7 ONT] L, OA. 86-91 ~ cRes50RIMPORTANT SAFETY NOTICE ERIN tccres a secons possiity of severe personal injury ar death if insructions are not fotowed. CAUTION: Indkates « mossibilty of personal inary or eguioment dame If nsructions are not foo wed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures safety principles and service operations are not included. Itis important to note that this manual contains some warnings and cations against some specific service methocs which ‘couki cause PERSONAL INJURY to service personnel ar couli damage # vehicle or rerder it unsafe, Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommenced by Honda might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigete al such ways Anyone using service procedures cr tools. whether or not recommended by Handa must satisty himselt thoroughly that neither personal safety nor vehicle safety will be jeona-dized by the service methods or tools selectedHOW TO USE THIS MANUAL Follow the Competition Maintenance Schedule recommendations (page 3-2) to en- sure that the vehicle is always in peak operating condition. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 15 describe parts of the motorcycle, grouped ac- cording to location: Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration and specifications, torque values, general instructions, tools and troubleshooting for the section. The subse quent pages give detailed procedures for the section If you are not familiar with this motorcycle, read Section 16, Technical features. It you don’t know the source of the trouble, see section 17, Troubleshooting, gf | icwmion system CONTENTS GENERAL INFORMATION | 1 | LUBRICATION rs MAINTENANCE El [ FueL system Ea ENGINE REMOVAL/INSTALLATION Ei "CYLINDER HEAD/CYLINDER/PISTON gE w Ln 9 H.P.P (Honda Power Port) [aeeey “| CLUTCH/GEARSHIFT LINKAGE; KICK STARTER = TRANSMISSION/CRANKSHAFT/ CRANKCASE COOLING SYSTEM ia ~ | FRONT WHEEL/SUSPENSION/ STEERING 7 3 REAR WHEEL/BRAKE/SUSPENSION ei 3 = = HYDRAULIC BRAKE B13 | SUB FRAME/EXHAUST PIPE/ REAR FENDERGENERAL SAFETY 1 SERVICE RULES 1 MODEL IDENTIFICATION 12 ‘SPECIFICATIONS 14 1. GENERAL INFORMATION TORQUE VALUES 16 TOOLS 1-8 CABLE AND HARNESS ROUTING 11 OPTIONAL PARTS LIST 1-22 GENERAL SAFETY Uf the engine must be running 10 do some work, make sure the ‘area is well-ventilated. Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide gas that ‘may cause loss of consciousness and lead to death. Brake dust may contain asbestos. a amt ae ene eee Naan Ueniiiooma arse meistol nue tae ae Gasoline extremely flammable and is explosive under certain conditions. Work in a well venilaced area with the engine stopped. Do not smoke or allow flames or sparks in your working erea or where gasoline is stored. SERVICE RULES The shock cbsorber has a gas-filled reservoir + Use only nitrogen to pressure the shock absorber. Theuse ‘of anstable gas can cause a fire or explosion resulting in serious injury. + The rear shock absorber contains nitrogen under high ‘pressure. Do not aliow fie or heat near the shock absorber. + Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock absorber. CAUTION Used transmission oil may cause skin concer if repeatedty left {in contact with the skin for prolonged periods. Alihough this is wrlikely unless you handle used oll on a daily basis, i sull advisable to thoroughly wash your hands with soap and weter as soon as possibie after handling used of. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or the'r equivalent, Parts that do not meet HONDA’s design specifications may damage the motorcycle Use the special tools designed for this procuct. Install new gaskets, O-rings, cotter pins, lock plates, exc, when reassembling When torquing bolts or nuts, begin with larger-diameter or inner bolt first, and tighten tothe spacified torque, diagonally, in incremental steps unless a particular sequence is specified 5. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 6, When installing @ new oll seal, make sure that the sealing lip is lubricated with graase. if an ol seal and related parts have been washed, apply proper grease to the lip of the oil seal 7. After reassembly, check all paits for proper instalation and operation, 8. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with any other type of fasteners. The use of incorrect tools and fasteners may damage the motorcycle. RIDERED tAGENERAL INFORMATION MODEL IDENTIFICATION ‘6: ‘90: After ‘90: 1-2 RIDE REDGENERAL INFORMATION 1) FRAME SERIAL NUMBER (2) ENGINE SERIAL NUMBER AN CX ‘The frame serial numbers stamped on the right side of the The engine serial rumber is stemped on the lower left side steering head. of the crankcase. ‘The carburetor identification number is on the left (Atter ‘BB: right! side of the carburetor RIDE RED 1-3GENERAL INFORMATION ee SPECIFICATIONS a SREGRCATINS Dimension | Overal engin 6,67, Ge | 2160 nm BEB 28 | 2388 nm 6. mt After "88: 2.188 rim (86.1 in) vera wath 38, 87, 88; 825 mm (92.5 i ~ ‘af 788:_| 835 nm (925 ‘Overall height ‘86, “87, “88: 3.215 mm (47.8 in) "98:_| 1.258 nm (493i ‘Aver 08. | 1.255 nm (494 ink ‘Wheelbase 86, 87, 88: 1,480 mm (68.3 in) 80;_| 1.405 nm (60.9 in) ‘Afr 88: [ 1.488 rm (686 in) ‘Seat height L "6. {860 rem (37.8 in} Bias | 960 nm S74 mh - Biwr'ag | 70 mm (982m) Foot wes Fah 6, 87.786. | 440 men 173 in} Bf 788—| 4a em 75h Goud Gewrane [66s 87.e| a0 en _ After “88: 350 mm (13.8 ind _| By waa 78k 214.00) 197.0 kg (213.6 1b) - - fm Sr: doule cradle Fn ST Telescope fork, 908 am (20 1 4 | R ausseision, ental Pro-Line, 380 mm 130 in). | tise prema @or100=21 iM, 16 pe TOD APa 10 Kalo tre se. peut 1OVT00- 184M, 1 ps (100 KP. .0 gem Fran, ect Single di, $29 an! GD so Shale di. 308 on! 7.3 sei Internal expanding shoas, 102.1 em! (15.8 sain) Sho de, $08 07.0 sain F brake, fning area Ri. brake, swept area Fusi capacity. “TOF US. gol. 15 imp. gal) C 7.51 Q0US. gal, 1.6 imp. gal) Caster angle _ 27930' - Deere wees _| 29°03" ] Ta 95: | “12 mma 37,708. | 114 mma 8 “a3 | 128 mia | Tite '69.| 125.8 mn 80 Fake copy 36,87. "aB: | “B64 oe 19.1 08 (Standard) ‘89: 887 ce (22.2 ov) i 90: | “640 ec (2.6 08 wii 96:_| 661 cc 12.0 08 tome Ui cooled, 2 Cried ag Single 7 iene tom varia aedeiate [See 72.0 mm (21x 2891 Daplacernt 249.3 on [16.2 and Compression ED eo [ear a7 [ant rae, [ 804 a [eat Fravao,|85 4 - Tananievon oicapacky |—88. "#7, 06.85: | 067 (04TUS at, O53 mE GET {at disassembly) ‘Attor ‘89: 0.83 1 (067 US. gt., 0.86 inp. at.) 1-4 RIDE REDGENERAL INFORMATION re SPECIFICATIONS Cataraor [Tepe [Piston vate dentition namber "a | Pua 87: | Pu26A 8 | wa] Pi2ec 30" | Ps2ea ‘ier90_|Fuzec Taint (tender) a8, 87, After 89 | #175 “88: wis “39: | #178 | Jet reedie and clip 86: R136BN 3rd groave from top. position 87, B8:_| _RISB7N 4th groove from top "B8:_| F959PS An groove fron top “90,_[RIGTONS Sed groove fom top ‘iver 90; | RiS6WNS ir groove tom top Siow et and 36] #80 are [98 ae: | #62 I 3. | #00 ier'89, | #55 Ta “6. | wwe After ‘86: 2.0 turns out Float height _ 16 rom (0.63 in} Dive wan | Clutch ype Wit, multpate type Tranerianon Taped eee Primary reduction 3.000: 1 ‘Goar ratio | - 1.800 = 1 (27/15) [ Gearraso 1.968 51 25178) | [ 1410 1 05/171 Gear rato w 1.1607 128/20) | | 1.210: 123/19) | Gearraia W 1000-1 2V/20) Geer rato V 0.889: 120729 0.893: 120/24) Final reduction 3.7861 : 361 ___ Bears patern Tiecteat —[gnton ‘Staring system Kick starter ‘Spark plug (Optiorall "86: | (CHAMPION) GN-86 INGK) BRBEG (ND) W24ESR-V Atror 88: (N26) [W24ESR.G) 87, 88 | (CHAMPION) ONS —(NGR)BRBEG — (NO) W27ESR-V {N596) (W2TESR-G) 1-5GENERAL INFORMATION TORQUE VALUES ENGINE = Thread aia Toraie pitch Nem kom Cylinder head nat axtas | 26-23 | 24-29 Cylinder nut ‘96,87, 'a8; | 10x128 | dBase | 38-8 | ‘aner‘es:| loxt25 | 35-45 | 35-45 weno | 58-65 | 59-68 soa | 80-28 Clutch spring ott ex 10 e-12 | O81 Primary rive gear bot 1x125 | 40-50 | 40-50 Gantt devin cantar pit Betas | a0-2 | 20-208 rensmission ol drain bok vaeis | ds-a5 | 25-36 *Countershett bearing set plate bx 10 e-12 | 08-12 fAfterneror cover sew 6x10 a5 | 03-08 Fiywhesl nut 125125 | so-co | 50-60 Crve sprocket bolt Getas | as-aa | 26-20 Water pump mele e125 | 40-14 | Vo-ta Fight cankesse cover bot 6x10 e—12 | o8-12 Flocker erm folder screw Bx 10 6-8 | 06-08 Exhoust valve rack hole plug axi2 | 8-12 | OB-12 shat Wales a nlog amin 60K nit Beto Bo | oe 08 (86, "87. After 88) Gearshift drum stopper arm bol | ex10 wo-14 | 10-44 Cylinder stud bole | roxtas | tocue | VOU Cylinder eoolat drain bok | ‘exto 8-12 | 08-12 Woter purse sover eoclane dain bolt 6x10 o-12 | oe-t2 Spark slug waxi2s | 18-20 | 15-20 Ol check bolt 6x10 3-12 | 08-12 Exhaust valve adjusting bot lock nut 5x08 5-7 | 06-07 Viator pump cover salt (after 88), 6x10 | 1-14 | 10-14 Cylinde and extoust velve cover bolt (After “88) oxto | wt | Venta "TAnply Honda Thread Lock or an equivalent. FRAME Thread dia Torase = xplteh Nm [kom te Steering stem nut 96, 67, 88, Aer G9: | 24x18 | GS-1 | BS-140| 69-101 e:| 24x40 | es-140 | 98-140) 69-101 Steering head adjusting nut 06, °87,88:| 26x18 12 | 01-02 | o7-14 ‘a9:| 26x ho 1-2 | ot-o2 | o7-na Atte "89; | 26018 8-12 | oe-n2 | “6-2 Fork tube pinch bol (Top) "86, "87, "88,"89:" | 8x125 | 18-26 | 18-25 | 13-18 ‘iter‘8a:r- | Gxt2s | g0-ae | Sonae | 22-25 (Gowom) —'86,"87, 88, 80:"* | axi26 | 1-26 | 1e-25 | 13-18 ‘ites 80.°* | 8x 128 zia—a0 | 17-22 Handlebar upper holder exi2s | teas | ta25 | 13-18 Handlebar lower holder nut 9,'87,"88:| 10%125 | s0-40 | 30-80 | 22-29 Front ene ‘as,7,'a8,"e0: | 124128 | se-70 | 58-70 | 40-61 ‘aneraa:| 16x15 | 60-03 | 80-93 | 58-67 st aie Hoke xt | to-tz | to-tz | 7-9 Bear axe nut wexts | &-105 | as-t0s| 61-76 Engine hanger bolt (10 mm) foxtas | se-a8 | 38-48 27-35 mm xtos | 2e-20 | 24-20 | 7-21 Engine mounting bolt 96, "87,80, "09:| 10x128 | see | 38-48 | 27-35 ‘ane ‘0a: | ioxtas | cone | so-70 | 43-51 Driven sprocket ‘a6,a7,"96, "03: | ‘Bxt2s | S237 | 32 23-27 Mier'éo"" | B8xt25 | 2-31 | 25 ta22 “Apply ot the treads 1-6 RIDE REDGENERAL INFORMATION ie Thesd din Toraie "rete Te as Shock sseorbe ape Toxizs | to-s0 | a0-s0 towet tori35 | Sense | Seno Frontrear spoke ec'ssmc40 | 26-20 | 026-080 Swvngarn pivot Blt 36,07: | dea 48 30-100 | “so-r00 | aren | texte foi | 80-100 Fork boet clamp serew "86, 87, “28h 15x08 da-18 | oos—o18 Fork cap bot 6, 07,88: "33610 18-30 ‘arar'88: | E019 joao | Som-80 Fork dan bot '86, 7, "00) | Oxte sa | o8-09 Shock arm (ang st) 12riae | sev | Bozo (shock tk ie) e6,e7,ee| 10x13 | so-se | s0-80 ‘anar'ee:| 12128 | deco | 5-70 | sock kame sie eoo7 ea | ton tae wus | S030 ‘atar'se:| t2xtas | Ss-a0 | 88-70 Fork corer bo 90,87, "88| tax to go-a0 | 30-40 gs | 22x10 | ion-as | S088 80:| 22x10 goss | G0-88 ator'90| arto to-s0 | 40-80 Shock absorber ack nut 3x15 go-100 | Bo-100 For eaplock nit se:| 1x10 tats. | Vat v7, 08,09,'90| jorto | ae—an6 | 198-38 ‘atar'90: | 1218 woe” | ‘20-24 Fork piston retainer (0, '97,"80) 22x10 36 | 62-08 Fork posector bo (attr 86) oxo te | Sacre | Fromtrear im ok sxizs | tons | tons Frome brake disc raining bot 86, 87, 88,88: | 8x 10 wie | tate ‘ater'ss:| 8xt2s | dongs | 40-88 Front whoo hub cover (86,87, "83, '90) axo7 r0-20 | 01-02 ater's0| 2407 Gs-10 | oos—oa Broke hese joint masta evinder sic) yortas | G0-40 | “So-eo Brake hee one nt ere Rote st) woxtas | iaove | 12-48 Sake hen bolt one eo | lortae tote | d0740 ee: | joxt2s | de | 25-35 Front mestr evinder holder bot 6x10 e127 | Oe-12 ‘Sate lever pot bot bxt0 a1 | oen2 Brake lover pivot tock nat 6x10 e127 | 09-12 Bake lovoracustor lock nut 5x08 7 | Gs-o9 Gach lever pret bolt 8x10 $3 | 85-03 Guten lever pot lock nit 6x10 aw | oan2 rote housing ever coro ttoo v2 | Sh 03 Goorsif pedal pinch bot 6x40 you | tote Ketatarer ped bot sxiz | m—30 | 24-30 Sent neunuog bot oxiae jen-zs | temas Sib rome mounting bot axias | tea | teas 8x125 | 24-30 2.4-3.0 Snack absorber banjo bot (86) wxto) | 27saazs | 27-325 Brake caper bed vave 8x 125 a7 | “oanor Guten iver node bot pear e-12 | oantz Tote housing bol 8x10 ez | Gantz aor brace orgie arm bit (96) bx 135 w-2 | Va-26 Rua brace mater yindr mousing bo (tr 2) er10 eae | vets Brake pel pivot bolt ‘ec| Sx tas te2s | ia2s aror’a6: | Ba 128 nz | 24-28 ‘Stancer case oot tts "80) bx08 a8 —9.00, din pag (Aer 88) roxio 02-99 Rear dise guard screw (After '86) Bx10 | 8B 96-08 Front bree cniper mounting Sot e6.-07.3¢| 8x25 | 20-20 | 20-90 ea | 8x 128 ose | 32-38 oo} arias uso | 24-30 After 90: ox125 joa | 2838 Front eaipr pin bolt (88%: upper 8x15 po-2 | 20-25 me ota is-2o | ts-20 tar 86) upper eitgs | ta | 203s tower ex 125 fore | 1-18 Ine caper pin bole (97, '96, 89 front se oxtae fone | Zo-25 ister 89): font sce 135138 as-a0 | 28-30 “roar ade" 8x 128 fone | tons Bake caliper pad pin 10x19 isc2o_| 1sa20 \pply Honda Thread Lock or an equivalent. APPIY oll to the threads. RIDERED tTGENERAL INFORMATION Thread dia Toraue ker soe} + ON x pitch Nem kom | fb Shock absorber drain bolt (87) 6x10 i218 | 12-18 | 8-1 Shock absorber compression damping valve 22x10 5-20 | 15-20 11-14 ater'90:| 24x10 | 18-22 | 18-22 | 13-16 Drive chain tensioner roller bolt vas:| ax125 | 24-30 | 24-30 17-22 afer’88:| 9 8x1.25 | 18-25 | 18-25 | 13-18 Rear damper rod nut 12x125 | 35-40 | 35-40 | 25-29 After ’90: | 12x15 2a—30 | 24-30 | 17-21 Chain guide lider 86,97, '98, "80; x 1.0 2-3 | 02-03 | 14-22 ‘aner'89: | 6x 1.0 ioe | Vota | 7-10 Engine stop switch serow 4x07 1-2 | 01-02 | 07-16 Front brake hose guide bolt (Atter ‘871 6x10 45-6 | 045-0160 33-413 ‘The torque values listed above are for the mostirmporiant tightening poirts. If atorque spectication isnot listed, use the stan- dards given on this page. STANDARD TORQUE VALUES SH TYPE: 6mm flange bolt with 8 mm head Torque T Torque Size ee Size | feb teib 5 mm bolt and nut 3-43) 5 mm screw 25-36 6 mm bolt end nut 08-12 | 6-9 6 mmscrew ans flange | & mm bolt and nut 18-25 13-18 | bolt SH TYPE) 7-11 | o.7-11 | 5-73) 10. mmboit and nu | 30-40] 30-0 |22-29| 6rvmtange bot andnur 10-14 | 1.0-14 | 7-10 s2mmbolt and mut | 50—60| 5.06.0 |36-43| Bren tange bot ond mt 28-30 | 243.0 | 17-21 10mm flange bok and nut__35-45 | 35-45 | 25-33, SPECIAL Description Toal No. Too No. Ref. page Universal bearing pul “107631 ~0010600 yEquivalent commorcialiy 8 Snap ring pliers 079143230001 H avaiable in US.A 13.9, 14, 15 Stenring stam socket 07816—KA50100 ab, 46 Bearing removor 079363710300 10 Fomover handle 079363710100 }910 Remover weight (077410010201 | slider weight 07336-3710200 | 9-10 Bearing remover set, 12mm | 079361660001 | Not available in U.S.A 0-8 “Remover welghe 077410010201 | Slider weight a79a6—3710200 | 10.8 = Remover assy, 12 mm 079361660101 -,Remover handle assy [073361660700 | 10-6 ~ Remover head, 12 mm 07336 1660110 q 106 — Remover shatt (073361660120 106 Attachment, 28 x 30 mm 073461870100 10.6,7 12.62 (After 88) Crankcase puler 979374300000 34 Water seal ariver (07345 —KA30000 | Mechanical sea netaier |GN-AH-066-415 | 10-7 Bearing ace remover ('85,'87) 07359-4250¢02 | Bearng race remover |07853-M}0008 | 11-46 (USA. only Steering stem driver 079464300101 | Steering stem driver | 07946 -M1B00000| 11-46 attachment GNHTBE (USA. only! Needle bearing driver | 07346—Kas0000 12-44, 45, 62 (86, "67, After 88) Fork seal driver attachment | 07847 -KA40200 11-28 (36, ‘87, '88) Fork seal driver ('86, "87, "@B) | 07347-KASO100 11-28 Assembly bolt 07385 ~ 1660200 9-12.13 ‘Assembly cotor 07085 1660201 | 212113 “Threaded adeptor 07365 ~KA30000 a2 1-8GENERAL INFORMATION Description [Tool Wo Alternative Tool No Ret. page Sider gude, 14 mm (07874 —KAa0001 1231 Slider guide attachment 07374—KA50101 | Not avaliable In US.A. 12-24 Piston base | 97358-3000000 12-25 Sleeve colar | 07974—Ka30201 12.24 Bearing remover, 7 mm 97931 —Ka30000 18 Bearing diver, 7 mn 07946—Ka30100 106 Spherical bearing driver, 14 mm | 07846—KA3O200 1250.51, (86, ‘87, "88 52, 53 Bearing retainer wrench ('87, ‘88) | O7HMA—KS70100 12:10, 13 Spherical bearing driver (86, '87. After '88) | O7GMF—KS70100 | Not available in US.A. | O7HMF—KS6O100, 12-40. 54 Retainer wrench ('86, “87, '88) | O7GMA—KS70100 | 11-18, 27 Pin spamer A 89201 —KS6—810 -rUse two pin spanners 12-19, 39, or After ‘85: Pin spamer 8 (186) | 9202-Ks6—g10 12-19, 39 Driver head (After '87) |0746—KM40701 | Driver head |o7946—KM40700 12-45, 52 Driver shaft (after '87) | 07946 —NJOO100 2-45, 50, 52 Bearing race remover (After '87) | 079484830100 11-46 Bearing remover set. (After 88) | 07936~3710001 1282 —Remover handle 07936—3710100 12-52 — Boating remover (079363710600 12:52 — Remover weight 077410010201 | sider weight /07936—3710200 | 12-52 Oil seat driver 07KMD—KZ30100 | “Fork seal diver J07KMD—K230108) 11-32 Fork slider spacer O7KMZz—Kz30101 | *Fork slider spacer orkM2-—KZ20108) 11-18, 33, 39 Soa! casa holdor 07kMB—K230200 | Attachment (07965 —uagoooo} 11:23, 32, 37, 38 evtine 7 3 *Cylinder holder on) 33 The tole marked COMMON Besson ToalN ‘rematve | TooiNe, | Rol ove Faalinal eve {27401 0010000 aa Soke wroten€, 5.8.6.1 mm | 07701~t020300 | Equlont commrcialy Soke wrench, 6.6 nm O7701 co20400 [tevalaie USA Beoungvetaner wrench @ | 7740040300 ya.10,13 (6, Aer "98) aria eneh by 07710. cor0401 12.10.13 Steket wrench, 30%32 mm | O7/16-0026400 [ Eauvalont ir48,47 Extension bar 07716-0020500 |{ commercially 11-48, 47 Univer ole 07726 -0020000 [| avalohe n U.S.A. oot reat teh canter hleor 07724000091 tee Gear hot 877240010100 [Equivalent commercial 93:14 neiibie nus A Fyne! pul 07793~0010000 | Fiywnee pur 079930010000 | 16-3 ftachment, 37x40 mm | O77a@ 0010200 on mow tm Grae eosoalo Bah 19.33, tas Piet, 25 mm 07749 -0040000 oat Phot, 20 mm O76 -ootosoo 12:12, 45, s2 ftachment 42x 47mm | 077460010300 oat, ata Phot, 22 mm 077460041000 ont a6, 87), tate, 38 (cont) RIDE RED 1-9GENERAL INFORMATION COMMON (CONT'D) Description Tool No, Alternative Tool No. Ret. page | Ashes 625 58 wa COTSED ED Aachgen 62 68mm | 01748-010%00 #0 ea Bearing remover head, 20mm | 07746 0060800 |! available in U.S.A. 12-10 finn Sette ous ie Bre Biraeossi93 1350 Rsthnen 7 mmo. vee | :448-S45408 Pe atten goimnlB, "SP inde aszsice 1320 Acsnen 20 an" ""| o:745-o010700 120,182 AcROENSE22Smm | SUE: SHe78 | 8 1-10CABLE AND HARNESS ROUTING Note the following when routing cable and wite harnesses, © A loose wire, harness or cable can be a safety hazerd. After clamping, check each wira to be sure it ie secure, © Do not squeeze wires against the weld oF end of its clamp when a weldon clamp is used. © Secure wires and wire harnessas to the frame with their spective wire bands at the designated locations, Tighten the bands so that only the Insulated surfaces contact the wires oF wire harnesses, © Route harnesses so they are neither pulled taut nor have ex cessive slack © Route wire harnesses to avoid sharp edges 0: corners. Also avoid the projected ends of bolts and screws. ‘© Proctect wires and harnesses with electrical tape or tubes ‘they doccontact @ sharp edge or corner. Clean the attaching surface thoroughly before applying tepe, © Do not use wires oF hamescor with broken ineulat Repair by wrepping them with protective tape, or replace them, © Keep wire hamesses away from the exhaust pipes and other hot parts, © Be sure grommets are seated in thelr grooves property. © Atter clamping, chock each harness to be certain that itie fot interfering with any moving or sliding parte, © Wire harnesses routed along the handlebar should not be pulled taut, have excessive slack, be pinched, or interfere with adjacent ar surrounding parts in all steering positions ‘© Aiter routing, check that the wire harnesses are nottwisted or kinked. © Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind, GENERAL INFORMATION = (3) WIRE BANDS = (1) THROTTLE \ mer (5) ENGINE STOP SWITCH WIRE (2) CLUTCH CABLE (6) REAR BRAKE HOSE RIDE RED 1-17GENERAL INFORMATION Bas (1) CARSURETOR AIR VENT TUBES. (4) CLUTCH CABLE (2) CRANKCASE BREATHER, TUBE (3) CARBURETOR OVERFLOW TUBE. (8) RADIATOR fiw wicinesron | oouUeH coven in Baron cmeLow swircHwine CABLE \ (7) BAND. (13) FRONT. ? ieeccnta tha. BRAKE clutch cable) (4) uTCH (10) ALTERNATOR. WIRE (12) ALTERNATOR ‘WIRE . (9) WIRE BAND (6) THROTTLE S (Secures the CABLE lakernator and CDI unit wires) (11) WIRE BAND. (Secures the overflow tube (6) RADIATOR and alternator ©) BAe Ow wire) Suge 1-18 RIDE REDGENERAL INFORMATION 1) THROTTLE CABLE (2) CLUTCH CABLE (3) WIRE BANDS. (8) ENGINE