASE ~~ (.7713—— | (.7710— |.D, CODE | 77170) | 4.7713 n]seaso=sso00mm |e] 8 | [| tazor—rseo1'w__wnewny | exces [5 | 49.000—48.010 mm B A (1,9291—1.9295 in) | (BLACK) | _ (BLUE) BEARING INSERT THICKNESS AIBLUE); 2.003—2.013 mm (0.0789—0.0783 int B (BLACK): 1.998—2.008 mm (0.0787—0.0781 in) € (BROWN):1.993— 2.003 mm (0.0785—0.0789 in) REPLACEMENT Press the main bearing out of the crankcase using @ hydraul press and special tools, NOTE ~ Always use a press to remove the main boaringe. Toots: Drive 077490010000 ‘Main bearing remover attachment O7HMF—MM30400 ‘Mark a vertical line below each side of the bearing tab. ‘Apply molybdenum disulfide grease to the outer surface of tho main bearing lign the marks on the bearing with the eroove in the bearing hole, and press the main bearing into the crankcase. CAUTION Be careful noi 10 damage the bearings. Toots. Driver 077490010000 ‘Main bearing driver attachment O7HMF—MNI90400 11-8 11) DRIVERCRANKSHAFT/TRANSMISSION ——S$. $A TRANSMISSION CONNECTING ROD/CRANKSHAFT 1) TABSiGROOVES INSTALLATION i /\ Irstall tho crankpin beerings on the connecting rods and bear- ing caps, aligning the tabs on tha baaring with the grooves in the rods and caps. Apply molybdenum disulfide grease to the crankpin bearings, Instat the connecting rods and besring cape and tighten the bearing cap nuts, TORQUE: 34 Nem (3.4 kgm, 25 fb) Nove + Tighten the bolis in a crisccross pattern in 2—3 steps + Make sure the connecting rods rotate smoothly after tiaht- ening the cap nute, Apply molybdenum disulfide grease to the mein journals. Remove the oil jets from the left and right crankcase. Check the pieces for clogging. Check the O-ring for damage. Install them and install the crankshaft to the left crankcase,CRANKSHAFT/TRANSMISSION TRANSMISSION REMOVAL (1) Main, wy \2) SHIFT DRUM SHAFT ae Remove the mainshaft, counvershaft, shift fork shaft and shift drum os on essembly. NoTE + Remove the cil pump (section 2) and crankshat, if itis ii cult to remove the transmission as an assembly. (3) SHIET EOAKS, Bend down the lock washer tabs and remove the bolt and lock (1) SHIFT FORK SHAFT (2) CENTER SHIFT washer from the center shift fork, “ Remove the shift fork shaft form the center shift fork. Disassemble the mainshaft and countershat (4) Lock (5) 80LT WASHER (3) TABS, Measure the 0.0. of meinshaft and countershatt. A A at ty 2490 10.9006) Shain 23 mn ose ©: cetusnng 2490 mr :980 5 Satuctin 2490 mn (0:90 Check the gear dogs, holes and tooth for excessive or abnormal wear, or evidence of insufficient lubrication. Measure the I.0. of each gear. SERVICE LIMITS: Ma, MB, C2, C3 goers: 28.04 mm (1.104 C1 goar: 24.04 mm (0.947 in} Measure the 1.0. and 0.D. of each gear bushing, SERVICE LIMITS: M4, MB, C2, C3 bushings 0.D.: 27.94 mm (1.100 in) 1 bushing 0.0. 24.94 mm (0.982 in) M4, C2, C3 bushing 1... 25.06 mm (0.790 in) (C1 bushing LD. 20.06 mm (0.790 in} 11-10CRANKSHAFT/TRANSMISSION _——].. $$ __ASHAPTITRANSMISSION Calcurate the bushing to shaft cl clearance. SEAVICE LIMITS: bushing to-shaft M4, C2, C3): 0.08 mm (0.002 in) (eer-to-bushing (Ma. MB, C1, C2, €3): 0.10 mm (0.004 in) Inspect the shift drum and shift ferk shaft journals tor exessive ‘wear or damage, Inspect the shift drum end for scoring, scratches, or evidence of insufficient lubrication. Check the shift drum grooves far damage, Measure th shift drum shaft O.D. at the loft sido journal. SERVICE LIMIT: 13.90 mm (0.547 in| ‘Check the shift fork shaft for scratches, scoring ot evidence of insufficient lubrication, Measure the shift fork shaft O.D. SERVICE LIMIT: 12.90 mm (0.608 in) Measure the right and loft shift fork |.0.8 end the shitt fork claw thicknose, SERVICE LIMITS: 1D 13.04 mm (0.813 in) CLAW THICKNESS: 5.63 mm (0.222 in) wrances and gear to bushing (1) SHIFT DRUM, 11-11CRANKSHAFT/TRANSMISSION ‘Turn the innor race of each bearing with your finger. The bear: ings should turn smoothly and quietly. Also check thot the bearing outer race fits tightly in the crankesss, Remove and discard the bearings if the races do not turn ‘smoothiy, quietly, or # they fit loosely in the crankcase (page 11-12) CRANKCASE BEARING REPLACEMENT LEFT CRANKCASE ‘Remove the left mainchaft bearing using the special tools. Toots: Beering remover cat — remover handle 97936-3710100 = bearing remover set 07936—3710600 — remover sliding weight 07741—0010201 or = remover weight (079363710200 Je the countershatt bearing and cil seal cut of the crank: case. Install a new mainshaft bearing plate with its projection facing Up into the left crankcase. ont NOTE + Apply eleen engine oil to now crankcase bearings before in- staliation, Install now bearings with the following tools. TooLs: Loft mainchatt bearing Driver ‘Attachment, 42x47 mm 077460010300 Loft countershaft bearing Dri 07749-0010000 Attachment, 52x55mm 077460010400 Pilot, 25 mm (07746-04060 SNe (2) COUNTERSHAFT.CRANKSHAFT/TRANSMISSION Install anew countershaft ol seal, Chock the geershift spindle oll seal for wear or damage, ro- TT COUNTERSHAFT OIL SEALE place if necessary, Ae) RIGHT CRANKCASE (2) COUNTERSHAFT BEARING Drive the countershaft bearing, mainshatt bearing and shift rum bearing out of the crankcase. Too.s, Right mainohstt bearing Dri 077490010000 Attachment, 52x 55mm 077460010400 Pilot, 22 men 07746-00410 Right countershaft bearing Driver 077490010000 Attachment, 42x 47mm 07746—0010300 Pilot. 20 mm 077460040500 TRANSMISSION INSTALLATION Assemble the mainshaft and countershatt. Apply molybdenum disulfide graaeo to the following, (51 STOPPER, ~ shift fork grooves (M3, C4, C5 gear) Waemey ~ inside and outside of the bushings 13) ca. (art (6) c3 (2st) ~ outside of the spline bushings (4) SNAP (7) BUSHING (2) BUSHING RING 1d6 ¢ (0 wo (1) ¢1 @sr). (10) ¢2 (327) (17) BUSHING (0 66 apm oafpec Gve Hue 2) Mi (aT) (13) a (247) cays (2m /i16) 98 (267) (78) SNAP RING (15) BUSHING (17) STOPPER WASHER 11-13CRANKSHAFT/TRANSMISSION Install the ME bushing onto the mainshait, aligning the holes in (1) MAINSHAFT ‘the bushing and mainshatt Check the gears for froe rotation on the shaft. Check the snap rings are seated in the grooves and align thelr fend gap with the land of the splines, oe Bet (3) M5 BUSHING 2) HOLES: Install the shift fork shaft through the center shift fork, aligning (1! SHIFT FORK 2) CENTER SHIFT FORK the bolt holes in the shaft and shift fork. SHAFT Tighten the bolt with the lock washer and bend up the tabs of the lock washer. (a) Lock (5) BOLT. WASHER, |g) TABS Install the right and left shift ferks with the locetions as (1), MARKS: i ‘shown. \ Note i + Install all shift forks with the marks on the shift forks facing i 10 the right crankcase. ‘Assembla the mainshaft: countershatt, shift fork shaft and (1) MAIN. (2) SENET Daal shift drum. SHAFT Install them to the left crankcase as an accombly. i NOTE install thom as follow, if tis difficult: ‘+ remove the oll pump (section 2) and crenkshatt. install the mainahst, countershaft and shitt fork sheft 2s.0n ‘essembly. + Install the shift erum, install the ail pump {section 2) end crankshaft.CRANKSHAFT/TRANSMISSION CRANKCASE ASSEMBLY Apply sealant to the crankcase mating eurfaces, Install the dowel pins, ‘Assemble the right and left crankcase halves, being coreful to align the dowel pins and shafts. ‘CAUTION + Do noi force the crankcase halves together; if there is exessive forve required, something is wrons. Remove the right crankcase and check for misaligned pers Apply oll to all erankoage bolts Install and tighten the right crankcase bolte in a crisecross pat tern in 2—3 steps. NoTe Tighten the 8 mm bolis frst, then tighten the 6 mm bol Install and tighten the leit crankeasa halves, bolts in s crise: cross patiern in 2~3 steps. Nore + Tighton the 8 mm bolts first, then the 6 mm bolts, Connect the neutraljcil pressure switch wires with the nut, bolt and clamp, then tighten the nut. Ril the rear cam chain drive sprocket over the crankshaft, aligning the extra-wide splines in the eprocket and crankshaft (1) SEALANT (3) NEUTRALIOIL PRESSURE SWITCH WIRE 11-15CRANKSHAFT/TRANSMISSION Rall the rear cam chain over the rear cam chain drive sprocket. NG (1) REAR CAM CHAIN Apply the locking agont to the threads of the becring sot plate attaching bolt. Install the bearing set plate an zighten the bot. TORQUE: 10 Nom |1.0 kg-m. 7 flb) Rall the front cam chain over the front cam chain drive sprock- ot. Inctall the cam chain tensioner set plate and tighten the bott. Inctall the remaining parts in the reverse order of removal (page 11-1)12. COWLING/MUFFLER/REAR FENDER SERVICE INFORMATION 12-1 MUFFLER/EXHAUST PIPES 124 COWLING 12-2 REARFENDER 12-5 SIDE COVER 12.4 SERVICE INFORMATION GENERAL a + Do not service the TORQUE VALUES Exhaust pipe band bolt 22 Nem (2.2 ko-m, 16 feb) Exhaust pipe joint nut 27 Nom (2.7 karm, 20 te) Muffler mounting bolt (front) 40 Nem (4.0 kg-m, 29 it) (ean 65 Nem (6.5 ko-m, 47 it.b) With cartier Reer carrier bolt (front/lft) 445 Nem (4.5 kg-m, 33 tb) ar) 27 Nem (2.7 kgm, 20 ft-lb) Turn signal stay bott 27 Nem (2.7 kom, 20 feb) 12-1COWLING/MUFFLER/REAR FENDER COWLINGIMUFFLER/REAR FENDER COWLING wae. UPPER COVER, ea REMOVAL RIGHT AND LEFT SIDE COWLING Romove tho throe scrows. Disconnect the turn signal connector and release the tabs on the side cowling that hold the center cowling. Romove the side cowling with releasing is upper tab from the upper cover groove. CENTER COWLING Romove the two boits and the center cowling RIGHT AND LEFT UPPER COVER 1) uppen coves Remove three screws and upper cover. NOTE + One of the screws also helde the side cowiing. (1) BOLTS/COLLARS FRONT COWLING ue Remove the side cowlings and upper covers. Remove the four bolts and collars, and the front cowiing. (2) FRONT CGWLING 12-2COWLING/MUFFLER/REAR FENDER LOWER COWLING (1) Lower COWLING Remove the three screws ond the two bolts, and remove the 5 lower cowling. WINDSHIELD Remove the four windshield mounting batts and nuts, then the windshield from the front cowling, NOTE + Bo caroful not to damage the wi INSTALLATION or Inatellton isthe reverse order of removal 19) side 17 eowune| <2 ra ie (1) WINDSHIELD. tse > (9) BOLT. (9) FRONT COWLING ® (8) CENTER COWLING—e4 (6) LOWER COWLING 12-3COWLING/MUFFLER/REAR FENDER SIDE COVER REMOVAL (1) SIDE Cover famove the bot and side cover by detaching the tab trom the frame hole, MUFFLER/ EXHAUST PIPES Do not service the exhaust system While this hon. REMOVAL Remove the right side cover. Remove the muffler mounting bolts, collar end mutfer. Remove the exhaust pipe joint nuts and exhaust pipes. Remove the protectors, femovo the exhaust pipe band by removing the two bend bolts and disassemble the exhaust pines INSTALLATION Gezemble and install the exnaust pipes and muttler in the to verse order of removal. TORQUE: Exhaust pipe band bolt: 22 Nom (2.2 ko-m, 16 fetby Exhaust pipe joint nut 27 Nom (2.7 kgm, 20 tb) ‘Muffler mounting bolt: (front): 40 N-m (4.0 kg-m, 29 ftb) (ean: 65.Nem (6.6 kgm, 47 fib) ~12) BAND BOLTS 22. Nem (2.2 kgm, 65 Nem (8.6 kgm, 16 t1b) 47 felb), 27 Nem (2.7 kg-m, 20 ftlb) 12-4 CeCOWLING/MUFFLER/REAR FENDER REAR FENDER (1) TALUGHT/TURN SIGNAL CONNECTORS REMOVAL/INSTALLATION Romove the side covers (page 12-4) and seat ipage 4-3.) Disconnect the taillightiturn signal connectors, Remove the four bolts and rear fender as an assembly. Remove tha two bolts (A), and turn signal stay and rear fender. jomble the roar ca Remove the bolt (B), and disassemble the inner stay ond ‘number piate bracket. Femove the two nuts and washers, and dissszemble the ‘number plate bracket and talllght assembly Remove the two bolts and the license plate assembly. Remove the three bolts and inner tender, Install the rear fender in the reverse order of removal TORQUE: Rear carrier roar two bolts: 27 Nem (2.7 kg-m, 20 teb) front loft bolt: 45 N-m (4.5 ko-m, 33 fb) (2) INNER FENDER front right bolt (mutfler rear stay bolt}: 65 Nem (6.6 kg-m, 47 feb) ‘Turn signal stay bolt: 27 Nem (2.7 kg-m, 20 fetb) (1) INNER FENDER SER ee \ UGHT (5) TAILLIGHT ASSEMBLY of 78) BOLT (3) (7) TURN SIGNAL (3) NUMBER PLATE BRACKET (3) INNER STAY (10) BOLTS (Ab 27 Nem (2.7 kg-m, 20 feb) 12-5FRONT WHEEL/SUSPENSION/STEERING 27 Nem (2.7 kg-m, 20 ft) (6.5 kam, 47 fb) 27 Nem (2.7 kg-m, 20 feb) 40 Norm (4.0 kgm, 28 Fb)13. FRONT WHEEL/SUSPENSION/STEERING ‘SERVICE INFORMATION 13-1 FRONT WHEEL 13-5 TROUBLESHOOTING 13-2 FORK LEGS 13-11 HANDLEBARS 13-3 STEERING STEM 13-18 SERVICE INFORMATION nn * A contaminated brake dise or pad reduces stopping power. Discard contaminated pads and clean a contaminated dise with a high quality drake degreasing agent, + Inhaled asbestos fibers have beer fournd to cause respiratory disease and cancer, Never use an ait hose or dry brush to clean brake assemblies. Inthe United States, use OSHA-approved vacuugn cleaner or alternate method approved by OSHA designed 10 mint. mize the hazard by air borne asbestos fers. GENERAL © /A jack or other support required to support the motorcycle. CAUTION + Do not support the motorescle by puiting a jack or other support under the oil flier © Naver ride on the whee! tim. SPECIFICATIONS, ITEM ‘STANDARD SERVICE LIMIT ‘Axla ohaft runout — [0.2 mm (0.07 in) Front wheel rim runout Racial — 2.0 mm (0.08 in) “ ‘Axial ay 2.0 mim (0.08 in) Fork spring free length 571.5 mm (22.50 in) 565.5 mm (22.26 ini Fork tube runout meee = 0.2 mm (0.01 in) Fork ley fluid capacity 549 cc (18.6 US o7, 19.3 Imp 02) — Fork leg fluid lovel 125 mm (4.9 in) = TORQUE VALUES Hanclebar upper holder 