1. GENERAL INFORMATION GENERAL SAFETY ol LUBRICATION & SEAL POINTS 118 ‘SERVICE RULES 1-2 CABLE & HARNESS ROUTING 0 7 MODEL IDENTIFICATION 1-3 EMISSION CONTROL SYSTEM SPECIFICATIONS 14 (U.S.A. only) ee TORQUE VALUES 1-13 EMISSION CONTROL INFORMATION ToOoLs 1-16 LABELS (U.S.A. only! 131 GENERAL SAFETY Carbon monoxide IF the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an en: closed area. ‘+ Tho exhaust contains poisonous carbon monoxide ‘gas that may cause loss of consciousness and may to death. Run the engine in an open area or with an exhaust evacu: ation system in an enclosed area Gacoline Work in a well ventilated area. Keep cigarattes, flames or sparks eway from the work area or where gasoline is stored, + Gasolina is extremely flammable and is explosive un- | der certain conditions. KEEP OUT OF REACH OF CHILDRE! Hot components * Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the e and exhaust system have cooled before handling these parts. Used engine/transmission oil WS ~ Used engine oll may cause akin cancer i rep laftin contact with the skin for prolonged periods, AL though this s unlikely unless you handle sed oon & daily bates, i is atl advisable to thoroughly wash YOUF hands with soep and water as soon as possible ‘ter handling used oll KEEP OUT OF REACH OF CHIL OREN. Brake dust Never use an air hose or dry brush to clean brake assem blios. Uso an OSHA-approved vacuum cleanor or alternate method approved by OSHA, designed to minimize the haz- ard cause by airborne asbestos fibers. Brake fluid CAUTION + Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel aver these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN.GENERAL INFORMATION Coolant Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. the ethylene glycol does ignite, you will not see any flame, but you can be burned. ‘+ Avold spilling engine coolant on the exhaust system ‘or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flome. + Coolant (ethylene glycol) can cause some skin irrita- tion and Is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN, + Do not remove the radiator cap when the engine hot. The coolant is under pressure and could scald If it contacte your skin, wash the affected areas immedi- ately with soep and water. If it contacts your eyes, flush them thoroughly with frosh water and get immodiate medical attention. If it is swallowed, the vietim must be forced to vomit, then rinse mouth and throat with fresh water before obtaining medical attention. Because of ‘these dangers, always store coolant in a safe place, eway from the reach of childron. SERVICE RULES Nitrogen Pressure For shock absorber with a gas-filled reservoir: * Use only nitrogen to pressurize the shock absorber. ‘The use of an unstable gas can cause a fire or explo- sion resulting in serious injury. + The shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock ab- sorber could lead to an explosion that could result in serious injury. Failure to release the pressure from a shock absorber before disposing of it may load to a possible explosion is 26. To prevent the possibility of an explosion, release the ni- trogen by pressing the valve core. Then remove the valve stom from the shock abeorbor reservoir. Dispose of the oll in a manner acceptable to the Environmental Protec- tion Agency (EPA) Before disposal of the shock absorber, release the nitro: gen by prossing the valve core, Then remove the valve stem from the shock absorber Battery Hydrogen Gas & Electrolyte + The battery gi flames and cigarettes away. Provide adequate ven- tilation when charging, The battery contains sulfuric acid (electrolyte). Con- tact with skin or eyes may cause severe bums, | Wear protective clothing and a face shield. =i electrolyte gets on your skin, flush with water =if electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. + Eloctrolyte ie poigonous. = If swallowed, drink large quantities of water or milk and follow with milk of megnesia or vegetable ci KEEP OUT OF REACH OF CHIL- 1.Use genuine HONDA or HONDA.recommeniied parts and lubrications or their equivalents. Parts that do not meet HONDA's design specifications may damage the motorcycle, 2.Use the special tools designed for this product. 3, Use only mevic tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The uso of incorract tools and fastenors may damage the motoreycle. 4,Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. ‘5.When tightening a series bolts or nuts, begine with the largor-diameter of inner bots first, and tighten to specified torque diagonally, in incremental stops nuless a particular sequence is specified 6.Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. T.After assembly, chock all parts for proper installation and operation. 