STOP. SWITCH WIRE (4) FRONT BRAKE HOSE 90: (9) InrTION con (e)GROUND wiRE 7 (2) cLUTCH CABLE After 89: (3) WIRE (1) THROTTLE BANDS CABLE (7) IGNITION Of COIL WIRE (5) ENGINE STOP ‘SWITCH WIRE (6) REAR BRAKE HOSE RIDE RED 1-19GENERAL INFORMATION 90: 1) CARBURETOR AIR VENT TUBES. (2) CRANKCASE BREATHER TUBE (3) CARBURETOR OVERFLOW: TUBE {Ay RADIATOR (6) RADIATOR (4) CLUTCH ON ERELOW (14) ENGINE stop TUBE ‘SWITCH WIRE Ohne a (7) BAND (Secures the (13) FRONT clutch cable) BRAKE HOSE. (4) cLuTcH CABLE (12) ALTERNATOR: (10) ALTERNATOR wWiRE WIRE (11) wie BAND (6) RADIATOR (9) WIRE BAND (Secures the OVERFLOW (Secures the (8) THROTTLE overflow tube TUBE alternator and Gente ang aerator CDI unit wires) 1-20 RIDE REDGENERAL INFORMATION (2) RADIATOR CONNECTING we Tue (1) RADIATOR OVERFLOW TUBE (3) IGNITION COIL WIRE (4) BAND (Secures the clutch cabie) (6) WIRE BAND (8) THROTTLE CABLE (Secures the overtiow tube land alternator wire) 7) CLAMP (8) CARBURETOR (Secures the clutch cable) AIR VENT TUBES (9) CRANKCASE BREATHER TUBE 10) CARBURETOR ‘OVERFLOW. TUBE (11) CLAMP 413) CLUTCH "3 (Secures the CABLE overflow tub (12) CLAMP breather tubs RIDERED 1-21GENERAL INFORMATION OPTIONAL PARTS LIST ITEM REMARKS FRAME + Driven sprockets "36, “87 After ‘87 Aluminum 517 ond 55 ‘Aluminum 497 and Steel 53T (mud/sard) 837 (Standard: 537) Steel 51T (mud/sand) (Standard 817) + Drive chains 116 links: RKB2OKZ (Atte “88: RKS2OKZ3 114 links: D1D5200S5 (Standerd: 116 links: 010820085, AKBZOKZ3) © graropig “26: Iontiication mark Type Song ate Identification mark [tare 4.4 gin (246.4 bind | Brown Merk Standard 4.8 kalmm (268.8 Ibjin) | _ Pink Mark Heavy 5.2 kg/mm (281.2 Ibn) | Black Mark "87: - [Tyee | Spring rate Identification mark S Light 4.8 kg/mm (268.8 tbvin) White Mark Scandard | 8.2 kglmn (291.2 tin) | Pink Mark Heavy 5.6 kgimm (313.6 Ibi) | Gwen Marke “ee Type Spring rate Identification mark Light 6.2 kgimm (281.2 tbfin) Pink Mark [eiandand [6.0 kai (319.6 ant | “Yelow Mink [Fony 38.0 kg/mm (898.0 bin) | Brown Mark 'B9: : Tee, Soring rte | _Wentification mark Light 4.8 kgimm (268.8 Ibiin) | Pink Mark ‘Standard | 5.2 kg/mm (291.2 twin) Nothing | [5.6 kg/mm (313.6 Ibiin) Yellow Mark Type Soring rate ‘Wentiication mark Light ‘4.8 kolmm (268.8 tbin) | Pink Mark [Standard | 6.2 kale (281.2 thin) Heavy 5.6 kaimm (313.6 Ibn) ‘itr ‘90: Type | Spring rate it [46 kg/m (257.6 Ibiin} | Standard 5.0 kg/mm (280.0 Ibjin} [teavy 5:4 kg/mm (902.4 tin 1-22 RIDE REDGENERAL INFORMATION TEM REMARKS + For oping "a6 87 Identification Type Spring rate Hentification mark Tight 0.385 kalmm 18.76 bind | 8 cols | coi Standird | 0.355 kgm (19.88 bin | 1 ol | Kean 0.376 kgimm 21.00 tin) | cole j "88 Type T_ Spring rate Identification mark Light 0.346 kg/mm 19.38 win) | 1 cot iin Standard | 0.370 hgimm (20.72 ton) | 2 coils = on 0.390 halrmm (21.84 tin) | 2 cole | 90: Tee | Seringrate | Wentifeation mark_| 3.cals ah 0.36 komm (20.18 bin) | 3 cole ~ stands (0.38 kg/mm (21.28 fin) | _1 col Heavy 0.40 Kym (22.40 ohn | Peo Aitr ‘90 Tye Song rte Gantifaton mark Tone 0.38 kgimm (21.28 bin) | 8 cols Standard | 0.40 ko/mm 22.40 b/n) | 1 col [Heavy [04a kg/mm 3.6210 | zeae | + Wotk stand + Air pressure gauge + Pin spanner + Seat Ss For maintenance/service For fork air prassize adjustment For shock absorber spring length Ipraload) adjustment (two required) Pin spanner A, B '86: A (two) After 'B6: 4 Pin spanner A (two) 86°87. 106 sm For optional height riding position 86: Standard: 122 mm (4.8 in| = £96 mm (9.9 in) \ S 82 mm [3.2 in} NS + Standard: 117 mm (4.6 in| . 93 mm (3.7 in) After ‘87: 80 mm [3.1 in) oa> oa> ‘Standard: 117 mm (4.6 In) 85 mm (3.3 in) o> Lh A: Standard: 117 mm (4.6 in) B : 90. mm (3.5 in) After ‘89: Seat A = Standard: 113 mm (4.4 in) Seat 8 | 96 mm (3.8 in) RIDE RED 1-23GENERAL INFORMATION ITEM Carburetor tuning paris Main jets Jot needles REMARKS 86, ‘87: #160—#199 (in increments of 2 or 3) Standard: #175, oan #170—#209 (in increments of 2 or 3) Standard: #185 et #168—#188 (in increments of 2 oF 3) Standard: #178. After ‘89: #165 #185 (in incremants of 2 oF 3) Standard: #175 Standard: ‘86, ‘B7: R1388N (02,685 mm 1°30) ‘88: R1357N [92.676 mm -1930") "89: R1389PS (62.695 mm -1°30' "90; R1370NS (92.705 mm ~1830") ‘Afior ‘90: R1389NS [62.695 mm -1°30") NEEDLE NUMBER, Glo, Taner angle van | GENERAL FLOW | TET NEEDIE [55 ,.., | TAPER) SPEOIFC FLOW cnaracrensnies | “nuMeen | 20: ANGLE _chanacreniies a ; cag | Ceara ony at Tt v6, a7 |_RI368N needle RS7ON, wees) 1°30" 1/4 throttle Fiche tan the stoak 3 Tag | Reka oniyat Te R1368N needle HIanEN A086 a 1/4 throttle Teaner than the sozk 1 Te ere RT | gg |_RISOM neede | RSBSN 2695 | 1°30" 1a throttle Ficher than the stock 239° Richer only at 1/8 to | RISerN needle aresn | 2056 | 1007 | Ta ont Leaner than the 10K | WISIGPS | ZOE] —yagge | eoner onip a TET spo |_Pid0oPorecde | miarirs | are w/a wont Ficher han ihe siock | wiso7es | 2675 | agg] Neher ony af VT MIOGQPS needle | AISEEPS | 2s t/a aeatte RI37INS needle RISTZNS Bus 13 1/4 throttle 30 R1370NS needle puns 2745 rao” 1/4 throttle Richer than the stock » Richer only at 1/8 to RI37ONS needle Wises zee ae 1/4 throttle ett an aor | Reha oa To RIQGONS needle BabesnS acen ae 1/4 throttle RITONS needle Ee ia oar 1/4 throttle anew. RI369NS needle ae ‘hina Teas 1/4 throttle | Ficher than the stock | "i 1 Richer only at 1/8 to | rissenSronae = | Maeons | 200s | eso" Tete Fiche han the : aT anger | Rlher ony 01786 ratng oF ie need Ruta (Exampie} eo SS ccxani 1-24GENERAL INFORMATION TEM REMARKS Slow jets ‘86: #55~ #65 (in increments of 2 or 3) Standard: #80 87, 89: #52 #62 {in increments of 2 oF 3) Stancard: #58 8: #58 #68 (in incremorts of 2 or 3) Stencard: #62 Alter '89: #50 —#60 (in Increments of 2 or 3) Standard: #55 NOTE 7 The eylindor cannot be bored & honed and only standard size pietone/ringe are available. ithe cylinder is damaged it must be replaced Bs RIDE RED 1-25MEMO2. LUBRICATION ‘SERVICE INFORMATION 2-1 ‘TRANSMISSION OIL 22 TROUBLESHOOTING 2-1 LUBRICATION POINTS 23 SERVICE INFORMATION GENERAL © This section describes inspection and replacement of transmission ol, and lubrication points © The Honda CR250R has » two-stroke engine that requites @ premixed gasoline-ail miature, SPECIFICATIONS Recommended engine pre-mix oil Honda 2-stroke oil oc equivalent Mixing ratio (Fuel: Oil) 20:1 Transmission oll capacity "86, '87, ‘88, 'B: 0.6 lit 0.63 US at, 0.53 Imp at) at disassembly 0.55 lit 0.58 US qt, 0.48 Imp q at ol change ‘After "88: 0.63 tt 10.67 US at, 0.55 Imp q:) at dsassembly 0.7 lit (0.74 US at, 0.62 Imp qt) at oll change Hondo 4 stroke Oi! SAE TOW-40 or equivalent, API Service Classification: SF or SG Recommended tranemi NOTE Viecosity selection should be based on the average atmo: spheric temperature in your riding area. Change to the ‘proper viscosity oll whenever the average atmospheric tem. erature charges substantially TORQUE VALUES Recommended tranemission oll viecouity: Oil drain bolt 25—35 Nem (2.5—3.6 kg-m, 18-25 fttb| SAE 10W:40_ Oil check bolt. 8-12 Nem (0.8—1.2 kg-m, 6-9. feb) TROUBLESHOOTING Engine does not have sufficient power + Deteriorated gasoline-oil mixture Engine stalls frequently + Detericrated gasoline-oil mixture ‘Spark plug fouled + Incorrect gasoline-oll mixture ratio + Deteriorated gasoline-oll mixture ratio ‘Transmission Oil Level Too Low + Worn right crankshaft 20a! (tansmission oil drawn into crankcase) + External ol leaks RIDE RED 2-1LUBRICATION TRANSMISSION OIL LEVEL CHECK Place the motorcycle on a box or workstand so it is level and both whesle are an equal distance from the ground. Oil shoule flow out of the check bolt hole If the oil does not flow out, add oil slowly through the oil filer hole until the oil starts to flow out of the check hole. Once it begins to flow out, stop adding ol and install the oil check bolt. TORQUE: 8— 12 Nem (0.8—1.2 kgm, 6-9 ft-b) ‘After checking cil level, install the ol filler cap and be sure that the cap and the oil check bolt are tightened securely Install the oll filer cap. OIL CHANGE NOTE + Transmission oil should be changed atleast every Sracesor 7.8 hours of running to ensure consistant performance and maximum service life of bath transmission and clurch com ponents, + Warm-up the engine before draining the oll, This ensures complete and rapid draining. Remove the ol filler cap from the right crankcase cover Place an oll drain pan under the engine to catch the oil, chen remove the drain bolt. ‘CAUTION Used transmission oll may cause skin carcer if repeatedly teftin contact with she skin for protoneed periods, Alihough this is unlikely unless you handle used oul on a daily bass, is tll a visable 10 thoroughly wash your hands with Soap and water as soon as possible after handling used ou Alter the oll has been completely drained, check that the drain bolt sealing washer is in good condition and install the drain bot TORQUE: 25—36 N-m (2.5-3.5 kg-m, 18-25 ft-lb) CAPACITY: "86, '87, '83, "89: 0.55 lit 0.58 US qt, 0.48 Imp qt) at oll change Attar ’89: 0.7 it (0.74 US at, 0.62 Imp at) at oll change RECOMMENDED OIL: Honda 4-Stioke Oil SAE 10W-40 or equivalent NoTE + Use this specified capacity only as a guide: add cil unti it flows out of the oil chock bolt hole, alow it to stop lowing ut, then reinstall and tighten the oil check bott, Use only high detergent, premium quality motor ail certified to mest or exceed USA automobile manufacturer's requtements for Servico Classification SF or SG Reinstall the oil filler cap. Start the engine and check for leaks. Stop the engine and re ‘check the oil level Gm + Uf the engine must be running 10 do some work, make sure the reals wall vnticted, Never run th engine In en encased at The exhaust contains polsonous carbon monoxide ga that can éause lost of consciousness and may lead t0 death, (1) Ol FILLER CAP AE (1) DRAIN BOLT a 2-2LUBRICATION LUBRICATION POINTS Unless otherwise specified, use general purpose areese. Apply oll or grease to the other sliding surfacesnot shawn here. CONTROL CABLE LUBRICATION Periodically, disconnect the throttle, and clutch control cables at their upper ends. ‘Thoroughly lubricate their pivot points with @ commercially available cable lubricant It isnot necessary to oil the cables. If clutch lever or tt. tle operation is not smooth, replace the cable. WHEEL BEARINGS Grease new wheol bearings and dust seals before installa: tion, Do not reinstall used wheel bearings or seals ‘86: Shown, After “89: Similar (2) SHOCK LINKAGE PivoT ST SEALS: MOUNT NEEDLE BEARINGS/ + SPHERICAL BEARING (quBRicant] (1) ORIVE CHAIN (13) BRAKE CAM | / (36: 1 a (12) WHEEL BEARINGS ('86:) oy (3) *SHOCK ABSORBER Apaly @ paste arease with 40% or more molybdenum di sulfide to the * mark components (2, 3 and 10 below! NoTE ‘Some sources of MoS: paste grease with 40% or more ‘molybdenum are: © Molykote? G-n Paste manufactured by Dow Corning, U.S.A, = Honda Moly 45 of 60 (U.S.A. only) = Rocol ASP manufactured by Rocol Limited, UK. * Rocol Paste manufactured by Surrico Lubricant, Japan. ‘Any other manufacturer's paste grease equivalent to the above may also be used. a (a) THROTTLECLUTCH CABLE PIVOTS a (6) THROTTLE GRIP a [6) BRAKE/CLUTCH LEVER PIVOT BOLTS eo (7) STEERING STEM - 7737 BEARINGS) . DUST SEAL Dust Seals (BRAKE PEDAL POT! Tho) #SWINGAAM PIVOT (363 BRAKE TORQUE DUST SEALSICOLLARS/ ARM Ivor Le BEARINGS RIDE RED 2-3MEMO3. MAINTENANCE SERVICE INFORMATION 3-1 FRONT BRAKE 39 COMPETITION MAINTENANCE REAR BRAKE 3.10 BEHEDUIE 32 CLUTCH SYSTEM 312 THACTILBOPERATION 39 EXPANSION CHAMBER/SILENCER 3-13 AIR CLEANER AIR FILTER) 3-5 EXHAUST VALVE DECARBONIZING — 3-14 SEAN ECG 36 susPENSION 314 DRIVE SEROCKET: 37 TiRES/WHEELS/SPOKES 3.16 RADIATOR COOLANT 37 STEERING HEAD BEARINGS 3.16 COOLING SYSTEM 3-7 controL castes 346 DRIVE CHAIN. 3-7 NUTS, BOLTS, FASTENERS 3.16 DRIVE CHAIN SLIDER 38 | DRIVE CHAIN TENSIONER ROLLERS 3.9 | SERVICE INFORMATION SPECIFICATIONS ( TEM | STANDARD. ]__ SeAvICE uMmer Trananisson a capacty| 66, 87, 88, 8; | 0.80 W(OBUUS gt, 0.48 mp al at of ange = ‘er 8 0.7 0.74 US al 0.62 inp ala of chinar | Recommended transmission ol Honda 4 Stroke Oil, SAE 10 W—40 or equivalent. APL Sonice Classification: SF or SG 10-20 mm (318-374 hi Recommended 26 ‘CHAMPION: QN-86 (GN-2G) spark p09, ator 88: Nek nace \ensev optional ND: W24ESR (W2IESR-GI a7, 68. CHAMPION) ON-84 (ON E9G Nok: BROEG (ERSEV) — ND: W27ESF (W27ESR.G) ‘Spark plug ga (0.50.6 mm (0.029—0.024 io) 21 INNER PRE aigned Ss Install the spring washers ond plain washers, and tighten the silencer case bolts. PF) is) wveision SAN 6.0 Nem a , ‘ TORQUE: 4.5-G.0NmI0.45-o.60k9m/3.3-43%eb) (6) suehicen ~S er Wipe off the surplus sealant. & 18) SPRING WASHER, Install the muffler (page 14-4) f RIDE RED 3-13MAINTENANCE Note + Be careful nat to damage the glass wool. EXHAUST VALVE DECARBONIZING Clean ust valves and valve clean 2-svoke ai SUSPENSION FRONT Check the action of the fork by compressing the front sus pension several times applying the brake lever, Check the entire fork assembly for signs of leaks, damage or loose fasteners: Loosen the lower fork boot clamps, slide the boots up, and remove any dirt that has accumlated on top of the dust seas al the fore boots and tighten the clamps. hich are unserviceable. ae ‘After “68: Fuk RIDE REDMAINTENANCE Place @ work stand or box under the engine to raise the front wheel off the ground, "86 through °90: Remove the ait valve caps, Check the ait pressure when the (ork is cold and fully extend: ‘ed. Never exceed the maximum sir pressure. oe Although a few psi cf pressure may help in some riding situa: tions. these air valves are generally used to relieve pressure that normally builds up from the action of the fork. ‘STANDARD AIR PRESSURE: 0 kPa (0 kg/cm? 0 psi) MAXIMUM AIR PRESSURE: 39 kPa (0.4 kg/cm’. 6 psid a Reinstall the air valve caps. After "90: Roloase tha bultup pressure in the fork tubes lin excess of rnoimal atmospheric pressure: 0 kPa.) caused by normal fork action while ring. The front wheel should be suspended above ground for this operation. REAR Bounce the rear of the motorcycle up and dow’ ‘proper operation check for Push and pull the rear wheel sideways to check for play ia the swingarm bearings. After ‘86: (1) REAR SHOCK y ABSORBER Remove the sub frame (page 14-3) ‘Check that the shock rod is not bent and oll isnot leaking from « the seal jor hose fittings, “86: ony) Check that the shack link and shack rod are not damaged Check that the shock spring preload adjusting nuts are tight ened securely. Disassembl, clean, inspect and lubricate the swingarm and sock tnkage pivot bearings each 3 races or about 7.5 hours Of running (pages 12-42 through 12°56) RIDE RED 3-15MAINTENANCE TIRES/WHEELS/SPOKES Chack the tire for cuts, imbedded objects or excessive wear TIRE PRESSURE (front and rear) "100 kPa (1.0 kglem:, 15 psi) 80/100-21 61M REAR 110/100-18 64M Inspect the wheel rims and spokes for demage. Tighten any loose spokes and rim locks. TORQUE: Fir lock: 10-15 Nem (1.01.5 kg-m. 7—11 ttt) Check wheel rim runout (pages 11:9, 12.9). STEERING HEAD BEARINGS Raise the front wheel off the ground and check that the fork pivots freely, Check that the control cables do not interfere with fork movement from lock to lock. If the fork pivots unevenly, binds, or has vertical movement, adjust the steering head bearings by turning the steering head adjusting nut (page 11.47) Clean, inspect and if necessary replace the staering head bear ingsif there is a gritty or grinding feeling 10 the pivoting of the fork. See page 11-44 for bearing inspection and maintenance. CONTROL CABLES Remove the throttle cable end cover Disconnect the throttle cable upper end from the throttle grip. Disconnect the clutch cable upper end from the clutcn lever. Thoroughly lubricate the cable pivot points with commercially avaliable cable lubricart NOTE + Itis not necessary to lubricate the eabies, If clutch lever or throttle operation is not smooth, replace the cable, (COVER (2) THROTTLE CABLE Connect the throtle cable to the thrattle arp Install the throttle housing cover and tighten the screws NUTS, BOLTS, FASTENERS ; Check that all chassis puts and bolts are tightened to their cor (Check that all cotter pins and clips are in place and properly (3) THROTTLE GRIP secured. 3-16 RIDE REDMemoFUEL SYSTEM 4-0 RIDE RED4, FUEL SYSTEM SERVICE INFORMATION 4-1 FLOAT/FLOAT VALVE/JETS 4-10 TROUBLESHOOTING 4-2 CARBURETOR ASSEMBLY an OPTIONAL PARTS 4-3 FLOATLEVEL ADJUSTMENT ant CARBURETOR THEORY 4-4 THROTTLE VALVE ASSEMBLY 412 MINOR CARBURETOR ADJUSTMENT 4-5 CARBURETOR INSTALLATION 413 MAJOR CARBURETOR ADJUSTMENT 4-5 REED VALVE 4-13 TUNING FOR SPECIAL CONDITIONS 4-7 FUELTANK 414 CARBURETOR REMOVAL 4-8 AIRCLEANER CASE 415 THROTTLE VALVE DISASSEMBLY 49 SERVICE INFORMATION GENERAL J20 caution whan working with gasoline, Always work in a well-ventilated area and away fram eparke or flames. © The flost chamber has a drain plug that can be loosened to drain residual fuel. © When disassembling fuel system parts, note the locations of the O-rings. Replace them during assembly. Gasoline is extremely flamable and is explosive under certain conditions. Work in a well ventilated area withthe engine stopped. Do not smoke or allow flames or sparks in your working area or where gasollae is stored. + Ifthe engine must berunning to do some work, make sure the area's well yentilaied. Never run the engine in an enclosed area. The exhaust contains polsonous carbon monoxide gas thet can cause loss of consiousness and may lead 10 death. CAUTION - + Do nor bend or twist control cables. Damaged control cables will not operate smoothly and may sick or bind. NOTE + Wha vehicle ie to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged jets resulting in hard starting or poor driveability. SPECIFICATIONS Furl tank capacty (989 7.0m (1.8 US, gat, 1.8 mp. om) latter '86:) 78 lt [20 US. gal, 1.8 Imp. oa) Fu Premium or uneoded gesaline [Octane ating 02-100, FON) on Honda ? State Ol or equtvalen Mining ratio Fut: 201 Carburetor = = z a [deiicaion mark [PI2SA [raze 268 Pane | reton vave[Peton valve Piet valve [Piston valve [Piston valve (0 mm (1-89 In) 38.0 mm (1-30 1n)'38.0 (1.60 188.0 mm 1,80 [38.0 mm 1.60 [rat teva 1:0 rr (0:85 18.9 mm 10.63 in 18.0 mv 0.68 In] 10.0 vn [0.69 118.0 rm 0.68 Ac acrew ine opesing|1-1/2tuns out [2 turns out 2 tum out [2 wns out (Zune ot st neede/cip postion [RIS6EN/S RIS67Nia___AIGGTNI4__—_|ATSEOPSM___[RIG7ONS | Wain jt e175 475 18s e178 75 Sew it #80 ese 002 [ese #55 (conta) RIDE RED +1FUEL SYSTEM. (eont’a Carburetor: Identification mark _|PJ28C Type Piston valve Venturi diam [38.0 mm (1.60 in Float level [16.0 mm (0.63 in ‘Air screw initial opening [2 turns o [Jet neecle/clip position [RI369NS/3 Main jot 175, Siow jet fa TOOL Float level gauge TROUBLESHOOT! Engine won't start No fuel in tank No fuel to carburetor Air cleaner clogged Deteriorated pre-mix Lean mixture Carburetor fuel jets cl Fuel fiter clogged Ful line kinked of Float valve faulty Float level 100 low Air vent tube clogged Air leaks + Worn crankshaft seal ING Too much fual getting into eylindor [No spark at plug (ignition maifunction) logged Fuel cap vent clogged or blocked ‘Advanced ignition timing (CDI side) (074010010000 Engine stalls, or runs poorly + Ignition matfurction + Low compression + Rich mixtue + Lean mixture + Air cleaner clogged + Air leaking into carburetor insulator + Fuel contaminated Rich mixture + Choke is on + Feulty float vaive + Float le + Atel + Retarded ignition tiring + Worn crankshaft seal (clutch side) + Carburetor jets not “‘adjusted’” for elevation (above sea level) and temperature {above or below 20°C/68"F) 4-2 RIDE REDFUEL SYSTEM OPTIONAL PARTS Cetra i pars 6224190 tn now 2 3) Ere 4206 incaent2o 7 as, ZrO 2108 in ncn ot 3 Mark After 89: Staneard: #175, Stancar: “86, 7: R1368N (92.686 mm — 1°30") "89: R19G9PS [92.665 mm — 1°30") ‘90: F1370NS (62.705 mm ~ 1°30 NEEDLE NUMBER — (CHARACTERISTICS NUMBER eo peep ANGLE CHARACTERISTICS aetna eo ae Lamas uenake ee ee Leaner than the HeCE 3 * ‘anes ely 0 1 ss RIge7N reece roca 20s 0. fo tid vote RIBEIN needle 360 20 eo wlserede | “es sais ton _| ee mae RIBTINS naodio Rra72S 2708 90" | stator he R1370NS pasdie mee sratin to 1d thottle: * licher then the otack Wehr only at 1/8 RISTONS needle: — | 2606 == | 14 thottle: RN