26 Nem (2.6 ko-m, 19 feb) Spokes 3.8. Nem (0.38 kg-m, 2.7 ft:lb) Brake disc 40 Nem (4.0 kg-m, 29 ttb) Front wheel hub cover 1.5 Nem (0.15 kgem, 1.1 feb) Front axle 65 Nem (8.5 kg-m, 47 tetb) Axle holder nut 12 Nem (1.2 ke-m, 9 tb) Fork slider socket bolt 20 Nem (2.0 ker, 14 feb) Fork leq pinch bolt (upper) 27 Nem (2.7 kg-m, 20 feb) lower) 35 Nem (3.5 ka-m, 25 feb) Fork tubo cap bolt 23.Nem (2.3 ko-m, 17 feb) 27 Nem (2.7 kgm, 20 fb) Steering bearing adjustment nut 3 Nem (0.3 ke-m, 22 ttdb) Tighten the nut with the steering stem pushed up. Stoaring stem nut 100 N-m (10.0 kgm, 72 fib) 13-1FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL/SUSPENSION/STEERING TOOLS Spocial Fork seal driver 07947—KASO100 Fork seal criver attachment (07947--KFO0100 Steoring stom socket 079163710100 Ball race remover (07983—-MA00000 or 07738 A01000A ‘Steering stem diver (079464300100 or 07946—MBO00OO with GN HT 54 Commen ing att 077460050100, pei arate roel eii? or econ equivalent commercially available in U.S.A. Driver (9748-0010000 Attachment, 32 x 38 mm 07746~-0010100 ‘Attachment, 42 x47 mm (077460010300 Pilot, 15 mm 07746-004000 Extension bat 07716 0020600, ee mg dono wel ore oot or equivalent commercially availabe in U.S.A. Hard Steering ‘Steering bearing adjustment nut 100 tight + Faulty stearing stem bearing|s) + Insufficient air in front ure Stoors ta One Side or Does Not Track Straight + Bent fork legis) + Bent front axle, wheal inctaliod incorractiy + Unequal ell quantity in tork tudes Front Wheel Wobbling + Distorted rim Worn front wheel bearings Loage o* broken epok: Faulty tire Axle or axle holder net tightened properly Soft Suspension + Weak fors springs. + Ineufficiont fluid in fork logs Herd Suspension + Fotk cil evel too high 4 + Fork tube(s) bent or fork slider|s) damaged d Front Suspension Noise 4 + Slider binding + Insufficient fluid in fork logs + Loose fork log fastenarsFRONT WHEEL/SUSPENSION/STEERING SS. aren SUS PENSION/STEERING HANDLEBARS REMOVAL Remove the following components: = Wire bands. Lott roar voiw mirror — Loft handlebars switch = Mesier cylinder. — Right handlebare owiteh Throttle housing, ~ Handlebars holder and handlebars. INSTALLATION Place the handlebars on the lower holders, aligning the punch marks on the handlebars with the upper surface of the lower holder. Instell the upper holders with the punch marks facing forward. Tighten the front bolts frst, then the rear bolts, TORQUE: 26 Nom (2.6 kg-m, 19 ft1b) (MIRROR (2) WIRE \ en winee7 BANDS \ BANDS (7) err, HANDLEBARS © SWITCH 45) RIGHT HANDLEBARS SWITCH (a) THROTTLE HOUSINGFRONT WHEEL/SUSPENSION/STEERING Install the startar/engine etep ewiteh, sligning the pin with the hole. Tighten the front screw first, then the rear sciew. Ifthe grips were removed, apply Honda Bond A of Honda Hand Grip Cement (U.S.A. only) to the inside surfaces of the grips ‘and to the clean surface of the left handlebars and throttle grip ba, pipe. Wait 3~5 minutes and install the grips. Rotate the grips for even application of the adhesive, (1) CABLE ENDS NoTE Allow the ‘an hour before using hesive to dr Apply grease to the throttle cable ende and cable gui Connect the throttle cable ends to the throttle grip and set the cable ¢) shown 12) CABLE GUIDE “— (1) PUNCH Set the throttle housing halves, align the slit of the housing ‘with the punch mark on the handlebars and tighten the upper screw first, then the lower one, (2) scRews. Install the front brake master cylinder and the master cylinder (1) MASTER (2) eunce holder with the "UP" merk fecing up. CYLINDER, MARK Loosaly install the holder bolts, ‘Align the alt of the master cylinder holder with the punch mark fon the handlebars and tighten the upper bolt first, then the lower bolt. Connect the front stop switch wires to the switch terminals. 4) "UP MARK (3) BOLTS,FRONT WHEEL/SUSPENSION/STEERING —-—-— —___ RRMHEEL/SUSPENSION/STEERING Install the left handlebars ewiteh, aligning the pin with the hole in the handlebars, and tighten the front screw first, then tho Align the slit of the cluteh lever nolder with the punch mark on (1) PUNCH MARC (2) SWITCH WiRES the handlebars and tighten the front screw first, then the tear screw. Connect the cluteh ewitch wires to the switch terminals. (3) SCREWS, Route the sinitch wiras and secure therm with the wire bands NIE SRE (page 1-9) Adjust the following: = throttie orip free play (page 2-4), ~ clutch lever free play (page 3-75) FRONT WHEEL REMOVAL Faise the front wheel off the ground by placing e box or work stand under the engine, cAUTION + Do noi support the moioreycte Dy placing a jack or other sup. port under the oil filter Disconnect the speedometer cable fiom the speedometer ‘geerbox at the tront wheal. Loosen the axle holder nuts and then remove the front axle. Remove the front whee!FRONT WHEEL/SUSPENSION/STEERING INSPECTION © AXLE Set the axle in V blocks and measure the runout. ‘The actual runout io 1/2 of the total reading, SERVICE LIMIT: 2 mim (0.01 in) © WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly end quietly ‘Algo cheek that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not tun ‘smoothly, quietly, or if they fit loosely in the hub. Nore + Replace wheel be rings in pairs For bearing replacement, soo page 13-8. © WHEEL Check the epokes and tighton any that aro loose. ‘TORQUE: 3.8 Nem (0.38 kg-m, 2.7 fo) Check the rim runout by placing the wheel on a truing stand. ‘Then spin the wheel with hand, and read the runout using a diel indicator. SERVICE LIMITS: RADIAL: 2.0 mm (0.08 in} AXIAL: 2.0 mm (0.08 in} WHEEL BALANCING ‘CAUTION + Wheel balance divectly affects the stability, handing and over- all safely of the motoreycle. Alivays check balance when the tire has been removed from the ri NOTE For optimum balance, the tie balance mark (a paint dot on the sidewall) must be located next to the vaive stem. ‘the tire if naces: (2) BALANCE MARKFi RONT WHEEL/SUSPENSION/STEERING Mount the front wheel in 8 inspection stand. Shin the wheel, allow it to stop, and mark the lowest theaviest) part of the wheel with chalk. De this two ar thres times to verify the heavisst area, the wheels balanced, it will not stop consistently in the: position, To bolance the wheel, install wheel weights on the highest Sido of tho rim, the side opposite to the chalk marks. Add lust ‘enough weight so the whee! will no longor stop in the same po- sition when itis spun. Do not add moro than 60 grams. DISASSEMBLY Remove the speedometer gearbex from the right side of wheel hub. Remove the dust seal and speedometer gear retainer. Femove the side collar front brake disc, dust seal and the hub (wee,FRONT WHEEL/SUSPENSION/STEERING SoArY Remove the wheel bearings and distance coller. (1) BEARING REMOVER. Tt TooLs: Bearing remover head 07746--0050400 F equivalent commercially available in U.S.A. Bearing remover shaft (07746—-0060100 ‘F equivalent commercially available in U.S.A. NOTE SITTIN (2) BEARING REMOVE! + Replace the wheel bearing with # new on bearing has been removed ASSEMBLY (1) SPEEDOMETER GEARBOX (2) DISTANCE COLLAR (3) BEARING (a) Disc (5), HUB CovER (6) DusT SEAL (7) SIDE COLLAR, Peck all bearing cavities with grease. [Rr aTAchven (2) DRIVER, 32.35 mm Drive in the tight beering first until it seats, Install the distance collar and drive in the left wheel bearing NOTE + Install the bearings with the sealed faces toward the out- side, Be sure to dirve the bearing in squarely. Toots: Driver 077490010000 Attachment, 32 x 35 mm 97746~-0010100 413) PILOT, 15 mm Plot, 18 mm’ (97746-0040300 = 13-8| FRONT WHEEL/SUSPENSION/STEERING Install the hub cover and tighten the screws. TORQUE: 1.5 Nem (0.18 kg-m, 1.1 feb) A Instoll the brake disc and tighten the bolts to the specified |= a torque. TORQUE: 40 N-m (4.0 kg-m, 29 fe1b) Apply grease to the dust seal lips and install it. Install the left side collar. Apply groase to the speedometer gear retainer and instal I, aligning the tabs with the grooves in the whoo! hub. ‘Apply crease to the speedomater gearbox and goar (1) WaSHEns Install the speedometer gear and two washers into the geat= box. Se eT CTR tT as Install the speedometer gearbox into the wh the tangs with the slots. el hub, aligning OT lean the brake disc with a high quality dagraasing agent.FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Place the front wheel between the fork logs, Fit the caliper over the brake disc, taking care not to damage the brake pads. Clean the axle and holder, Install the axle through the speedometer gearbox and wheel hub. Set the speedometer gearbox tab against the behind of the ‘ang on the right fork slider, ‘Whenever removed the axle holder, install with “UP! merk facing up. Inetall the axle holder nuts loosely. Tighten the axle shaft ‘TORQUE: 65 Nem (6.5 kg-m, 47 fib) Connect the speedametar cable to the gearbox and secure 1 with a screw, With the front brake applied, pump the fork up end down sov- ‘eral times to seat the axle. Tighten the axle holder nuts, the upper nuts first, then the lower nuts in 2.01 3 steps. TORQUE: 12 Nem (1.2 ko-m, 9 ft4D) 13-10FRONT WHEEL/SUSPENSION/STEERING FORK LEGS REMOVAL Remove the following components — Front wheel (pege 19-6) — Brake caliper from the left fork leg — Brake hose clamp from the left fork leg, — Front fender and stabilizer (1) FRONT FENDER Loose the fork cap. Loose the upper and lower pinch bolts and remove the fork log, DISASSEMBLY Loosen the boot band screw and remove the fork boot and boot band, (2) BAND, Remove the fork cap bott = + The cap bolts are under spring pressure. Take care when re. ‘moving and wear eye and face protection. (1) O-RING: Cheek the O-ring for damage.FRONT WHEEL/SUSPENSION/STEERING Remove the fork spring, seat washer and spacer. Pour out the fork fluid by pumping the fork up and dawn sever- al time Hold the fork slider in a vise with soft jaws or a shop towel Remove the fork slider socket bolt CAUTION {Do not distort the fork silder by clamping it too tightly in a Remove the dust seal and stopper ting. [iv OUST SEAT I Laut CAUTION + Be careful not to damage the fork ibe. (USTOPPER FING In quick, successive motions, pull the Fork tuba out ofthe slid- er. Nore ‘+The slider bushing that is pressed into the slic ‘tubo bushing, on the ond of the fork tubs, must be forced out. Remove the oll lock piece from the fork slider. Remove the piston and rebound spring {rom the fork tube. 13-12FRONT WHEEL/SUSPENSION/STEERING OT MEL /SUSPENSION/STEERING Remove the oll seal, back-up ring slider bushing from the fork (1) OL SEAL, (2) SLIDER BUSHING ‘ube, Do not remove the fork tube bushing until inspection determi 0s it is necessary (page 13-14). (4) BACK-UP RING (3) TUBE BUSHING INSPECTION @ FORK SPRING Measure the fork spring frae length, i SERVICE LIMIT: 568.6 mm (22.26 in) FORK TUBE/FORK PISTON/SLIDER Chock the fork tube, fork elider and piston for score marks, scratches, excessive or abnormal wear. Replace it necessary. Check the piston ring for wear or damage. Check the rebound spring for wear or damage, Set the fork tubs on V blocks ané meeoure the runout. The actual runout is 1/2 of the total indicator reacing, SERVICE LIMIT: 0.2 mm (0.01 in) 13-13FRONT WHEEL/SUSPENSION/STEERING BUSHING/BACK-UP RING (3) Check POINTS (4) COPPER SURFACES ASSEMBLY Greoncarane, . OLFORK TUBE (1) FORK CAP A ® ome ty ee oP pore aoe (Stat ge WASHER (19) bust Sea. Sin (6) piston Stoeren 18) FORK RING seine SUBER 116) 1 fesounp a 3 Spang / a (| ruse on a BUSHING > Fok ristow é if on. Lock {fe BACK-UP RING PIECE: (17) SLIDER BUSHING Install the fork piston with the rebound spring in the fork tube. Install the slider bushing and back-up ring ento the fork tube. Set the oll lock piece onto the end of the fork piston, then ingort the fork tube into the fork sider. ‘Temporarily install the fork spring, seat washer, spacer and fork cap. 13-14FRONT WHEEL/SUSPENSION/STEERING Place the fork slider in a vise with soft jaws of a shop towel ‘Apply a locking agent to the socket bolt threads and tighten the bottom socket bolt TORQUE: 20 Nem (2.0 kg-m, 14 ftb) Coat a new oll seal with ATF (see next page) and ins! the fork tube with the marks facing out. lit onto in place using @ fork seal driver and attach- Fork socl driver 07947—KA50100 07947—KF00100 Install the stopper ring into the groove of the fork slider secure- (1) STOPPER ¥ pper ring rr te Install the dust seal securely,FRONT WHEEL/SUSPENSION/STEERING Remove the fork cap bolt, spacer, washer and fork epring, Pour in the specified amount of ATF. ‘SPECIFIED FLUID: ATF CAPACITY: 549 ce (18.6 US oz, 19.3 Imp ox) Compress the fork tube all the way and measure the oll level from the top of the tube. STANDARD OIL LEVEL: 125 mm (4.9 in) Wipe any oll off the fork spring Install the epring into the fork tube with the narrow pitch end facing down. Insta the spring seat washer and spacer. Tempocerily install tho fork cap bolt Install the fork boot with the breather holes facing rearward Loceely install the band with the ecrow head facing out. aged ao a (1) DOWN, ILM |1) FORK CAP BOLT (4) BAND, 13-16INSTALLATION Inetall tho fork tube through the steering stom end top bridge while rotating. (2) LOWER PINCH BOLTS ‘The bottom edge of the fork cap should be flush with the top of the fork bridgo, y Tighten the upper and lower fork pinch bol. TORQUE: Upper pinch bolt: 27 Nem (2.7 kgm, 20 feb) Lower pinch bolt: 36 Nem (3.8 kg-m, 25 fb] Tighten the fork cap bolt to the specified torquo. TORQUE: 23 Nem (2.3 kg-m, 17 fb) Push the fork boots up until they just touch the steering stem and tighton the boot bands.FRONT WHEEL/SUSPENSION/STEERING Inotall tho stabilizer and front fonder. Install the brake caliper to the left fork leg ‘TORQUE: 27 Nom (2.7 kg-m, 20 feb) Secure the brake hose with the clamp. Install the front wheel (page 13-10), STEERING STEM REMOVAL Remove the following components, Front wheel (page 13-5). Lowor brake hose holder belts. — Front ouard plate. — Handlebars (page 13-3) — Upper brake hose holder bol, Ignition switeh (page 19-5}. (1) FRONT FENDER (1) CLAVE, (2) CALIPER (1) GUARD PLATE, (2) BOLTS} 1) Bout (2) IGNITION SWITCH 13-18FRONT WHEEL/SUSPENSION/STEERING. Femove the bolt, side stend indicator and the fuse tox ‘SIDE STAND INDICATOR (2) FUSE BOX Remove the following, = storing stem nut, ~ fork legs (page 13-11). ToL Lock nut wrench. 