8.Route all electrical wires as shown on pages 1-20 through 1-27, Cable and Harness Routing. aMODEL IDENTIFICATION GENERAL INFORMATION (1) FRAME SERIAL NUMBER ‘The frame serial number is stamped on the right side of the steering head. (2| ENGINE SERIAL NUMBER ‘The engine serial number is stamped on the right of the upper crankease. (3) VEHICLE IDENTIFICATION NUMBER “The Vehicle Identification Number |VIN} is attached on right side of the frame. (4) CARBURETOR IDENTIFICATION NUMBERS The carburetor identification numbers are onthe carbure- tor body intake side as shown. (6) COLOR LABEL ‘The color label is attached on the frame under the right, side cover as shown,GENERAL INFORMATION SPECIFICATIONS Fuol tank capacity Fuel tank reserve capacity Cylinder arrangement Bore X Stroke Displacement Compression ratio Valve trai Intake valv ENGINE fopens at 1 mn (0.04 in) lit (49 state/Canada type) (California typo) Intake valve closes at 1 mm (0.06 in) ft (49 stata/Canada type) (California type) Exhaust valve opens at 1 mr (0.04 in) lit (49 stata/Canada type) (California type) Exhaust valve closes at 1 mm (0.04 in) lit (49 stato/Canads type) (California type) Lubrication system Oil pump type Cooling system Air filtration Engine weight (49 state/Canade type) (California type) Firing order Cylinder number GENERAL rem ‘SPECIFICATIONS DIMENSIONS | Overall longth 2,085 mm (80.9 in) Overall width 685 mm (27.0 in) Overall height | 1.135mm (447 ind Wheelbase 1,405 mm (66.9 in| Seat height 810 mm G1. Ground clearance 130 mm (5.1 in) Dry weight (49 state/Cenade type) | 184 kg (406 Ibs) (California type) 186 kg (408 Ibs) Curd weight (48 stato/Canads type) | 208 kg (484 Ibe) (California typ 208 kg (459 Ibs) Maximum weight capacity (US.A. type) | 178 kg (388 Ibs) (Canada typo)| 180 kg (397 Ibe) FRAME | Frame type Diamond | Front suspension Telescopic fork | Front wheal travel 118 mm (4.5 in| Rear suspension ‘Swingarm Rear wheel travel 103 mm (4.29 in| Roar damper Nitrogen gas fillad damper with reserve tank Front tire size 120/80 ZR 17 Rear tire size 160/80 ZR 17 Tire brand (Bridgostono) Front | BTBOF RADIAL G Rear | BT50R RADIAL J (Michelin) Front. | MACADAM g0Xx Roar | MAGADAM 0x Front brake Hydraulic dual disc Rear brake Hydraulic single dise Caster 25° 10 Trail 94 mm (3.7 in) 170 2 (4.5 US gal, 2.7 Imp gal) 3.0.8 (0.8 US gal, 0.7 Imp gal) Vertical 30° inline four 65.0 X 45.2 mm (2.56 X 1.78 in} {600 cm? (36.6 cusin) 1 Silant multi-link chain driven DOHC 16 BIDC 5 BTOC 35° ABDC 40° ABDC 28° BEDC 40° BEDC. TATOO 10" ATDC Forced pressure and wat sump Trochoid Liquic cooled Viscous paper element 61.9 kg (138.4 Ibs) €28 ka (138.4 Ibs) 124-3GENERAL INFORMATION GENERAL (cont'd) vem | SPECIFICATION CARBURETOR | Corburetor type Constant velocity Throttle bore 38 mmm (1.4 in) DRIVETRAIN | Clutch System Multi-plate, wet Clutch operating system Cable operating Transmission -spocd Primary reduction 1.803 (82/44) Gear ratio Ist 2.928 (a1/14) Gear ratio 2nd 2.082 (33/16) 1.647 (28/17) Gear ratio 4th 1,308 (20/18) Gear ratio 5th 1.200 (24/20) Gear ratio 6th 1.086 (25/23) Final reduction 2.886 (43/15) _ Gear shift pattern Left toot operated return system | -N-2-3-4-5-5 ELECTRICAL | Ignition system Full transistorized ignition Starting systom Elootrie starter motor Charging system ‘Triple phase output aternator Rogulator/rectifior typo SCR shortodtriplo phase, full-wave rectification Lighting system. BatteryGENERAL INFORMATION California ype [— LUBRICATION SYSTEM a TEM STANDARD SERVICE UM Engine oll eapacity ateraining 44 £ (36 US at, 3.0 Ima —_ at ciesncombly 42 # (MAUS at, 3.7 Imp at) —_ [[avoitfiterchange _|__ a7 ¢ (89US qt. 33 Impad) — Recommended engine oil Use Honda GN4 4-stroke Oil or equi-| — [PI Senvee Clasifeaton: SF or 86 Viscosity: SAE 10W-40 Oil pressure at ll pressure saltch @OCHTEA) 790.4 kPa (60 Kalen, 71 pei at 6.000 — ‘om it pump rotor tin clearance 0.15 (0.008) 0.20 0008), body clearance 0.45 -0.29 (0.006 - 0.009) 0.36 (0014) “end clearance 0102 ~ 0.07 (0.001 - 0.003) 0.10 (0.004) Oil pump drive sprocket collar O.D. 34,060 ~ 34.075 (1.3405 ~ 1.3475) 34.03 (1.35) Oil pump drive sprocket 1D. 35,025 -35.076 (1.3789 1.3809) | 96.10(1.38) FUEL SYSTEM wren SPECIFICATIONS Carburetor donifcation | 4 stato typo VPaTA pumber California type. me ‘P62 Canada type vP60a Main jt 19 otato, Canada type or #195, No. 2A earburator #138 | california type _ 135 Slow jet #0 Pilot crow initia/final opening See page 5-22 high athude adjustment a See poge 523 Float vel 137 rim (tin) Idle speed — 49 state, Canada type 1,200 + 100 rpm 1,400 + 100 rpm Carburetor vacuum difference Within 30 mmHg (1.2 inlig) Base carburetor: No. 3 Throttle grip free play 26mm (1/12 1/4 indGENERAL INFORMATION [— COOLLING SYSTEM rem ‘SPECIFICATIONS, Coclent