SVONS needle ee || Se 0 tome inat AT3e9NS needle 1370NS - fot tattle RIIEINS needle ee oe Med 0 14 thottle: ‘Taper angle 1°30" CQ 0.0.2.208 mm Se 20 ‘a eee Sore oe = Boe ey RIDE RED 4-3FUEL SYSTEM CARBURETOR THEORY FLOAT CHAMBER “The float valve and float maintain constant fuel level in the float chamber. The float level affects the mixture throughout the entire range. — Although it is possible to alter the fuel mixture by changing the float level, itis not recommended, STARTING/IDLE CIRCUIT When the choke valve is opened [knob up), fuel is metered by the starter jet and is mixed with aie from the primary ait passage to provide a rich mixture to ease starting, When the choke vaive is closed (knob down}, it reduces the mixture to a more normal level for idling, With the knob down, the actual flow of fuel/airis regulated by the adjustment of the chokelidle speed knob. The end af the thresded choke/idle speed knob acts as» ‘miniature throttle valve in the primary ait jet passage. With the nob threaded all the way down, it cuts off al fuel/air from this passage (no idle speed) and with it threaded all the ‘way up, it allows maximum amount of fuel/air through this passage (high idle speed). + This circuit has two main functions; to start a cold engine {knob up) or to supply encugh fuel/air to allow the engine to ile (knob down and adjusted accordingly. SLOW CIRCUIT Fuel is metered by the slow jet and ie mixed with air that has been metered by the air screw. The mixture enters the venturi through the bypass and stow jet circuits, + This circuit affects idle-to-1/4 throttle, — The mixture can be altered by changing the slow jet or the air screw adustment. MAIN CIRCUIT As the throttle valve is raised, fuel is metered by the needle jet, jt needle, and the throttle valve cutaway. The fuel is mixed With air from the alr jet and enters the venturi at the nozzle + This beginning portion of the main circuit affects 1/8-t0-3/4 throttle, = In the 1/8-t0-1/4 throttle range, the mixture can be altered oy changing the jet needie O.D. —In the 1/4-t0-3/4 throttle range, the mixture can be altered by adjusting the jet needle clip position, (1) FLOAT VALVE (2) FLOAT (1) ORIFICE (9) SLOW JET = (a) STARTER JET (2) CHOKE/IOLE SPEED KNOB. (3) PRIMARY. AIR PASSAGE (a) al screw (1) NEEDLE JET: (2) JET NEEDLE 44 RIDE RED (a) NOZZLE |+ This final portion of the main crcuit affects 1/2-to-full throt We. — The mixture can be altered by changing the main jet. CARBURETOR OPERATION The operation of the carburetor is broken into throttle opening ‘segments; each of the metering units is reponsible for one seg: ment. There is always overlap from one segment to the next, so any change will always atfect the next segment up or down, Be- cause of this, making carburetor adjustments for altituce or temperatura should be done in a methodical manner. See page 45. MINOR CARBURETOR ADJUSTMENT (Idle mixture end idle speed) To adjust the idle speed, warm up the engine and push the choke/idle speed knob down to the off position. Tuen the choke/idle speed knob clockwise to decrease engine speed, oF ounterclackwise to increase engine speed. NOTE + For a stable idle speed, turn the choke/ide speed knab at least 6 turns (36 clicks) counterclockwise from the fully seated position, Idle mixture can be adjusted by turning the airscrew: turning it in ichens the mixture, while turning it out leans the mixture. To adjust: turn the al screw in until it seats lightly, thon beck it ut to the initial setting INITIAL OPENING: "88: 1-1/2 tums out Atter ‘88: 2 turns out Start the engine. Whan the engine is warm enough to run with ‘out the choke, make fine adjustments in the air scraw setting Until the engine revs up smoothi ‘Test the adjustment by accelerating away from a slow corner. Readjust as necessary ‘A combination of a slightly rich mixture and an idle speed that's 2et 100 high mey lead to plug fouling when srutting off for tight secticns of the track. Reduce idle speed if this occurs. MAJOR CARBURETOR ADJUSTMENT (For temperature and altitude) 1). Check that the carburetor is adjusted to the stendard set: tings. NOTE + For the following recommendations to be accurate, you must use these standard settings as a baseline. FUEL SYSTEM (1) Main jot (2) Jet needle (Tapered section} | <> (2) ain CLEANER (8 connects \ Ae RIDE RED 4-15ENGINE REMOVAL/INSTALLATION "86: 18-25 Nim (1.8-2.5 kgm, 13-18 fei) Ba—48 tom. 27-36 feb} 3 Sa 100 Nem (8.0—10.0 kam, 58—72 ftb) SK 24-29 Nem / (2.4-2.9 kg-m, fo 17-20 te) 38—48 Nem (3.84.8 kom, 27-36 fb) Nps 3-6 nn 0.306 kom, 2-4 feb) 5-0 RIDE RED5. ENGINE REMOVAL/INSTALLATION ‘a7: 1825 Ni a 82.5 kg-m, eb) 58—72 frlb) 728-29 Nem \ / (2:4=2.9 kom, fo 7-20) RIDE RED 5-1ENGINE REMOVAL/INSTALLATION. 38-48 Nem (3.8-48 kgm, 27-35 feb} (2.4-2.9 kgm 17521 tt) 5-2 RIDE REDENGINE REMOVAL/INSTALLATION —T 18-25 Nem (1.82.5 kom, 13-18 Feb} 38—48 Nem (3.84.8 kgm, 27-38 feb) 5 \ 80-100 Nem (8.0—10.0 kgm, \\. sia \ > (2.42.9 ke-m, feb) 38-48 Nm (3.8—4.8 ko-m, 27-38 trib) 2-5 Nem (0.90.8 kam a RIDE RED 5-3ENGINE REMOVAL/INSTALLATION Attar 89) 18-25 Nem (1.372 5 kgm, 13-18 feb) 38—48 Nem (3.8-4.8 kgm, 27-36 fete) 6070 Nem (6.0—7.0 kg-m, 4381 ft-lb) ~_ Nem aa NB @ ee BB are 60-70 Nem (6.0-7.0 kgm, 43-61 feb) 38-48 Nm (3.8-4.8 kg-m, 27-25 feb)ENGINE REMOVAI SERVICE INFORMATION ENGINE REMOVAL 5-5 ENGINE INSTALLATION 57 56 SERVICE INFORMATION GENERAL ‘© Parts requiring engine removal for servicing + Crankshaft + Transmission + Shift drum and shift forks. SPECIFICATIONS Engine diy weight ('86, 88, After ‘88:) 37) Trensmission cil Transmission oll capacity (86, ‘87, ‘88, “89:) (Atter '89:) TORQUE VALUES Engine hanger bolt (10 mm) (8 me) Engina mounting bolt ('86, ‘87, ‘88, '89:) (alter '89:) Swingarm pivot bolt Radiator hose clamp Altarnator caver screw Seat bolt Atter “86: Rear brake pedal pivot After “87: Shock absorber lower mounting bolt 23.6 kg (52.03 (ib) 23.5 ka (51.81 Ib) HONDA 4-STROKE OIL SAE 10W—40 or equivalent, API service classification: SF or SG 0.6 lit 0.63 US qt, 0.5 Imp qt) after disassembly 0.56 lit [0.58 US qt, 0.4 Imp qi) at oll change (0.63 fit (0.67 US qt, 0.55 Imp qt) after disassembly 6.7 lit (0.74 US qt, 0.62 Imp qt) at oll change 38—48 Nem /3.8—4.8 kg-m, 27—36 feb) 24-29 Nem (2.42.9 kg-m, 17—21 feb) 38-48 N.m /3.8—4.8 kg-m, 27-35 feb) 60—70 Nem |8.0—7.0 kg-m, 43—81 feb) 80-100 Nem (8.0-10.0kg-m, 58~72 ft-lb) 0.71.0 Nem (0.07 0.1 kg-mn, 0.60.7 feb} 3—5 Nem (0.30.5 kg-m, 2—4 ft-lb] 18-26 Nem |1.8—2.5 ko-m, 13-18 Feb} 2428 Nem 2.42.8 kg-m, 17—20 feb) 38~48 Nem [3.84.8 ko-m, 27—36 frib) RIDE RED 5-5NGINE REMOVAL/INSTALLATION ENGINE REMOVAL (SPRING ig Vio spanes Drain the transmission ol (pege 2-2) $21 aQts Place a workstand or jock Under the engine Remove the seat and fuel tank (page 4:14) FRomave the right side cover ('86, 87) Remove the expansion chamber and muffler connecting spring (86 onl. Remove the expansion chamber mounting springs and bolts, ‘and then remove the expansion chamber. Remove the exhaust manifold (page 6-5). Drain the radiater coolant (page 10-2), Remove the brake pedal pivot and spring (Alter ‘86: page (1) RADIATOR HOSESWA, 12-171 Disconnect the radiator hoses from the cylinder head and the water pump Remove the radiators (After ‘88! Disconnect the spark plug cap. [2) SPARK PLUG. cap Loosen the carburetor connecting tube and insulater bands and remove the carburetor (page 4-8). m~ Loosen the wire band and disconnect the alternator and pulse generator wire connectors NOTE + After 8 model has two wire bands clamping the aternator ‘and pulse generator wires (page 1-18) 2) ALTERNATOR AND FULSE GENERATOR WIRE CONNECTORS| 5-6 RIDE REDENGINE REMOVAL/INSTALLATION Remove the alternator cover. TM) cluTcy CABLE gy si € Disconnect the clutch cable from the cluten lifter lever by loesening the clutch cable adjusters Remove the drive chain retaining clip and disconnect the drive chain Remove the upper engine mounting bolts and hanger plates. mown Remove the front and lower engine mounting bolts. Ni RRREH FATES Remove the swingarm pivot bott =e CT Remeve the shock sbsorberlowar mounting belt (After “871 asa ing eo nh ode ENGINE INSTALLATION ‘ : wore (a1 FRONT Ae ees s. ITs ae + Use the correct bolts in their proper positions. + Tighten the bolts to the specified torque values. Route the wires and cables properly (page 1-11 through 21) TORQUE: ENGINE HANGER BOLTS: 10 mm 38—48 Nem (3.84.8 kg-m, 27—35 feb) 8 mm 24—29 Nem (2.4—2.9 ka-m, 17—21 ftb) ENGINE MOUNTING BOLTS: 5 of ee, '87, °68, 89: (4) 10 mm BOLT 38-48 Nem (3.8—4.8 ka-m. 27-35 ftlb) After ‘89: 60-70 N-m (6.0—7.0 kg-m, 43-51 ftdb) z x SWINGARM PIVOT BOLT: = (9) ENGNE (2) SWINGARM 80— 100 N-m (8.0— 10.0 kg-m, 58—72 ft) Ne coe ww. NSARM SHOCK ABSORBER LOWER MOUNTING BOLT PINOT BOL) Alter '87; 38-48 Nem (3.8—4.8 kgm, 27-35 feb) BRAKE PEDAL PIVOT. After ‘86 2428 Nem (2.4—2.8 kom, 17~20 ft-b} {After installirg the engine, perform the following inspections ‘and adjustments: Transmission oil level (page 2-2). Coolant level ipage 10-2) Throttle grip free play (page 3-5) Rear brake pedal froe play (page 3-10}, ('86:) Drive chain siack (page 3-8). Clutch lever free play (page 3-12). Check that exhaust gas is not leaking past the expansion chamber connections, —_— RIDE REDCYLINDER HEAD/CYLINDER/PISTON After "89: 24-28 Nem (2.4-2.9kg-m, 17-21 ft) (2.4-2.9 kom 10-14 Nem 17-21 Feo} (1.0-1.4 kg-m, 7—10 feb) After ‘87:6. CYLINDER HEAD/CYLINDER/PISTON SERVICE INFORMATION 6-1 CYLINDERHEAD 63 TROUBLESHOOTING 6-2 CYLINDER/PISTON 64 SERVICE INFORMATION GENERAL © This section covers maintenance of the cyinder and piston, These services can be done with the engine installed in the frame, ‘© The cylinder has a Nikesil coating and cannot be rebored. If itis damaged, it must be replaced, © Before disassembling, clean the engine thoroughly to keep dirt from entering the engine, (© Remove any gasket material from the mating surtaces. ‘© Do not use # screwdriver to remove the cylinder head. Clean all paits before inspecting. © Before assembling, apply olean 2-stroke engine cil to all sliding surtacos. 12 Undor racing conditions, the piston and rings shoidd be replaced after 7.5 hours of running. Replace the piston pin and con: necting rod small end bearing after 22.5 hours of running, '@ Refer to section 4 for reed valve inspection SPECIFICATIONS mm (in), Ta aoe avai oma Se aaaee aon a raa=aaTn| eae weet Tee — “Lseteooai | ona = ——Tansrenen ro a Tes e002 aa [een — ee a0 =a. Se TIATED | 86.26(2.600 | seme, on pintow a5 7. 6 $8.007—180190-7089-0,7082) | 18.810.710) sae +2,007716,008 0.7067-0.7080) | 16.02 (0-700 [roansn “Hisee=teoes 10:7086=0.7067) | 17.68.0700 | Felon eon ["86, "87. "88 | 0:007-0.019 0.0003--0.0008/ | 0.0910.000) cleprance After ‘88: 0.020.014 (0.0001 0.0006) | 0.02 (0,001) Gaon mpeg ['9087" [Tar | 008=0.05 0.001002, | ~0.9710.008) woot clesrance [aecons [0000.06 .001=0.002" | 0.070.008) “Gees Tor | oa5-0.07510.0018-0 0020) | 0.098 0.0087| SECOND | ~0:02520.085 (00010000221 | 0.075 0.0000) meres [tor | 0.080=0-10010.002~6.008) | 0.120 0.00871 L sEc0nD | 0 08070,080 10.007 =0.008) | 0.09610.0037) i T | 0.810.070 sn Hs "88,89: 0510.01-0.02) | _0.6 (0.024) | ier 85 | bad 0.98 (0016-00221 | 0.85 10.076 [eRe oars aoe 0.075 60016-0.00807 | 0.1 0.08 conan Rama aaoon aa.014 w a882—0.0667) | 22.0310.867 inter eae —— 0108 0.0021 TORQUE VALUES Loic iene Alin te SoM Sri tae ee SanegN ER as hem 27-9 Be en eecacapm: 2630 (bl set So ee gi anata avenue tid eagle Se hWae-RRECONE er SNe CSS aren ecg 1 ee oemCYLINDER HEAD/CYLINDER/PISTON SSS TROUBLESHOOTING Low compression, hard starting or poor performance at low speed + Blown cylinder head gasket. + Loose spark plug Worn, stuck or broken piston rings. Worn or damaged cylinder and piston Faulty reed valve. Worn crankshaft seals High compression, overheating or knocking + Excessive carbon build up in combustion chamber, or on piston top. ‘Abnormal ncise— piston + Worn or cracked piston, + Worn cylinder and piston, + Worn piston pir or piston pin hole, + Worn connecting rod small end bearing. Abnormal ncise— piston tings + Worn, stuck or broken piston rings. + Worn oF damaged cylinder Contaminated coolant Leating cylinder head gasket, eee a 6-2 RIDE REDCYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD THT RABIATOR Hoses REMOVAL im 2) HANGER PLATE Drain the radiator coolant (page 10-2). Remove the seat and fuel tank (page 4-14). Loosen tre radiator hose clamps and remove the radiator hoses from the cylinder head Disconnect the spark plug cap. Remove the rubber eap from the left hanger plate (After '87 only) Remove the upper engine mounting bolts and hanger plates f (3) RUBBERCAF | (4) SPARK PLUG CAP. (After ‘87 only) | After ‘87 show remove the spark plug. Remove the six cylinder head nuts end the cyiinder head. CAUTION + To avoid warping the cylinder head, use a crisscross pattern 10 loosen each rut about 1/4 turn, then rentove the nuts Remove the cylinder head gasket COMBUSTION CHAMBER DECARBONIZING Remove the caibon deposits from the combustion chamber. Clean the heed gasket surface of any gasket material, CAUTION + Use care not to seraich the combustion chamber or the head gasket surface. INSPECTION Check the cylinder head for warpage in diagonsl directions with a stiaight edge and a feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in}CYLINDER HEAD/CYLINDER/PISTON INSTALLATION 86°87, 88: Clesn the cylinder head mating surface, teking cate not to drop any gasket material into the cylinder bore and liquid cooling passages. Placing small portions of a clean paper towel in each liquid passage and a clean shop towel in the eylinder will hlp prevent this gasket debris from entering these areas. A lignt blast of commpressed air across the top of the cylinder priot to removing the paper towel portions and shop towel will aid in this procedure Install a new gasket aligning its tab to the rear After ‘88: Inetall a new gasket with its "UP" mark facing up. Install the eix cylinder head nuts end tighten to the specified torque in a crisscross pattern in 2 or 3 steps. TORQUE: 24—29 N-m (2.4~2.9 kgm, 17—21 feb) Install the spark plug. Install te spark plug cap. Install the hanger plate and tighten the bolts ‘TORQUE: 10 mm bolt: 38—48 Nem (3.84.8 kg-m, 27—35 ft-tb) 8 mm bolt: 24— 29 Nem (2.42.9 kg-m, 17—21 fb) Install the rubber cap to the lett hanger plate (After ‘87 only) Connect the radiator hose to the cylinde head. Pour the recommended coolant mixture up to the correct level (page 10-2), (a) RUBBER CAP | Install the fuel tank and seat, TA) SPARK PLUG CAP (After ‘7 only) CYLINDER/PISTON CYLINDER REMOVAL “Ee ox 12) CARBURETOR] Remove the following ~ seat ard fuel tank, ‘ight side cover ('88, 87:1 — expansion chamber (page 5-6) — drain the radiator coolant (page 10-2), — cylinder head (page 6-3), — radiator hose from the cylinder — carburetor (page 4-8, — radiator (page 10-4). ‘exhaust menifold (After ‘87) 6-4 RIDE REDCYLINDER HEAD/CYLINDER/PISTON Romove the four flange nuts attaching the cylinder to the {iT (1) CYLINDER (2) REED VALVE crankcase, Remove the cylinder. CAUTION + Do net pry or sirike on the eylinder. Place a clean shop towel into the crankcase to keep do! is out Remove the read valve from the cylinder (page 4-13) 86, '87: Romove the exhaust manifold and gasket from the cylindsr, (1) GASKET. CYLINDER DECARBONIZING (1) EXHAUST Clean carbon ceposits from the exhaust port area. cauTION ‘Do not damage the evlinder bore CYLINDER INSPECTION Inspect the top of the cylinder for warpage. Use a straight edge and feeler gauge to check the heed gasket surface on the cylinder for warpage. If warpage is beyond the service limit, correct a8 necessary. SERVICE LIMIT: 0.05 mm (0.002 in} Check that the cylinder studs are tight. If any are loose, remove them, clean their threads with contact cleaner, then reinstall hem using Honda Anaarabic Thread Lock, or equiva: tent TORQUE: 10-14 Nem (1.01.4 kg-m, 7—10 feb) RIDE RED 6-5CYLINDER HEAD/CYLINDERIPISTON Use a micrometer and dial bore gauge te inspect the cylinder r bore for wear or damage, ) c Measure the eyindar LD. at X and Y axis at three locations. ‘SERVICE LIMIT: 66.44 mm [2.616 in) ‘ Calculate the taper and out of round. eh SERVICE LIMITS: x Teper: (0.05 mm (0.002 in) ‘Out of round: 0.08 mm (0.002 in) y PISTON REMOVAL ®, » (Piston Ne psrotien Remove the piston pin clips using pair of neodle-nose pliers. Press the piston pin out of the piston, and remove the pisten ‘CAUTION Do not damage the piston. + Always support the piston when pressing out the pin. Do mos let the clins fall into the crankease Note + Under racing conditions, the piston and rings should be re- placed after 7.6 hours of running. Replace the p’ston pin find connecting rod small end bearing after 22.5 hours of running ‘Spread exch piston ring and remove by lifting it up ot 2 point Just opposite the gap. CAUTION + Do not damage the piston rings by spreading the ends too Jar. PISTON INSPECTION ‘Measure the piston 0.0. at 25—30 mm (0.98—1.18 in} from the bottom of the exhaust side skiet and with vertical to the piston pin hole, SERVICE LIMIT: 66.28 mm (2.609 in) If tho 0.0. ie undor the earvice limit, replace the piston with 2 Calculate the piston-to-cylinder cl SERVICE LIMIT: 0.1 mm (0.04 in) 66 RIDE REDw CYLINDER HEAD/CYLINDER/PISTON Measure the piston ring-to-groove clearance, SERVICE LIMIT: "86, ‘87: TOP: 0.07 mm (0.003 in) : SECOND: 0.07 mm (0.003 in) "88, "69 | TOP: 0.095 mm (0.0037 in| SECOND: 0.075 mm (0.0030 in| After ’89: TOP: 0.120 mm (0.0047 ini : SECOND: 0.095 mm (0.0037 in| “Measure the piston pin bore 1.0. SERVICE Linn: ‘86, '87, ‘B8: 18.03 mm (0.710 in} ‘After ‘B8: 18.02 mm (0.708 in) Check the piston pin for wear and excessive discoloration, Measure the piston pin 0.0. SERVICE LIMIT: 17.98 me (0.708 in} Calculate the piston pin-to-piston clearance. SERVICE LIMIT: ‘86, “87, “88: 0.03 mm (0.001 in) ‘After ‘88: 0.02 mm (0.001 in) PISTON RING INSPECTION Insert the piston rings into the cylinder. Use the piston to place ‘the ring squarely in the cylinder. ‘Measure each piston ring's end gap with a fesler gauge. ‘SERVICE LIMIT: "86: 0.5 mm (0.020 in) °B7, "88, “89: 0.6 mm (0.024 in) ‘After ‘89: 0.65 mm (0.026 in) If the end gap is still over the service limit with a new ring, the ‘eylinder must be replaced. Z \4 (1) PISTON FING, Z; RIDE REDCYLINDER HEAD/CYLINDER/PISTON CONNECTING ROD INSPECTION Install the bearing and piston pin in the connecting rod smell tend and check for axcessive play. fit feels loose, measure the small end |.D. SERVICE LIMIT: 22.03 mm (0.867 in) If the |.D. is not over the service limit, replace the piston pin and amall and bearing If the 1,0. is still over the service limit, replace the crankshaft assembly, CYLINDER INSTALLATION Clean the piston ring grooves Lubricate the piston rings and piston ring grooves with clean 2 stroke oil Install the piston rings on the piston. NOTE + Install the piston rings with the marks facing up. + Locate the piston sing end gaps on the pins in the ting grooves, Lubricate the small end beanng and piston pin with clean 2 stroke oll Install the connecting rod small end bearing, piston and piston pin, NoTe the inteke side Install the piston pin clips CAUTION Use new pin cips, Never reuse old clips + Do not let the clips fal into the crankeare, Clean off any gasket material trom the gasket surta crankcase. of the Note + Be careful net to damage the gasket surface or let gasket materia fall into crankcase. (1) MARK \ \ (cine MARK. 13) PISTON PIN. 6-8 RIDE RED iaimston pmscubCYLINDER HEAD/CYLINDER/PISTON Install the dowel pins and new cylinder base gasket on the (1) GASKET crankcase, o Remove the left and right exhaust valve covers from the eylin de Remove the lett and right cylinder upper covers (Atter °87). Install the reed valve in the cylinder (oane 4-13). Install the gastet, spacer and exhaust manifold onthe cylin. | oer i ring end gap with the piston ring stoppers in the ring groove, Ate ar: Wi WATER ja) SPINDLE Remove the spring retainer shaft cap and turn the spring re- | PUMP. CAM (5) CRANKCASE taner shaft counterclockwise 90 dacrees with a flat blade (3) To N MATING screwdriver or a 8 mm socket to disengage the governor pisencace) | SURFACE ‘mechanism Position the spindle cam so that It faces straight ahead, with its centerline parallel