30x 32mm —07716—0020400 OF equivalent commercially Available in U.S.A, Extension bar 07716—0020500 0F equivalent commercially available in U.S.A. Remove the steering bearing adjustment nut. TooL: Steering stom socket 07916~3710100 Extension bar 07718—0020500 (F equivalent commercialy available in U.S.A. (3) STEERING STEM SOCKET" Remove the following (1) UPPER SEAL (2) STEERING STEW ly ~ upper seal ~ steering stom and upper bearing, Chock the bearings and outsr races for wear or damage, Replace if necessory. sl 3) UPPER BEARINGFRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT (i) DUST SEAL Install the steoring stom nut onto tho top ond of the steering stem to pravent the threads from damaging Remove the lower beating and dust seal using 8 punch or chis- al Replace the cust seal with a new one whenever itis removed. Remove the upper and lower races using a ball ace remover Toot: Ball race remover 07963-—MA00000 or Adjustable bearing remover __07736—A01000A with commercially available slide hammer. Drive in;new inner races. ToaLs: Driver 07749-0010000 Attachment, 42 x 47 mm 077460010300 Inetell the dust ses! and lower bearing using a hydraulic press {{(1) STEERING STEM and steering stem driver. DRIVER TooL: Steering stem drive 07946~-4300100 or Steering stem driver (07946—MB00000 ing bearing attachment GN HT 54 13-20 (2) DUST SEAL AND BEARINGFRONT WHEEL/SUSPENSION/STEERING INSTALLATION (1) upPER Sea Pack the upper and lower bearing cavities with greas Insert the steering stom through the steering head from the bottom. Inetall the upper be: ng. Pack the upper seal with grease, Install the upper seal onic the steering stem. Install the steering bearing agjustment nut and tighten it with the etooring stem socket, TORQUE: 3 Nem (0.3 kg-m, 22 ft-lb) NOTE > + Tighten the nut with the steering stem pushed up. Toot (| STEERING sre} Steering stem socket 079163710100 BOCES Extension bar 077160020500 (or equivalent commercially available in U.S.A. Turn the steoring stor lock-to-lock several tines to seat the beerings. Repeat the bearing tightoning and eteoring stom turning sequence two more times. (1) EXTENSION BAR, Install the fork bridge. Temporarily install the fork lags, Tighten the steering sxem nut, TORQUE: 100 N-m (10.0 kg-m, 72 fb) TooLs: Lock nut wrench, 90 x 32mm 077160020400 oF equivalent commercially available in U.S.A, Extonsion bar 07716~-0020500 or equivalent commer available in U.S.A, (3) LOCK NUT 3032 mm bee 07 WRENCH’ (2) STEM NUT Recheck the steating stem adjustmont. Install tho following porte: = Fork logs (page 13-17) = Brake hose holders, = Front wheel (page 13-10) = Side stand indicator and fuse box. Check the steering bearing preload (page 13-22). 13-21FRONT WHEEL/SUSPENSION/STEERING STEERING HEAD BEARING PRELOAD Place a stand under the engine and raise the front wheel off ‘the ground. Position the etoering eter to the straight shead position Hook @ spring balance to the fork tube end measure the steer- ing head bearing preio NOTE Make eure that thore le no cable and wire harness interfer- The preload should be within 1.1~1.6 kg (2.43~3.63 Ib) for fight and left turns. If the readings do not fall within the limite, put the front wheal ‘on the ground and adjust the bearing adjustment nut. After making sure the beering preload is cerrect, install the re moved parts in tho raverse order of removal. 13-22 (3) SPRING BALANCE | (1) STEERING STEM (2) FROK TUBE |REAR WHEEL/BRAKE/SUSPENSION 46 Nem (4.6 kom, 33 FID) 110 Nem (11.0 kg-m, 80 feb) 7 tote f (No kgm, 7 Feb) & a o 65 Nem (8.6 kgm, 47 ftlb) 14-014, REAR WHEEL/BRAKE/SUSPENSION ‘SERVICE INFORMATION 14-1 BRAKE PEDAL 14-10 ‘TROUBLESHOOTING 14-2 SHOCK ABSORBER 14-10 REAR WHEEL 14-3 SHOCK LINKAGE 14.14 REAR BRAKE 14-7 SWINGARM 14-16 SERVICE INFORMATION GENERAL ‘¢ A.work stend or box is required to support the motorcycle ‘CAUTION + Bo no! support moioreyele by placing jack or other support under the oll filer. '¢ Use only genuine Honda replacoment fasteners for the rear suspension, Note the installation direction of the bolts. The shock absorber contains nitrogen gus under high pressure. Do not allow fire or heat near the shock absorber. + Before disposal of the shock absorber, release the nitrogen (see page 14-12). Inhaled asbestos fibers have been found to eause respiratory disease and cancer, Never use an ais hose or dry brush to clean brake assemblies. In the United states, use an OSHA-approved vacuumt cleaner or alternate method approved by OSHA designed fo ‘minimize the hazard caused by airborne asbestos fibers, SPECIFICATION me STANDARD SERVICE LIMA Roar wheal runout Reda! 2.0 mn 10.08 im | E Avia — > 2.0 mm (0.08 in) Rear axle runout m — [0.2 mm (0.01 in) brake drum 1.0. 130.0 mm (6.12 ini 181 mm (6.2 in) brake lining thickno 4.0mm (0.16 in| 2.0 mm 10.08 In) Shock absorber spring free length 268.5 mm {10.57 in} [263.0 mm (10.35 in) Fear suspension damper compression 33 kg (72.75 Wb) 28 kg (61.73 16) TORQUE VALVE Spokes 3.8 New (0.38 kgm, 2.7 feb) Driven sprockat nut ‘NA Nom 4.4 kgm, 92 Feb) Rear axie nut 95 Nem (9.5 kg-m, 69 fb} Shock absorber lower mount lock nut 8 Nem {6.8 kg-m, 49 ftb| Shock absorber spring lock nut 90 Nem 49.0 leg-m, 85 ft-lb) Shock absorber mounting bolt (upper/lower) 45 Nem {6.5 ka-m, 33 f-lb| Shock arm-to-ewingarm nut 105 N:m 10.5 kg-m, 76 feb) Shock link-to-shock arm nut 5 Nem (6.5 kg-m, 47 ftlb| Shock link-to-frame nut 985 Nem (6.5 ka-m, 47 tb] Swingarmiengine pivot nut 110 Nem (11.0 kgm, 80 fb) 14-1REAR WHEEL/BRAKE/SUSPENSION TOOLS Special Neecle bearing driver 07948 —KA50000 Driver shaft (07948—MJO0100 Common Pin spanner 89201 —Kaa-811 89202 -KA4-611 Beering remover shart 077480050100 Bearing remover head, 17 mm 077480050500 Driver 077490010000 Aitachment, 37 x 40 mm 077480010200 Attachment, 42 x 47 mm 07746-0010300 Attachment, 32 x 36 mm 077460010100 Plt, 17 mm) 07480040400 Attachment, 24 x 26 mn 07748—0010700 TROUBLESHOOTING Wobble or vibration in motoroycle Bent im Loose wheel bearing(s) Loose or bent spokes Damaged tire Axle nut tightened properly ‘Swingarm pivot bearing worn Chain adjusters not adjusted equelly Bent frame or swingarm Soft suspension + Weak soring + Improper shock absorbar spring preload Hard suspension + Improper shock absorber spring preload + Bent shock abeorbor rod + Swingarm pivot bearings damaged + Bent frame or swingarm ‘Suspension noise Faulty rear camper + Loose fastonors + Worn shock linkeae pivot bushingls) Poor brake performance Improper brake adjustment Worn brake shoes Brake linings oily, groacy or dirty Worn brake cam Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area 14-2REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Raise the roar whee! off the ground by placing a box or work: ‘stand under the engine. CAUTION * Do not support the motorevete by placing a jack or other wap. Por! under the ol filter. Loosen the chain adjuster on each side Remove the following componente: Brake rod from the brake aim. ~ Axle nut and axle, = Chain from the sprackot. ~ Rea: wheel, INSPECTION © AXLE ‘Set the axle on V blocks and measure the runout ‘The actual runout is 1/2 of the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) © WHEEL BEARING Remove the driven flange ipage 14-4), Tum the inner race of each bearing with your finger. The bearings should turn smoothly and quietly Also chock that the bearing outer race fits tightly in the hub and flange Remove and discard the bearings if the races do net turn smoothly, quietly, or if they fit oosely in the hub and fiange. e po SS ie a ee ‘Replace wheel Bosrings : (1) WHEEL BEARING For bearing replacomont, ae poges 14-4 and 14-6, ere © WHEEL, Check the spokes and tighten any that are loose, TORQUE: 3.8 N-m (0.38 kg-m, 2.7 ft-lb) | ‘Check the rim runout by placing the wheel on a truing stand, Turn the wheel by hand and measure the runout using a diel in | dicator. SERVICE LinmTs: RADIAL: 2.0 mm (0,08 in) AXIAL: 2.0 mm (0,08 in}REAR WHEEL/BRAKE/SUSPENSION ‘© FINAL DRIVEN SPROCKET Check the condition of the final driven sprocket teeth. Feplace @ worn or damaged sprocket. (1) 6000 (2) REPLACE | NOTE | The drive chain and drive aprocket must aleo ba inspected if the driven sprocket is worn or damaged. Never install a new dive chain on worn sprockets oF a worn chain on new DAA Sprockets, Both chain and sprocket muct be in good cond |. PAL in tion or 2 new replacement chain or sprockets will wear rep- aly WHELL BALANCING Rofer te page 13.6. COLLAR DISASSEMBLY Remove the axle collar and dust seal Remove the final driven flange and damper rubbore. Note + When removing the driven sprocket, loosen the sprocket bolt with the driven fiange installed. 11 the driven flange fit tightly in the hub, drive i out by tapping ‘coveral ocations with wood block. (1) DRIVEN FLANGE | Drive out the driven flange beering and collar, if necessary (COLLAR 14-4REAR WHEEL/BRAKE/SUSPENSION Drive out the wheel bearings and the distance collar Nore + Whenevar the bearings are removed, they should be re placed with new on Too.s: Bearing remover shatt 07746—0050100 Bearing remover head, 17mm — 07746—0050500 (2) BEARING REMOVER HEAD, 17 mn, ASSEMBLY 44 Nem (4.4 ko-m, 92 feb) (12) Othe threads (7) DAMPER FUBBER (9) BEARING of the eprocket bolts betore / Sie inetaling the mute, (3) TRE @ oe a 1) BEARING (2) DISTANCE COLLAR (8) FINAL DRIVEN FLANGE (13) SIDE COLLAR (10) DUST SEAL ne (11) DRIVEN SPROCKET 6) COLLAR (4) ORING (5) BEARING Pack the bearing cavities with grease, Sis Drive in the right bearing with the ealed side of the beering facing out, Be careful not to tilt the bearing while driving It into the hub and meke sure that itis fully soated. Install the distance collar into the hub, then drive in the left bearing with it's sealed side facing out PORN + Grease on the brake drum reduces stopping power. Keep grease off the vrake drum, "Wire DriveR pias (2S APTACHMENT, 37x 40 mm 077430010000 Attachment, 37 x 40 mim (077480010200 Plot, 17 mm. 07748—0040400REAR WHEEL/BRAKE/SUSPENSION Pack the bearing cavities with grease (11 couan, Inotell the driven flange collar to e new flango beering from the cd side as shown, ‘CAUTION ‘Do noi damage ihe bearing. (2) DRIVEN FLANGE BEARING SBR Drive in the criven flange bearing with its seated end facing {il (GP ATTACHMENT, TooLs: Driver 077490010000 Attachment, 42 x 47 mm 077480010300 Pilot, 17 mm 07748 -0040400 Install the damper rubbors. 1) DAMPER: Apply crease to a new O-ting and install it onto the groove of FUBBER, ‘the wheel hub, Pack the inside of the driven flange with grea Install the driven flange. Apply grease to the dust seal lip and install it. Install tho side collar Install the driven sprocket If removed. NOTE + When tightening the driven sprocket bolts and nuts, apply oll to the threads of the bolts, ‘TORQUE: 44 Nem (4.4 kg-m, 32 feb) 14-6REAR WHEEL/BRAKE/SUSPENSION INSTALLATION (Tatton Install the brake panel to the whoo! hub. Place the rear wheel between tha swingarm ané rail the drive chain over the driven sprocket Lift the rear wheel and set the boss on the swingarm in the slot In tho brake panel, then insert the rear axle trom the left side ‘through the swingarm. Loosely inctall the lock washer and axle nut. ‘Adjust the drive chain (page 3-11), Tigivien the rear axle nut TORQUE: 95 Nem (9.5 kg-m, 69 fb) Connect the brake rod to the bieke arm. ‘Adjust the rear brake pedal free play ipage 3-14), REAR BRAKE INSPECTION Remove the rear wheel ipage 14-3) Remove the brake panel Measure the rear brake drum |.D. SERVICE LIMIT: 131 mm (5.2 in) Measure the rear brake lining thickness. ‘SERVICE LIMIT: 2.0 mm (0.08 in) Replace the brake shoes if they are worn beyond the service limi 14-7REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY Remove the brake shoes and springs forn the brake panel. Note + Merk the shoes to indicate their original positions before re moving thom. Remova the following parte form the brake panel Bolt and nut, then brake erm = Indicator plate Brake com — Thnust plate ‘thoroughly. (10) BRAKE CAN ASSEMBLY (7) THRUST PLATE fy io ougr eens a (4) INDICATOR PLATE (3) BOLT (BRAKE ARV, Install the dust saals into the brake panel.REAR WHEEL/BRAKE/SUSPENSION Apply grease to the thrust plate and instllt by aligning the ont oe se Beeson cern Sin Apply groace tothe brake cam and inal it Apply grease to the brake anchor pin Intell the indicator plate onto the brake cam, aligning its tab (1 INDICATOR PLATE. ‘with cut-out on the brake car. ES Install the brake arm by aligning the punch marks. Install the bolt and tighten the nut securely, (3) BRAKE ARM Position the brake shoes in their original lovetions and install 6 the springs. om _ * Grease on the brake linings will reduce stopping power. Keep grease off of the brake linings, Wipe excess grease off the eam and anchor pin. Inetall the brake panel into the wheel hub en tuhee! (oage 14-7). 