capacity radiator and engine 2.4 E (0.63 US gal, 0.53 Imp gal) reserve tenk 0.35 £ (0.09 US gal, 0.08 Imp gal) Radiator cap relief pressure 108 197 kPa |1.1- 1.4 kgicm’, 16.6 - 19.8 psi) Thermostet [ begins to open 80 ~ 94°C (176 180°F) fully open 95°C (2037) valve lift 8.0 mm (0.31 in) minimum Thermo valve siarts to dose 73-77 (163 171F) [— CYLINDER HEAD/VALVES nies TEM STANDARD SERVICE LIMIT Cylinder compression - 4,275 ~ 1,314 kPa (13.0 ~ 13.4 kg/cm’, — 15-18% psi Valve dearance 1N 0.16 + 0.09 (0,006 + 0.000) = x (0.22 + 0.03 (0.009 + 0.001), = Cylinder head warpage = 0.10 (0.900 Camshatt | Camlove | [49 state, Canaca type | 36 140 - 96.300 1.4226 — 1.4525) 35.11 (1422) height ‘ California type 34.540 — 34.780 | 1.3598 ~ 1.3698) 34.51 (1.359) | x 49 state, Canada type 35.300 ~ 35.540 |1.3898 - 1.3992) (35.27 (1.389) California type. 93.580 - 33.820 (1.3220 ~ 1.3318) 33.55 |1.321) Runout = 0.08 (0.002) Oi clearnee 0102 - 0,062 (0.0006 - 0.0024) 0.4 (0.004) Journal 0.0, | _73.959 23.980 (09433-09441) | 24.985 (08826 Carshatt holder 1D. 24,000 24.021 (0.9449 - 09457) — Vatvoand vane] Valve stem 0.0. iN 975 ~ 3.980 (0.18965 - 0.1871) 3.965 (0.1561) guide ex 3.965 — 3.980 (0.1561 - 0.1567) 3.955 (0.1557) Valve guide |. IN 4.000 - 4.072(0.1575-0.1580) 4.040.189) x “4000-4072 (0.1675 -0.1500) | —_~4.04 (0.160) Stem-to-guide clearance [IN 0.010.037 (0.0004-0.0015) | _0.075 0.0029) x (0.020 0.047 (0.0008 0.0079) 0086 (0.0088) Valve guide projection IN 13.1 133(0.516-0.524) — above cylinder head EX 11.3 - 11.8 (0.445 — 0.453) — Seat width INEX (0.91.1 (0036 — 0.043) 18 (006) Vaive spring | Free length inner | 3192 (1287) 20.62 (1.206) Outer 38.36 (1.392) 3386 1.333) Valve liter | 00. 26.070 - 26.003 1.0028 1.0732) | 2897 (102 Bora |.D. 26.010 - 26.026 (1.0240 - 1.0246) 26,04 (1.025)GENERAL INFORMATION [— CLUTCH/GEARSHIFT LINKAGE Let rom tinh rem STANDARD SERVICE LIMIT | Clutch levor free play 10-20 (3/8-3/4) = Clutch spring free length - 49.7 (1.96) 48.3 (1.90) Clutch se thickness 292-208 [0.116 0.121) 2.60 (0.102) [e — 0.30 (0.012) Clutch plate werpage Cluten outer guice Mainshaft 0.0. at clutch outer guide [ oo. 34.975 - 34.991 (1.3770 - 1.3776) 34.965 (1.3768) 21.994 — 22.007 (0.8659 - 0.8864) 21.980 - 21.993 (0.8654 - 0.8689), 22.017 (0.8668) 21.95 (0.864) TRANSMISSION Hints oun (i) rem STANDARD SERVICE LIMIT Trans: | Gear .D. Ms. Me 28.000~ 28.021 (1.1024 1.1032) | 28 0817.108) mission 2,03, 6a 31,000 31.025 7.2205 1.2215) | _91.04(1.222) Gear bushing 0.0. M5, M6 27.969 — 27.960 (1.1007 ~ 1.1018) 27.94 (1.109) 2 __ | 30969-30980 (.2189- 1.2197 | _9094 7.218) 3,68 30.950 - 30.975 (1.2185 - 1.2105) | 3008(7.218) Gear bushing ID Ms 24,965 - 25.006 (0.9637 - 0.9845) | 26.016 (0.9648) a 27.986 ~ 28,006 (1.1018 - 1.1028) 28.024 (1.1032) Gear-to-bushing clearana at MB, MB gear 0.020 ~ 0.082 (0.0008 - 0.0024) at C2, C3, C4 gear 0.020 ~ 0.070 (0.0008 - 0.0028) Mainshatt 0. ats gear bushing| 24.967 — 24.980 (0.9830 - 0.9635) | 24.960 (0.9827) atclutch outer guide| 27.980. 21.999 (0.6654 0.8659) | 23.95 (0.8604) Countershafi 0.0, at C2 geer bushing | 27.967—27.980(1.1011~ 1.1018) | _ 27.96 (1.101) Gear bushing-to-shatt | at MB gear 0.005-0.039(0.0002-00015 | — clearence at C2 gear 0.005, 0.039 (0.0002 - 0.0015) — sit Fork claw thickness 5.98 ~ 6.00 (0.233 ~ 0.236) 8.90 (0.232) shaft _Fork LD. 12.000 - 12.021 (0.4724 - 0.4733) _| 12.030 (0.4736) Shat 00, 11.957 —11.968 (6.4707 0.4712) | _11.95 0.470)GENERAL INFORMATION [— CYLINDER/PISTON/CRANKSHAFT Un mm fe TTEM ] STANDARD SERVICE LIMIT cyinder — | 10. €5,000- 65.015 (25591-2.5506 | _66.10(2.669) Taper : — _ | e210 10.008 ow ot round — | o1010.008) [ warpage — ___ 0.100.008) Piston, Piston mark direction “IN* mark facing tothe inteke side | — picon ingFston 0. 94.870 ~04.990(2.9879- 2.8687) at | 64.90 (2555) pe 11 (044 from bottom of skirt, Piston pin holo LD 17002 17.008 [0.6604 - 0.6696) 17.02 (0670) Cyinder-to-piston clearance 0.010 ~ 0.048 (0.0004 - 0.0078) 0.10;0.008 | Piston pin 0.0) 16.994 17.000 [0.6600 - 0.6692) 16.38 (0.668) Piston-to-piston pin clearance (0.002 ~ 0.014 (0.0001 - 0.0008) 0.08 (0.0016) Connecting rod to-piston pin clearance | 0.016 - 0,040 (0.0006 - 0.0018) 0.08 0.0024) Piston ring-toring groove Top 0.028 - 0.060 (0.0010 - 0.0028) 0.08 (0.003) Searane Second 0.015 0.060 (0.0006 - 0.0020) 0.08 (0.003) ‘Piston ring end gap | Top 0.20 ~ 0.38 (0,008 0.014) 05 (0.02) Second 0.35 -0.60(0.014- 0.020) 07 (0.03) Oil (side rai) 02-07 10.01-0.03) 7.0 0.04) | Piston ving mark Top ‘or'R' markfocing up - Second | __ *T"or “RN” mark facing up = | crantsnar, | Connecting rod small end 1. 