to the crankease mating surface, as shown, (6) FLAT SIDE (2) SPRING RETAINER (7) PARALLEL SHAFT RIDE RED 69CYLINDER HEAD/CYLINDER/PISTON Lubricate the piston and rings with 2-streke oil and apply a dab of Honda Moly 45 or 60 grease (U.S.A. only) or molybdenum disulfide paste (containing more than 40% molybdenum disul fide additive) to the spindle cam pin. Algn each ring end gap with the piston ring pins in the ting lane and slip the cylinder ‘over the top of the piston while compressing the sings snd holding both exhaust valves fully closes. CAUTION Do noi rotate the eslinder, since this may cause the paston rings to snag a eylinder port and break. Hold both of the exhaust valves fully closed (E-clips touching valve guides), and lower the cylinder completely over the piston aligning the pin of the spindle cam with the cut-out of the rack NOTE + The cylinder will not seat completely against the erankease because the H.P.P. actuating machanism Is not yet gaged propery. + To align the H.P.P mechanism for proper engagement, pull ‘open the right exhaust valve. When the valve is near fully ‘pen, the cylinder will drop down onto the crankcase fully, The cutout in the underside of the rack and the cam spindle pin are now proper valve closed. NOTE + Before tightening the cylinder nuts, make sure that there fare_no clearance between the cylinder and crankcase mating surface. Install the four flange nuts and tighten to the specified torque. TORQUE: 35—45 Nem (3.5—4.5 kg-m, 25—33 fttb) Insert a #2 flat blade scrowdrivar into the slotin the top of the fight pinion shaft and turn it counterclockwise 1/8 to 1/4 beyond the point where spring tension isfelt. This ensures that the valve is fully closed and all sack ie ramaved from the sys NOTE + Be sure that the exhaust valves are fully closed. W thoy aro not fully closed, adjust the H.P.P. (Honda Power Port) [page 7-17 through 7-20). Then, while holding tension on the pinion shaft with one: Screwdriver, engage the spring retainer shaft by turning it cloc- kwise 90 degrees with another screwdriver (or 8 mm Socket). ‘The retainer shaft should engage easily. You will feel the slight Getent when the shat reaches the 90 cegree detent. To.confirm engagement, try to turn the pinion shaft clockwise Alight spring resistance should be falt. If it turns freely, the shaft is not proverly engaged (1) BLADE SCREWDRIVER SHAFT 1) SPRING RETAINER SHAFT [3) SCREWDRIVER (OR 8 MM SOCKET) 6-10Install the four flange nuts and tighten to the specified tore, TORQUE "6, ‘87, "BE: 3848 Nom (3.84.8 kg-m, 28-35 ft-lb) After 88: 35—45 Nem (3.5—4.5 kg-m, 25—33 fro) 86, '87: NOTE + Be sure that the exhaust valves are fully closed. ii they are not fuly closed, adjust the exhaust valves page 7.17 through 7-20) Install the gaskets and the left and right exhaust valve covers onto the cylinder. Install the left and right cylinder upper covers. NOTE + Check the exhaust valves for sooth operation by turning the pinion shaft. Inepect the aezembly of tho rotamer ehatt ‘end follower cam if the exhaust valves do not operate smoothly, Adjust the exhaust valves (page 7-19) Install the following: — Exhaust manifold (After °87) — cylinder heaa (page 6-4). — Radiator hoses, Expansion chamber and springs. — Carburetor (page 4-13) — Radiator (page 10-4), Pour the recommended coolant mixture into the radiator up to the correct level (page 10-2) Start the engine and check for the follawing: — Compression leaks. = Abnormal engine noise Seconcary air leaks ~ Coolant leaks CYLINDER HEAD/CYLINDER/PISTON (1) Pinion [ er 6-11H.P.P. (Honda Power Port) if ve ye) Se J or 6-8 Nem : : (06-08 kom SNES / gh Be aaa Y, of 7 oe a 7-0 RIDE RED7. H.P.P. (Honda Power Port) After ‘87; After 88: 10-14 Nem (1.0—1.4 kgm, 710 fib} 7 Nem (0.5-0.7 kg-m, 5 fb) 5—7 Nem 10.8-0.7 kam, 4-5 feb) After ‘28 1014 Nem (1.01.4 kg-m, ny B-12N: 6-9 fe (0.81.2 kgm, After BB: 10-14 Nem (1.0~ 1.4 kgm, 7-10 feb) Nem (0.60.8 ka-m fle RIDE RED 7H.P.P. (Honda Power Port) SERVICE INFORMATION 7-2 EXHAUST VALVE LINKAGE rT TROUBLESHOOTING 7-2 GOVERNOR/CAM 715 EXHAUST VALVE DECARBONIZING 7-3 EXHAUST VALVE ADJUSTMENT TAT SERVICE INFORMATION GENERAL ‘This section covers the maintenance of the H.P.P, (Honda Power Per) © Decartonize the valve every 2.5 hours of running {approximately each race) © Adjust tho valve system only whan — the valves don’t close properly ~ the linkage is removed. — related parts (governor, cam, water pump shaft) are removed or replaced. TORQUE VALUES ‘Adjusting screw lock nut (°86, °87:) 8-8 Nem (0.6-0.8kg-rm, 4— feb) Rack hole plug 8-12 Nem (0.8—1.2 kg-m, 6-8 fttb) Adjusting bolt look nut (Aftor ‘87: 5-7 Nem (0.60.7 kgm, 46 feb) Cylinder and exhaust valve cover bolt 10—14Nem (1.01.4 kg-m, 710 fib) larger flange than SH type bolt (Afar 88) TROUBLESHOOTING Poor performance at law speed + Exhaust valves do not close fully = Improper adjustment Faulty governor = Broken vaive set spring ('86) — Wom exhaust valve governor cam ~ Bent pinion shaft = Broken rack + Excessive carbon build-up in exhaust valves and valve guides + Damaged exhaust valve Poor performance at high speed + Exhaust vaives do not open fully. = Impraper adjustment Faulty governor — Broken valve spring = Wom rack andor pinion — Bent pinion shaft + Exepssive carbon build-up on exhaust valves and valve guides + Damaged exhaust valve 7-2 RIDE REDH.P.P. (Honda Power Port) EXHAUST VALVE DECARBONIZING Ramave the expansion chamber (page 14-3) Remove the cylinder upper covers, exhaust valve covers and gaskets. “20: Remove the lock nuts and pull the valve set springs off of the ‘Separate the adjuster levers trom the valve levers Pill the exhaust vaives out of the valve guides while separat- ing the exhaust valve pins from the valve lever pave, Remove the valve guide stopper bolts and washers. Pull the valve guides out of the cylingar. 2) VALVE GUIDEH.P.P. (Honda Power Port) 7 87: Remave the lock nuts and collars, Separate the adjuster levers from the valve levers, ull the exhaust valves out of the valve guides while separat ing the exhaust valve cut-out from the valve lever, Remove the valve guide stopper bolts and washers. Pull te valve guides out of the cylinder. laawe 87 After'87: Removal of the exhaust valve and valve quide is similar to the "87 model's procedure. (3) VALVE GUIDE oS (4) ADJUSTING BOLT (5) VALVE (7) vatve ah a@ EVER 16) ADJUSTER LEVER 86 shown: Remove the E-clips from the exhaust valves. I Clean carbon deposits from the exhaust valves and valve guides Check the parts for weer or damage: replace if necessary Note 3) E-CLIP * Decarbonize the exhaust valves and valve quides each € every 2.8 hours of running (approximately each race) [1 VALUE GUIDE (2) EXHAUST VALVE | “a6: Assemble the E-clps onto the exhaust valves. Install the valve guides by aligning the locating pins on the eyl- inder with the valve guide's cut-out. Install the washers and tighten the valve guide stopper bolts securely. 7-4 RIDE REDH.P.P. (Honda Power Port) "87: Assemble the E:clips onto the exhaust valves. Install the valve guides by sligning the locating pins on the cy! inder with the valve guide's cut-out Install the washers and tighten the valve guide stopper bott se: curly. Aligning the groove of the valve with the lug of the valve lever, install the valves into the valve guides until the E-clips touch the valve guide surfaces (the valves are fully closed.) Align the stud bolts of the valve tever with the holes in the ad. juster lever ‘6: Setting the valve lever pawls onto the exhaust valve pins, in stall the valves into the valve guides until the E-clip touch the ‘uide surfaces (the valves are fully closed) 86, '87: Install the adjuster levers over the valve lever bolts After 87; pee Aligning the groove of the valve with the lug of the valve laver Install the valves into the valve guides, Install the collars through the aduster levers and valve levers, 6: ut the collar into the valve set spring Loosely install the lock nuts Hook tha valve set spring ends on the valve levers j (a) SPRING e RIDE RED 75H.P.P. (Honda Power Port) 86: ‘CAUTION + Be sure that the exhaust valves are fully closed. If the exhaust valves aren't fully closed after installation, adjust the exhaust valve (oage 7-17) Tighten the lock nuts. NoTE + Be caretul not to damage the vaive set springs “a7: Install the collars Loosely install the lock nuts, Make sure the vaives are fully closed, and tighten the lock nuts securely. Adjust the exhaust valve (page 7-18), Alter ‘87: After ‘07: (i) VALVE LEVER LOCK NUT Install the adjusting bolts through the adjuster levers and valve Tighten the valve lever lock nuts. Tighten the adjusting bolts loosely. Adjust the exhaust valves (page 7-19) BOLT (3) ADJUSTING BOLT | tock NuT Install the gaskets and covers Tighten the cover bolts, TORQUE (After '88): (larger flange than SH type bolt) 10-14 Nem (1.01.4 kg-m, 7—10 ft) Install the expansion chamber (page 14-4) (1) covers 7-6 RIDE REDH.P.P. (Honda Power Port) EXHAUST VALVE LINKAGE REMOVAL Remove the cylinder page 6-4). Remove the cylinder upper covers, exhaust valve covers and gaskets, "86: Remove two lock nuts, the collars and set springs trom both linkages. (2) COLLAR 87: Remove the two lock nuts and collars trom both linkages, ('88: Only) (3) SPRING After ‘87: After °87 (1) PINION SHAFT Remove the pinion shaft assemblies, lock nuts, collars and ASSEMBLY adjusting bolts from both linkages. Disasserrble the pinion shatt assemblies. 86, "87. “86, "87: MEN ay ia) COLLAA Remove the upper valve spring collars, valve springs and lower valve sprng colars. ul the pinion shafts out of the cylinder. Remove tne washers tom tne picion shat. (3) VALVE SPRING RIDE RED 7-7H.P.P. (Honda Power Port) Remove the adjuster lavers, valve levers and washers. Pull the exhaust valves out of the valve guides, Remove the valve guide stopper bolts and washers. ull the valve guides out of the cylinder. 80, '87: Remove the rack hole slug and sealing washer. Loosen the lock nut. Remove the adjusting sorew, socket bolt end sealing washer. 1s) ao.uStiNG is) SEALING SCREW (8) SOCKET BOLT ~~ WASHERS After '87: Remove the rack hole slugs and sealing washers. 1) PLUGS, SEALING WASHERS 7-8 RIDE RED. (Honda Power Port) Remove the rack from the evlinder. INSPECTION “a6, 87, Check the pinion shaft gears and collars for wear or damage; replace if necessary, Check the valve springs for fatigue or damage: replace if nec: essary. After ‘87 Check the pinion shaft gears and collars for wear o1 damage: replace if necessary. Check the valve springs for fatigue or damage; replace if nec After inspection, clean all parts and assemble them. 86: Check the valve levers and adjuster levers for wear or damage replace it necessary. (Check the ser springs for fatigue or damage; replace if neces- sary, ee, Z™~N ( RACK ‘96, (87: (1) coutans (2) PINION SHAFT (3) VALVE SPRING After '87 (2) PINION SHAFT oe (1) COLLAR @ (9) VALVE SPRING (1) VALVE LEVER (2) ADJUSTER (3) SET SPRING \ LEVER oe S RIDE REDH.P.P. (Honda Power Port) "87 shown: After 86: 11) VALVE LEVER (2) COLLAR Check the valve levers, adjuster levers and collars for wear or damage; replace if necessary. (3) ADJUSTER LEVER (Check the rack for wear or damage; replace if necessary. (1) RACK INSTALLATION “86, 87: (1) VALVE SPRING. 5 coutars Le cava.ve sree eS ('86: Only) 188: ont s (3) ADJUSTER LEVER eee ae 2 ed a vavve tever S ea” (12) vatve Sue aE (11) exaust c3 vane ~ om o (10) &-cUP a. —~1s: pus (6) RACK a ja) Lock nur“ ~~) socer wot pian Sa 7-10 RIDE RED(Honda Power Port) PD 12) vatve spans a (3) PIION SHAFT (7) RACK After ‘82 (3) VALVE SPRING Y COLLAR (10) EXHAUST VALVE “96,07: Temporailly install the sealing washer and rack hole plug inthe right socket bot hole to locate the rack ‘Apply molybdenum disulfide grease to the rack Install the rack into the cylinder as shown. ‘The teath for the tight side faces te tear; the teeth for the lett side faces forward) Atter "87: Tighten the right rack hole plug with a sealing washer TORQUE: 8—12 N-m(0.8—1.2 kg-m, 6-8 felb) Apaly molybdenum disulfide grease to the rack. Install the rack into the cylinder from the left rack plug hole Until the right rack end contacts with the right rack hole pug. RIDE RED (1) Pus. ) RACK HOLE PLUG (2) WASHER (3) RACK (3) SEALING WASHER (2) RACK 7-11H.P.P. (Honda Power Port) Apply 2-strake ol to the exhaust valves and valve guide sliding) WASHER surfaces, Install the vaive guides into the cylinder and tighten the stop: per bolts with the washers (Washers: "BE: ¢16 mm, thickness 2.3 mm) (After '86: $16 mm, thickness 1.2 mm}, NOTE Each valve guide has the identification mark. Assemble the E-clips onto the exhaust valves and install the valves into the guides. Install the washers ('86: $18 mm, thickness 1.0 mm, blue PR SLEEAUET VALVE: 6 4 NOTE Each valve lever has the identificaiton mark (2) lus ‘a7: Install the valve levers end adjuster levers, aligning lug of the adjuster levers with the groove in the vaive levers. Install the collars, Note Each valve lever has the identification mark. Atter ‘87. in) BouT (2) VALE stall the valve guide by aligning the lecetion pin with the ov > GUIDE Inder groove. Secure the guide with the bolt and washer " (6) WASHER Insert the exhaust valve into the valve quide with the valve Lia) annove ‘groove facing up. Install the washer over the valve lever stud bolt [p) WASHER Ht 712 RIDE RED Ye) exHausT VALVE(Honda Power Port) The valve lever and adjust fever have the identification marks for Right side: R, and Left side: L ore - Install the valve lever with the identification mark facing down, + Install the adjuster lever with the identification mark facing up "86, '87: Install the E-clip and washer onto the left pinion shaft. ‘Apaly molybdenum disuifide grease to the gear teeth and slid ing surface of the pinion shaft. Install the left pinion shaft into the cylinder while being sure thet the tack touches the plug in the right socket bolt Hole NOTE + Himay be nacessary to turn therack sightly so that the gear teeth of the pinion shaft and the rack align. + A slot is provided in the end ef the rack 59 that it can be turned with a screwdriver Install the E-cllp and washer onte the right pinion shart Apply molybdenum disulfide grease to the gear teeth and slid Ing surface of the pinion shaft. Install the right pinion shaft into the cylinder in a symmetiical form to the Inft one as shawn. (In this case, both slots are not symmetrical.) (1) RIGHT PINION SHAFT. After 87 Install the valve lever, aligning the lug of the valve lever with, the groove in the exhaust lever. Install the adjuster lever onto the valve Install the collar through the adjuster and valve fevers. Install the nut end tighten Vertically align the adjust bolt holes to receive th but don’t insert the adjust bolt yet. With the valves fully closed, install the pinion shaft Install the adjust bolt and nuts. adjust bot, (2) AbsuSTER LEVER Os (VALVE LEVER (3) MARKS ©, GV ECuP (2) WASHER (2) PINION. sHaet_ || (2) VALVE LEVER TIP @ (1) abJUST BOLT ‘AND NUT. 7-13H.P.P. (Honda Power Port) "86, '87: Install the lower valve spring collars, velve springs and upper valve spring callars on the pinion shafts NOTE + Right side valve spring's lower hook is longer than left side "86, 87: Place the collars (in the valve set springs: ‘B6: Only} and install them on the stud bots. Loosely install the lock nuts. NOTE Be careful not to damage the valve set springs. + Right side valve sst spring's hook ie longer than left side "86: Hook each valve set spring to the valve lever "86, '87: Remove the sealing washer and rack hele plug from the right side and reinstell them at the lett socket bolt hole. Install the sealing washer and socket bolt at the right socket bolt hole, and tghten the bolt, TORQUE: B—12 Nem (0.8~1.2 kg-m, 6~8 ftlb) Install the adjusting screw and lock nut. Tighten the lock nut TORQUE: 6-8 Nem (0.6—0.8 kg-m, 4—6 ft-lb) Install the cylinder (page 6 Adjust the exhaust valve (page 7-17 through 7-20). Attar 87; Tighten the left rack hole plug with a sealing washer. ‘TORQUE: 8~12 Nem (0.8-1.2 kg-m, 6-9 feb) Install the cylinder (page 6-8). Adjust the exhaust velves (page 7-17 through 7-20) ad PRION SuART ff Pad a aur ‘A ixsmbreos (2) VALVE SET SPRING (a) SEALING WASHER) :SDOCE NUT / (8) SOCKET BOLT WASHER (2) PLUG (6) ADJUSTING SCREW =.) 7-14 RIDE RED© H.P.P, (Honda Power Port) GOVERNOR/CAM GOVERNOR REMOVAL Remove the right crankcase cover (page 8-3} While pressing down on the spring end of the governor rocker farm, loosen and remove the screws and racker arm. \, (2) SCREWS “96, ‘87: After ‘87: Remove the governor spring and spring seats ('86, ’67:) (1) RETAINER Remove the spring retainer shaft and governer spring (Alter y SHAFT 971 \ Remove the governor and steel balls, (1) GoverNoR Check all parts for wear or damage; replace it necessary. (2) STEEL BALLS ~ me # CAM REMOVAL (1) FOLLOWER CAM (2) BUSHING Remove the right crankcase cover (page 8-3) Remave the cylinder (page 6-4). Pull the clip from the cam spindle and remove the follower Remove the eam spindle and bushing from the crankcase RIDE RED 7-15H.P.P. (Honda Power Port) Check the clip, cam, bushing and spindle for wear or damage: (2 SPINDLE (a) BUSHING replace if necessary. } (CAM } q a | ot GOVERNORICAM INSTALLATION. Clean all disassombied parts and apply a paste grease with 40% or more molybdenum disulfide (page 2-3) to them. Install the bushing and cam spindle and follower cam in the crankcase, Install the clip. Install the cylinder (page 6-8) (2) BUSHING ‘Apply @ paste grease with 40% or mare molybdenum disulfide (1) GOVERNOR (page 2-3) to the steel balls, wf Install the etoel bale (weighte) in the water pump drive gear. Install the governor. "86,87: i Install the spring seats and governor spring a 12 SPRING Poston the governer rocker aim and tighten the screws, oy go _/ SEATS posing be orelequiet heel i Note + Note the direction of the spring seats, + Align tha racker arm ands with the bosses of the governor \v Sano Reinstall the right crankes cover (page 83) (4) SCREWS 7-16 RIDE REDH.P.P. (Honda Power Port) After “87; (1) RETAINER Install the governor spring and spring retainer shaft. SHAFT — Position the governat rackar arm and tighten the screws, pushing the arm against the spring. NOTE + Align the rocker aim big end with the basses of the gover Reinstall the right crankcase cover (page 8-3) EXHAUST VALVE ADJUSTMENT Remove the expansion chamber (page 5-6). Remove the cylinder upper covers, exhaust valve covers and gaskets, Check thot E-clips on the valves touch the valve guide surtac 8, indicating that the valves are fully closed. NOTE + Always check before each race oe (1) EXHAUST HM E-clips do not touch the valve guide surfaces, loosen thelack | ‘"| Vat ve ‘uta. The valves will lose themselves automatically by means of the action of the valve set springs. (2) VALVE auIDE Once the valves ara fully closed, tighten the tock nuts. \t4i ECU RIDE RED 7-17H.P.P. (Honda Power Port) ‘87: If E-clips do not touch the valve guide surfaces, loosen the lock ‘nuts ond push the exhaust valves by hand unt E-clips touch the guide surtaces, Tighten the lock nuts securely. Turn the lft pinion shaft counterclockwise with a screwdriver unti the exhaust valves are fully open. ‘Turn the adjusting screw until the distance Is 20.5—21.0 mm (0,810.83 in} betwaen the outer face of E-clip. and valve guice surface. Tighten the lock nut, TORQUE: 6~8 N-m (0.6—0.8 kg-m, 4—8 fib} NoTe + Adjust right and left exhaust valves. [EXHAUST VALVE (2) VALVE ee, GUIDE (2) VALVE SyiDe (3) E-CuP TH) PINION SHAFT a | '2) Lock NUT 13) ADJUSTING SCREW a7. (9) ADJUSTING SCREW (2) VALVE —— GUIDE (1) CLIP 20.5—21.0 mm (0810.83 in) 7-18 RIDE REDP. (Honda Power Port) Attar “87: ‘Check that the E-clips are in contact with the vaive guides. If the E-cips are in contact with the valve guide surfaces, tighten the adjusting batt lock nuts, TORQUE: 5—7N-m(0.5—0.7 ko-m, 4—5 tub) If there s any clearance between the E-clips and valve guides, adjust the exhaust valve following below procedures. To close the valves fully, loosen each adjusting bolt lock nut ‘then turn the left adjusting bolt counterclockwise ard the right adjusting bolt clockwise. Tighten the adjusting bolt lock nuts with the €-clips contacting with the valve guide surfaces (the valves a fully closed). Hf there is any clearance between the E-clips and valve guides after adiustina. remove the exhaust valves and valve quides, land decarbonize them (page 7-3} (Cheek the air gap batween the pinion shaft arm spring and. acjust lever pi. ‘SPECIFIED AIR GAP: 00.5 mm (0—0.02 in) If the airgap is exceeds 0.5 mm (0.02 in), disassernble and in spect the valve mechanism. NOTE + Make sure that the E-clins contact the valve quides betore ‘making this inspection. Turn the pinion shaft with a serewdliver until the exhaust valve is fully epen. NoTE + Right exhaust valve: turn the right pinion shaft clockwise. + Left exhaust valve: turn the left pinion shaft counter clockwise, Measure the distance between the outer suface of the E-clip ‘and valve quide surtace on each exhaust valve. [SPECIFIED DISTANCE: 24.5 mm (0.96 in) minimum H the detance between the outer surface of the E-clip and valve guide surface is not in the specified distance, decarbonize the exhaust valves and valve guides (page 7-3), disassemble and check the valve actuating mechanism for wear or damage. (HV ECLP —— (3) ExHAOST /ALVE (2) vatve GUIDE “ (1) ADJUSTING BOLTS (3) ADWSTING BOLT Se (ecur LOCK NUTS (2) CUP (1) ADJUSTER (2) ADJUSTER LEVER LEVER PIN (3) SPECIFIED AIR GAP (1) PINION | SHAFTH.P.P. (Honda Power Port) "86 and AFTER: Install the gaskets, cylinder upper sovers and exhaust valve Tighten the cover bolts. TORQUE (Aftor "38: 10—14Nem (1.0~1.4 kom, 7—10 ftsb) Install the expansion chamber (page 14-4), 7-20 RIDEREDMEMO —CLUTCHIGEARSHIFT LINKAGE/KICKSTARTER G, Siti poe $047 Hae WN * 2 pte 90: ) Q \.80"84 Nem iS 7 (8.0—8.4kgm, af geen SSO y \ After 89: \ 24—30Nm (2.4—3.0 ko-m, 17-22 feb) 8-0 RIDE RED8. CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER SERVICE INFORMATION 841 CLUTCH 85 ‘TROUBLESHOOTING 8-2 GEARSHIFT LINKAGE 8-11 RIGHT CRANKCASE COVER 83 KICKSTARTER 8-14 SERVICE INFORMATION GENERAL 4 The clutch, kickatartor and shift linkage can be serviced with the engin ina {© Remove any gasket material fiom the erarkcase mating surfaces. Do not allow dirt in the enaine. # Be careful not to damage the case mating surfaces during disassembly. Clean all parts before inspecting. Coat all contact surfaces with clean trensmission ol before assembly, SPECIFICATIONS mm tn) Trem STANDARO SERVICE LIMIT Clutch lever free play 10~20 (9/8-3/4) Clutch spring Free length 86 43.3 (1.79) 47.5 11.63) 87, 88: 43.1. (1.70) 41.3 (1.63) ‘88 44.8 (1.781 43.0 (1.69) ‘After 69) 44.2 (1.78) | 42.4 11.67) Clutch plate warpage — 10.20 (0.008) Kickstarter spindle 0.0. 