14-9REAR WHEEL/BRAKE/SUSPENSION BRAKE PEDAL REMOVAL Remove the brake adjuster Disconnect the brake pedal return spring and rear brake light switch return spring Remove the brake pedal mounting bolt and nut, Remove the brake pedal and dust s INSTALLATION Install the brake pedal in the re NOTE Lop, ar ‘Align the punch mark on the pedal shaft with the slot of the + Apply grease to the dust seals and brake pedal shaft. epee a oP iy SHOCK ABSORBER are ovine SOT (3) LOWER MOUNTING BOLT REMOVAL Reise the roar wheel off the ground by placing a box or wrk ‘stand under the engine. Remove the shock link to-ehock arm bolt. Remove the shock absorber upper and lower mounting bolts, ‘and remove the shock absorber. (3) SHOCK LINK TO. SHOCK ARM BOLT DISASSEMBLY (1/ PIN SPANNER Hold the shock absorber uppor mount ine vice with sett jaw ‘or shop towel Remove the lock nut and adjusting nut using pin spenners. Toots: Pin spanner 99201—Ka4—811 202-KAA—811 Remove the shock spring. 14-10REAR WHEEL/BRAKE/SUSPENSION = __ REAR WHEEL/BRAKE/SUSPENSION, Loosen the lock nut. Remove the lower mount, seat stopper. spring guide, spring sseet and damper rubber (1) LOCK NUT (2) Lower MOUNT lean the locking agent off tha damper rod and lower mount leck nut threads. I + The damper unit is filled with nitrogen gas under high pressure, do nor try 10 disassemble. (4) DAMPER: RuaBER (3) SEAT STOPPER, INSPECTION Measure the spring free length, SERVICE LIMIT: 263 mm (10.35 in) = (1) DAMPER UNIT ‘The damper untt bs fited with nitrogen gas under high pressure, do not iry to divassemble, rT] Chock the damper unit for oil leaks or other camage and the damper fod for trueness. Check the spring sect, and spring guide, damper rubber end spring seat stooper for weer or damage Check the upper mount bushing for weer or damage, (2) UPPER MOUNT BUSHING F& the 10 mm position as shown af the damper rod. ey ce the damper rod on a scale and measure the force re qured to compress the damper until 10 mm (0.4 inh. COMPRESSION FORCE: 33 kg (72.75 1b) Ifthe force required is less than 23.8 kg (51,81 Ib), gasis lo ing Fxamino the damper rod and replace the damper uit if it is Ger oF scored. j i 40 mm (0.4 in) }REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Center punch damper case 10 mark the driling point, approxi: mately 2.0 mm (5/64 in) from the top surfeco, ‘Wap the demper unit inside a piastic beg. Support the damper unit upright in a vise as shown. “Through the open end af the bag, insert a dril motor with a sharp 2—3 mm (5/64—1/8 in) dell bit. mm + Donot use adull dill bit which could cause a builiup of exces. ‘sive heat and pressure insite the damper, leading «0 explosion ‘and severe personal injur +The shock absorber contains nitrogen gas and oil under high ‘pressure. Do not dri any farther down the damper case thant ‘the measurement given above, or you may aril ino the oil ‘chamber; oil eseaping under high pressure may cause serious. personal injury. + Always wear eye protection t0 avoid getting metal shavings in ‘our eves when the gas pressure is released. The plastic bag is ‘nly incended ¢0 shield you from the escaping a. Hold the beg around the aril motor and briefly run the cri ‘motor inside the bag; this will inflate the bag with sir from the motor and help keep the bag fiom getting caught in the bit ‘when you start. ASSEMBLY i (4) AMPER UNIT Lock ADJUSTING Nur (3) SPRING (@) ORL BT (1) PLASTIC BAG a | P2.0 mm (564 in | 5 ae Vioadver wr (91 SPRING SEAT (7) DAMPER. ss (10) DRAIN TUBE (11) Lower, ‘MOUNT (6| SPRING GUIDE, 14-12es) REAR WHEEL/BRAKE/SUSPENSION AR HEEL/BRAKE/SUSPENSION Install the spring seat, dampar rubber epring guide end spring (1) Lock nur sat stoppe ‘Apply a locking agent to the tod thr fut. Serew the lock nut on full Screw the lower mount onto the damper rod fully, hold it and tighten the lock nut ide ard install the lock Toraut 18 N-m (6.8 kg-m, 49 feb) (3) DAMPER RUBBER (2) LOWER MOUNT ‘Align the lower mount cutout with the locating pin on the spring seat stopper as shown, Install the spring, Install the spring adjusting nut and tock nut. Turn the spring adjusting nut until the spring length is as speci- (1) Lock nut tie. ‘A; DECREASE THE SPRING LENGTH (2) ADJUSTING J B: INCREASE THE SPRING LENGTH ies g ap Spediigecibons STANDARD SPRING LENGTH: 264.9 mm (10.43 in) MAXIMUM LENGTH: 287.6 mm (10.53 in} MINIMUM LENGTH: 258.0 mm (10.18 in} One ‘urn of the adjusting nut changes the spring length by 1.5 mm, Tighten the lock nut (1) UPPER MOUNTING NUT TORQUE: 90 Nom (9.0 ka-m, 65 ftb) Install the breather tube. INSTALLATION Install the shock absorber with the drain tube torward the front ‘nstall anc tighten the upper mounting bolt and nut, TORQUE: 45 N-m (4.5 kg-m, 33 ft-lb) oy a 14-13REAR WHEEL/BRAKE/SUSPENSION Install and tighten the lower mounting bolt. fit) LOWER MOUNTING BOLT) TORQUE: 45.Nem (4.5 ky-m, 39 ftb) Install the shock Iink-to-shock arm pivot bolt and nut, TORQUE: 45 Nem (4.5 kg-m, 33 feb) (2) SHOCK LINK-TO-SHOCK ARM PIVOT BOLT ‘Check the operation of the shock absorber. SHOCK LINKAGE REMOVAL Raise tha rear wheel off the ground by placing a work stand or box under the engine. Remove the following components: = Exhaust pipesimuttier (page 12-4) Shock link -te-ahock arm pivot bolt. = Shock link-to-frame pivot bolt = Shock tink. — Shock arm-to-swingarm pivot bolt = Shock absorber lower mounting bol ‘Shock arm, INSPECTION [UINEEDLE BEARING @ Femove the dust seals and pivot colars from the shock link | ‘and shock arm. Chack the dust seals, collars and needle bearings for weer or damage. © (2) COLLAR | wnusrsia Hey, 14-14PIVOT BEARING REPLACEMENT Shook a Press the needle bearings out of tha shock arm. TooL: Drivor ehatt 07948-00100 Press @ new needle bearing into the shock arm with the mark- ings facing out, TooLs: Driver 977490010000 Attachmont, 24 x 26 mm, 077460010700 Shock link Press the noodle beerings out of the shock link TooL: Diiver shaft 97946—m,00100 Press a new needle bearing into the shock link with the mark lings fecing out, TooLs: Driver 077480010000 Attachment, 24 x 26 mm 07746—0010700 REAR WHEEL/BRAKE/SUSPENSION ——REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Apply molybdenum cisuifide pasts grease to the pivot collars, insides of the needle bearings and the dust seal lips. Instal the pivot collars and cust seais property Install the shook arm and shock link, and loosely instal each bolt and nut Tighten the each nut to the specified torque. TORQUE: ‘Shock arm-to-swingerm nut: 106 Nem (10.5 kg-m, 76 feb) ‘Shock absorber lower mount bolt: 45 Nom (4.5 kg-m, 33 fib) Shock link-to-shook arm nut: 65 Nom (6.5 kg-m, 47 feb) ‘Shock link-to-frame nut 65 Nem (6.6 kg-m, 47 ft1b) (8) SHOCK LINK (2) BOLT Install the exhaust pipes/muffier (page 12-4). SWINGARM REMOVAL AT CHAIN COVER Flomove the rear whool (page 14-3). Remove tha twa chain cover bolts Flmove the chain cover bolt and chain cover. 14-16REAR WHEEL/BRAKE/SUSPENSION ——— SAR HEEL BRAKE/SUSPENSION Remove the brake pedal return spring. ham Remove the chock arm-to-swingerm pivot bolt CULRETURN SPRING Remove the swing arm nut cap. [2)SWINGATMNUT CAP ngs J a2 stock anw To cwinoanmrivor so A Remove the swingarm/ongine pivot bolt and awingerm. THLSWINGARMENGINE PIVOT BOLT DISASSEMBLY Remove the chain slider and chain guide protector. Remove the dust seals and pivot collars. Hid (4) CHAIN SLIDER INSPECTION Inspect the swingarm for deformation or cracks. Check the neodle bearings, collers and dust seals for wear or damage. COLLAR 12) NEEDLE BEARINGS 14-17REAR WHEEL/BRAKE/SUSPENSION PIVOT BEARING REPLACEMENT Drive the bushing out of tho ewingarm. le bearing out with the special tool. Noodle bearing driver 07946~KA50000 (1) NEEDLE BEARIN DRIVER CCatefully press the cuter needle bearing with the bushing into the swingarm pivot. (2) ATTACHMENT, 32 35mm NOTE + Install the bearing with the marks fecing out. TooLs: Driver 07749-0010000 Attachment, 32 x 35 mm. 077480010100, aT (4) NEEDLE BEARINGS i! ‘Mark the needle bearing driver on the specified point as shown AiR ea Inthe new inner needle bear marking point. RK ‘and press I le bearing to the marking point. ee : BEARING ee DAIVEA ‘Neo bearing driver (07948-KA5O000 / a INNER BEARING Secuanny conus Install the chain slider and chain guide protector. ‘Apply grease t0 the dust seal lips. Install tho pivot collars, then dust seals 14-18REAR WHEEL/BRAKE/SUSPENSION INSTALLATION NT CAP | Install the swingarm to the frame Install the ewingarm/ongine pivot bolt and nut, end tighten the ‘ut to the specified torque TORQUE: 110 Nem (11.0 kgm, 80 feb} Install the swingarm nut cap securely Install tho brake pedal return spring, Install the shock arm-to-swingarm pivot bolt and nut, and tighten the nut TORQUE: 105 Nem {10.5 kg-m, 76 fib) Install the chain cover onto the swingarm aligning the bosses of the ewingarm with the grooves of the chain cover, Install the chain cover bolt Inctall the two chain cover bolts Install the rear wheel (page 14-7)HYDRAULIC BRAKE v z ao Be j $f .5 Nem (0.85 ko-m, 4 feb) Ty 17 Nem (1.7 koe, 12 ftlb) 5.5. Nem ( “4 felb) 36 Nem (2.6 kg-m, 25 fttb} "23 Nem (2.3 kg-m, 17 ft-lb) 27 Nem (2.7 kgm, 20 feb)15. HYDRAULIC BRAKE Ee i DAA SERVICE INFORMATION 15-1 BRAKEPAD/DISC 15-4 ‘TROUBLESHOOTING 15-2 MASTER CYLINDER 18-7 BRAKE FLUID REPLACEMENT/ BRAKE CALIPER 15-9 . AIR BLEEDING 15-3 SERVICE INFORMATION GENERAL 9 Use DOT 3 or 4 brake fluid © If che hydraulic system has been opened, or if the brakes feel spongy, the 19 not allow foreign material to enter the system when filling the reservoir, Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fuid, protect the painted, plastic and rubber perts by covering them with a shop towel If uid does get on these parts, wipe it off immediately with clean shop towel. ® Always check brake operation batore riding the moteroyde. * A koniaminated brake disc or pad reduces xopping power. Discard contaminated pads and clean a contaminated dso witha high (quality brake degreasing agent. ++ Inhaled asbestos fers have been found to cause respiratory disease and cancer. Never use an ais hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimis the hacard caused by airborne asbestos fibers, 1m must be bled, SPECIFICATIONS mm tin) Tem STANDARD. SERVICE LMT [isc thickness 45 (0.18) 3.5 10.14) Dise runout a = (0.30 (0.012) Nester cylinder 1D. ___12,700—12.743 (0.60000 6017) 12.760.60a ‘| Nester piston 0.0. 12.657 12.684 (0.4983 0.4994) 12,08 (0.498) 30.230 90.280 (1.1902—1.1921) 30.29 11.193) 30.148—30.280 (1.1859—1.1921) 30.14 (1.187) 5.5 Nem (0.55 kg-m, 4 ft) 27 Nem (2.7 kgrm, 20 feb) 36 Nem (3.6 kgm, 26 fe1b) 17 Nem (1.7 kg-m, 12 felb) bracket bolt 27 Nem (2.7 kg-m, 20 feb) hose bot 35 Nem (3.5 kgm, 26 feb) pivot bolt 23 Nem (2.3 kg-m, 17 feb) 9 fina pliers 079143220001HYDRAULIC BRAKE TROUBLESHOOTING Brake lever soft or spongy + Air bubbles in hydraulic eyoter. + Low fluid lave + Hydraulic system leaking. + Faulty dust seal or piston o: Brake lever too hard + Sticking pistons}. + Clogged hydraulic system. + Pads glazed or worn excessively. Brake drag + Hydraulic system sticking + Sticking pistonisi Brake grab or pull to one side + Pads contaminated. + Dise or wheel misaligned Brake chattor or squeal + Pads contaminated. + Excessive disc runout. + Caliper inetallod incor + Disc or whee! misalioned 15-2HYDRAULIC BRAKE —). Ae BRAKE BRAKE FLUID REPLACEMENT/AIR (1) RESERVOIR CAP BLEEDING \ 4 CAUTION + Be careful not 10 enter dust or water into the brake system when Filing the reservoir. + Do not mix different types of fluid since they are not compatible, Avoid spitting fluid on painied surfaces. Place a rag over the uel tank whenever the sysiom is cerviced, Check the fluid levol with the fluid reservoir level to the ‘round. Remove the reservoir cap and claphragm, BRAKE FLUID DRAINING Connect a bloed hess to the bleed valve. Loosen the caliper bleed vaive and pump the brake lever. Stop operating tho lever whon fluid stops flowing out of the bleed valve. + A contaminated brake disc or pad reduces stopping power. Dis- ‘ard contaminated pads and clean a contaminated dise with a ‘igh quality brake degreasing agent BRAKE FLUID FILLING(AIR BLEEDING (1) CASTING LEDGE CAUTION + Do roi mix different iypes of fluid since they are not ‘compatible. Close tho bieod valve, fil the master cylinder with Dot 3 or 4 brake fluid to the casting ledge level Bleed air from the bleed valve on the master cylinder using the following procedure before bleeding air at the caliper instal the diaphragm. Pump up the system pressure with the lever until there are no air bubbles in tha fluid flowing out of the reservcir small hole and lever resistance is fat. 1) Squaeze the broko lover, than open the bleed valve 1/2 tuins and close the valve. (1) BLEED VALVE nore * Do not release the breke lever unt the bleed valve has been closed. 