17.016 - 17.096{0.6698 0.6706) 17.04 (0.671) Sarrea8Ccpreaingedbig onde soware | 010-025 000 - C01 cane | Cranksheft runout — 0.05 (0.002) Cranipincilclerance —~=~=~=«|;~=C*«GB-0.06210.0011 - 0.0020) 0.06 (0.002) Main journal ol! clearance | c20- 0.045 0.0008 - 0.0078) 06 (0,002,GENERAL INFORMATION ;— FRONT WHEEL/SUSPENSION/STEERING Unit: mm (in) rreM STANDARD SERVICE LIMIT Minimum tire tread depth - eo — 1.5 (0.06) Cold tire pressure UP to 90 kg (200 Ib) load 36 psi (2.50 kg/cm’, 250 kPa) Upto maximum woight capacity | 36 psi (250 kafer, 250 KPa) = ‘Axle runout oO - al _— ~~ 0.2(0.01) ‘Wheelrim runout | Radial = 2.0 (0.08) Axial = 20 (0.08) ‘Whee! balance weight — — 80g (2.1 08) mex. Fork spring free length . 317.9112.6) 311.5 (12.3) Fork pring diretion With tightly wound eo facing down Fork tube runout ee = 2.0 (0.08) Recommended fork fluid Pro Honda Suspension fluid SS-8 Fork fluid level 117 (4.81) Fork fluid capacity 463 ce (1.7 US 02, 16.3 Imp 02) Spring pra-load adjuster standard position 3rd groove Rebound adjuster standard position T elicke out from full in ‘Steering stem bearing pre-load 0.18 0.20kg-m (1.1— 1.6 1b-ft) Unit: mm {ind [— REAR WHEEL/SUSPENSION Trew STANDARD SERVICE LIMIT Minimum tire troed depth — 2.0 (0.08), Cold tre pressure | Upto 90 kg (200 1b) load 42:psi (2.90 kalom?, 290 KPa) = Upto maximum weight eapacity 72 psi (2.90 kgler?, 290 KPa) Axle runout es _ 0.2 (0.01) Wheel im runout | Radial — 2.90.08) Paxil — 2.0 (0.08) ‘Wheel balance weight 60g (2.1 oz) max. Drive chain slack 18-25 [58-1 Drive chain sizailink | RK RKSOMFO/108 — DID bipsov4/708 Drive chain slider thickness To the indicator Damper gas prossure/compressed gas Spring pre-load adjuster standard position 10 kg/er? (980 ka) Nitrogen 2nd Rebound adjuster standard position ‘turn out from full in Compression adjustor standard position ‘turn out from full in 1-10Coed GENERAL INFORMATION ES NE ,— HYDRAULIC DISC BRAKE - Unit: mm {i ITEM. ‘STANDARD SERVICE LIMIT Speciied brake fluid DOT 4 brake fluid = Brake pad weer — To the groove Brake diss thickness FR 38-42 (015-9. 3510.14 FR 485.2 (019-020) 400.16) Brake dise runout - _— 030.012) Matser eylinder LO. FR 12.700 ~ 12.743 (0.5000 - 0.5017) 12.76 (0.502) - RR 74.000 14.013 (0.5512-05529 | 14.055 10.5633) Master piston ©.D. FR 12.075 ~ 12.684 (0.4969 0.4994) 12.65 (0.498) RR 13.957 - 13984 (05495-05806) | 13.945 0.5480) Caliper evlinder LD. FR | _25.400- 26,450 (1.0000 - 10020) 25.46 |1.002) AR £36,180 36.250 (1.5081 — 1.6061) 30:24 (1.608) Caliper piston 0.0. FR 25.336 - 25.368 (0.9974 - 0.9987) 28:33 (0.997) RR 38,096 - 38.148 (1.4999 15019) 3809 (1.500) r— CHARGING SYSTEM/ALTERNATOR eM SPECIFICATIONS Current leakage 1.2 mA maximum ‘Alternator charging coil resistance [At 68°F/20°C)_ 01-100 Regulatorirectilier regulated voltage 73.0- 15.5 V at 5,000 cpm Battery | Capacity 12V-8Ah Charging rate Normal 0.9 5-10 hr Quick ANNO | Voltage Fully charged Over 120 Needs char Bolow 12.3 IGNITION SYSTEM TEM ‘SPECIFICATIONS Spark plug Standard - NGK _NIPPONDENSO CRIEHO UZTFERS Spark piug gap - (0.809 mm (0.031 - 0.035 in) Ianition cil primary peak voltage 100 V minimum Ignition pulse generator peak voltage 07 minimum - Ignition col Primary 25-310 (a 20'6/68F) Secondary: with plug cap 21-25 ka. Secondary: without plug wire vi 18K2 Ignition pulse generator resistance (At 20°C163F) 460-5800 Ignition timing "F* mark | 49 state, Canada type 10° BTC at 1,200 + 100 rpm California type 5° BTDC at 1,400 + 100 rpm. ee 1-11GENERAL INFORMATION [— ELECTRIC STARTER/STARTER CLUTCH Vale ren it rem ‘STANDARD SERVICE LIMIT | Starter driven goarO.D. 51,699 ~ 51.716 (2.0954 - 2.0361) 51.684 (2.0348) ~Starerroter bush ong 120-180\047-051) | AS 08 ! ;— UGHTS/METERS/SWITCHES TEM, SPECIFICATIONS , Fuse | Main - 304 Sup 1AX1,10AX3 Bulb —_ Headlight (high/low beam) 12: V ~ 6O/EBW - Broke/tal light 12Y- 32/8 ep License lant 12V-4en Front turn signalrunning ight 12V=9273 epX2 [Rear turn signal light _2V-S20pX2_ Instrument light W2V-17WXK4 - High beam indicator 12V-17W Turn signal indicator 12V-3Wx2 ‘Neutral indicator RVv-17W Side stand indicator 12V-1.7W os - Oil pressure warning indicator | vw Fuel pump flow capacity (min /minute) 700. (23.7 US o7, 24.8 Imp 02) Coolanttompertre | 80CAI6 — ray — sonsorressanes ape ae qo-200 " Fan motor switch Start to close (ON) 96 ~ 102°C (208 - 2167) ‘Stope to open (OFF) 99 - 97°C (198 - 207)GENERAL INFORMATION ieee TORQUE VALUES _ STANDARD TORQUE rastener ves | TORQUE FASTENER TYPE Tem tke-m, tf ‘Nem (kgm, Ib) 5mm hox bolt and nut 5 (05,35) ‘5mm sorew 4104.3) ‘6mm bolt and nut 10(1.0,7) 6 mm screw 8 (09,7) ‘8mm bolt and nut 22(22, 16) {6 mm flange bolt 8 mm head) 909.7) 10mm hex bolt and nut 35 (35,25) 6 mm flange bolt (10 mm head 12(1.2,9) ‘Yamm hex bolt and nut 55/55, 40) and nut 8mm flange bolt and nut 27 (27,20) 10 mm flange bolt and nut 40 (4.0, 29) + Torque specifications listed below and on pages 1-14 and 1-16 are for mportant fasteners. + Allothers should be tightened to the standard torque values listed above. NOTES: 1. Apply sealant 10 the threads, 2. Apply a locking agent to tho throads. 