21,960 21.980 (0.8545-0.8654) | 21.95 (0.864) kstarter pinion 1D. 22,020~22,041 (0.8869-0.8678) | 22.06 (0.869) Kickstarter ier gear | Gountershaft 0.0 16.966 16.984 (0.6580-0.6687) | 16.95 (0.667) Gear LO. 041 (0.7882—0.7890) | 20.07 (0.790) Cuicrase iene [__282-3.08(0.119-0121) 285 (0.112) Kickstarter tle gear | 1.0. |” ¥7.900-17.018 (0.6899-0.6700) | _ 17.08 0.671) bushirg 0.0. [18.979 20.000 10.7866-0.7874)_| 18.96 (0.786) TORQUE VALUES Clutch center rut 5565 Nem (5.5—6.5 ke-m, 40-47 ft1b) After'90: 8084 Nem (8.08.4 kg-m, 5861 ft) (Clutch spring bolt 8-12 Nem (0.81.2 kgm, 6-9 Right crankcase cover bolt 8-12 Nem (0.8—1.2 kg-m, 6-9 ft-lb} Shift drum center pin 20~24 Nem [2.02.4 kgm, 1417 ftb) Apply locking agent to the threeds Kickstartor pedo! bolt 24—30 Nem /2.4—3.0 kem, 17-22 ft-1b) Brake pedal pivot bolt 196: 18-25 Nem (1.82.5 kq-m, 13-18 feib) After’66: 24—28 Nem |2.4—2.8 kgm, 1720 tb) Stopper arm bolt Weter pump cover bolt (After ‘88) TOOL ommon Clutch center holder 10—14 Nem |1.0—1.4 kgm, 7—10 fb) 10-14 Nem |1.0-1.4 kg-m, 710 feb) larger flange than SH type bolt 077240080001 or Equivalem commercially available in U.S.A. RIDE RED 8-1CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER TROUBLESHOOTING (Clutch slips when accelerating + No free play + Dises worn + Springs weak Clutch operation feels rough + Outer drum slots rough Motoreycle creeps with clutch disengaged + Too much free play + Plotes wareed Excessive lever pressure + Clutch cable kinked, damaged or dirty + Lifter mechanism damaged + Clutch cable not routeé properly 8-2 RIDE REDCLUTCH/GEARSHIFT LINKAGE/KICKSTARTER AEKSTARTER PeSAD tg 4 RIGHT CRANKCASE COVER REMOVAL TPRADIATOR HOSES Drain coolant by removing the drain bolts (page 10-2) Drain the transmission oil ipage 2-2). Disconnect the radiator hoses from the right crankcase cover Romave the kisketarter pedal. Remove the rear brake pedal pivat bolt and spring ‘After 87 Remove the spring retainer shaft cap. Turn the spring retainer shaft counterclockwise 90 degrees to unlock: '3) TO DISENGAGE Remove the bolts from the right crankcase cover Remove the right crankcase cover, gasket andiwo dowel pins INSTALLATION Install the dowel pins and 3 new gasket. NOTE + Make sure that the washer is on the kickstarter spindle a5 shown RIDE RED 8-3CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER After ‘07. Cylinder installed Betare installing the right crankcase cover, push the follower cam in completely (cylinder installed) {Be sure the spring retainer shaft is positioned as shown, align- ing the smaller cut-outs in the shaft with the governor rocker ‘arm small end. NOTE + The exhaust valve will not operate properly, if you instal ‘the retainer shaft incorrectly. Cylinder Removed + Position the spindle car as below, with its centerline side parallel to the crankcase mating surfa: (4) SPINDLE, (5) CRANKCASE CaM MATING SURFACE (6) FLAT SIDE (7) PARALLEL 86 and AFTER: NOTE + Install the right crankcase cover while engaging the water pump gear with the primary gear on the case. It may be ecessary to temporarily install the kickstarter pedal and crank the engine slowly by hand, in order to align the gears, properly. Inatall the right crankcase cover and tighten the cover mour- ting bolts, TORQUE: 8-12 Nem (0.8—1.2 kgm, 6~9 ft-lb} NOTE + After '88: water pump cover bolts have larger flange than SH type bok. Tighten them to specified 10-14 Nem (1.0=1.4 kgm, 7—10 fetb) torque. After 87: \Whie holding tension on the pinion shaft with one screwdriver (see page 6-10), engage the spring retainer shaft by turning it clockwise 90 degrees with enother screwdriver. The retainer shait should engage essily. You will feet the slight detent when the shaft reaches the 90 degree detent. To confirm engagemert, try to turn the pinion shaft clockwise A slight resistance should be fet. If it turns freely, the shaftis not properly engaged. 86 and AFTER: Connect the radiator hoses to the right crankcase cover. Install the brake pedal and spring, Comect the brake cable (86). Apply grease to the brake pedal and brake torque link ('85) pivot bolt. Tighten the pivot bolt (page 12-15, 16) TORQUE: 18-25 Nem (1.82.5 kg-m, 13-18 feb) After 86: 24—28 Nem (2.4—2.8 kg-m, 17-20 trib} Install the kickstarter pedal TORQUE: 24—30 Nem (2.4~3.0 kg-m, 17~22 fib) (7) FOLLOWER CAM (2) RETAINER SHAFT Cc a] Kick STARTER PEDAL (2) RADIATOR, HOSES Pe er at (4) PIVOT BOLT og (3) BRAKE PEDAL 84 RIDE REDCLUTCHIGEARSHIFT LINKAGE/KICKSTARTER €(1) MOUNTING BOLT: Fill the transmission with recommended oil to the correct level {eee page 2-2) Pour the recommended coolant mixture inte the r the correct lavel (page 10-2) After "88: Route the carburetor right side air vent tube correct: ly (page 1-16). Stat the engine and check for leaks. CLUTCH REMOVAL istor up to Drain the transmission oil (page 2-2) After ‘86: Remove the rear brake pedal pivot and spring ipage 12-171 Remove the six mounting bolts and clutch cover. "86: Remove the right crankcase cover (page 8-3). "B6 and AFTER: Romove the six clutch spring bolts and clutch springs. NOTE Loosen the bolts ina crisscross patton in 2 or 3 progreesive steps. Remove the clutch pressure plate. "86, 87, 88, "89: ‘96. ‘87, "88, ‘89: Atter 89: Remove the clutch lifter, steel ball and clutch lifter rod. TT) LieTeR ROD P¥12) CLUTCH DISCS AND PLATES IS NOTE seo \ + To avoid losing the steal ball, be careful when vou remove the clutch After ‘89: Ramove the clutch lifter and clutch lifter rod, NOTE + Turn the lifter bearing plate of the clutch lifter bearing with your finger. The bsaring plate should turn smocthly end, quietly. Discard the clutch lifter if the bearing platedoes not turn smoothly, "86, ‘87. '88, “89: = Remove the seven clutch friction discs and six clutch plates. Atter 89: Remove the eight clutch friction discs and seven clutch plates, Streighten the tabs of the lock washer. Hold the clutch center with the clutch center holder Remove the lock nut, lock washer and thrust washer. Remove the clutch center. aT OR EQUIVALENT COMMERCIALLY AVAILABLE “I (3) CLUTCH CENTER HOLDER 07724-00500 USA. RIDE RED 8-5CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Remove the thrust washer and clutch outer. Romove the needle bearing and clutch outer guide. CLUTCH LIFTER LEVER REMOVAL RCH CAGLE "86, '87, '88, 'B9: Remove the spring and clutch lifter lever from the left erank- CLUTCH LIFTER LEVER INSPECTION ‘Check the cluteh lifter lever for damage. Check the oll seal for wear or damage. CLUTCH LIFTER LEVER INSTALLATION Coat the clutch lifter lever with a paste grease with 40% or mote molybdenum disulfide (page 2-3) then install the clutch Tier ever an spring A Install the removed parts in the reverse order of removal Reinstall the alternator cover. molybdenum disulfide (Check ignition timing and clutch operation. paste grease 8-6 RIDE REDCLUTCH/GEARSHIFT LINKAGE/KICKSTARTER "86, 67, 88, 69: INSPECTION (1) CLUTCH LIFTER, \ ‘CLUTCH UFTER/STEEL BALL 'R6, ‘87, 8, '29: Check the clutch lifter and stee! ball for damage. After ‘89 Turn the lifter plate with your finger, check that the clutch litter needle besring turns smoothly Replace the bearing and stop ring as a set % OK \| Bs U (3) Stee BALL (2) LeTeR PLATE CLUTCH LIFTER ROD. (1) CLUTCH LIFTER ROD Check the clutch lifter rad for damage, and straightness. CLUTCH SPRING Measure each clutch spring's free lenath. SERVICE LIMIT: "86: 41.5 mm (1.63 in} "87, ‘88: 41.3 mm (1.63 in} "89: 43.0 mm (1.69 in} After 89: 42.4 mm (1.67 in) te NOTE ge ff RIDE REDCLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Check for plate warsage on a surface plate, using a feeler fl snvse. : eo [SERVICE LIMIT; 0.20 mm (0.008 in} % < - Sk ‘CLUTCH OUTER Check the slots in the outer drum from nicks, cuts or Indentations made by the fiction discs. Measure the clutch outer 1D. SERVICE LIMIT: 32.05 mm (1.262 in) Check the needle bearings tor wear or damaga, MAINSHAFT Check the mainshaft surface contacts with the clutch outer guide for wear or damage. CLUTCH OUTER GUIDE Measure the clutch outer guide 0.0. SERVICE Lin 0.0: 27.97 mm (1.101 in) INSTALLATION Install the clutch outer guide and needle bearing onto the main shaft 88 RIDE REDCLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Ingtall the clutch outer and thrust washer. A> «i i | ASHE Install the eluteh center onto the mainshatt Install the thrust washer and a new lock washer onto the main: shatt by aligning the lock wesher tabs with the groove of the clutch center. Nao coce wasren gy (1) CLUTCH CENTER HOLDER 07724—0050001 OR EQUIVALENT COMMERCIALLY AVAILABLE USA, Install the olutch center nut and tighten the nut to the specified torque by holding clutch center with the clutch center holder... ‘TORQUE: 55—65 Nem (5.5~6.5 kg-m, 40-47 ft-lb) ‘After ‘90: 80—84 Nem (8.08.4 kg-m, 58—61 fib) Bend the tabs of the lock washer up against the clutch center RIDE RED 8-9CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Cost the clutch plates with transmission oil ‘86, ‘87, ‘88, ‘89: (1) CLUTCH PLATES Install the seven frietion discs and six clutch plates alternately, B starting with a disc After '88: Install the eight clutch discs and seven clutch plates alternate- ly, starting with @ clutch dis: ‘Apply grease to the steel ball and clutch lifter rod. Insert the clutch lifter rod inte the mainshaft. “86, ‘87, ‘88, ‘89: Insert the steel ball into the clutch lifter and install the clutch lifter. After ‘89: Install the clutch lifter anto the rod @nseecea | Ma OUrcn urren a Gbron ure (2) eRESSURE PLATE Install the clutch pressure plate. 1) O-RING gf Install the six clutch springs and bolts. ae Tighten the bolts in @ criss-cross patten in 2 of 3 steps. ‘TORQUE: 8—12 Nem (0.8—1.2 kg-m, 6-9 fib) ‘86: Inctall tho right crankcase cover (page 8-9). After 'B6: Install a new O-ring with the clutch cover Install the clutch cover and tighten the cover mounting bolts in {2 crisscross pa:torn in 2-3 steps. 8-10 RIDE REDCLUTCHIGEARSHIFT LINKAGE/KICKSTARTER GEARSHIFT LINKAGE REMOVAL Remove the right cranke: ‘eave (page 8-3) and the clutch tooge 8 remove the geurshit pada and pl she gees spina cut Sw (1) GeARSHIFT SPINDL Ravers Taanfiny deipglnoeursantngSiormantiit: Tb Aner beitpayes tne a csc kt anny ear apace nea (a) GeARsHiET Senne , dremeur ‘ Ma |) WasHeR ee ee S ao Sea a ives * - (al anrren cotter conn Saree Raliiove thetewsopot semy Weisner ana venue spring TTyoaum CENTER DISTORT Bye Wii aarboter bloom sash ois enc os o y 14) CENTER PIN 2) RETURN SPRING RIDE RED 8-11CLUTCH/GEARSHIFT LINKAGE/KICKSTARTER GUIDE PLATE ASSEMBLY = (2) RATCHET Apply clean transmission oil to the ratchet pawls, springs and « PAWIS plungers, ie 1) PLUNGERS | eee 2 x .@.- (4) series BE (a) onum suieren Aceomblo the drum shifter, springs, plungers and ratchet (1) SUIDE PLATE ppamis in the guide plate as shown. INSTALLATION CChook the stopper arm and return spring for demoge, Install the stopper arm, return spring and plain washer and tighten the bolt. TORQUE: }0— 14 Nem (1.0-1.4 kg-m, 7—10 ftb) Check the stopper arm for proper operation. Install the dowel pin into shift drum Install the drum center by aligning the hole with the dowel pin Of the shift drum while holding « per arm, (1) HOLE (2) Dowel Py 8-12 RIDE REDCLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Apply Honda Thread Lock or an equivalent to the threads of the drum centar pin and tighten the drum center pin TORQUE: 20-24 Nem (2.0-2.4kg-m, 14—17 feb) Set the drum center'in a position other than neutral \gstall the drum shifter with the quide plate while holding onto the ratchet pawis. Install the guide plate and tighten the bolts. Install the shitter colar onto the drum shifter ‘Assemble and install the gearshift spindle, aligning the return pring with pin and guide plate hole with shifter collar. NOTE + Do not forget to install the thrust washer onto the gearshift spindle. ‘Check that the shift deum turns smoothly. Install the gearshift pedal, Install be clutch (page 8-8) Install the right crarkcase cover (page 8-3) (2) GEARSHIFT SPIND! zee RIDE RED 8-13CLUTCHIGEARSHIFT LINKAGE/KICKSTARTER KICKSTARTER Ti) RETURN SPRING J REMOVAL q ‘ Remove the right crankcase cover (page 8-3) Remove the clutch (page 8 5) Unhook the kickstarter return spring from the crankcase, and pull the kickstarter spindle assembly out Disassemble the spindle by removing the following: | a) RATCHET spring thrust washer and collar. return spring from the kickstartar spindle mi Se ee nn ee Tae 60 00G— | (2) PINION GEAR Check the return spring and ratchet spring for wear or damage. ae 3) KICKSTARTER SPINDLE | a aol 0 five RATCHET SPRING So cc IDLER GEAR REMOVAL Remove the right cranksase caver (page &-2) Remove the cluteh (page 8-5, Remove the idle gear and bushing IDLER GEAR/KICKSTARTER INSPECTION Measure the ilar gear 11. SERVICE LIMIT: 20.07 mm (0.790 in) Measure the countershett 0.0. SERVICE LIMIT: 16.95 mm (0.667 in) Measure the idler gear bushing |.D. ‘SERVICE LIMIT: 17.04 mm (0.671 in) Measure the idlet gear bushing 0.0, SERVICE LIMIT: 19.96 min (0-780 in <4 ann® / 3) COUNTER (IDLER GEAR (2) BUSHING [@ H COUNT 8-14 RIDE REDCLUTCH/GEARSHIFT LINKAGE/KICKSTARTER Measure the kickstarter spindle 0.0, SERVICE LIMIT: 21.95 mm (0.864 in} Measute the tickstarter pinion gear |.D. SERVICE LIMIT: 22.06 mm (0.669 in) a (1) PINION GEAR (21K! ASSEMBLY a= — Assemble the kickstarter spindle following the below proce. | (4) CQLAR Install the kickstarter pinion and circlip. Install the thrust washer, and return spring aligning the spring fend with the hola in the shaft Install the collar, aligning the groove of the collar with the spring, and irstall the thrust washer. 5 (2) RETURN 3) WASHERS Sree Install the starter ratchet, aligning the aunch marke (1) RATCHET Install the ratchet spring and thiust washer. TS ruven MARKS INSTALLATION Install the starter idle gear bushing and idle geer onto the countershatt, Insta the kickstarter spindle and hook the return spring end to the crankease as shown, Install the clutch ipage 8:8. Install the right crankcase cover (page 8-3) (2) HOOK RIDERED 8-15TRANSMISSION/CRANKSHAFT/CRANKCASE 9-0 RIDE RED c9. TRANSMISSION/CRANKSHAFT/CRANKCASE SERVICE INFORMATION 91 CRANKSHAFT a8 ‘TROUBLESHOOTING 9-2 CRANKCASE BEARING CRANKCASE SEPARATION ag; HEPEAGEMENE et ‘TRANSMISSION DISASSEMBLY 9-4 CRANKCASE ASSEMBLY on ‘TRANSMISSION INSTALLATION 97 SERVICE INFORMATION GENERAL ‘© The crankcase halves must be separated to service the transmission and crankshaft. Remove the following parts before separating the crankcase + Clutch (section 8) + Kickstarter (section 8) + Gearshift linkage (section 8) + Cylinder head (section 6) + Alternator (section 15) + Cylinder/pston (section 6) SPECIFICATIONS mm tiny TEM STANDARD SERVICE LMT Shift fork 1.0. € "86, 87. 11,000—11.021 (0.4330—0.4339) 11.04 (0.435) ‘Atter'@7: | _11,003—11.021 (0.4332~0.4339) | 11.08 (0.435) ma 121981=12.080 (6.4740~0.6740) | 1207 (0.478) Shift fork pew! thickness 4,935.00 (0.194—0.197) 4.80.19) Shift fork shaft 0.9, ¢ 70.966— 10.984 10.4917-0.4828 | 10.95 (0.431) — iL 11 40411 .82 ©.4729-0.471@) | 11.9810.472) Gear 1D Ma ge 28.007—26.028 (1.1026-1.1035) | 2805 (1.108) [TMS gear 25,020~76.041 (0.9860 0.9809) | 25.07 0887 1 gear 22.020--22.041 (0.8669~0.8678) | 22.07 (0.869) [eo 30.020- 30.041 (1.1819- 1.1827) | 30.07 (1.184) [ee scr —_~*|_26.020-26.04; (0.9850-0.9859) | 250710987) | Manshalt 0.0. at M5 gear 24,959—74.980 (0.9926 0.9835) | 24.94 (0.982) | Countershatt 0.0 ‘At C3 goar 24.959-24.979 (0.9826~0.9839) | 24.96 (0.983) ‘At C2 bushing 26.959—26.980 =1,0622) | 28.94 11.081) | ‘At Ci bushing 18.959- 18.980 (0.7464~0.7472) 18.94 (0.746) Bushing 10. cr 19.000 19.021 ©.7480--0.7489) | 19.04 (0.760) _| 2 27,000—27.021 (1.0830— 1.0638) 27.04 (1.064) | Bushing 0.0. CI 21.978 22,000 (0.8653 0.8661) 21.95 0.864) | c2 29.979-90,000 (1.1802 1.1811) | 29.95 (1.178) [oma 27.959—27.980 (1.1007 1.1015) 27.94 (1.100) Connecting rod big end side clea 0.2-0.6 (0.01 0.02) 0710.03) Connecting ‘od big end 86 ‘87; | _0008-0.020 (0.0003—-0,0008) 0.03 (0,001) exiauradial lay ‘After’87, | _0.010-0.022 (0.0004 0.0008) 0.03 (0.001) [ere perma cunout L = = {105 10.002) Wie RIDE RED 9-1‘TRANSMISSION/CRANKSHAFT/CRANKCASE TORQUE VALUES Primary drive gear bolt Drive sprocket bolt Countershaft bearing set plate TOOLS Special Crankcase puller Universal bearing puller Assembly bolt Assembly collar Threaded adapter Bearing remover, 17 mm Remover handle Remover weight Common Universal holder Attachment, 82x 88 mm ‘Attachment, 62 x 68 mm Pitot, 17 mm Pilot, 22 mm ('88, ’87) Attachment. 42 x 47 mm Attachment. 