2} Release the brake lover slowly and wait several seconds after it reaches the end of its travel Repoat steps 1 end 2 until bubbles ceas at the end of the hose. Tighten the bleed valve, 0 eppearin the fluid TORQUE: 5.5 Nem (0.55 ko-m, 4 feb)HYDRAULIC BRAKE Blood air from the bleed valve on the caliper using the same procedure as the master cylinder bleed valve (page 16-3) after bleeding air at the master cylinder. Tighten the bloed valve. ‘TORQUE: 5.5 N-m (0.55 kgm, 4 ft) 11 the broke bleeder is available, perform the following proce- dure. Connect the Mityvac Brake Bleeder to the bleed valve. NOTE + Check the fhid level often while bleeding the brakes to pre ont air from boing pumped into the system. + Do not mix brake fluid types and never reuse the contami hated fluic which has been pumped out during air bleeding, because this will impair the efficiency of the brake system. + When using @ brake bleeding 1001, follow the manufactur er’s operating instructions, Pump the brake bleeder end leosen the bleed valve. [Add fluid when the fluid level in the master cylinder is low. Repeat the procedures above unt no alr bubbles appear in the plastic hose. ing the bleedor from around the bleed valve threads, seal the threads with teflon tape. Fil the raservoir with Dot 3 or 4 brake fluid to the casting ledge level. Roinstall he diaphrage and master cylinder cep. + A contaminated brake dise or pad reduces stopping power. Discard contaminated pads and clean « contaminated dis with a high quality brake degreasing agent. BRAKE PAD/DISC PAD REPLACEMENT NOTE ‘Always replace the brake pads in pairs to assure even disc sul Remove the pad pin retainer Remove the ealipor bolt Pivat the calipar up out of the way Ti WiTVVAC BRAKE BLEEDER (1) CASTING LEDGE \ ii) CALIPER BOLT, 15-4HYDRAULIC BRAKE Fry one old pad egainst the caliper with a screwdriver to push the pistons into the caliper. Pull the pad pins out of the caliper. Remove the brake pads, Position the pad spring in the caliper as shown. Install new pacss in the caliper. Install one pad pin first, then the other pin by pushing the pads ‘gainst the calipar to depress the pad spring.HYDRAULIC BRAKE Place the pad pin retainer onto both the pad pins. Push the re- ‘ainer down 10 secure the pins. Install the pad pin retainer bolt. Apply silicone grease to the ealiper pivot bolt and ingort it into the pivot hole of the caliper bracket. Place the caliper down 80 the brake disc is positioned between the pads, boing careful not to damage the pads, Apply silicone giease to the caliper bolt. Install the caliper bolt and tighten it. TORQUE: 27 Nem (2.7 kgm, 20 ft) Tighten the rotainer bolt securely. Operate the brake lever to seat the pistons against the pads. DISC THICKNESS Measure the thicknose of the dice. SERVICE LIMIT: 3.5 mm (0.14 in) BRAKE DISC WARPAGE Measure the brake disc for warpage with a dial indicator as shown. SERVICE LIMIT: 0.30 mm (0.012 in) 15-6HYDRAULIC BRAKE AU LIC BRAKE MASTER CYLINDER REMOVAL (1) MASTER CYLINDER (2) BRAKE Hose Drain brake fluid trom the hydraulic system. Remove the brake lever and rear view mirror {rom the master cylinder. Disconnect the brake hose CAUTION ve * Avoid spilling brake fluid on painted surfaces. Place a rag over | a: iil nk whoo he te oe sense” REAR VIEW MIRROR = (3) BRAKE LEVER PIVOT BOLT] NOTE + When removing the oll hose bolt, cover the end of the hose t0 prevent contamination, Secure the hose to prevent iluid trom leaking ut. (1) BRAKE LIGHT switcH Remove the master cylinds DISASSEMBLY Remove the breke light switch and boot / (2) 3007 Remove the nap ring (1) SNAP RING Remove the piston and spring, TooL: Snep ring pliers 079143230001 Clean the inside of the master cylinder, ro Piston with clean brake fluid. vein, spring and 11) RESERVOIR (2) SPRING / Pe, ay masren aHYDRAULIC BRAKE INSPECTION Measure the master cylinder LD. ‘SERVICE LIMIT: 12.76 mm (0.502 in) Check the master cylinder for scores, seratches or nicks. ‘Measure the master piston 0.0. at the position as shown. (1) PRIMARY CUP. ‘SERVICE LIMIT: 12.65 mm (0.498 in) Check the primary and secondary cups for demoge bofore es. sombly. (2| SECONDARY CUP ASSEMBLY ™ (1) PISTON CUPS. cauTion + Handle the master evlinder piston, cylinder and spring a 0 set Coat all parts with clean brake fluid before assembly. Install the spring and piston. Vy caution 7 Wher isting the cps do wot allow the Ups t tr nse 2 ae ny + Install the spring with ts wide end toward inte. (2) PISTON Bigy Install the snap na (1) SNAP FING CAUTION + Be certain thai the snap ring is seated firmly in the groove. TooL: Snap ring pliers 07914 3230001 15-8HYDRAULIC BRAKE —- HAUL IC BRAKE Install the boot and brake light switch ae shown, (1) BRAKE LIGHT SWITCH (2) Boor INSTALLATION (@) Jon NUT ‘Set the master cyiinder onto the handlebars with the holder “up"” mark facing UP. ‘Temporarily install tho holder bolts, aligning the slit of the ‘master cylinder holder with the punch mark on the handlebars. Tighten the upper bolt first, then the lower bolt. Connect the brake light switeh wire, Install the rear view mltror and brake lever. Install and tighten the hose joint with a new sealing washer i! removed. TORQUE: 35 Nom (3.5 kg-m, 26 ft1b) Connect tho broke hose to the hose joint and tighten the joint hut to the specified torque, TORQUE: 17 Nem (1.7 kgm, 12 ft) Fil the reservoir with Dot 3 oF 4 brake fluid to the casting lodge “ (a and bleed the brake system according to page 15-3. ) r BRAKE CALIPER i REMOVAL a) HOSE BOLT Place 9 clean conteiner under the cali brake hose from the caliper. ‘end disconnect the CAUTION + Avoid spilling brake ftuid on painted surfaces eS (1) PAD SPRING (2) BRACKET } Loosen the pad pin retainer bo't and ealipar bolt. Remove the caliper bracket bolts and caliper with bracket. DISASSEMBLY Femove the following components from the caliper ~ Retainer, pad pins and pads, / ~ Caliper bracket. (a) vor — Pad spring. COLLAR (8 Boors. Boots and pivot collar 15-9HYDRAULIC BRAKE Hf necessary, apply compressed air to the caliper fuid inl to {got the piston out. Place a shop rag under the caliper 10 cush- ‘on the piston whan it is expelled. Use the air in short spurts. Push the cust seals and piston seals in, and pry them out and I1) PISTON SEALS siscard them. Clean the oi seal grooves with brake fluid. CAUTION + Be careful not 10 damage the pision 3 112) DUST SEALS INSPECTION Check the pistons for scoring, scratches or other faults. Measure the piston 0.0, SERVICE LIMIT: 30.14 mm (1.187 in} Check the caliper cylinder for scoring, scratches or other faults. Moacure the caliper cylinder ILD. ‘SERVICE LIMIT: 30.29 mm (1.193 in) ‘ASSEMBLY (1) COLLAR, The piston seals and dust secls must be replaced with new (3) oust ‘ones whenever they are removed. Coat the seals with brake SEALS fluid before assembly. Instell the pistons with the open ends | toward the pacs, | (rrtstons Install the pad spring. h Fee oe ee ian / % J Sn arapemne “eso yyHYDRAULIC BRAKE the booi to the bracket (1) BRACKET Apply silicone grease to the caliper pivot bolt and instal the % Caliper braket 10 the calipor, q \ (2) 8007 (3) PIVOT BOLT Install the pade, pad pins and retainer to the caliper. Instat the caliper assembly to the lit fork oo thet the disc 1g Positioned between the pads, CAUTION 1 Be careful not to damage the pads Apply silicone grease to the caliper bolt and temporarily instal i Install ond tighton the caliper bracket bolts q l BRAKE HOSE BOLT ILEAUPR ROUT ORME HOSE kT i S TORQUE: 27 Nem (2.7 ko-m, 20 415) Tighten the caliper bolt. TORQUE: 27 N-m (2.7 kg-m, 20 ft.ib) Connect the brake hose to the caliper with the hose bott and two new seating washers. TORQUE: 35 Nim (3.5 kg-m, 25 #115) Bleed the air from the brake eystom (oage 18-3) 15-11BATTERY/CHARGING SYSTEM. (1) IGNITION swiTcH 48) FUSE 15.4 ALTERNATOR (0) FUSE As (6) MAIN FUSE 304, y aw 7 meley r t ¥. ay ia [@ BaTERY 12Vi2 AH Hp ay ounen swe (3) REGULATOR: RECTIFIER ees (4) ALTERNATOR 16-0\ a aa 16. BATTERY/CHARGING SYSTEM SERVICE INFORMATION 16-1 CHARGING SYSTEM 16-6 TROUBLESHOOTING 16-2 REGULETOR/RECTIFIER 16-7 BATTERY 16-3 ALTERNATOR 16-8 SERVICE INFORMATION GENERAL + The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. + The battery contains sulfurte acta (electrolyte). Contact with skin or eyes may cause severe burns. ~ If electrolyte gets on your shin, flush with water. = If electrolyte gets in your eves, Flush with water for ot least 1S minutes and call a physician. + Electrolyte ts poisonous. = If swallowed, drink large quantities of water or milk and follow with milk magnesia or vegetable oll and cail a physician. + Ifthe engine must be running to do some work, make sure the area's well-ventilated. Never run the engine in an enclosed area, The exhaust contains postsonous carbon monoxide gas thas can cause loss of consciousness and! may tea to death, ‘© ofer 10 Service Letter #48 and Operation Manual (or the Honda Battery Tester and the Civistie Battery Charger for: Proparation of now betteries — Battery testing = Battery charging ‘© The following color codes are used throughout tho oloctrical ssetion: Bu = Blue G = Green Lg = Light Green R= Red. BI = Black Gr = Gray © = Orange W = White Br = Brown Lb ~ Light Biuo P = Pink Y= Yellow ‘© The battery fluid level should be checked reguialy. Fill with distilled water when necessary, ‘© Quick charge @ bortery only in an omorgency; slow-charging ie proforrod. @ Remove the battery from the motorcycle for charging. If the battery must be chargad on the motorcycle, disconnect the battery cables. '* When inepocting the charging eystem, check the eystem components and lines step-by-step according to the trouble- shooting on next page. All charging system components can be tasted on the motorcycle, © Altomator removal is given in Section 8. SPECIFICATIONS Regulatorirectifier Type Tew STANDARD (DO"CIBA*F aa, T gees. = 1V—12AH Soeeiinar py aly charaed 1.270-1.280 Tika SG Below 1.280 Charging current: 1.2 Amex, - Gann mes aiigaena cian ‘Alternator Capacity - 0.31 KW/5,000 rom. Charging coil r 0.1-1.09 Charging stert 1,000 pm | _Transistorized nor-adiusiable Regulated volage 18.515. V at 6,000 rpm 16-1BATTERY/CHARGING SYSTEM. TOOLS circuit testo (SANNA) 07908 0020000 er real tontor KOWA) Sheen or Dostal multester(KOWAY 078110020000 or KS-AHIM 32-003 (5.4. only? Heede betty seta 7eMs--0010000 Grails bate ofeve? Me 1OI22 (SA. nl) Tiesesra the better Tenaga Taga TES] ABNORMAL oro ahe_cequatr ici reeetaaTBS] ” tween each regulator/rectifier terminals |page [tee NORMAL NORMAL chon shout in wee reel ApwonmaLl—e- Faulty inion utah (Check for an overcharged battery (page 16:3), | OVERCHARGED Faulty roguletor! ‘HOE Ta CHE Me eT a rectifier NOT CHARGED REGULATED «Faulty battery Bsa einer Measure the voltage between the RIW (¥) and G (-) with terminals of the regulatorirectifior OP (Open oF shart circuit in wire harness connector. (wire hamose side} (page 16-7) + Loose connector NOVOLTAGE i BATTERY VOLTAGE COMES. [sree ae atemeto beter cot reue: +—-ABNORMAL Pasay wtetor tanes inept 18 ‘ NORMAL NORMAL Check the regulatoritecrifier resistances be- [oes each reguiatoritectitiar terminal (page ——ASYORMAL _. eauky regulator’ 16:8) rectifier ar NORMAL >> Fautty bettery 16-2BATTERY/CHARGING SYSTEM —_--H>}AANA]]____ 20 TERY CHARGING SYSTEM + The battery gives off explosive gases; Keep sparks, flames and cigarettes away. Provide adequate ventilation when charging, + The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. — If electrolyie gets on your skin, flush with water — If elecirolte gets in your eyes, flash wlil water for atleast 15 minutes and call a physican, + Electrolyte s potsonous. =I swallowed, drink large quantities of water oF milk and Follow with milk of magnessia or vegetable ofl and call « Physician, OT POSTTIVE: 12) NEGATIVE CABLE (-) REMOVAL CABLE (4) ‘ ? Remove the right side cover (page 12-4). Disconnect the negatve terminal first, then positive terminal ‘a the battery, Remove the bolts and battery holder. Disconnect the battery breather tube, Pull the battory out of the battery case, and remove the bat: tery. TESTING SPECIFIC GRAVITY Tost each cell with # hycrometer. SPECIFIC GRAVITY: 1.270~1.290 (20°C/68°F} 1.270 1,290 Fully charged (1) HyDRO- Bolow 1.260 Undercharged ee NOTE ‘The betiery must be recharged if the specific gravity is bolow 1.230, + The specitic aravity varies with the temperatur inthe accompanying table. * Replace the battory if aulfation is evident or if the space © p-———— below the cell plates is filed with sediment. out® (Ti) ELECTROLYTE TEMP. VS SPEGIIG GRAVITY 6 shown, 7 - | warn + The baitery contains sulfurie aeid. Avold contact with skin, eves, or clothing. Antidote: Flush ih ater and get prompt medical attention, (3) SPECIFIC GRAVITY > A 7 0192) 10 (50) 20 168) 40 (86) 40 (Toa) (2) ELECTROLYTE TEMPERATURE °C (°FI—= ss 16-3BATTERY/CHARGING SYSTEM TESTING NOTE + Rofer to tha Service Lotter #48 and the Operation Manuel for the Honda Battery Tester and the Christie battery Charg- ‘er for battery Testing Procedure. NoTE + Use the Honda battery Tester (07GMJ—0010000) to test the battery, Remove the battery. ‘Securely connect the tester's positive (+) cable first, then ‘connect the negative (-) cable. NOTE + For accurate test reaulte, bo eure tho testers eoblos and ‘clamps are in gcod working condition and that a secure Connection can be made at the betiery. ‘Set the temperature switch to “HIGH” ot fon the ambient temperature OW" depending HIGH: 18°C (60°F) or higher LOW: 15°C (60°F) or lower Push in the ‘“9.6An-16An" test button for thrae seconds and. ead the condition of the battery on the meter. NOTE + Be sure to push the covract test button. For the first check. DO NOT charge the battery before test- ing. CAUTION + Tester damage can result from overheating when: = the test button ts pushed in for more thar three seconds. — testing more than one battery and the testers not allowed to ‘coo! for at least one minute hetween texts — more than ten tesis are performed consecutively without al- lowing at least a 30-minute cool-down period. rain the GREEN “Tho battary ie OK if tho meter roading ro 16-4 [Serer Test Buttons leco0soo0 = —BATTERY/CHARGING SYSTEM —= .