3. Apply molybdenum disulfide ol (a 50/50 mixture of engine oil and molybdenum disulfide grease) to the threads and seating surface. 4. Lett hand threads. 5, Stake. 6. Appiy oil to the threads and seating surface. 7. Apply clean engine oil to the O-ring. 8. Torque wrench scale reading using a special tool. 9. Apply grease to the threads and seating surface. 10. UBS bolt. 11, Do not apply molybdenum disulfide oil to the threads and seating surface. ENGINE THREAD ITEM ory | ont han) REMARKS. Lubrication System Oi drain bolt 1 2 30 (3.0, 221 Oil fiter cartridge 1 20 1011.0, 7) NOTE 7 Oil fiter boss 1 20 1811.8, 13) Nore 2 Oil pump driven sprocket bolt 1 6 35115, 11) NoTE 2 il cooler sealing bolt 1 18 50 (5.0, 36), NOTE 2 Oil pump cover bolt 1 6 810.8, 5.8) CT Bott Cooling System ‘Thermosensor 1 | erve 10(1.0, 7), NOTE? Fan motor switch 1 — 1011.0, 7) NOTE 1 Water pump belt 3 6 1311.3, 9), CT Bolt 1 2 35 (35, 25) Cylinder Head Cylinder head bolt 10 9 48 (4.8, 39) NOTES Spark plug 4 10 12112, 9) Cylinder head cover bolt 6 6 10(1.0, 7), Camshaft holder bolt 20 | 6 1241.2, 9) NOTE 5 Gylinder head cover breathor plato bolt 2 6 12(1.2,8) NOTE 2 Cylinder head stud bolt 8 8 26 (2.6, 19), Cam sprocket bolt 4 7 20120, 14) NoTE2 Cylinder head sealing bolt 2 8 33 (3.3, 24) NOTE ‘Water hose joint 2 10 25 (25, 18) Vacuum joint 3 5 2.5 (0.26, 1.8) Cam chain tensioner slidercap nut 1 6 12(1.2, 9) | Clutch/Gearshift Linkage: Cluteh conter lock nut 1 20 10 (11.0, 80) NOTE 5,6 Gearshift spindle return spring pin 1 8 23123, 17) Shift deum contor bolt 1 8 2312317) NoTE2 Clutch spring bolt 4 6 12(1.2, 9) Drum stopper arm bolt 1 6 12(1.2, 9) Right crankease cover bolt 10 6 121129)GENERAL INFORMATION ENGINE (cont'd) TORQUE mem GY: aon REMARKS | Nem tko-m, lb-ft) Crankcase/Cylinder/Piston ] Crankzase 8 mm bolt 2 | 6 12(12,31 Crankcaso B mm bolt eke © 24 (24,17) Main jounal bott 10 8 25126, 18) NOTES, 11 Crankoaes 10 mm bolt 1 10 404.0, 29) Connecting rod bearing cap nut 8 7 25126. 18) NOTEE, 11 Neutral switch 1 10 12(1.2,9) NOTE? Oil pressure swith 1 | pT 1201.2,9) NOTE 1 Sealing bolt 2 | 2 3013.0, 22) NOTE 1 1 14 2512.5, 18) NOTE 1 Charging System/Alternator : Flyywheol bott 1 10 105 (1055, 76) NoTE6 Starer clutch bolt 6 6 1611.6. 12) NOTE 2 Stator bolt 4 6 1211.2,9) Stator wice clamp bolt 1 6 1011.0, 7) Ignition System : Ignition pulse generator rotor cover cop 1 45 1811.8, 19) Notes Ignition pulse generator rotor cover bolt 8 6 12(1.2,9) NOTE Ignition pulse generator rotor bolt 1 10 60 (6.6, 43) FRAME, TORQUE mem ery | THREAD REMARKS | PIALenm) | pam (cg-m, ft) Frame/Body Panels/Exhaust System : | Exhaust pipe joint nut 6 7 20(2.0,14) Exhaust pipe band bolt 2 8 21 (2.1, 18) Muffler mounting bot 1 8 272.1,20) Sido etand pivot bolt 1 10 1011.0, 2) Side stend pivot lock nut 1 10 3013.0, 22) Side stend bracket bolt 2 | 10 55 (6.5, 40) Side stand switch bolt 1 | 6 10(1.0,7) Upper fairing stay bott 2 8 2712.7, 20) Footpeg holder bolt 8 8 27 (2.7,20) Engine Mount : Engine hangor plete bolt 2 10 45 (45,33) Front engine mounting bottinut 2 10 (65,47) Rea’ engine mounting nut 1 10 45(45, 33) Rear lower engine mounting bolt 1 10 45 (45, 33) Engine mounting adjust bolt 1 20 15(15, 11) Engine mounting lock nut 1 20 65 (6, 47) Drive sprocket bolt 1 io 95 (6.5, 40) Gearshift pedel pinch bolt (pedal side) | 1 8 27 (2.7, 20) (erm side) | 1 6 2012.0, 14) Front Wheel/Suspension/Steeting Ignition switch bolt 2 8 25125, 18) Handlebar pinch bolt 2 8 27.2.1, 20) Fork cap bolt 2 | a 2312.3, 17) Fork socket bott 2 8 2012.0, 14) NoTE2 Steoring stem nut 1 24 4105 (10.5, 70) 1-14GENERAL INFORMATION = FRAME (cont'd) * TORQUE is wrem ory | THREAD nemancs | | (em) Nem (kg-m, lb-ft) Steering adjustment nut toa 6 25 (2.5, 18) NOTE 6 | See page 1225 Fork pinch bolt (upper! 2 2312.3, flower) 2 0 40 (40,29) Front axle bolt So4 4 60 (6.0, 43) Frontaxle inch bot (4s 212.216) Front brake disc bolt | 12 6 20 (2.0, 14) NOTE 2 Rear Wheel/Rear Suspension : | Drive chain adjuster lock nut ba) 8 2212.2, 16 Rear axle nut ; 1 18 95 (9.5, 69) Shock absorber mounting nut (2) 40 45 (45,33) Shook lnk nut {frame sie) + | 10 45(45, 39) ‘Shock link nut (shock arm side) 1 | 10 45 (4.5, 33) Shock erm bol 1 | 10 45 (65,38) Swingarm pivot nut 1) M4 110,13., 80) Drive chain elder serew 2) 6 5.31053, 38) Rear brake dice balt te 49 (49,31 Driven sprocket nut 4 12 90 (9.0, 66) Brake System : Rear master cylinder push rod lock nut 1) 8 18(18,13) fear master cylinder mounting bor 2) 6 9108.7) Rear brake master cyinder reservoir bolt 1 |) 6 12112,0) Front brake caliper bracket bolt 48 31 08.1.2) NoTE2 Brake hose bolt 5 | 10 35 (85, 25) Front mastar cylinder holder bolt 2) 6 12112,9), Front broke light switch screw +4 120:12,09) Front reservar cover esrow 2] 4 15(045,1.0 Brake lever pivot bolt 1) 6 101,027) Brake lovor pivot nut 1) 6 6108, 43) Breed valve 3.