37 x 40 mm Pilot, 25 mim Pilot, 28 mm Driver Gear holder TROUBLESHOOTING Engine Vibration + Excessive crankshatt runout Engine Noise Worn crankpin bearng + Worn crankshaft bearingls) Worn tranern sion boaringts} Transmission Jumps Out Of Gaar + Gear dogs and holes worn + Shift fork bent or damaged + Shift fork shaft ber + Shift drum stopper damaged Hard To Shite + Clutch not adusted propely Shift fork bent Shift fork shaft bent + Shift spindle pawl bent or damaged 40-50 Nem (4,-5.0 kg-mn, 29-36 fr} 26 29Nem (2.6 2.9kgm, 18-21 frlb) 8-12 Nem (0.81.2 kgm, 6-9 fe-lb] Apply I ing agent to the threads 073374300000 (07831 —0010000 or Equivalent commercially available in U.S.A. (07965~1660200 079651660301 07365~KA30000 073363710300 073363710100 077410010201 or 079383710200 077250030000 077460010400 077460010500 077460040400 077460041000 07460010300 077460010200 077460040600 077460041100 07749-0010000 077240010100 or Equivalent commercially available in U.S.A, + Worn or damaged shift drum cam grooves RIDE RED‘TRANSMISSION/CRANKSHAFT/CRANKCASE CRANKCASE SEPARATION CRANKCASE SEPARATION Remove the engine from the frame [Section 5). Remove the following: Cvlinder head) Cylinder Section 6 Fiston J Cuteh Gearshift tinkage | Section 8 Kick starter Alternator Section 15. Remove the engine mounting colar, Remove the dive sprocket guar and drive chain quide by re moving the two bolts, Loosen the drive sprocket bolt by holding the drive sprocket with the universal holder. <¢ Install the clutch outer guide, needle bearing and clutch outer WIV GEAR HOLDER 077240010100 4 ‘reo the molshan and stiach the gaarNeldet btwaen the pr OR EQUIVALENT ConivERCAL ge outer guide. By ® as ia_—_ lntaig RIDE RED 93‘TRANSMISSION/CRANKSHAFT/CRANKCASE Remove the crankcase bolts. ‘Attach the cranksase puller to the left crankcase, (2) CRANKCASE PULLER Remove the left crankcase wile taping the cases 8 few times 678374300000 with @ soft hammer. er cAUTION + Do not pry the crankcase halves apar i () Cer pees une ele ene (CRANKCASE. river. Romove the gasket and dowel pins. TRANSMISSION DISASSEMBLY \», Hal GEARSHIFT FORK/SHIFT DRUM/ TRANSMISSION GEAR REMOVAL (1) SHIET ORUM Separate the crankcase halves, Remove the dowel pins and gasket. (2) SHIFT FORK Remove the shift fork shafts and shift forks. _ Remove the shift drum, Remove the mainshaft and countershatt assemblies as a set. (1) MAINSHAFT. (2), COUNTERSHAFT from the right crankcase. 9-4 RIDE RED‘TRANSMISSION/CRANKSHAFT/CRANKSASE ——— ‘TRANSMISSION GEAR DISASSEMBLY Ma Ms (1) MAINSHAFT Disessemble the mainshaft and countershaft gears. TRANSMISSION GEAR/SHAFT INSPECTION Inspect each gear for wear or damage and replace if neces- sary, ‘Check the gear teeth and engagement dogs for wear or dam- age. Check the mainshaft and countershaft splines and sliding sur- faces for wear or damage. tp Te 2) COUNTERSHAFT C3 C5 .C1 (2) COUNTERSHAFT (2) COUNTERSHAFT RIDE RED 9-5TRANSMISSION/CRANKSHAFT/CRANKCASE Measure the I. of each spinning gear and the|,.D. and 0.D, of the gear bushings. SERVICE LIMITS: Gear |.D. MS: 25.07 mm (0.987 in} MA: 28.05 mm (1.104 int 1: 22.07 mm (0.869 in) €2: 30.07 mm (1.184 in) C3: 25.07 mm (0.987 in) Bushing L.D. C1: 19.04 mm (0.760 in) C2: 27.04 mm (1.084 in) Bushing 0.0. C1: 21.95 mm (0.864 in} 62; 29.95 mm (1.173 in) Ma: 27.94 mm {1.100 in) ‘Measure the 0D. of the mainchaft and countershaftin the lo cations shown, SERVICE LIMITS: ‘AIMS gear: 24.94 mm (0,982 in) 8 (C2 bushing): 26.94 mm (1.061 in) © (C3gearl: 24.96 mm (0.983 in) D (C1 bushing): 18.94 mm (0.748 in) SHIFT FORK/SHIFT FORK SHAFT/ SHIFT DURM INSPECTION Check that the shift forks are not bent, worn or damaged. Measure the I.D. and shift pawl thickness. SEAVICE LIMITS: Pav thickness: 4.8 mm (0.19 in) 1LD.: RIL: 12.07 mm (0.478 in} 211,04 mm (0.435 in} (Check that the fork shafts are not bent, worn, or damaged. Measure the O.D. of tho fork shafts. SERVICE LIMIT: RIL: 11.98 mm (0.472 in} C: 10.95 mm (0.431 ind i ss + mel (1) RIL SHIFT FoRK SHAFT / (2) CENTER SHIFT FORK SHAFT 9-6 RIDE RED‘TRANSMISSION/CRANKSHAFT/CRANKCASE Inspect the shift drum grooves. bs vs Foplace the drum if the grooves are damaged or show exces 1) Stier Deut sive weer. TRANSMISSION BEARING INSPECTION Tum the inner race of each bearing with your finger. The bear ings should turn smoothly and quietly Remove and discard the bearings if the races do not turn smoothly For bearing replacement, see page 9-10, TRANSMISSION INSTALLATION Clean the erankease Assemble the transmission gears and shafts Coat each gear with transmission oll and check for smooth movernent Engage the manshatt and countershatt gears and place into (1) MAINSHAFT——w lez) COUNTER ‘the right crankcase, RIDE RED 9-7‘TRANSMISSION/CRANKSHAFT/CRANKCASE 86: Install the shift drum and shitt forks with their marks facing the left crankcase. After ‘86: Install the shift forks and shift drum, NoTE + Face the shift fork marks as follows: — fight and left fork marks to left crankcase — center shift fork merk to right crankeas ‘Slide the shitt fork shafts through the shift forks, and into the ‘crankcase, After installing, check for smooth transmission operation. ‘Assemble the left crankcase onto the right crankcase (page ot), CRANKSHAFT REMOVAL, moving, installing and inspecting the crankshaft, ‘ul nat to damage or nick the crank weights. ‘Separate the ciankcase (page 9-2). Remove tha transmission (page 9-4) Remove the crankshaft from the right crankcase by using a hy draulic press, as shown. CRANKSHAFT BEARING REMOVAL Remove both crankshaft bearings using a bearing puller, if ‘they are left on the crankshaft CRANKSHAFT BEARING INSPECTION ‘Tum the inner race of each bearing with your finger. The bear ings should turn smoothly and quietly Replace the bearings if the races do not turn smoothly. (1) BEARING PULLER, (07631—0010000 OR EQUIVALENT COMMERCIALLY AVAILABLE IN USA. RIDE REDTRANSMISSION/CRANKSHAFT/CRANKCASE CRANKSHAFT INSPECTION ‘Measure the crankshaft runout. SERVICE LIMIT: 0.05 mm (0.002 in) ‘Support the crankshaft at points (A)end 8) and then measure the runout at points (6) and ©) H runout exceeds the service limit, replace the crankshaft Measure the connecting rod big end side clearance. SERVICE LIMIT: 0.7 rom (0.03 in} Hf the clearance is beyond the service limit, replace the crank shatt. Measure the connecting rod big end axiairadie! play. SERVICE LIMIT: 0.03 mm (0.001 in} If the play Is beyond the service limit, replace the cranksheft. Install the piston pin in the connecting rod small end bearing | (1) CONNECTING ROD ‘and chack for bearing play. If there is play, measure the con- necting rod small end I.D. (page 6-8) (2) PISTON PIN H not over the service limit, replace the small end bearing and piston pin. Hf over the service limit, replace the crankshaft INSTALLATION Refer to page 9-12. RIDE RED 9-9‘TRANSMISSION/CRANKSHAFT/CRANKCASE CRANKCASE BEARING REPLACEMENT (1) OWL seats CRANKSHAFT BEARINGS. Remove the crankshalt ol seals and bearings from both crank: :. a \ ad MORNE oT ee eee Bet Shin 09940" 6001100 TRANSMISSION BEARING REPLACEMENT (1 counrensnact err BEARING SET PLATES, BEARING, LEFT CRANKCASE BEARINGS Remove the manshaft bearing Remove the countarehatt bearing eet plates by removing the Remove the gearshift drum bearing. (4) DRUM, BEARING (3) BEARING REMOVER 07936 — 3710 REMOVER HANDLE 07836--3710100 REMOVER WEIGHT 077416010201 OR (07836- 3710200 Remove the countershaft oll seal and countershatt bearing 11) OW SEAL from the left crankcase. (2) COUNTERSHAFT BEARING 9-10 RIDE REDTRANSMISSION/CRANKSHAFT/CRANKCASE Drive in a new gearshift drum bearing. Driver (07749-01000, Attachment: 86, ‘87: 42x 47 mm 077480010300 After 87: 37 x 40 mm 077450010200 Drive in a new countershaft bearing. Driver (077490010000 Attachment, 62x 56mm 077460010400 Pilot, 22 mm ('86, 87) 07748-0081000, ‘Apply locking agent to the countershaft bearing set plate screws and tighten the screws with the set plates. TORQUE: 8—12 Nem (0.8—1.2 kg-m, 6-9 feb} Drive in a new mainsnatt bearing Apply grease to the lip of the countershatt oil seal andinstal it RIGHT CRANKCASE BEARINGS Remove the mainshaft and countershaft beatings. Remove the shft drum bearing s2t plates and drive out the shift drum bearing toward the inside of the case. Drive in anew mainshaft bearing. Driver Attachment, 52 x 55 mm Pot, 25 mm 077490010000 077480010400 077480040600, Drive in a new gearshift drum bearing. Driver '07749—0010000 Attachment, 42 x 47mm 077450010300 Pilot, 25 mm 07748 — 0040600 Install the gearshift drum set plates and tighten the bolts se- curly. Drive in a new countershatt bearing CRANKCASE ASSEMBLY Clean the crankcase mating surfeces before assembling and check for wear or damage. NOTE «+ if there is minor roughness or iregularties aa the crankcase mating surfaces, dress them with an oil stone. [After cleaning, lubricate the crankshaft bearings with clean 2-strote oll + Lubricate the transmission bearings with transmission cil, RIDE RED (1) MAINSHAFT BEARING DRIVER 077490010000 RE AER age (4) COUNTERSHAFT BEARING] a) MAINSHAFT BEARING, (1) COUNTERSHAFT BEARING DRIVER 077490010000 ATTACHMENT, 37 x 40 mm (07746 -0010200 PILOT, 17 mm 07746—0040400‘TRANSMISSION/CRANKSHAFT/CRANKCASE. Install the thre Jed adaptor onto the erankshatt i (1) THREADED. "| Apaptor (07965~-KA30000 Inscall the crankshaft into the right crankcase using the special tools Toots: ASSEMBLY BOLT 07965—1660200 ASSEMBLY COLLAR 07965~ 1660301 THREADED ADAPTOR 07965—KA30000 (3) ASSEMBLY aoe (2) ASSEMBLY BOLT Assemble the transmission gears and shafts (page 9-7) into (1) DOWEL the right crankcase, PINS (2) GASKET Install the dowel pins and new gasket. Install the crankcase breather tube to the left crankcase. (1) ASSEMBLY BOLT Pace the left crankcase onte the right crankcase and assemble, (07965 1660200 the crankcase halves using the crankcase assembly tool. — (2) LEFT CRANKCASE . (a TuBe SPASSEMEDY cOULAR A eae 9-12 RIDE RED‘TRANSMISSION/CRANKSHAFT/CRANKCASE Pack grease into the cavity between the oil seal lips. ross tho oll seal into the crankcase with the crankcase as- ‘sembly too! until seal Is lush with the case. Toots: ASSEMBLY BOLT 07985~1660200 ASSEMBLY COLLAR 07985—1660301 Install and tighten the crenkcase bolts. NOTE + Tighton the bolts in @ criss-cross pattern in 2 to 3 stops. ‘Trim the protruding gasket material from the cylinder base gaekar surface ‘CAUTION + Do mot let gasket material fall into the crankcase + Do mot damage the base gasket surface Goat the O-ring and the inside of the collar with grease. ino-nine Install the O-rng and collar onto the countershatt. (2) COLLAR Install the dtive sprocket onto the countershatt as shown. (2) WASHER 11) DRIVE SPROCKET Install the cone washer with the “OUTSIDE” mark out. AT IN Hold the drive spracket with the universal holder and tighten the sprocket bolt to the specified torque. TooL: UNIVERSAL HOLDER 07728—0030000 TORQUE: 25-29 Nem (2.5—2.9 ka-m, 18-21 ftib) RIDE RED‘TRANSMISSION/CRANKSHAFT/CRANKCASE Instat the collar onto the crankshaft Install the primary drive gear as shown, Install the cone spring washer with the “OUT” mark facing out. Install the clutch outer guide. needle bearing and clutch outer ‘onto the mainshaft and attach the gear holder between the pri maty drive and driven gears Tioh the primary drive gear bolt TORQUE: 40-50 Nem (4.05.0 kgm, 29~36 feb) Install the remaining pants in the reverse order of removal. + Kickstarter (Page 8:15) + Shift linkage (Page 8:12) + Cluteh (Page 88) + Cylinder head and cylinder (Page 6-4,6-8) + Alternator (Page 15-4) + Engine (Seetion 5) (1) COLLAR in eriniany DRIVE CEART A (2) CLUTCH OUTER 9-14 RIDE REDMemoCOOLING SYSTEM a 6-8 Nem (0.8-0.8 kgm, 4-6 fib) 8-12 Nem (0.8—1.2 kg-m, 6-9 fib) 10—14 Nem (1.01.4 kgm, 7-10 #) Go. 86%) ow a ‘After ‘88; 10—14 Nem (1,0—1.4 kg-m, 710 feb) 10-0 RIDE RED10. COOLING SYSTEM SERVICE INFORMATION 10-1 COOLING SYSTEM INSPECTION 10-2 TROUBLESHOOTING 10-1 RADIATOR 10-4 RADIATOR COOLANT 10-2 WATER PUMP 10-4 SERVICE INFORMATION GENERAL 1@ To service the water pump ssl, remove th right erankease cover All cooling system services can be done with the engine in the frame. ‘© Do not remove the radiator cap when the engine is hot to keep from being scalded. The engine must be cool before servic: ing the cooling system. © Avoid spilling coolant on painted surfaces. After servicing the system, check for leaks. SPECIFICATIONS Recommended coolant Use oniy @ high quality ethylene glycol based antifreeze containing corrosion protection inhibitors specifically recommended for use in aluminum engines. A 160/50 mixtura of anti-freeze and waters recommended for most operating con ditions. (See anti-freaza container label for other mixture ratios) Coolant capacity "86, ‘87: 0.99 lit (1.046 US at, 0.871 Imp qt) at disessembly 0.95 it (1.014 US at, 0.845 Imp qt) at coolant change After ‘87: 0,84 lit (0.888 US qt, 0.739 Imp qt) at disassembly 0.81 lit (0.856 US qr, 0.713 Imp qt) at coolent change TORQUE VALUES Weter pump impeller 10-14 Nem |1.0—1.4 kg-m, 7—10 fulb) Coolant drain bolt 8-12 Nem (0.81.2 kgm, 6-9 feb) Water pump cover bolt (After ‘8) 10—14 Nem |1.0—1.4 kg-m, 710 frlb) —larger flange then SH type bolt TOOLS Special Water seal driver 07945~—KA30000 or GN-AH-085-415 (U.S.A. Only) Boating remover sat, 12 mm (079361660001 Not available in U.S.A, — Bearing remover assy, 12 mm (07936~ 1660101 or 07336—1600100 — Remover head, 12 mm 07936—1660110 = Shatt 07936- 1860120 ~ Slider weight 077410010201 or 07836~3710200 Attachment, 28 x 30 mm 07946-1870100 Bearing remover, 7 mm (07931—KA30000 aring ¢fiver, 7 mm. 07946—KA30100 Common Driver 07749--0010000 Pilot, 12mm 07746-0040200 TROUBLESHOOTING Engine temperature too high + Faulty radiator cap Insufficient coolant + Passages blocked in radiator, hoses or water jacket. Gootant leaks + Faulty water pump oll seal = Deterirated water coat jaciincneeieesnT RIDE RED 10-1COOLING SYSTEM RADIATOR COOLANT COOLANT CHANGE + The engine must be cool before servicing the cooling system, or ‘you could be scalded, Remove the radiator cap with the machine upright. Remove the coolant drain bolts at the evlinder and water pump, and drain the coolant (Check that the drain bolt sealing washers are in good cond: ton, then instal the drain bots. TORQUE: 8—12N-m (0.8—1.2 kg-m, 6—9 feb) Pour the recommended 50/50 coolant mixture (page 10-1) slowly through the radiator filer hole up to the filer neck. CAPACITY: '86, ‘87: 0.96 lt (1.014 US gt, 0.845 Imp atl at coolant change After ‘87: 0.81 lit (0.856 US gt, 0.713 Imp qt) at coolant change Lean the machine approximately 20 degrees right and left sev- feral times to blesd air tapped in the cooling system. If the coolant level drops, add more coolant and repeat air bleeding procedure, (1) DRAIN BOLT Install the ‘adiater cap securely, COOLING SYSTEM INSPECTION (1) RADON SHOUD 2) MOUNTING BOLTS RADIATOR CORE/HOSE Remove the radietor shrouds by removing the radiator shroud ‘mounting belts. 10-2 RIDE REDCOOLING SYSTEM Remove the rediator grilles (i) RADIATOR GRILL Chack the radiator fins for clogging, bent fins or other damage. Straighten bent fins and blow out any obstructions between fins Check the radiator cap gasket and spring for damage. \ (1) Hoses Check the water hotes for cracke and replace any, if noses: say. Check the water hose clamps for damage. RADIATOR CAP/RADIATOR (1) COOLING SYSTEM TESTER (COMMERCIALLY AVAILABLE) Prosaure test the radiator cop. Replace the radiator cap i it does not hold pressure, or if raliet pressure is too high o too low. It must hold specified prossure for at least six seconds: NOTE | «| + Before intalng te capin the tester. anol watts seana RADIATOR CAP RELIEF PRESSURE: 110-140 kPa (1.1—1.4 kglem?, 15.6—19.9 ps) Pressurize the radiator, engine and hoses, andchack for leaks. | (1) RADIATOR: CAUTION + Excessive pressure can damage the radiator. Do nol exceed 2.0 Kg/em® (28.4 psi) lest pressure. - Ropar orreplace components if the system wil not hold speci fied pressure for at least six seconds. RIDE RED 10-3COOLING SYSTEM RADIATOR REMOVAL Drain the radiator coolant (page 10-2) jemove the fuel tank (page 4-14 Remove the radiator grils. Loosen the water hose bands and the radiator mounting bolts Remove the radiator (2) MOUNTING BOLTS INSTALLATION Installation ie essentially the reverse order of removal Pour the recommended 50/50 coolant mixture up to the filler neck (page 10-2), After installation, check the radiator and radietor hoses for leaks. WATER PUMP WATER SEAL AND OIL SEAL INSPECTION ‘Chock the inspection hole for signs af coolant or transmission oll leakage Replace the water seal and oll seal if coclant is leaking (page 10-7), Replace the oil seal if oll is leaking (page 10-7). If the inspection nole is blocked with packed dirt or sand, care fully clean out tne hole. Twist a small drill bit between your fir gers while gradually moving it up into the hole. WATER PUMP DISASSEMBLY Drain the radiator coolant (page 10-2) Remove the follawing: ‘water pump cover attaching bolts anc water pump cover — outer gasket and plate (2) GASKET 10-4 RIDE REDCOOLING SYSTEM Then remove: — Inner gasket and dowel pins — impeller and plain washer. ~~ right crankcase cover (page 9:2) wv Y While pressing down on the spring end of the governor rocker arm, loosen and remove the screws and rocker arr. (2) SCREWS After ‘87: he governor epring and spring seats |'86, ’87:). Remove the spring retainer shaft and governor spring (After - (1) RETAINER SHAFT ‘em el Remove the water pump shaft from the right crankcase cover. (i) WATER PUMP SHAFT Chock the water pump shalt end gear to be sure they are not bent or otherwise damaged. RIDE RED 10-5COOLING SYSTEM WATER PUMP BEARING REPLACEMENT Check the water pump shaft bearing in the fight crankcase caver and right crankease. Turn the inner race of beating with your finger. The bearing should turn smoothly and quietly. Remove and discard the bearing if they do not turn smoothly ‘and quietly using the special tools. Toots: BEARING REMOVER, 12mm 079381680101 — REMOVER HEAD. 12mm 07935—1680110 — SHAFT 079351660120 - (1) REMOVER SET, 12 mm BEARING REMOVER 07935~ 1650100 SLIDER WEIGHT 077410010201 or 07935—3710200 * (1) Driver 3 077480070000 Inatell a new beating into the right erankcase cover. (2) ATTACHMENT, 28 x 30 mm 07946—1870100 (2) PLOT, 12mm (077460040200 Remove the water pump shaft bearing from the right crank case using the special tool Drive in the new water pump shaft bearing intothe right crank: case using the special too! Bae (1) BEARING DRIVER, 7mm 07946—KA30100 10-6 RIDE REDCOOLING SYSTEM WATER SEAL AND OIL SEAL REPLACEMENT Remove the water pump bearing from the right crankcase: cover (page 10:6) Remove the cil seal and bearing. Drive out the worn or damaged water seal from the right ‘crankcase cover. Install the new water seal into the right crank NOTE + Do not damage the water seat lips. + Apply grease to the lip of a new oil seal Install a new bearing and oil seal WATER PUMP ASSEMBLY Install the following ~ oil seal, bearing and water seal (pages 10-6 ané 7), — water pump shaft and gear into the right crankcase cover — bearing into the sight crankcase (page 10-6) ‘6, ‘97 Install the spring seats and governor spring. Position the goverror rocker arm and tighten the sc pushing the aim against the spring. NOTE + Note the diction of the spring seats. + Align the rocker arm ands with the bosses of the governor. Reinstal the right crankcase cover (page 8-3) After ‘87; Install the governor spring and spring retainer shaft, Position the governor rocker arm and wghten the screws, pushing the aim against the spring NOTE + Align the rocker arm big end with the bosses of the gover Reinstal the right crankcase cover (page 8-2} (2) WATER SEAL (1) DRIVER, 97749- 0910000 Saws (2) PLOT, 12 mm 077480040200 fi x (a) WATER SEAL ORIVER 97945430000 or 13) AMTACHMENT 28% 30 mm GN-AH-065-415 979461870100 (1) RETAINER SHAFT ~— (4) SCREWS: RIDE RED 10-7COOLING SYSTEM Install the following ~ Right crankcase cover (page 8-3). — Plain washer onto the water pump shaft. = Impetier onto the water pump shaft and tighten it. ‘TORQUE: 10-14 Nem (1.01.4 kgm, 7 10 F41b) — New inner gaskat and two dowel pins Plate and a new outer gasket. — Water pump cover with the four bolts. TORQUE (After '88) 10—14 Nem (1.01.4 kgom, 7—10 feb) #1) WATER PUMP: covER Connect the raciator hoses to the water pump. (1) RADIATOR CaP Tighten the hose clamps. | Pour the recommended 50/50 coolant mixture up to the filer eck Bleed air from the cooling system (page 10-2) Install the radiator cap, start the engine and check for leaks. bid 10-8 RIDE REDMEMOFRONT WHEEL/SUSPENSION/STEERING "86,87, "88: 18-26 Nem (1.82.5 kom, woe g > 95-140 Nem (8.5140 kgon, a 89-101 Fb} ‘> 1.2 Nem (0.10.2 km, ?3—— e 0.81.6 Nem (0.08-0.16 kam, 0.6—1.2 feb) 18-25 N-m (18-25 kg-m, 13-18 feb) 55—70 Nun (5.5—7.0 kam, 40-51 fib) (1.75—2.25 ko-m, 427—16.3 tt} 20-30 Nem (2.0—30 kg-m, 14—22 feb) 10-12 Nem (1.0-1.2 kgm, 7-9 fib) 30-40 Nem {9.0.4.0 ka-m, 22-29 frlb} 11-0 RIDE RED eo eo o 0 o11. FRONT WHEEL/SUSPENSION/STEERING 18-25 Wm [1.82.5 kgm, 13-18 feb} 95-140 Nem 30-40 Nem 9514.0 4g, 30-101 kis) te ae: — - 22-28 tb Fete S Bf 1.75-2.25\¢m, oR 127-163 tb) sxe s | 5 ‘as 20% 8 poe ese 30-34 Num (203.4 kgm ] a 22-28 feb) 12-14.Nm (12-1 kgm, & 9-10 felb) eM) f yf > ‘a9: 32-36 Nem (3.23.6 kgm, 23-26 fb) ~ 90: 24-30 Nm (2.43.0 kgm, 17-22 fe 1b) (4.04.5 kgm, 29-33 feb) "30: 50-5 oss m, 96-40 fe1b) ac (8.09.3 kom, 38-67 "Tb) 11-1FRONT WHEEL/SUSPENSION/STEERING Attr 90: 18-25 em (1.8-2.5 kgm, 13-18 felb} 30-24 Nem (30-34 kom, 2328 trib) 30-40 Nem (3.0-4.0Kq-m, 95— 140 Nem ‘a 3 . 