-w— $$ _ BATTERY CHARGING SYSTEM Uf the meter reading registers in the YELLOW or RED zone, [or cchargo the battery, ond re-test and judge it in accordance with the chart beiow. Battery Check (First check! GREEN YELLOW RED i i | oK Charge Charge ae Battery check (Second check] Batiery check (Second check) onéen YeL‘ow ne YEUSW Reo I I | ' OK Replace OK Recharge Replace Battery check (Third check) GREEN YeLLow ok neploce CHARGING NOTE *+ Use the CHRISTIE Battery Chargar [MC 1012/2) to charge the battery. Before operating the charger: * Bo sure the area around the charger is well ventilated and clear of flammable materials, heat, humidity, water and dust. * Cloan the battery terminals and position the battery as far away from the chargor ae the leeds will permit * Do not place the battery below the charger; gaoae from the botiory may corrade and damage the charger. * Do not place the bettery on top of the charger. Be sure the air vents are not blocked. = * During operation, the charger will generate heat. To avoid ‘causing a fire, always elear the work area of flarimable mater. als such as gasoline, brake fluid, electrolyte, or cloth towels. ‘Turn the Power Switch to the OFF position Set the Battery Amp. Hr. Solactor Switch to the “9.6 to 16" position. Set the Timer to the position indicated by the Henda Battery ‘Tester: RED—3. RED-2. or YELLOW 1. If you are charging # ‘new battery, set the ewiteh to the NEW BATT position, ‘Attach the clamps to the battery terminals: RED to Positive, BLACK to Nogative, cauTioN + Connect the battery cables only when the Power Swi Turn the Po ‘Switch to the ON position, (2) YELLOW 2) (1) BATTERY AMP HR. SELECTOR SWITCH 5109.0 9.510 18 18.5 t0 30 5 3.6 to 6.0 00 3.0, (2) Set the appropriate amp. hour rating New (2) TIMER BATT > |3) RED (4) YELLLOW 1-2-3 Fh 16-5BATTERY/CHARGING SYSTEM Whon the timer reachse the “Trickle” position, the charging eyele is complete. Turn the Fower Switch OFF end disconnect the clemps. NOTE + The chargor will automatically ewiteh to the Trickle mode after the set charging time has elapsed. Re-test the bettory using the Honda Bettory Tester and ro: charge if necessary using the above steps. NOTE + For accurate test results, et the bartery cool for at least ten ‘minutes oF until gaseing subsides after charging INSTALLATION Install the battery in the reverse oider of the removal. After installing the battery, coat the terminals with clean grease. CAUTION toute the breather tube as shown on the battery caution label + Make sure the breather tube does not bend, afier the battery ‘has been instalied into the case. CHARGING SYSTEM NOTE + When inspecting the charging system, check the system components and lines step-by-step according to the ‘oubleshooting on page 16-2. + With laige capacity circuits that exceed the ratings of the fuse contained in the tester, measuring errors can cause damage 10 testing equisment Bofore etarting each test, got the taster at the high capacity range first, then adust it to the small capacity circuits range in order that you have the correct range. LEAKAGE INSPECTION CAUTION + When measuring small capacity circuits, keep the ignition switch off. Ifthe switch is sudldenty turned on during atest. the Lester fuse may biow. ‘Check the battery ampere leakage before making th voltage inspection ‘Turn the ignition switch off and disconnect the battery negs- tive cable trom the battery Connect the tester between the negative cablo and the nega: tive battory terminal egulated “The tester should indicate within 1 mA with the ignition ewiteh OFF ZX CAUTION (2) PIPING AS SHOWN BELOW (@) BATT. BREATHER TUBE (@rBarr ELBOW (5) (INSERT THE Barr. ereanen Ee (2) BATTERY NEGATIVE CASLE 16-6BATTERY/CHARGING SYSTEM REGULATED VOLTAGE INSPECTION Nore + Be sure the battory isin good condition before perfor this t ‘Warm up the enaine to the normel operating temperature. am aca xhtust contains poisonous carbon monoside on, {hal ean cause toss of consctousness and may lead te aur Stop the engine, Remove the tight side cover (page 12-4 Connect the voltmeter és shown, CAUTION + Be-carehul not to let the batery positive cable contact the ane White testing Seats the engine and alow it to fale, then increase the engine Speed gradualy. ‘The voltage should be controlled ae epecitied betow: STANDARD: 13.5—15.5 V at 5,000 rpm (20°c1¢a°F} REGULATOR/RECTIFIER INSPECTION Remove the seat (page 4-3), enannect the 3P and 6P connectors of the regulateriractif Cho Hare ‘eauleted voltage reacing is not within the specitied renge harness side, following the chart below, Te TeRWINALS Ln ST ERE Bevery charging ine le 7 snd Ground) | etary vologs about eee | ~Feedbick ine | elec) ene Ground 1 “Battery voltage sheuld come wi | os = veer |_ the orton sean oe? ond a Te ee ince aoe Aerator siting | “vatow med Yat ieeeBATTERY/CHARGING SYSTEM UNIT INSPECTION (1) 6 P CONNECTOR Provided the citeuit at the wire harass side aro normsl and there are no loose connections at the connector, inspect the regulatorirectifier unit by measuring the resistance betweon the torminals. NOTE / + You'll get false readings if the probes touch your fingers. + Use the specified multitesters. Using other equipment may not allow you to obtain the correct results. ma Ma ea This is due to the characteristic of semiconductors, whicn | Beenie have different resistance values depending on the applied (2) 2p cowNectoR voltage hs ~ a SPECIFIC MULTITESTERS: = 074110020000 (KOWA Digital type) Unk — KS—AHM—32—003 (KOWA Digital tyDe: U.S.A. onlv! KS pase = = 07300-0020001{SANWA Analogue type) ome T ou | ty | vetow | vetw | vtow | Gm pee i es i aieee [Sa [ao 100] 1e-00 | 18-00 | ea [108 + Select the following range, ete |= = SANWA: ki Yelew [= if OWA: x10 Yalow [= ci + An old battery stored in the muithester could cause iraceu- yaa] a a rate readings. Check the battery ifthe muttester resis. fe" | =. tance incorrectly + When using the KOWA multitester, remember that all read ings should be multiplied by 100. Replace the regulator/rectifir unit if the resistance value bo. ‘twoen the terminals is abnormal ALTERNATOR INSPECTION NOTE + Its not necessary to remove the stator coll to make this test, Remove the seat (page 4-3) Disconnect the alternator 3P connector from the regulator! roctifior Measure the resistance between the yellow wire terminals and chock for no continuity between each terminel and ground, STANDARD: 0.1~1.0 0 (20°C/68°F) Replace the stator if the resistance is out of specification or It ‘there Is continuity between any yellow wite terminal and ground. For the alternator replacement, see section 8 16-8IGNITION SYSTEM (1) IGNITION swiTcH = (81 SPARKPLUGS (7) PULSE GENERATORS. (6) NEUTRAL SWITCH (5) SIDE STAND SWITCH (1) MAIN FUSE 90 A, (6) SILICON DIODE Pi— Io IF 12) BATTERY 1 [mi sbestano Vi2A Sree (3) IGNITION Lee SwiicH ~~ ni aur 4 ¢ ‘ 18) ENGINE = ies, 5 ~ Sie eae 18) TO IGNITION (10) TO IGNITION SWITCH (wiren (ey ueuTaaL swircn @ 12) won af cous an |) nn|| ra) er - ae i1@) veuwow (7 ue TT use TUE eu e119 19) SPARK fees? an |e 82 cae ” (aera S ¢ 2 Generator == : + t wean ! (9 cova | [oe ova (FRONT tReet : Ge i 4 i NN Hise GeNeRaron FRONT 17-017. IGNITION SYSTEM IY, IGNITION SYSTEM SERVICE INFORMATION 17-1 PULSE GENERATOR 17-5 TROUBLESHOOTING 17-2 SIDESTAND SWITCH 17-6 SYSTEM INSPECTION 17-4 SILICON DIODE 17-6 IGNITION com 17-4 IGNITION TIMING 17-6 SERVICE INFORMATION GENERAL. ® Iorition timing cannot be adjusted since the CDI (Capacitive Discharge I incotrect, check the systam componente and replace tie feulty parte, * hon inspect the ignition system, check the system component and ios step-by-step accorcing to the troubleshooting fon next page. {¢ Each pair of the spark plugs (FRONT and REAR) has its own ignition creuit. For spark plug gap inspection and adjustment procedure, see page 3.6. tor removal and installation, see page 7-8, SPECIFICATIONS lanition! unit is non-acjustable. If ignition timing is i ITEM SPECIFICATIONS (20°C/68°F) Spark plage NG. NO Standard DPRAEA-8 X24EPRUD For cold climate (@elow 6°C/41 °F DPRTEA® X226PR-U9 “For extended high speed driving DPROEA-9 X27EPR-U9 Spork pug aep ©.8-0.9 mm (0.031 0.036 in) Ignion timing [initia mer f de 10° BTDCiicle ‘Advance starts 2,000 rpm. Full edvance 30° BTOC/4,500 rpm Ignition coil resistance Primary Z| 0.1-0.20 Secondary | Witheap | 7410.8 ka me |_ Without cap 36-45 Ko Cail resistance ile 360-540 0 Front 232° —Resr—488° Front TOOLS Circuit tester (SANWA) or 973080020000 Grrovit tester (KOWA) of TH—SH Digital multitester (KOWA) 07411 ~0020000 or KS-AHM-32.003 (U.S.A, only) 17-1IGNITION SYSTEM. TROUBLESHOOTING oom + When performing a spark test, keep open flames or sparks away jrom the work area No spark at ail plugs Foplace with known good epark plugo, conduct the spark plug test No spane [ chara io: poor coneeceed of leamper pty] ri WiSS00 borba we ete lla ag SOE into the spark plug we. No span Cheek fer loces or poorly connected CDI unit. | Correct it and conduct the spark piua t T NO SPARK t Disconnect CDI unit connector and check rolat fed circuit at the connector Measure resistance of the secondary coll (page 17-4) i ABNEAMAL heck components individually. Compare resuits with the measured value above. NORMAL (If measurements differ) + Pooily connected component connector. + Broken wire harness between unit and compo: ent. SPARK Faulty plugs. SpADK. Loose wires SPARE Poorly connactad COI unit connector. NORWAL, Fauity CDI unit ABNORMAL (Same measure- ments) + Fauky related components, 17-2IGNITION SYSTEM Sido stand eireuit ENGINE Does Star the engine with the varomieen mre |_ MOT S1ART ee fe |_NOLSIART_.F Grech sien dd pape 178] noma. | aenonwaL ENGINE sranTs Xray sce tove ‘Squeeze the clirtch lever and shift the transmis. | + Faulty neutral switch, iia tower ese ter + Deer oe ar crete rio tween the CDI unit and neutral switeh, ENGINE STOPS | ENGINE DOES NOT STOP - — — | Check the side stand switch (oage 17-6) NORMAL, ABNORMAL * Faulty sido otand switch, Check that the side stand indicator comes on | + Fauity‘noutral awiteh, with the side stand lowored and goes cut with + Short citcut in wire harness between the CDI ‘the side stand retracted unit and the side stand switch or the neutral Sot witch, NORMAL ABNORMAL ______________, | Check the side atand awitch (page 17-6) NORMAL ABNORMAL, * Faulty side stand switch, ’ System is OK + Faulty side stand indicator circu, 17-3IGNITION SYSTEM SYSTEM INSPECTION (1) CDI UNIT CONNECTORS NOTE + Chock the system components and lines step-by-step ac- cording to the troubleshooting on page 17-2. Remove the seat (page 4-3), Disconnect the CDI unit connectors and check the related cuit at the wire harness side accerding to the following chart: : a ren eens | stanoanos (2orcraeer) CDI UNIT (FRONT) [COI UNIT (REAR) Ignition coil (primary col) BuBu and 6 BUY and G 010.20) Ignition coil (secondary coi) Gand spork plug oa 7410.8 0 swith sperk plug cap ‘ perk Pla oaP, Pulse genorator Bu and 6 Yond 360-640 0 Battery power supply circuit | BIW (+) and G (-) with the ignition switch simshslor sould eaves line ON" and engine stop switch “RUN”. Paattasvientioge should compe Neutral switch La’y and body ground with the side stand | There should be continuity with the witch connector disconnected. tranemission in noutral and ne eon NOTE tinuity with the transmission in Note the polarity of the tester probes be | 9°" cause this circu has a diode. Connect the tester negative probe co LglY wire and the positive proke to ground for a positive {round ohmmeter. Reverse the tester probes when @ negative ground ohmmeter is uscd. pines lta beanie Naneen = i eS Side stand witch LgiY end body ground with Th diode removed. sida stand retracted and no continu: ity with the side stand lowered. IGNITION COIL INSPECTION Remove the fuel tank (pege 4-3}. Measure the primary coll resistance by checking the primary terminals (1) SECONDARY COIL (WITH CAP) STANDARD: 0. 