-| 8 6 (0.6, 4.3) Brake pipe three way joint bot + 68 12(12,9) Front brace hose elamper bolt + 8 1212.9) Front brake pipe stay bor 2) 6 12112, Brake pad pin 2) 8 18 (18,13) Brake pad pin plug 3 8 2.51025, 18) Brake pipe flare nut 2 10 trina, 12) Front caliper brecket pin bok 2 5 133,91 noTe2 Front brake caliper pin bok 2) 8 23123, 17 NoTe2 Rear brake caliper bracket bolt or) 23128. 19) Rear brake caliper pin Bolt 1 | 10 2812.8, 20 1-15GENERAL INFORMATION TOOLS DESCRIPTION Drive chain cutter Link plate holder Oil filter wrench Oil pressure gauge Oil prossure gauge attachment Flost level gauge Pilot eorew wronch Pilot elbow wrench, Pilot serew wrench Valve spring compressor Valve compressor attachment Tappet hole protector Velve guide driver, 4mm Valve guide reamer, 4.008 mm Valve oat cutter 24.5 mm (EX 45°) Valve seat cutter 27-5 mm (IN 45°) Valve seat cutter 24 mm (EX 32°) Valve seat cutter 27 mm (IN 32°) Valve seat cutter 22 mm (EX 60°) Valve seat cutter 28 mm (IN 60°) Cutter holder, 4.0 mm Valve ouide driver Compression gauge fachment Driver Clutch center helder Pilot, 12mm Pilot, 35mm Attechment, 37 > 49. mm Attachment, 42x 47 mm Attachmont, 28 x 30. mm Inner driver Attachment, 25 mm |.D. Attachmont, 30 mm |.D. Bearing remover shaft remover head, 20 mm Attachment, 42 x 47 mm ‘Attachment 62 x 55 mm Pilot, 20 mm Fork seal driver Fork seal drivor attachment Steoring stem socket Ball race remover ‘river attachmont -criver handle Ball race remover Stooting stem driver Pilot, 22 mm ‘Attachment, 24 x 26 mm Attachment, 32 x35 mm Pilot, 17 mm Pilot, 25 mm Drivor shaft Bearing remover attachment Fin driver ‘TOOL NUMBER ‘APPLICABILITY REFER TO SECTION(S| OTHMH-MA10102, {or O7HMH-MA10108 OTNMH-MW00110— or 07NNH-MWWO011, OTHAA-P70100 07506-3000000 ——-or equivalent com- 07510-4220100 (97401 -0910000 mercially available in USA. O7KMA-MS60101—|-or 07MMA-MT30108 =| O7PMA-112201 10. ‘o7908-8220201 (07787-0010000 (07959-KM3010% with O7PMA-MZ201 1 ‘O7HMG-MR70002—-orenuivalent soe page 8-11) ‘07GMD-KT70160 ‘O7MMH-Mv30100 (07780-0010100: for OTMMH-MV3010A 0780-0010200 —| 07780-0012600 —| 07780-0013300 —| o7780-0014202 —| 07780-0014500 —| 0781-0010500— 07743-02000 (O7RNJ-MY50100—or equ 07749-00100 ‘or equivalent com- mercially aveilable in USA. nt comer Iyevelablein USA. (07.JMB-MN50300—} or 07HGB-001000 07748-0040200 07748.0040800 (07748-0010200 07745-0010300 (07948-1870100 07748-0030100 (07748-0030200 (07748-0030300 07745-0050100 —-+ or equivalent com- (07748-0050600 107748-0010300 07748-0010400 107748-0040500 07947-KA50100 07947-KF00100 07916-3710101 (07953-MJ10000: (07953. MJ10100. (07953-M.J10200- (07946-37 10500 (07946-MB00C00 (07748-0041000 (07746-0010700 (07748.0040400 (07746-0040500 07746-0070100 (07946.MJ00100 O7LMCc-KV30200 07GMD-KT80100. mercially available in USA, or 079163710100 tachment (0953 MU TOCOA 00799510008), Driver (07349-37100) and Attachmort, 37x40 mm (07745010200 Not available in U.S.A, Driver (07849, 3710001) and Pilot, 22 mm (07746-0041000) 912,13, 8 12 12 13 13 13 13 13 13 13 13GENERAL INFORMATION ace (cont'd) DESCRIPTION Toounumecr | appuicapitrry | RefeR TOSECTINS) Remover handle 97936:3710700 3 Bearing remover 07936.3710200 3 Remover weight 07741-0010201 —}-or 07936-3710200 | 13 Snap ring piers (IN) 97914-2730001 4 Digital muimater (KOWA) oravi-o0zo000 | Ks-atM-s2-003 | 15,16, 17,18 (USA only) Analog multimeter (SANWAD 07308-0020001 15, 16,17, 18 Analog multimter (KOWA) THEH 16, 16.17.18 Peak voltage adaptor 07HGJ-0020100 ——}-oF Imrie diagnostic | 16 tester (model 625) Inspection adaptor o7GMu-MAL80100 16 Flywhest holder 7826 wE8C000 —|- or eauivalen conenar] 17 oh’ Rotor puller 07733-0020001 07933-2160000 Ww (SA on Flywheel holder 07725-0040000 v Torx bit (T 30) 07703-0010200 ‘or equivalent commer-| 17 Tors bit (740) Orvos-ooroi0g —) | galyesiablein | 38 1-17GENERAL INFORMATION GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE LOCATION MATERIAL REMARKS Cylinder heed somicireular cut-out Liquid sealant Wipe the excess of sealant Crankcase mating surface Camshaft lobessjourn Molybdenum disulfide oi! Valve liter sliding surtaces (a 50/50 mixture of engine Valve stem (valve guide sliding surface) oil and molybdenum disul- Conneeting rod small end inner surface fide grease) | ‘Main journal bearings Connecting rod bearings Mai. C5. C6 gear shift fork groove Cylinder head bolt thr Crankshaft thrust surfaces Clutch outer sliding surfaces Startor idle gear shaft sliding surfacos ll