22-28 ftlb) (95-140 kom, 69-101 feb) aa io \ 20-24 Nem (20-24 ko-m, 14-17 eo) 80-93 Nem (8.0-9.3 kgm, 58-67 ft-lb} / 2B~34 Nem (2.8—3.4 kom, 20—25 fri) 10-12 Nem (1.01.2 kgm, 7-9 feb) \ 40-50 Nem {.0—5.0 kg-m, 29-36 ‘tb) 11-2 RIDE REDFRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 14-3 FRONT WHEEL 11-8 ‘TROUBLESHOOTING 11-5 FORK 14-15 HANDLEBAR 11-6 STEERING STEM 11-44 SERVICE INFORMATION GENERAL © This section covers maintenance of the front wheel, fork and steering stem. Optional fork springs are avalable. Refer to General Information, Section 1 for detail © A box or workstand is required to support the motorcycle «© For optimum suspension performance, the fork shauld be completely disassembled and cleaned after the first three hours of riding. Thereafter it should be disassembled and cleaned on a regular basis to ensure maximum service from the internal parts SPECIFICATIONS ITEMS STANDARD SERVICE LIMIT ‘Axle runout Front whee! sim runout = 2.0 mm (0.08 in) — 2.0 mmm (0.08 in) aa [560.0 man 28 a) | 48 on 8 562.8 rm (22.16 m) | 57.2 rn (21.98) 0.0 mm (20.08 in) 1504.9 mm (19.88 in) | 503.9 mm (19.84 in 603.0 mm (20.04 in) Fork tube runout = 0.2 mm (0.01 in) 564 ce 119 (687 cc (22.2 02) — Fork oll capacity 0) | = 651 ce (22.0 02] = Fork ol vl 86.87 136 mm (6.95 in c 38 126.88 iy | "a8 118 mn (4.58 in) = "90: 124 mim (4.88 in) = i a | a 7 - a Maximum Pressure Fovk ot pes et ee eee eee RIDE RED 11-3FRONT WHEEL/SUSPENSION/STEERING TORQUE VALUES Steering stem nut Steering head adjusting nut (°86, '87, °88, 89) ‘After 89: Fork tube pinch bolt (Top) "88, ’87, ’88, '89), ‘After ‘89: (Bottom) ('86, ‘87, ‘88, ‘@9) After ‘89 Handlebar upper holder Handlebar lower holde "86, "87, ‘88) Front axle (86, "87, "88, '89), After ‘89: Front axle holder Spoke Fork cap 86, °87, °98) After ‘88: Fork drain bolt ('86, '87, '88) Fork center bolt "86, '87, "38) 89) 30) After ‘90: Rim took Front brake disc retaining bok ('86, ’87, "88, "89) ‘after ‘89: Front wheel hub cover (86, °87, "88 '90) ‘After 90, Thvattle hcusing bolt Clutch lever holder bol Master cylinder holder Fork cap leck nut Fork piston retainer Fork boot clamp scrow (86, "87, 88) Front brake caliper mounting bolt ('86, °B7, 'B8) (89) 90) After ‘90: Fork protector batt (after ’38) Front brake hose guide bolt (after '87) 95—140 Nem (9.5~14.0 kgm, 68-101 feb) 1-2 Nem (0.10.2 kg-m,0.7—1,4 Feld 8-12 Nem (0.8—1.2 kg-m, 5—8 fb) 18-25 Nem (1.82.5 kgm, 1318 fe} 30-34 Nem (3.0- 8.4 kg:m, 22 25 ft-tb} 18-25 Nem (1.8~2.5kg-m 13-18 fio) 24-30 Nem (2.43.0 kam, 17-22 feo} 18-25 Nem (1.82.5 kgm, 13-18 feb) 30-40 Nem (3.04.0 kg-m, 22-29 ft-b} 55-70 Nem (5.5—7.0 kgm, 40-51 fb) 80-93 Nem (8.09.3 kg-m, 68-87 ft-b) 1012 Nem (1.01.2 kg-m, 7—9 ftp) 2.55.0 Nem (0.25~0.50 kg-m, 1.8—3.6 ft-lb) 15-30 Nm |1.5- 3.0 kgm, 11-22 feb) 9040 Nem [3.0—4.0 kg-m, 2229 ft-bo) 6-9 Nem (0.60.9 ko-m. 4-7 feb) 30-40 Nm (3.04.0 kg-m, 2229 fb) 40~45 Nem (4.04.8 kg-m, 29-33 tt) 50-55 Nim (5.0—5.5kg-m, 36-40 ft-lb) 40-50 Nem (4.05.0 kg-m, 29~36 ft 10—15 Nom (1.0—1.8kg-m, 7—11 feb} 14-16 Nem (1.41.6 kam, 10-12 ft 40-45 Nem (4.0-4.8 kg rm 20-33 feb) 1.0-2.0 Nem (0.10.2 kg-m, 0.7-1.4 ft-lb) 0.5-1.0 Nem (0.05—0.1 kgm, 3.8—0.7 fr.lb) 12 Nem (0.8—1.2 kg-m, 6-9 fb} 12. Nem (0.8-1.2kg-m, 6—9 fib} 2 Nem (0.8-1.2 kg-m, 69 fr} 12=15 Num (1.2~1.8kg-m,9—11 ft-lb) 17.5=22.5 Nem (1,78—2.26 kgm, 12,7—16.3 ft-lb) 20-24 Nem (2.0—2.4 kg-m, 14—17 fb) 36 Nem (0.30.6 kom, 2.24.3 feb) 0.81.6 Nem (0,08-0.16 kg-m, 0.6—1.2 ft-lb) 20-30 Nom (2.03.0 kg-m, 14-22 flo) 32-36 Nem (3.2-3.6 kg-m, 23-26 fro) 24-30 Nem (2.4—3.0kg-mm, 1722 feb) 28—34 Nem (2.8—3,4 kg-m, 20-50 fi-lb)— Apply a locking agent 10 the threads 12-14 Nem (1.2—1.4kg-m, 910 feb) 4.5—6.0 Nem (0,450.60 kg-m, 3.34.3 ftb) SSS 11-4TOOLS Si Ramana ri Sua wen saver Font soa dvr 8.87, "8 Folk sealer tachment 98,87, "8} fren tons CS8r°87 68 Oars: Sus cote hole (ater 28) Syende tae Ator 3) Oitseletver ator 8) Co common Driver Pilot, 17 mm Bearing remover head, 17 mm Bearing remover shaft Socket wrench, 30 x 32 mm Extension bar Attachment, 42 x 47 mm ‘Attachment, 32 x 36 mm Spoke wiench C, 6.8.x 6.1 mm Attachment, 52 x 55 mm (After ‘89) we TROUBLESHOOTING Hard steering + Steering head adjusting nut too tight Faulty steorng head bearings + Damaged steering head bearing Insuificient tie pressure ‘Steers to one side or does not track stesight + Bent fork tube + Bent front axl, whee! installed incorrectly + Unequal air pressure in each fork log + Unegual oil quantity in each Terk leg Front whee! wobbling ‘Bont en | Warton wheatnestrate + ent spokes + Faulty tire + Axle not tightened properly Soft suspension + Fork ol level too low + Fork ai viseasity 269 thin eu + Weak fork springs-—if tree length is OK, go to optional sttfer sping FRONT WHEEL/SUSPENSION/STEERING (079594250002 01 07953—MJ1000A (U.S.A. only) (079464300101 a; 07946 —M800000 and GN—HTS4 |U.S.A. only (07316 -KA5O100 (07347 -KA5O100 (07347—KAaC200 ‘O7GMA-KS70100 (073484830100 ‘OTKME-KZ30200 ot 07985 -MA60000 (OJKMB -K230100 or O7KMB—KZ3010A (US.A. only) O7KMzZ—KZ30101 of OTKMZ—KZBOIOA (U.S.A. only) (O7KMD—KZ30100 or 07KMD—K23010A |U.S.A. only) 07749-0010000 077480040800 07748 -0050500 ) 07748-05010 | 077160020400 (97716-02050 07746 -0010300 077460010100 (07701 0020300 o equivalent commercially available in U.S.A. (07746-01040 ‘of equivalent commercially available in U.S.A, Hard suspension + Fork oil evel to0 high (toa much oi) + Fork oil viecosity too thick + Fork tubels) bent andor fork sliders are damaged, Front suspension noise + Slider binding + Insufficiont fluid in fork Fork boks are loose Improper brake performance 'No brake fluid of fluid tow + Brake pads worn + Dise andlor pads contaminated + Lever is contacting throttle; reposition the throttle and master eylinder to their respective punch marks on the handlebar (page 11-7) RIDE RED 11-5FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Remave the mounting bolt and the collar and unhook the hold ing tab. Remove the front number plate. Disconnect the engine stop switch wires, 4) FRONT NUMBER PLATE a Y= (3) ENGINE STOP SWITCH 24 Remove tre wire bands securing the engine stop switch wire (1) ENGINE STOP SWITCH ‘and remove the engine stop switch. (2) WIRE BANDS Disconnect the clutch cable and remove the clutch laver brack- et (3) CLUTCH CABLE (4) CLUTCH CeveR BRACKET Remove the front brake master cylinder and keap it upright to prevent air from entering the system, Remove the throttle housing and disconnect the throttle cable from the throttle grip. P TV FRONT BRAKE (2) THROTTLE MASTER CYLINDER” HOUSING Oo Remove the handlebar holder bolts, upper holders and handle (1) BOLTS: bar. (2) UPPER HOLDERS, 11-6 RIDE REDFRONT WHEEL/SUSPENSION/STEERING INSTALLATION (1) UPPER HOLDERS (4) HANDLE BAR Install the handlebar. Align the punch mark on the handlebar with the top of the lower holders. Place the upper holders on the handlebar with the punch marks facing forward (3) PUNCH MARKS fi Tighten the forward handlebar holdor belts first, then tighten (1) BOLTS, the rear bolts. - (2) LOWER HOLDERS TORQUE: 18-25 N-m (1.8-2.5 kg-m, 13-18 ft-lb] Hf you remove the rubber grip, clean the grip area of the left ‘handlabar and throttle pipe and apply Honda Bond A, Honda Grip Cement (U.3.A. only) to the inside surface of the grips. Wait 3.~6 minutes and install the grips. Rotate the grips for even application of tho adhesive. NOTE + Allow the adhesive to dry for an hour before using Ae hacstsototesegautocset tm motaate yan! Teesite Comect the thot cable and othe tote gi 5 Inst the those by agning the st of he housing with the punch markon te handaber Tighten te upper ol at hon tahtan the aver bl = | TORQUE: 8—12 Nem (0.8—1.2 kg-m, 6-9 feb) (4) PUNCH MARK (1) MASTER CYLINDER. ‘Set the front brake master cylinder on the handle Install the master cylinder holder with the “UP” mark up and ign the end of the holder with the punen mark on the handle bar. Tighten the master cylinder holder bolts as noted below. NOTE + Tighten the upper bolt first, then the lower bolt TORQUE: 8—12 Nem (0.81.2 kg-m, 6-9 ftib) (3) PUNCH MARK (2) “UP MARKC RIDE RED 11-7FRONT WHEEL/SUSPENSION/STEERING Install the clutch lever brackst and holder with the punch mark (1) CLUTCH LEVER BRACKET fon the holder up by aligning the end af the holder with the \ punch mark on the handlebar. NOTE + Tightea the upper bolt fist then the ower bolt TORQUE: 8—12 N-m(0.8—1.2 kg-m, 6-9 fib) Connect the clutch cable. (3) PUNCH MARKS (2) ENGINE STOP SWITCH, Foute the engine stop switch wire Install the engine stop switch on the handlebar Install the engine stop awitch wire bands, Connect the engine stop switch wires. (1) Wine BANDS Install the front number plate (3) ENGINE STOP SWITCH WIRES FRONT WHEEL “A AN REMOVAL ‘ Raise the front wheel off the ground by slacing a workstand or sy Dox under the engine \ ‘86, °B7, "88, '8: Loosen the axle holder nuts and remove the front axle. Flemave the front wheel (1) FRONT AXLE 1} (2) AXLE HOLDER After ‘89: Remove the side axle holder nuts and holders from both fork Remove the front wheel and axle shaft as an assembly SEG =A ee Han ) AXLE SHAFT (2) AXLE HOLDER 11-8 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Remove the eale nut from the axle shaft, then temove the axle a shaft and side collar (AXLE tay Axe NUT INSPECTION AXLE Set the axle in V blocks and measure the rurout. ‘SERVICE LIMIT: 0.2 mm (0.008 in} WHEEL BEARING Turn the Inner race of each bearing with your finger. The bear- ings should turn emoothly and quietly ‘Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the rac smoothly, quietly, of if they fit loosely in the hub, do not tum NOTE + Replace wheal bearings in pars. = For bearings replacement, see page 11-10. FRONT WHEEL RIM Check the rim runout by placing the whee! on a truing stand. ‘Then rotate the whee! by hand, and read the runcut using & dial indicator SERVICE LIMITS: Radial 2.0 mm (0.08 in} Axial 2.0 mm (0.0 Check the spokes and tighten any that are loose. TORQUE: 2.5-5.0 Nem (0.28~0.5 kgm, 18—3.0 fb) RIDE RED 11-9FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY (I)RIGHT SIDE COLLAR (2) LEFT SIDE COLLAR eo "86, '87, ‘88, “89: Remove the right side collar and dust sea. Remove the left side collar and dust seal ‘86, ‘87, '88, After ‘9: Remove the wheel hub cover from the die. Remove the brake disc retaining bolts ard disc. ‘89: Remove the brake disc retaining bolts and disc Remove the wheel hud cover er = \ Seawecrus cover (3) DUST SEAL Sf rm "36,87: ~ (1) DUST SEAL Remave the wheel side washer. (2| WHEEL SIDE WASHER Remove the wi hub, besrings and distance collar from the wheel NOTE + Never reinstall old bearings; once the bearings have been removed, they must be replaced with new ones. Remove the tite, tube, rim band and the tim lock. Remove the spckes and rim from the hub. (1) BEARING REMOVER SHAFT 077460050100 BEARING REMVOER HEAD, 17 mm 077460050500 (OR EQUIVALENT COMMERCIALLY AVAILABLE INUSA 11-10 RIDE REDFRONT WHEEL/SUSPENSION/STEERING ASSEMBLY ie ax SA apres ce sabes st 8 é, | wm soem @ (5) LEFT SIDE me rata 5 ei (7) OIse 7” ey (1) RIGHT SIDE (g, ac COLLAR peaning off (2) BEARING aa Re] PRY (3) LET sive WV / oN COUAR (4) HUB COVER } a ais (8) RIGHT SIDE DISTANCE DUST SEAL After ‘89: (2) BEARING (3) BEARING (51 DISC (4) LEFT SIDE (1) RIGHT SIDE COLLAR, COLLAR \ 9 (9) RIGHT SIDE q DUST SEAL COVER (8) DISTANCE COLLAR (7) LEFT SIDE DUST SEAL RIDE RED 11-11FRONT WHEEL/SUSPENSION/STEERING Place the rim on the work bench. Place the hub with the dise side dawn and begin lacing with new spokes Adjust the hub position so that the distance from the hub left side surtace to the side of rim ig 23.25 mm {0.915 in) as shown, Tighten the spokes in 2 or 3 progressive steps by measuring ‘TORQUE: 2.5—5.0 Nom (0.25—0.5 kg-m, 1.8—3.6 fb) RIM RUNOUT (Radial and Axial); 1.0 mm (0.04 in} maximum Toot: SPOKE WRENCH C, 5.8 x 6.1 mm 077010020300 ‘OR EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A. Install the rim lock, rim band, tube and tive Pack all bearing cavities with grease. Drive in the right bearing first and install the distance collar into place. Drive in the left beating squarely with the sealed side facing ‘out, and make sure that tis fully seatec. BL_ PLOT, 17 mm 077480040400 Install the wheel side washer in the wheel hub (Aker '87 model does not have the whee! side washer.) Pack the dust seal lip with grease and install the left side dust seal "Bo, '87, "88, Atter 89) Inscall the brake disc onto the wheel hub. Tighten the brake diss retaining bolts TORQUE: 186, ‘87, "BB: 14—16 Nem (1.4—1.6kg-m, 10— 12 ftb) After '89: 40-45 Nem (4.0—4.Skg-m, 29-33 ft Clean the brake disc with a high quality degreasing agent Install Wheel hub cover, (2) LEFT SIDE SURFACE 23,25 mm (0.916 in) (ny Aus ) “Ww oust Seay we “(2) WHEEL SIDE WASHER ~ (1) BRAKE DISC RETAINING EOLT——— 11-12FRONT WHEEL/SUSPENSION/STEERING BS shown “9: (1) “DRIVE” MARK Install the whee! hub cover. V7 SS Install the brake disc with its DRIVE mark facing outside. Tighten the brake disc retaining bolts, (@) psc ‘TORQUE: 14—16 Nom (1.4—1.6 kgm, 10~12 feb) Install the loft side collar. Pack the dust sea! lip with grease and install the right side dust eo Install the right side collar INSTALLATION ('86, ‘87, ‘88, ‘89) Fit the caliper over the disc, taking care not to damage the brake pads. Clean the axle shaft and holder. Install the holder with “'UP" facing upwards. Install the axle holder nuts but do not tighten at ths time Tighten the asle to the specified torque. TORQUE: 55-70 Nim (5.5—7.0 kg-m, 40-51 ft-b) With the front brake applied, purp the fork up and down sev- eral times to seat the axle and check front brake operation, Tighten the upper axle holder nuts, then tighten the lower cuts, (1) AXLE, f TORQUE: 10—12 Nun (1.0—1,2 kg-m, 7—9 feb) INSTALLATION (After ‘89) fo Coat the axle shaft with small amount of grease snd insert the asle shaft onto the wheel Install the left side collar and axle nut and tighten the axle nut to the specified torque. (2) AXLE NUT TORQUE: 80-93 N-m (8.0--9.3 kg-m, 5887 fro) RIDE RED 11-13FRONT WHEEL/SUSPENSION/STEERING 90 shown Place the front wheel and axle shaft as an assembly between the fork legs. (1) FRONT. AXLE, (2) HOLDER NUTS CAUTION + Fit the brake caliper over the ise, taking care not to damaze the brake pads. Clean the clamping surfaces of the axle shaft and axle holders. Install the axle holders with the “'UP"’ mark facing upward, Install the side axle holder nuts on both sides and snug them ‘with @ wrench, but do not tighten them to the specified torque at this time. Sung the upper axle holder nuts first, then sung the lower nuts, eG "90 shown: ‘Make sure that the axle nut is seated firmly onto the left fork fg inner surface ‘With the front brake applies, pump the fork up end down sev- feral times to seat the axle and check front brake operation, Tighten both axle holder nuts to the specified torque. ‘Tighten the upper axle holder nuts fist, then tighten the lower puts, (2) HOLDER, NUTS TORQUE: 10-12 Nem (1.01.2 kg-m, 7-9 ftlb) CAUTION When torguing the exle holder nuts, be sure the axle nut is) cated firmly onto the left fork leg inner surface as shown in the |\ litstration on this pege. 11-14 RIDE REDFRONT WHEEL/SUSPENSION/STEERING FORK aft Wiirosttne REMOVAL Remove the front number plate (rage 11-6) "86, '87, '88, ‘89, "90: Remove the valve caps and release the air from each fork tube, CAUTION + Be sure 10 release fork air pressure before disassembling. Loosen the fork upper pinch bolts, then loosen the fork caps, bbut do net remove them yet. CAUTION + Do notuse an adjustable wrench to loosen the fork cops: it may damage the caps "86, '87, ‘88: Romove tho frent whoa! (page 11-8) Remove the brake hose clamp bolts, Remove the caliper mounting bolts and caliper from the left fork leg, (2) CALIPER MOUNTING BOUTS “80, 87, 88: & (1) UPBER PINCH BOLTS I tre fork will be disassembled, loosen the center bolts at the bottom of the sliders, But do not remove them vat. Also, remove the oil drain bolts and drein the ol. _ Loosen the fork boot clamp, fork tube upper pinch bolts and lower pinch boits, then pull the fork tubes down and out (3) FORK BOOT CLAMP. “28, 90: (1) Lowen PINc Botts Tanove he fk protector bolts and prota S< Remove the caliper mounting bolts and caliper from the left a \ ~ A i th — (2) cauiren RIDE RED 11-15FRONT WHEEL/SUSPENSION/STEERING REMOVAL (Aiter '0) ni PINCH Remove the front wheel (page 11-8) Remove the fork protector and brake caliver | When the fork is to be disassembled, loosen the fork cap as follows: Loosen the fork top and bottom pinch bots. Pull the fork tube down approx. 100 mm (2.9 ja) and tighten the bottom pinch bolts Loosen the fork cap, CAUTION + Do nol use an adjustable wrench to loosen the fark caps: it may damage the caps. Loosen the fork bottom pinch bolts, and pull the fork tube (1) 8007 ‘down and out DISASSEMBLY ('86, “87, '88) Loosen the fork boot clamps and emove the boot from the (2) BooT CLAMPS Unthread the fork cap from the fork tube, and slightly com press the fork leg. Pour out the fork oll by pumping the fork leg up and down sev- eralimes oo ‘Move the spring spacer to one side, and loosen the fork cap (1) FORK CAP (2) SPACER. (3) SPRING Jock nut as shown, LOCK NUT £46, "87 ry) Remove the fark cap, spacer, spring seat and fark spring n VG '5) FORK CAP (4) SPRING SEAT 11-16 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Place the fork slider in a vise with a shop towel or sctt jaws to avoid damage. Remove the center bolt. NOTE If the center bolt was loosened before fork removal, you ‘can remove it without clamping the fork in 3 vies Remove the fotk piston connected with the piston rod from the fotk tube Remave the dust seal Remove the oil seal stopper ring ‘CAUTION + Be careful not to seraich the fork tube. In quick successive motions pull the fork tube out of the slider NOTE + The sider bushing is pressed into the slicer and the fork tube tushing, on the end of the fork tube, must force it out Romove the ail lock pioee form the fork slider Remave the oil eal, back-up ring and slider bushing from fork tube Do not remove the fork tube bushing until inspection determi nes it is necessary (page 11-20). (OY CENTER Gr (2) FORK PISTON x ? Ae” ay FORK TUBE a ; (a) PISTON ROD (1) DUST SEAL (2) OIL SEAL STOPPER RING (1) Fork TUBE (21 FORK SLIDER \ f (1) DUST SEAL (a) FORK TUBE \, (2) STOPPER LING BUSHING \ (3) OW SEAL \ \ . 