0.2.0 (20°C/68°F) ‘Measure the secondary coll resistance with the spark plug cap in place by checking the plug cap and green terminal STANDARD: 7.4—10.8 kf! (20°C/68°F) (2) PRIMARY COIL_ © IGNITION SYSTEM If the resistance is out of specification, remove the spark plug ep and measure the resistance between the spark plug wire and green terminal STANDARD: 3.6—2.5 4a (20°C/68"F) L (1) SECONDARY COIL WITHOUT CaP) REPLACEMENT. Remove the fuel tenk (page 4-3) Disconnect the primary torminels from the wire hamesses. Remove the spark plug cap from the sperk plug. Remove the front or reer ignition coll stay bot and front or rear ‘anttion coils. Remove the ignition coll from its stey. Install a new ignition coll in the reverse order of the removel. NOTE + Install the coils properly according to their marks. FR-R: front-right, FR-L: front lef, AR-R: rearright, RR-L: rearleit + Connect the primary wire terminals property, FFI col: black tarminal-biack/blue wire ‘green terminal-green wire [AR coil: black torminal-biack/vellow wire green texminal-green wire PULSE GENERATOR INSPECTION Nove (1) PULSE GENERATOR Ie ie not necessary to remove the pulse generator to make - Be COUNGETOR this inspection, Remove the fuel tank (page 4-2). Disconnect the pulse generator 4P min! connector. Measure the resistance between the yellow and white with Yellow tube wires for the rear pulse generator, and between the blue and white with blue tube wires for the front one. STANDARD: 360-640 4 (20°C/68°r) For the replacement, refer to section 7IGNITION SYSTEM SIDE STAND SWITCH Remove the seat (page 4-3) Disconnect the side stand ewitch 3P connector. SIDE STAND RETRACTED | SIDE STAND LOWERED (RELEASED! (PUSHED) Check the continuity between the conrector terminals as fol: ie w a Tinie Me jpmiiip | uanana 7 [oomanaty a] | \rantine WARNING rotractod (RELASED) |p ana G UGHT UGHT 'No continuity resid =P: “i 2) 7 — i270 With the side stand [Lg/V and @ | No contineity Col uNiT LY? counrr lowered (PUSHED) Continuity =." s 1g SILICON DIODE Remove the fuel tank (page 4-3) Ramove the silicon diode from the main wire hamess. Check for continuity with an ohmmeter. Connect the positive probe to the @ terminal and the negative probe to the © terminal of the diode. There should be continuity, then with the probes reversed, there should be no continulty, NOTE +The test results shown ate for a positive ground ohmmeter ‘and the opposite results will be obtained when a negative ‘ground ohmmeter is used IGNITION TIMING NOTE ‘+ The Capacitive Discharge tgniton (CDi) system is factory pre-set and cannot be adjusted. Igrition timing inspection procedures aro given to inspect the function of the CDI components. ‘Warm up the engine to the normal operating temperature. + Uf the engine must be running to do some work, make sure the area is well-ventilated, Never run the engine in an enclosed. The ‘exhaust contains polsonous carbon monoxide xas that can cause loss of consciousness and may lead 10 death. Flomove the timing inspection hole cap on the lett crenkcase Ee 2) TIMING, Connect the timing light, ucHT 17-6IGNITION SYSTEM The sng fs contact the“ mark alone with the index | 11 INDEX MARKS ’ maricon the left crankcase cover at 1,300 * 100 rpm for each OD vice 10d t0 4,500 rpm, The index mark should be botwoon the advanced marks for each cylinder aioe the engin ©) | (31 “F" MARK (2| ADVANCED MARKS | ©) ©) © € © 17-7ELECTRIC STARTER 2} IGNITION SWITCH ARTER MOTOR (6) NEUTRAL SWITCH (5) SIDE STAND SWITCH (4) STARTER RELAY SWITCH (2) STARTER RELAY SWITCH (9) MAIN FUSE (5) CLUTCH SWITCH (71 SIDE STAND sw! jal: = Loi (f ty dh) ws} (M wsucne Ee] | ve DIODE (ay BATTERY | is ie) NEUTRAL Tur | L| on Lot. _—— a '9) CLUTCH DIODE 6 OG YIR +4 LR ee (10) IGNITION SwitcH 11) FUSE 10 (12) STARTER SWITCH 18-018. ELECTRIC STARTER ———______16. ELECTRIC STARTER ‘SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18.6 TROUBLESHOOTING 18-2 CLUTCH DIODE 18-7 STARTER MOTOR 18.3 SERVICE INFORMATION GENERAL © Tho starter motor can be removed with the ongine in the frame. SPECIFICATIONS mm tin) ITEM ] ‘STANDARD SERVICE LIMIT Starter motor brush length 12.0-13.0 (0.47-0.51) 6510.26 18-1ELECTRIC STARTER TROUBLESHOOTING NOTE ‘mission is in gear with the side stand UP. + Chock for the followinge before troubleshooting the system. Blown main 30 A or sub 10 A fuses. — Loose battery and starter motor cables. — Discharged battery, Starter motor does not turn 2: Check the starter hy swish votage|__NO VOLTAGE ipage 18-71. : BATTERY i VOLTAGE COMES i" _ stern E SWITCH “4, Check the starter relay switch for continuity |__ABNORMAL (page 18-71 NORMAL 18-2 eS ‘+The starter motor can turn whan the transmition isin the neutral position or when the clutch lever is pulled in and the trans. 1-1. Check the starter relay switch for opera “CuICK” _e a tion. You should hear the reley “CLICK” HEARD 1-2, Apply battery voltage to the sterter motor when the starter switch button is do. | directly and check the operation pressed (page 18-0). | = “ runs | DOES NOT TURN = + Loose connector + ‘Faulty etarter motor CLICK" NOT HEARD + Faulty starter relay (wage 18-3) snitch Ipage 18-6) ae ABNORMAL 2. Check the nevttal indicator fer function. | Faulty neutral switch (page 8-6) Loose neutral switch connector Faulty ignition switch (page 19-6) Loose ignition switch connector Faulty side stand switch (page 17-6) Loose side stand switch connector Faulty clutch switch page 18-9) Loose clutch switch connector Faulty starter switch (page 19-6 Loose starter switeh connector Faulty clutch diode (page 18-7) Loose clutch diode connector Faulty silicon diode Ipage 17-6) Faulty starter relay switch (oage 18-6) Open oF short circuit in wire harness Faulty starter relay switch Loose starter relay switch connectorREMOVAL * With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Disconnect the starter motor cable Remove the motor mounting bolts and motor. (2) ECLTS, DISASSEMBLY |2) FRONT cover Remove the following component = Motor case bolts, = Front covar and roar cover. = Armature, NOTE INSPECTION Meacuro each brush length, SEAVICE LIMIT: 6.5 mm (0.26 in) Cheek for continuity from the cable terminal to the motor case ‘ard from the eablo terminal to the black brush wire CABLE TERMINAL—MOTOR CASE (4) BLACK BLUSH NO CONTINUITY: NORMAL CABLE TERMINAL—BLACK BRUSH WIRE CONTINUITY: NORMAL Disassemble them It necessary. (2) No (3) CABLE TERMINAL ersand 18-3ELECTRIC STARTER Inspect the commutator bars for discoloration. The bars discolored in pairs indicate grounded armature coils. (1) COMMUTATOR BARS Cheek for eons ity botwoan pairs of commutator bare, There should be continuity. Check for continuity between individual commutator bars and the armature shett, ‘Thore should be no continuity. (Check the dust seal in the front cover for we (1) FRONT cover (2) DUST SEAL 18-4Se i ELECTRIC STARTER $$ __FECTRIC STARTER ASSEMBLY (a CASE | aN (4) ARMATURE (9) BRUSH HOLDER [101 BRUSH SPRING 4 (11) O-RING: rE (6) SMS (FRONT COVER 75) srams (O-RING |8) CABLE TERMINAL AND BRUSHES Pa (12) REAR COVER € Align the starter motor ease notch with the brush holder tab. e Set the brushes on the brush holder. (1) BRUSH SPRINGS |(2) ALIGN |)| (3) BRUSHES Inetall the armature into tho c Set the brush springs. |nstal the shims in the same location and number when disas sembled, Install the O-ring onto the case. Install the rear cover, aligning ite slot with the brush holdor pin. (5}O-RING (4) SHIMS (3| REAR COVER 18-5ELECTRIC STARTER ELECTRIC STARTER Install the shims in the same location and number when disas sembied. (1) DUST Seal (2) FRONT. cover Install the O-ring onto the case. Install the lock washer, aligning ite tabs with the slots in the Apply grease to the dust sel. Install the front cover « y «@ St0T8, fo dyvock waste (7) O-RING | (6) SHIMS Align the indox marks en the front cover, case and rear cover [1 ALIGN, (2) O-RING. fas shown. Tighton the zw mounting bolts securely. ‘Apply oil to the O-ring and install it onto the front cover. (3) BOLTS INSTALLATION Install the starter motor to the engine Install and tighten the moter maunting bolts securely. NOTE ‘Connect the ground cable to the starter motor with one mounting bolt as shown, Connect the motor cable to the motor terminal Install the rubber cap 10 the terminal Connect the battery negative cable. STARTER RELAY SWITCH OPERATION INSPECTION Depress the starter switch button with the jgnition ON. The coil is normal if the starter relay switch clicks. (1) STARTER RELAY SWITCH, 18-6VOLTAGE INSPECTION If the ewitch ‘CLICK’ is not heard, measure the voltage bo: tween the yellow/red (+) and greenired (-) wires af tha relay Connector. The battery voltage should come when the starter ‘witch button ie doprosced with tho igrition ewitch ON and neutral position. Perform the following inspection If the battery voliage ap: ppoarod betwoon the yollovi/red end greenired wires. CONTINUITY INSPECTION Remove the sterter relay switch. Connect an ohmmeter to the sterter relay switch large term: pale Connect a fully charged 12 V bettery positive wire to the stert- ‘or relay switch Vallow/Red wire terminal and battery negative wire to the Green/Red wire terminal. Check for continuity between the starter relay switch termi nals, ‘Thore should be continuity while 12 V battery is connected to the starter relay switch terminals and should be no continuity when the battery is disconnected, CLUTCH DIODE NOTE [Clutch diode is located in the fuse box INSPECTION Check for continuity with an ohmmeter at the connector. NORMAL DIRECTION: CONTINUITY FEVERSE DIRECTION: NO CONTINUITY ELECTRIC STARTER | eB =19, LIGHTS/INSTRUMENTS/SWITCHES a aaoméOOOO_ Esse mths 6 _9-—_— SERVICE INFORMATION 19-1 HANDLEBARS SWITCH 19-6 TROUBLESHOOTING 19-1 OIL PRESSURE SWITCH 19.7 HEADLIGHT 19-2 TEMPERATURE GAUGE 19-8 STOP & TAILLIGHT 19-3 TACHOMETER 19-8 LICENSE LIGHT 19-3 NEUTRAL SWITCH 19-8 TURN SIGNAL LIGHT 19-3 BRAKE LIGHT SWITCH 19.9 INSTRUMENTS. 19-4 CLUTCH SWITCH 19-9 IGNITION SWITCH 19-5 HORN 19-9 SERVICE INFORMATION GENERAL '® Some wires have different colored bands arcund them near the connector. These are connected to other wires which cor respond to the band color. © All plastic connectors have locking tabs that musi be released before disconnecting, and must be aligned when reconnecting. © To isolate an electrical falure, check the continuity of the electrical path through the part. A continuity check can usually be made without removing the part from the motorcycle. Simply disconnect the wites and connect a continuity tester ov volt-ohmmetar to the terminals or connections. '* A continuity tester is useful when checking to find out whether or not there is an elactrieal connection between the two Points. An ohmmotor ie needed to measure the resistance of a circuit, such as when there is a specific col resistance In Yolved, or when checking for high resistance caused by corroded connections, ‘© For the inspection of the thermosensor and thermostatic switch. refer to section 5. ‘SPECIFICATION wna By isin et oon aves Nae € TROUBLESHOOTING 19 | + oem Petite bored Sa \ Scritngteceet bstorer tau | All lights come on, but dimly, when ignition switch is ‘tumed ON: Batiery voltage low + Wiring or switeh has excessive resistence 2 ®. : 19-1LIGHTS/INSTRUMENTS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the right upper cover (page 12-2) Disconnect the headlight connactor and remove the dust olease the retainer clip and replace the headlight bulb with 3 CAUTION + Weara glove when installing the halogen bulb. Ifyou fouch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its easly failure. Install the dust cover with its TOP mark Fecing vp. (1) bust cover (2) TOP MARK Connect the headight connactor securely. Va Inotall the right upper cover (page 12-2) \ REMOVAL Fe Remove the front coming ipage 12-2) ij lity Disconnect the headlight connector. ve re i is) Remove the three screws and headlight case holder. Remove the headlight i i INSTALLATION Hi dll cute Insta the headlight casein the reverse order of removal tua), 7 a Adjust the heedlight aim (page 2-14) 19-2LIGHTS/INSTRUMENTS/SWITCHES HEADLIGHT BULB REPLACEMENT Remove the right upper cover (pede 12-2) Disconnect the headlight connector end remove the dust cover. Release the retainer clip end replace the headlight bulb with a CAUTION + Weara plove when installing the halogen bulb, if you touch the bulb with your bere hands, clean it with a cloth moistened with alcohol to prevent its early failure. Install the dust cover with its TOP mark tacing up. (1) bust cover (2) TOP MARK Connect the headlight cennsetor securely. Install the right upper cover (page 12-2) REMOVAL Remove the front cowiing (page 12-2), Disconnect the headlight connector. Remove the three screws and heaclight case holder. Remove the headlight. INSTALLATION Install the headlight case in the reverse order of removal [Adjust the headlight aim (page 3-141. 19-2LIGHTS/INSTRUMENTS/SWITCHES STOP & TAILLIGHT BULB REPLACEMENT Remove the stop & tailight lene by removing the two screws. Remove the bulb by pushing it in and turning t counter. clock wieo, Install a new bulb in the reverse order of removal. LICENSE LIGHT BULB REPLACEMENT Remove the two bolts and the license light from the rear mudguard Remove the two sctews and the license light lens, (1 BOLTS. Remove the bulb by pushing it in and tuming it counter: A) BULE clockwise, Install a new bulb in the reverse order of removel TURN SIGNAL LIGHT (ioe BULB REPLACEMENT re fi feneie am n ee naa inh ele eoryeek vies a met on, Rano ootab ara eobecmans cone ne tet rol is ape ite dot ava (2) sober 19-3ee LIGHTS/INSTRUMENTS/SWITCHES ‘ Remove the attaching screw and lens. Se Fossa eum OF ewr fue jun care 6 Sad atest cen eantieee Install the lens and tighten the screw securely. (2) SCREW rN (3) BULB INSTRUMENTS BULB REPLACEMENT Remove the front cowling (page 12:2), Pll the bulb socket out of the instrument end remove the bulb from the socket, Install a new bulb in the reverse orcer of removal, REMOVAL Remove the front cowling (page 12-2) Disconnect the speedometer cable, Dicconnect the 9P connector end black!yellow wire connec: tor. Femove the three instruments mounting nuts and instruments from the setting stay. Romove the six serows, two clamps and instruments uppor 19-4LIGHTS/INSTRUMENTS/SWITCHES Remove the following 3 : TACHOMereR 7 Three eonnoctors-and four screws TEMPERATURE GAUGE ~ Three screws, ‘SPEEDOMETER — Two serews, (9) TACHOMETER LIGHT | (2) SPEEDOMETER LIGHT INSTALLATION Install the instrumente in the reverse order of removal NoTE Insta the temperature gauge wives with screws accovara 10 the support on the tower cover + Route the wire properly (page 1-8) IGNITION SWITCH INSPECTION Rumove the right upper cover (page 12-2), Disconnect the ignition switch red 4P eonnector Check for continuity betwoon the ig terminals in each switch position, jon switch connector Continuity should exsist between the color coded wires in the chert below: TERMINAL | Oca "ONRORES “BROCK, ee ___covon. 