pressure switch threads Lower erankeaso soaling bolt threds Cylinder head sealing bolt threads Alternator grommet Ignition pulse generator grommet Ignition pulse generator rotor cover bolt threads. (Marked by "A" mark) ‘Thermosensor threads Cylinder head cover breather plate bolt threads Locking agent (Clean and apply to the threads Cam sprocket bolt threads il pump driven sprocket bolt threads Shift crum bearing set plate bott threads ‘Sterter clutch outer bolt threads Oil cooler sealing bolt threads Shift drum center bolt threads Gearshift apindle oil soal sot piste bolt threads Mainshaft bearina set plate bolt threads Oil filter boss threads Clutch center lock nut threads Engine oi! Staner clutch sliding surfece Piston sliding surface. piston ring grooves. pin bore Piston pin surface Piston rings Lower crankcase bolt tireads and seating surface (main journal tightening) Connecting rod cap nut threads and seating surtace Cemshaft holder bolt threads and seating surface Flywhool bott threads Cam chain tensioner collar sliding surface Cam chain tensioner and slippor surface Gear teeth and rotating surtace Oil seal lip without dust lip) Cluten disks O-rings Bosrings Clutch titer piece Multipurpose grease Ignition pulee generator cover cap threads il seal lip (with dust ip) eee 1-18GENERAL INFORMATION $$ CENERAL INFORMATION -— FRAME LOCATION MATERIAL REMARKS. Side stand pivot bott sliding surface Gearshitt pedal pivot Brako podal pivot Whee! dust seal lips Rear wheel; driven frange sliding area Rear wheal side collar inner surface Stecring stor bearing Steering stem dust seal lip Threttle cable end ‘Throttle grio sliding surface, flange groove Swingarm pivot dust seal lips Swingarm pivot needle bearing Shock arm pivot dust seal lips Shock arm oivot needle bearing Shock link pivot dust seal lips Shock link pivot needle bearing Rear shock absorber lower mount dust seal lips. Rear shock absorber lower mount needle bearing Main stand pivot sliding surface Multipurpose g ‘Steering adjustment nut threads Engine oil Handlebar grip rubber inner surface Honda Hand Gri (USA. only) Coment Brako reservoir Master piston/piston seals Caliper piston aliper piston seals DOT 4 brake fluid Brako caliper boots inside Mester cylinder rubber boots inside Foar master cylinder push rod top Fear brake caliper pin bolt sliding surface Front master cylinder piston; lever contact area Caliper dust seals Silicone grease Caliper pin bolvbracket pin bolt threads Fork socket bolt threads Looking agent Clean and apply to the threads Fork oil seal lips Pro Honda Suspension fluid ssa Air cleaner housing inlet tube joint SealantGENERAL INFORMATION CABLE & HARNESS ROUTING (1) LEFT HANDLEBAR SWITCH (10) RIGHT HANDLEBAR SWITCH (2) COMBINATION METER WIRE CONNECTOR. Wrannatace ‘WIRE CONNECTOR (9) IGNITION SIMITCH WIRE CONNECTOR [SP WHITE) (9) ENGINE STOP SWITCH WIRE CONNECTOR (4P MINURED) 8] COMBINATION METER WIRE CONNECTOR |) AIR VENT SOLENOID VALVE RELAY (7) FUSE BOX (6) TURN SIGNAL FELAY (6) LEFT HANDLEBAR SWITCH WIRE CONNECTOR’ (3? MINYBLACK) (17) THROTTLE (12) LEFT HANDLEBAR CABLES, (19) CLUTCH SWITCH WIRE (16) RIGHT HANDLEBAR. SWITCH WIRE (13) CHOKE ‘CABLE (15) FRONT BRAKE Hose (14) IGNITION SWITCH WIRE 1-20GENERAL INFORMATION (1) CLUTCH CABLE (2) LEFT HANDLEBAR SWITCH WIRE (IGNITION ‘SWITCH WIRE (5) FAN MOTOR SWITCH) FAN MOTOR WIRE 1-21(1) THROTTLE CABLES (11) SPEED SENSOR 3P CONNECTOR. (2) RIGHT HANDLEBAR L SWITCH WIRE, (10) RADIATOR SIPHON TUBE (9) RESERVE TANK Aj) | x y } }} BREATHER TUBE / \ (wy cLuTcH (o) MAIN WIRE CABLE (7) OIL PRESSURE SWITCH (5) PULSE SECONDARY AIR INJECTION ‘WIRE (PAIR) CONTROL VALVE TUBE (CALIFORNIA TYPE ONLY) (6) PULSE SECONDARY AIR INJECTION (PAIR) i CONTROL VALVE AIR INTAKE HOSE (CALIFORNIA TYPE ONLY)GENERAL INFORMATION (1) BRAKE) TAILLIGHT WIRE (2) GROUND WIRE (3) REAR BRAKE LIGHT SWITCH WIRE |5) REAR BRAKE HOSE (4) SHOCK ABSORBER RESERVOIR HOSE (6) RIGHT REAR TURN, SIGNAL W/IRE (8) LEFT REAR TURN SIGNAL WIRE (7) LICENSE PLATE LIGHT WIRE. 1-23GENERAL INFORMATION (1) ALTERNATOR 3P (WHITE) CONNECTOR (2) SIDE STAND SWITCH SP(GREEN} CONNECTOR 18! GROUND WIRE PULSE [ GENERATOR (7) THROTTLE Position N SENSOR WIRE (6) ALTERNATOR, \ WARE < Z (4) REAR BRAKE LIGHT (9) SIDE STAND SWITCH thal eh WIRE’ (9) VENT FILTER DRAIN TUBE (12) FUEL TANK DRAIN TUBE (11) RESERVE TANK BREATER TUBE (70) CARBURETOR DRAIN TUBES 1-24GENERAL INFORMATION ‘CALIFORNIA TYPE ONLY:GENERAL INFORMATION (1) No. 6 TUBES (2) No. 1 TUBE (TO FUEL TANK) (9) EVAPORATIVE EMISSION PURGE CONTROL VALVE (4)No. 4 TUBE HOSE [TO AIR CLEANER) (10) PULSE SECONDARY AIR IMPULSE SECONDARY AIR INJECTION ~ INJECTION CONTROL VE CONTROL VALVE TUBE (TO No. 3 CYLINDER INTAKE ‘p MANIFOLD) U 1-27GENERAL INFORMATION EMISSION CONTROL SYSTEMS (U.S.A. only) ‘The