19-5LIGHTS/INSTRUMENTS/SWITCHES REMOVAL NOTE + You can remove the ignition switch without removing the front cowling Remove the left upper cover (page 12-2). Disconnect the ignition ewitch connector. Remove the two ignition switch mounting bolts and ignition switch, Remove the wire clamp. (1) Lugs Romove the three scrows, push the lugs in the slots and pull h the contact base out of the cylindar INSTALLATION Install the ignition switch in the reverse order of removal (2) SCREWS Bae ig) CLAMP 14) CONTACT BASE: HANDLEBARS SWITCH Remove the right upper cover page 12-2), Disconnect the 6P connector of the lett handlebars switch, Disconnect the SP connector of the right handlebars switch, (Check the components of the handlebers switches for electric Continuity as follows. Continuity should exsist between the color coded wires in each chart below. RIGHT HANDLEBARS SWITCH Bee ea TCH STARTER SWITCH ‘emwnat [ara] rm FREE oO ust = Gua wee iae ea | ENGINE STOP SWITCH TERMINAL BATS. iG OFF RUN O56 coLon aun BIW 19-6@ LIGHTS/INSTRUMENTS/SWITCHES LEFT HANDLEBARS SWITCH (1) DIVIMER SWiTcH DIMMER swiTcH TERMINAL Bop Hi [eaves oo fe 2 ei Hi oo 6 coon | eu wee es (3) TURN SIGNAL SWITCH (2) HORN SWITCH TERMINAL Ww R t R o— +o N haces ——~o COLOR G wb ° HORN SWITCH [TERMINAL Ho BATO [— Free io PusH coLOR OIL PRESSURE SWITCH GY OIL WARNING Licht Make sure that the oll warning light comes on with the ignition switeh “ON”: 41 the light does not come on, inspect as follows, Remove the drive sprocket cover Disconnect the oil pressure switch wire from the switch by re ‘moving the terminal screw. Short it to ground using ajumper wire, Turn the ignition switch Fae The oil warning light ehould come on, If the iaht does not come on, chock the bulb, sub fuse (15 Al and wires for a loose connection or an open eireult Stert the engine and make sure that tho light goes off, if the light does not go off, check the oil pressure (nage 2-4 If the oll pressurs is normal, replace the oll pressure switch with anew one (nage 2-4),HTS/INSTRUMENTS/SWITCHES LIGHTS/INSTRUMENTSISWITCHES TEMPERATURE GAUGE (2) TebeRATURE GAUGE Remove the fuol tank (page 4-3). Disconnect the sensor wire fram the thermosensor and short t ‘0 ground using a jumper wire ‘Turn the ignition switch ON. ‘Temperature gauge should move all the way to "H'* mark on too ie c CAUTION , is © Do nt leave te termosenor wie rounded fortonger tana [LD THERMOSENSOR few seconds, or the temperature gauge wil be damaged. If the gouge does not move, check the sub fuse (15 A) and ‘wires for a loose connection oF an opan circult; it normal, re- place the gauge with a new one Ipage 19-5). TACHOMETER If the tachometer does not work properly, remove the front ‘cowiing (page 12-2) and turn the ignition switch ON, Check the voltage between the black (+) and green I-) wire connec: Thera should be battery voltage. If the voltage does net come on, check tho eub fuse {15 A) and wire for @ loaee connection oF an open ereuit If there is good condition, check the black/yellow wire for open circuit between the tachometer and rear CDI unit Ifthe problem ati ‘one (page 19-5) | ay INSTRUMENT ™ Lo Se connecTOREN. _— NEUTRAL SWITCH INSPECTION Remove the drive sprocket cover, and temporarily instal the ‘gearshift pedal. Check the neutral switch for continuity betwoon the ewitch teminal and body ground as shown. ‘There should be continuity when the transmission in neutral ‘end should be no continuity with the tranemission in any gear. 19-820. WIRING DIAGRAM20. WIRING DIAGRAM Ey] & dale blag # ie tow be — ES Be21, TROUBLESHOOTING TROUBLESHOOTING POOR PERFORMANCE | ENGINE DOES NOT START p ® OR IS HARD TO START. ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Chock if fuel is getting - . to the carburetor GETTING To CARBURETOR 2. Remave spark plug Day 3. Try epark toot SPARK 4, Test Eylinder compression COMPRESSION NORMAL i 1 5. Start by following normal starting procedure ENGINE DOES NOT FIRE Start with choke applied 21-1 ATHIGH SPEED 21-2 POORHANDLING 21-3 ENGINE DOES NOT START OR IS HARD TO START 214 21-4 Probable couse NOT GETTING To —_—_____,. CARBURETOR, WEAK OR NO SPARK». Low compression». ENGINE FIRES BUT—————__,. SOON STOPS . No fuel in Fuel tank + Clogged fuel tube or fue! titer oF fuel strainer Clogged float vaive Clogged fuel tank eap breather tube Carburetor flooded Carburetor chok closed ‘Throttle valve excessively open Clogged air cleaner alomont rxcoscively GO TO PAGE 17.2 Valve clearance too small Valve stuck open Wern cylinder and piston rings Damaged cylinder head gaskot Improper valve timing Improper valve and seat contact Seized valve Choke excessively open Carburetor pilot screw excessively open Air leaking past intake pipe Improper ignition timing (CDI unit oF pulse generator Faulty) 21-1TROUBLESHOOTING ENGINE LACKS POWER 1. Reise whee! off ground and spin by hand WHEEL SPINS. \ 2. Check tire procure with tiro gauge EELY PRESSURE NORMAL, + 3. Try rapid acceleration from low to second ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED 4. Lightly accelerate engine ENGINE SPEED INCREASES heck ignition timing using timing light CORRECT 8. Check valve clearance conRECT ; 7. Test cylinder compression using compression gauge NORMAL 1 8, Check'carburetor for clogging NOT CLOGGED ‘ 9. Romeve spark plug NOT FOULED OR DISCOLORED | Probal WHEEL DOES NOT SPIN + FREELY : PRESSURE TOO Low ——— ENGINE SPEED DOES NOT ————»+ CHANGE WHEN CLUTCH IS. : RELEASED : ENGINE SPEED DOES NOT ————»+ INCREASE SUFFICIENTLY : INCORRECT FOULED OR DISCOLORED + Brake dragging Worn or damaged wheel bearing Wheel bearing needs lubrication Drive chain too tight Axle nut excessively tightened Purctured tire Faulty tire valve Clutch stipping Worn clutch disc/plate Warped clutch dise/plato Carburetor choke closed Clogged sir cleaner Restricted fuel low Clogged fuel tank breather tube Clogged muffler Faulty COI unit Faulty pulse generator Improper valve adjustment Worn valve seat Valve stuck open Worn oylinder and p Lesking head gasket proper valve timing Improper valve and soat contact ton rings Carburetor not serviced frequently ‘enough Plug not serviced frequently enough Use of plug with improper heat renge 21-2” o” i) oe” @” @” @” ‘TROUBLESHOOTING 10. " 12. 13, Remove oll level gauge and check «il lovel and tor dirty oil connect Remove the valve adjusting cover and inspect lubrication VALVE TRAIN LUBRICATED PROPERLY Check if engine overneats Accelerate or run at high speed ENGINE DOES NOT KNOCK Probable couse OW LEVEL INCORRECT —————» + VALVE TRAIN NOT ————_» LUBRICATED PROPERLY : OvERHEATED ——________,. POOR PERFORMANCE AT LOW AND IDLE SPEEDS Check ignition timing and velve clearance CORRECT Check Carburetor pilot screw adjuetmont connect Check if air is leaking past intake Pipe NOT LEAKING Try opatk tost GOOD SPARK il leve! to0 high Oil level t09 low Clogged oil passage Clogged oil control orifice Contaminated cil Faulty cil pump Excessive carbon bi bustion chamber Use of impropor quality of fuel Clutch slipping Fuel air mixture too lean Worn piston ring and cylinder Fuel air mixture tao lean Use of improper grade of oil Excessive carbon build-up in com bustion chamber Ignition timing too advenced (Faulty CDI unit) Probable causa INCORRECT INconRect ——__________». Leaking ——____- WEAK OF INTERMITTENT SPARK Improper valve clearance Improper ignition timing (Faulty CDI unit and pulse generator! Fuel air mixture too lean (Te correct, screw outh Fuel air mixture too rich (To correct, screw in) Doteriorated insulator O-ring Loose carburetor Damaged insulator GO To PAGE 17-2 21-3‘TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Probable cause 1, Check ignition timing and valve INCORRECT». clearance 3 CORRECT 2. Disconnect fuel tube at carburetor FUEL FLOW RESTRICTED >. Improper valve clearance Faulty CDI unit Faulty puleo gonerator Lack of fuel in tank Clogged fuel tube Clogged uel tank breather tude Clogged fuel valve Clogged fue! strainer 3. Remove carburetor and chock for CLOGGED». Clean clogged jet Nor cLoaceo 4. Check Vaive timing INCORRECT + Cam sprocket not installec! property CORRECT 5. Chock Saive 1 Weak». Fauity spring NOT WEAKENED POOR HANDLING — + check tre and suspension pressure Probable cause 1. If steering je heavy 2. If eltner whee! is weboling ————____________,. 3. If the motoreyole pulls to one side... Boaring adjustment nut too tight Damaged steering head bearings Bend steering stem Excessive whi Bent im Improperly installed whee! hub ‘Swingarm pivot bearing excessively Bont frame | bearing play Incorrect crive chein adjustment Front and teat wheels not alignod Bent fork lags Bent ewingerm Bent frame 21-4yp” yp” 22. INDEX ——-2ANN a INE Air Closnor Case oi Aiternator/Starter Cluteh Alternator BatteryiCharging Seta Battery . Brako Calipor Brake Fluid ‘ Replacement/Air Bleeding Broko Light Switeh seu. Brake PadiDise Pedal... Shoe/Pac Wear System Cable & Harness Routing Camshaft Installation Removal Carburetor Assembly .. Choke .. Disassembly Idle Speed Installation Removal . Separation/Combination . Synchron zation Cheraing System Clutch/Gearshift Linkage ~ Diode instalation Removal Switeh .. 19-9 System 318 Conmesting RedCrarkat netaton porno le Coolant Replacemont Cooling System Cowling/Muffler/Fear Fender Cowling Crankcase Assemoly .. Bearing Replacement Broather ‘Separation Crankpin Bearing ...-.. Crankshaft/Transmission es Crankshafi/Connecting Rod Removal .. 11.4 Cylindor Head/Valve: Compression Cylinder Piston .. Cylinder Hoad Assembly =... Cylinder Head Cover Inetallation Removal .. Cylinder Hoad Installation ‘ 9-15 Removal pe ead 1 Cylinder installation 106 Romoval 10-2 Drive Chain .. ‘ jcnmuanneealt Drive Chain Sider oasssns 342 Electric Starter .. 181 Emission Control Informstion Labels (U.S.A, only) oa 168 Emiesion Control Systems a Engine Removal/Installatian Installation... Engine Ol) Change... ee eee) Fitter Replacement... ce errs Level Cheok au A amu Engine Removal 62 Evaporative Emission Control System (California model only} « 310 Flywheel installation as Removal ... 82 Fork Logs 13-11 Front Wheel uension Sowing 134 Wheel .. 13.5 Fuel System at Line 34 Strainer Screen, a4 Tank Valve =. Gearshift Linkage General Information Safety . Hendlebars ‘Switeh Meeaant High Akiteds| Adjsimet | WS. Oniy) HOF so Hydraulic Brake Ignition System Col... Switch Timing Instruments i Loft Crarkcase Cover Installation Femoval License Licht Ughto!instruments/Switches Lubrication Points Main Bearing Maintenance ‘Schedule Mactor Cylinder ‘Model Identification MufflerfExhaust Pipes Noutral Switch Nuts, Boks, Fasteners Oil Pressure Check. ‘Switch D1 Pump. Pict Siew Adjustmont sc. Piston Installation Removal. Ring Installation Primary Drive Gear Pulse Generator Purge Control Valve Inspection (California model) Redistor i Coolant Rear Wheal!Brake/SuspensionINDEX te Wheel Reguletor/Rectifier Reserve Tank . Right Crankcase Cover Inetal Removal ‘Service Information ‘Altamator/Stortor Clutch a4 Battery/Charging System ‘asia! 1841 Clutch/Gearshift Linkage and ae Cooling System 54 Cowling/Mutfler oar Fender vue .nenee V2 Cranksheti/Transmission anny val Cylinder HoadiValve 94 Cylinder Piston nsceeseeen 10-1 Electric Starter con 181 Engine Romovaliinatallation - 64 Front Wheel Suspension(Steering sawn 191 Fuol System wveneeeoe ripe vedeth Hydraulic Brake 154 lanition System al Lights/Instruments/Switches s-vcescssae 10-4 Lubrication 24 Maintenance. 3d Roar Whoel/Brako/ Suspension 144 Service Rules ww Shock Absorber... onretnne sis VIO Linkage Side Cover Side Stang ‘Switch, Silicon Died Spark areser (USA. ony idee ONG Plugs vaxcmes | 38 Specifications 13 Starter Clutch reve BATON 83 Motor cebereasst 18.3 Relay Switch 186 steering Head Bearings vane gi. 8. StOM wosreceeoe 13.18 Stop & Tailight 19:3 Suspension ic 316 Swingarm 1416 System Inspection am ausdaacTtT Testing net 62 .chometor rae TAA ROB ADS Temperature Gauge eH ROOTES Thermosensor se .en ane BB Thermostat eae 53 Thermostatic Switch 55 Throw cen Se Toole Be 17 Torque Values 18 Transmission Installation ailiied ack 1-14 Removal vnssceen 11-10 Troubleshooting Battery/Charging System eens 1 6 Cluteh/Goarshift Linkage 7 ‘ling System 8 CrankshafuTransmission 4 8. 0. 8 Cylindor Head!Valve Cylinder Piston tt Eleouic Starter «... 1 Front Wheel/Suspension/Staering Fuel System Hydraulic Broke ignition Systam Liahts/instrumants Switches Lubrication Rear Wheel/Brake/Susoension Turn Signal Light, Valve Clearance rena Guide Replacement Seat Inspection/Retacing Wiring Diagram... 132 42 15.2 172 194 22 142 193 a7 10 S11 56 317 204 22-2 (26a)“wue3-B0400Mu93-£13008«oewao3—Fo600a*Mwo3-P10008awanss-F26000MMO R-F 31004TRIO LD As c 1 Mew a—FsnOTdi mo3-F31028ng 3-F3.103MAWS-E0201 49 _ > Be 14- 20-5 ee 7 § an SS 41 ez 1e@—91 3 7 -& f= 15 1 13 2 10) e193 Bis Maw3-B0300Maw3-£0500fe, mawa-20700 ayMaw3-E1800Mh v5 ) / xMAW2-FO6O0i «& & Z zCaeMAWs-F1600f‘Mawa-F2700MAW3-F2701_S i cl r\4 i * AUT paMAW3=F330015Pe srr E0700 "|RANW- EI700WANE £1800MAR £1900‘MARR F200,%, 4NA FOBOO A,Pa é = 5Ray g :ot? 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