U.S. Enviromental Protection Agency and California Alr Resources Boerd (CARB) require manufactures to certify that their motoreycles comply with applicable exhaust emissions standards during their useful life, when operated and main- tained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise ‘omission standarde for 1 year or 6,000 kilometers ( 3,730 miles) after the time of sale 1o the ultimate purchaser, when operated ‘and maintained according to the illustrations provided. Compliance with the terms of the Distributer’s Warranties for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in offoct. ‘SOURCES OF EMISSIONS ‘Tho combustion process produces cerbon monoxide end hydrocarbons. Control of hydrocerbons is very important because, tuncer certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not Feactin the same way, but itis toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydracar- bone. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emmisions into the atmospher. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. (1) AIR CLEANER, (2) CARBURETOR ‘) <3 Fresh aR “ tem Blows cas 1-28GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) This vehicle complies with the California Air Resources Board evaporative ission regulations. Fuel vapor from the fuel tank and carburetors is routed into the evaporative emission canister where itis absorbed and stored hile the engine is stopped. When the engine is running and the evaporative emiscion purge control valve is open fuel veporin the evaporative emission canister is drawn into the engine through the carburetor. At the same time, the evaporative emission ‘rburetor air vent solenoid valve Is open and air Is drawn into the carburetor through the valve. EVAPORATIVES. EMISSION. PURGE CONTROL VALVE my Evaporative” Fank EMISSION CANISTER <4) FRESH AIR, = (7) EVAPORATIVE <1 (5) FRESH AIR EMISSION CARBURETOR AIR VENT SOLENOID VALVES fmm = (6) FUEL VAPOR _ NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purpose of meintenance, repair or repli ‘ment, of any device or elemant of design incorporated into any new vehicle for purpose of noise control prior to its sale or delivery to the ultimate purchaser or while tis in use; or (2) the use of the vehtice after such device or element of design thas beon removed or rendered inoperative by any person. AMONG THESE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 4, Removal of, or puncturing the muffler baffies, header pipes or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any parts of the intake system, 2 Lack of proper maintonance. 4, Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with perts other than those speci fied by the manufacturer. ——$$ eee 1-29GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission control system is composed of leen carburetor setting and no adjustment should be made except idle speed adjustment with the throttle stop screw. PULSE SECONDARY AIR INJECTION SYSTEM (California type only) ‘The exhaust emission control system consists of a pulse secondary air injection (PAIR) system which introduces filtored into the exhaust gases in the exhaust port. Fresh air is dravmn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. ‘This charge of frosh air promotas burning of the unburned exhaust gases and changes a consi carbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. ‘This model has the pulse secondary air injection contrel valve; it consists of PAIR chock valve ary air injection control vaive. ‘A PAIR check valve prevents reverse air flow through the system. The pulse secondary air injection control valve reacts 10 high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system, fable amount of hydto- ‘No edjustment to the pulse secondary air injection system should be made, although periodic inspection of the compo- nents is recommended. (INTAKE PORT (2) PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE (sy EXHAUST Bae (3) PAIR CHECK VALVES <= (6): FRESH AIR <— (7: VACUUM PRESSURE 1-30"EMISSION CONTROL INFORMATION LABELS (U.S.A. only) ‘An Emission Control Information Label is located on the frame und side cover as shown. It gives basic tune-up sp. jons. The lott side cover must be re: ‘moved to Raferto page 2-2 for left side cover removal VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL Aer making a high altitude carburetor adjustment, attach {an update label to the frame under the left side cover as shown Reterto page 2-2 for lett side cover removal. VACUUM HOSE ROUTING DIAGRAM LABEL {California type only) ye Vacuum Hose Routing Diegrem Label is on the air ner case cover as shown. to page 2-4 for fuel tank removal. (1) VACUUM HOSE ROUTING LABEL GENERAL INFORMATION VACUUN HOSE ROUTING DIAGRAM EVAPORATIVE FAMILY