7 6 \Z BUSHING 6 wilt UP RING 11-17FRONT WHEEL/SUSPENSION/STEERING ae Remove the fork piston retainer anc oil lock piece from the fork (1) FORK PISTON (2) RETAINER piston with the retainer wrench, WRENCH wrench 07GMA—KS70100 ° (3) Ol LOCK PIECE Romove the fork cap lack nus [1] FORK CAP LOCK NUT Remove the piston rad from the fork piston, CAUTION + Be careful noi to damage the guide bushing inside the fork \w ober ahe path pon a —=— . : \ (3) PISTON ROD (2) FORK PISTON Remove the fork cap ftom the fork tube. To avoid damaging the dust seal, install the special tool at the |{1) FORK SLIDER | lower end of the slider and lower the fork tube gently onto this SPACER inet te divert oie en ones | SORE ezaoioo | a t21 FORK TUBE ok — KZ30108 = (5.8. only) 11-18 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Remove the fork cap from the piston rod by holding the lock “9: Push the spring collar down, then remove the spring seat, Remova the spring collar and lock nut ‘90: Push the spring collar down, then remove the lock nut. Remave the spring seat and spring coll. Remove the special too! from the slider, CAUTION jen the Jork cap & remaved from the piston rod, the tube can move up and down freely in the slider. Always hold both the fork tube and slide pipe with your hends after removing the ‘Fork cap, or the guide and slide bushings might be damaged and “Fork oil will leak from the fork slider. Remove the fork spring. Pour out the fork oil by pumping the fork lag and piston rod B~10 times. ‘Set the lower end (axle holder) of zhe fork slider in a vise with @ ‘shop towel or soft jaws to avoid damage. Hold the fork cylinder with the special tool Remove the fork center bolt and specie! washer. RIDE RED (1) FORK CAP 2, / (2) LOCK NUT (4) SPRING SEAT 73) COLLAR 90: (2) Lock Nor | _® (1) SPRING SEAT (3) SPRING COLLAR (1) SPRING [ Ty GYENDER HOLoEA ‘O7KMB—KZ30100 or kL. ‘O7KMB—K230108 Tails: ont! (2) center | BOLTFRONT WHEEL/SUSPENSION/STEERING Barove the fot piston od ond ak eine fom the ok) FORK suber -—*(2) FORK CMLINDER Ramave th ston 0 rom th faked S \ 5 \- caution , ‘Be careful not to damage the guide bushing inside the fork ext inder with the threads of piston rod. e a \ \ (2) FORK CYLINDER (3) PISTON ROD. Remove the dust seal and stop ring (1) STOP RING CAUTION + Be careful not to seratch the fork tube. 2) bust SEAL In quick. successive motions, pull the fork slider out of the fark tube. NOTE “The tube bushing is pressed into the ferk tube and must be forced our. Slide the slide bushing off of the fork slider by prying the bushing mating surface with # screwdriver (1) DUST SEAL 12) OL SEAL w (a) Guibe BUSHING * Remove the following from the fork sider — guide bushing back-up ring — stop ring ust s0al CAUTION + Bo not dameze the slider bushing, especialy the sliding surface. prevent loss of tension, do not open the bushing more than (6) wo / (4) SLIDER necessary STOPRING BACK-UPRING ,° BUSHING 11-20 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Check the bushings for damage. Replace them if necessary. Remove the stop ring and slider from slider wes worn to oll seal case surface. Hi necessary, slide the oil saal case down than remove tha stop fing on the fork slider and oil sea! case 12 oll seal case if the NOTE + Tap the oil seal case with soft hammer if i is stuck on the fork tube. DISASSEMBLY (After ‘90) Clean the fork especially the sliding surface ef the fork stder land the bottom of the fork slider around the center bolt belare disassembling the fork caurion + Be careful not to seraich the fork sider or damage the dst seal + When removing the center bolt, turn the compression damping ‘adjuster counterclockwise 10 the softest pation to prevent damage to the needle of the adjuster. (Record the number of clicks 10 the softest position.) Install the fork slider spacer (special tocl) on the axle holder of ‘the slider pipe Hold the fork tube, remove the fork cap and side the fork tube down onto the slider spacer. Held the lock nut anc remove the fork cap from the piston rod. Remove the spring seat from the fork cap. Remave the fork spring CAUTION + When the Jerk cap is removed from the pision rod, the fork slider can move up and down freely in the fork tube. Always hhold both the fork tube and Jork slider with your hands after removing the fork cap, or the guide and slide bushings might be damaged end fork oi! will leak from the fork slider. (1) STOP RING. [on the case) (2) SuDER (4) OW SEAL CASE (3) STOP RING {on the fork tube) (2) FORK CAP (Fon CENTER BOLT [7V FORK SLIDER SPACER (O7KMZ—K230100 or o7kMz— KZ3010A (S.A. only) (2) FORK TUBE (4) AXLE HOLDER 43) DUST seaU’ (1) FORK CAP 210% wut . (3) FORK SPRING (4) SPRING SEAT 11-21FRONT WHEEL/SUSPENSION/STEERING Remove the lock nut and spring guide from the piston rod. (1) SPRING GUIDE (2) Lock NUT We Remove the fork spring. Pour the fork of out of the fork by pumping the fork leg and piston rod 8— 10 times. Setthe lower end (sxle holder) of the fork sliderin a vise with a ‘shop towel or shop Jaws to avoid damage. Loosen and remove the center bolt CAUTION + Do not overtighien ihe vise on the axle holder ‘+ Handle the center bolt carefully 10 prevent the neeile of the bolt from damaging or bent. If the needle is damaged or bent, the compression damping Sree will be impaired Loosen and remove the fork center bolt Remove the sealing washer from the center bolt. NOTE + Ifthe conter bolt le difficult to loosen, tomperarily install the fork spring and cap. Remove the for from the vise. 1) FORK PISTON Remove the fork slider spacer (Special tool) from the fork end. pie Remove the forkpiston from the fork ser. Pour the fark ol out of tha ‘ork piston by pumping the pi rod 8— 10 times. E 11-22 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Remove the dust seal and stop ring. CAUTION + Be careful not to scratch the fork slider Check thet the fork slider moves smoothly in the auter tube. If itdoes not. check tho fork slider ‘or ber or damage, and the bushings for wear or damage (page 11-26). Hf the fork slider and bushings are mormel, check the outer tube. In quick euceeseive motions, pull the fork al tube. Jor out of the fork, NOTE + Tho guide bushing @ pressed into the outer tube and must be forced out. Slide the slider bushing off of the fork slider by prying the bushing mating surface with a screwdriver CAUTION + Be careful not 10 scratch the teflon coaling of the bushing + Do not pry open the bushing more than necessary Remove the guide bushing, back-up ring, oll seal, stopring and ‘oust seal from the fork slider When the oil leaks between the cil seal case and fork tube, remove the oil seal case and replace the O-ring NOTE Do not remove the ail seal case from the fork tube uniess Move the oil seal case inward and ramave the stapper rg (1) STOP RING (2) bust seat (1) FORK SLIDER (2) FORK TUBE 1) SUDER BUSHI (IY SHDER SUSHING (3) BACK-UP RING / ¥ / / (5) STOP RING (2) GUIDE BUSHING (4) OW SEAL MS (6) DUST SEAL ~ CASE (1) Ol SEAL, (2) ATTACHMENT from the fork tube. ~ Remove tha of sel an utng the spa! too roots: DAtechment, 52x88mm 077460010800 ‘Sh Diver 97748 0010000 Fork eal sas ah peawo_x250200 RIDE RED 11-23FRONT WHEEL/SUSPENSION/STEERING INSPECTION FORK SPRING FREE LENGTH Measure the fork spring free length. SERVICE LIMIT: 86, °87: 548.8 mm (21.61 in) 88: 557.2 mm (21.94 in) "89 "90: 504.9 mm (19.88 in) ‘After ‘90: 503.9 mm (19.84 in} Replace the spring if iis shorter than the service limit. FORK PISTON RING/REBOUND SPRING ('86, '87, '88) Check the fork piston ring for wear or damage. (Check the rebound spring for fatigue or damage PISTON ROD ('86 through 90) ‘Check the piston ring on the end of the piston rod for wear or PISTON ROD/OIL LOCK VALVE {After ‘80) Check the piston rad of the damper for bend, wear or damage. Check the oil lock valve for wear or damage. AAALAAAN v (1) PISTON RING. (2) FORK PISTON (3) REBOUND SPRING "86 shown (1) PISTON FING (1) OL LOCK VALVE = / > / © / ‘ / (2) PISTON ROD ———* 11-24 RIDE REDFRONT WHEEL/SUSPENSION/STEERING SPRING COLLAR ('89, '90) Check the spring collar ring for wear or damage. Replace the ring if necessary. (i) RING “86, “87, “88 shown PISTON ROD/FORK PISTON/FORK TUBE/FORK SLIDER J (1 FORK SLIDER (2) FORK ((86, '87, "88 f \ PISTON Check the piston rod, fork piston, fork tube and Fork sider for S score marks, sctatches, excessive or abnormal wet —~ Replace any components which are worn or damaged. _ ae i (4) FORK TUBE (3) PISTON ROD Atter ‘90 shown: FORK DAMPER/FORK TUBE/FORK SLIDERISPRING GUIDE SpRING ((89 and After cube Chock the fork tubo for damage or deformation SS Check the fork slider, fork cylinder ('89, '90), fork damper (after 90) and spring quide (After ‘90) for scare marks, scrat ches, excessive or abnormal wear. (2) FORK DAMPER} (4) FORK TUBE (3) FORK SUDER ‘Set the fork tube (fork slider, '89 and After) on V-blocks and measure the runout SERVICE LIMIT: 0.2 mm (0,008 in} (1) Fork TUBE RIDE RED 11-25FRONT WHEEL/SUSPENSION/STEERING "86, ‘67, 8B shown: Check the bushings for excessive wear o scratches. (1) FORK TUBE BUSHING ie Hf copper appears on the entire surface orif bushings have any ‘scratches, replace the bushings. Replace the back-up ring if there is distortion, (2 SLIDER BUSHING “ (3) Back-up rins \ CENTER BOLT (1) CENTER BOLT ASSEMBLY “86, ‘87, '88, After ‘90: Check the center bolt assembly and neadle for damage. If the needle has any camage or scratches, replace center bolt assembly, (3) SEALING WASHER (2) NEEDLE "89, ‘90: (1) CENTER BOLT ASSEMBLY (2. O-RING Check the center bolt assembly for damace. i Replace the special washer and O-ring with new ones. ASSEMBLY ('86, ‘87, '88) (0) FORKLEG 919 FORK ruBe \21oust [fa Sea a rd aon 15) SEAL BACKS (3) SPECIAL ashen oe (16) Fon te Se / “/oAP /ousHing iat spacen Rep: fa Ii (18) Piston 117 gan go 0, aoe fat & hai I hoes i (14) FORK PISTON \o7 / |stecia/ Bin / [oi tock (981 Resouno ad fvinsreny, [rome L/ pect Span a) NGG Bin a an, if (24) 0 Lock CHESTER Pp (19) BOTTOM NUT sor OS f ee df (10) RUBBER: (13) FORK TUBE G_-(20) RETAINER / / PLuG: BUSHING UY (28) SPRING 11-26 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Install the piston rod into the fork piston from the bottom (1) FORK PISTON | (2) PISTON ROD Thread the fork cap tock nut on the piston rod: all the way \ down by hand while being careful of the lock nut direction as : shown. cauTION Be os at ee : (2) LOCK NUT + Be careful not 10 damage the walde bushing Inside the fork Se piston with the thread of piston tod. ad (a) more than JO men 0.3 in) instal the bottom pieze inta the fork piston (1) FORK PISTON RETAINER Tighten the teteiner into the fork piston with the retainer wrench, (2) BOTTOM PIECE Toot: s { Teel Sem AH Seekers soe ile =" NOTE Apply fork 01 to the O-ring of bottom pivce and the inner ‘contact surface of fork piston. Check that the retainer edge is inside fork piston ull the piston rod to full extension, slip the fork piston with piston rod into the fork tube. (1) PISTON ROD Pt SF Ks g » mee (2) FORK TUBE oF 3) PORK PISTON ce f(a) REBOUND SPRING sal th oc ples onto he fk pon Ina te se using and aciup ingot the ok tube, 7 FORK TUBE 2) rorK STON (3) SLIDER, (4) OIL LOCK PIECE RIDE RED 11-27FRONT WHEEL/SUSPENSION/STEERING Install the canter holt and spacial wshar Hold the slider in a vise with a shop towel or soft jaws to avoid damage, then tighten the center bolt. TORQUE: 30—40 Nem (3.0—4.0 kg-m, 22~29 feb) NOTE + Turn the compression demping adjuster counterclockwise to the end, before installing + Check the both center bolts ae in the same adjustment po: sition, Place the slider jer bushing over the fork tube untl it rests an the NOTE + Tape the upper edge of the fork tube to avoid damaging the il seat lip, while installing the oil seal Using a fork seal driver and attachment, drive the bushing into place. Install the back-up ring with the chamfered side facing the slider bushing ‘Coat the oil ses! lip with the recommended fork oil Drive the oil seal into place using » fork seal driver and attach- ment Install the oll seal stopper ring and the dust seal. ‘96, "B7 Pour in the specified amount of fork oil, while pushing the piston rod up and down siowly RECOMMENDED Olt: Pro-Honda Suspension Fluid $S-7 or ‘equivalent STANDARD CAPACITY: 564 cc |19.1 02) “88: our the recommanded fork cil into the piston rod until a litle amount of oll lows out of the side bresther hole. Wipe off all oil that flowed out with a clean, lint-free shop towel Next pour the recommended fark ail into the fork tube to the proper level with in the maximum and minimum level, pusting the piston rod up and down slowly, Stroke the fork tube slowly more than five times and the piston rod more than 10 times then, with the fork leg compiately col lapsed, measure the fork oil level from the top of the tube, NOTE + Bia sive the oll lavel isthe same in both fork tubes [STANDARD OIL LEVEL: "86, ‘87: 136 mm (5.35 in) "BB: 124 mm (4.88 in) ————— { (3) DUST SEAL ba (4) STOPPER RING \ (5) OIL SEAL (6) BACK-UP RING (1) FORK SEAL DRIVER 07947-KAS0100 (2) ATTACHMENT 07947~-KA40200 VO (1) om LeveL 1 01 11-28FRONT WHEEL/SUSPENSION/STEERING (2) BREATHER HOLE Maximum | °86: Slightly stiffer ae it level 117 mm (4.61 in) nears full compres- capacity 584 cc (19.802) _ sion "87: 116 mm (4.57 in) (1) OW LeveL 585 cc (19.8 02) 88: 115 mm (4.53 in} 573 cc (19.4 a2) Minimum oi | "86, “87: Shaghtly softer ask fever | 169mm (6.65 in| nears tl compres capacty | 528.0117. 902) | sion "88: 170 mm (6.69 in) 516 oc (17.6 02) Clean the fork spring with high flash point solvent and dry it with alr pressure. Install the spring into the fork tube. Install the spring seat and spacer, slightly comprass the fork, then thiead the fork cap onto the piston rod Tighten the fork cap lock nut, ‘86,87 only TORQUE: \ 17,8— 22. Nem (1,752.25 kg-m, 12.7-16.3 ftb) (2) FORK CAP LOCK Nut NOTE LE Z| + Be careful not to spill the oll out of the fork tubes. (1) FORK BOOT Install the fork cap bolt. to the fork tube but do net tighten it yet. Install the fork boot with its end breather holes onto the slider and side breather holes towards the rear. \Z 2) BREATHER HOLES RIDE RED 11-29FRONT WHEEL/SUSPENSION/STEERING (a) sToP RING {on the oil seal case) ASSEMBLY ('89, '90) (5) O-RING. (6) FORK nas: (1) FORK cap TS assem 9) O-RING. (3) Fon COLLAR 2) / Tue lock uty ae — (18) suven, (22) ag // 07) ou sea MY /] case’ 2 Ts Ol seat case // SEAT STOPPER ih STOP ana Ne J) / gu / / = / Jaa SLIDER ane (4) cuIDE / / / / / ” CYLINDER f L / 15 wd [ * “(ho P ROD (12) = ‘Olt SEAL’ -@ Ra PORE wn onsea A STOP RING 10, i} si (4) SEAT ‘STOPPER —» (10 dais Bust seAt «v9 toe ans «1 Fore « (8) sean ong: (18) oN (2) O- mt (9) FORK (17) OL SEAL ee CA Stor (sr tock nu \ ang QS std SS 0 a © f 413) on : / vian\ fai cue seal sustine (| | | (5) FORK cyuinper —»/ 2) j SUDER oS | /eusHing’ fii ees | [packs | RING Sisson 4 oe / SEAL e758 — oN oust | SEAL (10) OWL SEAL (23) SEALING STOP RING (ni cab WASHER (7) SPRING (22) FORK (6) PISTON Center ROD BolT RIDE RED 11-30FRONT WHEEL/SUSPENSION/STEERING Install a naw O-ring in the oil seal case groove. Apply small amount of oil to the O-ring Install the oll seal case onto the fork tube. (1) OW SEAL CASE Install the stop ring in the fork tue groove. Pull the oll seal case until it seats against the stop ring (2) STOP RING Wrap the end ofthe fork slider with tepe (1 bust SEAL Cost new seal ips with fork oi ts canawls Install the following onto the fork slider: — Dust seal — Stop ring = Oil se (3) TAPE NOTE + Install the oll seal with its marked side facing the dust seal (4) O1L SEAL Remove the tape trom the fork sider. ~ Back-up ring (1) BACK-UP FING = Guide bushing > = Slider bushing tg NOTE + Remove the burrs from the bushing, taking care not to peel off its coating. (2) SUDER BUSHING ‘Tape or tio the dust seal and stop ring, so it won't get in the way. (3) GUIDE BUSHING RIDE RED 11-31FRONT WHEEL/SUSPENSION/STEERING Install the fork slider into the fork tube. (1) FORK TUBE Hold the oil seal case using the special tool as shown. (1) OIL SEAL DRIVER (@) DUST SEAL Drive the guide bushing with the back-up ring into the fork O7KMD—KZ30100 or ) tube frst using the special to) o7kMD- Drive the ol sealinto ol seal case using the special too (ped 230108 | a) stop INS } 4 WSA. only) Install the stop rng and dst soa | 4 Sy | wyou seat f { \ esr exccue CAUTION RING | ~The ork tab car mane aad da rayon the Jr » | wrcue | © susnine Always hold both the Jork slider and fork tbe with your hands, or the guide and slider bushings and dust seal might be damased. ) SEAL CASE HOLDER O7KMB.~K230200 or 07966 -MASO000 To avold damaging the dust seal, install the special tool page (1) FORK CYLINDER 11-18), Install the piston rod into the fork cylinder from the bottom. CAUTION + Be careful not to damage the guide bushing inside the Fork cylinder with the threads of piston rod. (2) PISTON ROD Install the fork evlinder and piston rod into the fork sider (1) FORK TUBE x (2) FORK CYLINDER 11-32 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Install the fork center bott Hold the fork with a vise with soft jaws or a shop towel and hold the fork cylinder using the special toa! Tighten the fork center bok. TORQUE: 89: 40—45 Nem (4.0~4.5 kgm, 29-33 fulb) ‘30: 50-55 Nem (5.0~5.5 kgm, 36-40 feb) NOTE + Check that both of the damping adjusters adjustment position "90: Temporarly install the lock nut on the pisten rod with its cutout facing up so as not ta drop the rod ina the cylinder, Tighten it by hand as far as it goes. Collapse the fork leg completely onto the special fork spacer. NOTE + You must use the fork slider spacer (PIN O7KMZ KZ30101) to make an accurste oll level adjustment Pour half the amount of the recommended forkil inte the fore tube. Pour the recommended fork oil inte the giston rod until a small ‘amount of oil flows out from the side treather hole with the piston rod at minimum stroke Pump the piston rod and fork log slowly & Compress the fark leg fully and leave it for 5 minutes to sertle sho oil Io 10 times. Measure the fork oil level from the top of the tube. RECOMMENDED OIL: "89: Pro Honda Suspension Fluid ‘88-7 or equivalent '90: Pro Honda Suspension Fluid SS.7M (U.S.A. only) oF equivalent STANDARD CAPACITY: ’89: 657 cc (22.2 02) “90: 640 cc (21.6 o2) STANDARD OIL LEVEL: ‘89: 115 mm (4.53 in} ‘90: 124 mm (4.88 in) (1) CYLINDER HOLDER G7KMB—K230100 or C7KME™KZ30108 U.S.A, on) PR (2 1 Genrer gout (2) LOCK NUT (3) PISTON ROD (1) cur-our A (1) FORK SLIDER, SPACER (O7KMZ~KZ30101 ‘O7KMZ-3010A WS.A. only!FRONT WHEEL/SUSPENSION/STEERING NOTE Be sure the oil level is the same in both fork logs. + Support the fork lag vertically whenever measuring the oil level, Ba | oom csem [SE Wesre | sgzmm som | Sem te on 636 cc (21.5 o2) " torn | saan .crm | Smt ste . ———| “Thvead the lock nut onthe piston reall the way down by hand (1) THREADS until it seats. Clean the fork spring and spring collar with high lash point sol vent and dry with ai pressure Install the spring into the fork tube oe (2) Lock NuT | ROD He ‘90; J) serine Install the spring with tapered end facing up. "COLLAR Use the underside of the fork cap a8 © gouge to determine il which end of the fork spring is tapered. Only the taparedi end will ft inte cap. Install a piece of wire (300 mm/12 in or more length) to the Jock nut tc pull up the piston rod. Install the spring collar ane pull the piston rod up with the wire. (2) WRE Romove the wire from the piston rod. 11-34 RIDE REDFRONT WHEEL/SUSPENSION/STEERING NOTE + Measure the distance between the nut and the top of the piston rod. it should be at least 14 mm (0 85 in) 14 mm (0.98 in) OR MORE "99: Install the seat stopper correctly between the lock nut and cedlar while pushing the collar down against the fork spring tension. ‘90: a (2) LOCK NUT Remove the lock nut. Install the spring seat and lock nut while | pushing down on the collar ‘Screw the lock nut onto the piston rod by hand until it stops. | (1) SPRING There should be 14 mm (0.55 in) of threads showing. =~) ra (3) sPRAIG COLLAR i on the Fork cop. %. (1) FoRK J CAP ‘Aaply ol to a new O-ring and ins Screw the fork cap bolt to the piston rod by hand unti it touch- f¢ the lock nut. ‘Tighten the piston rod lock nut against the fork cap by holding the fork cap. 12) O-RING TORQUE: 17.5~22.5 Nem (1,182.25 kgm, 12.7—16.3 feb) Install the fork cap 10 the fork cube. Remove the spacer from the Fork slider. (3) Lock NUT ee RIDE RED 11-35FRONT WHEEL/SUSPENSION/STEERING NOTE Clean the disassembled parts thoroughly with high flash aint or non ilammable solvent and ay with air pressure before assembly. + Replace the ol seal and dust seal as an assembly. (9) SLIDER BUSHING (1) FORK CaP ——__rm, aad - (2) 0-RING — . SPRING SEAT——wc § , 5 vo | | (5) SPRING GUIDE —e! (srrork Aj GUIDE #—— (15) FORK I fi rupe L/ay Sysusting / SLIDER Boveor CYLINDER, (6) FORK SPRING [| (17) PROTECTOR (1a) oust SEAL (16) CeNTER Bout When the oil seal case was removed. install as follows Install a now O-rng into the eil sea! case Apply recommended ferk oil 1o the O-ring, PS, / (1) Ol Seat case (2) O-RING Coat the end of tho fork tube with the recommended fork ol and install the oil seal case onto the fork 7ube. Instal the stop ring into the groove in the fork tube properly (2) STOP FING (1) OIL SEAL CASE 11-36 RIDEREDFRONT WHEEL/SUSPENSION/STEERING Slide the oil seal case over the stop ting and hold it with the seal case holder Press the fork tube until the stop ring contacts the oil seal case 1) DRIVER ith the special toot *5 | (2) ATTACHMENT, TooLs: 52x55 mm Attachment, 52 x 58 mm 977460010400, ig sf Driver 077490010000 SL BEAL CASE HOLDER wv Seal case holder O7kMB—K230200 ae ‘Wrap the end of the fork slider with a tape (a TAPE Install the cust ‘and stop ring onto the slide pipe j ‘Coat the new oil seal ips with recommended fork oil and install it with the morkinga facing the dust seal = : t (2) 0ST SEAL Install the back-up ring and guide bushing. (STOP RING (2) RACK.UPRING jemove the tape and install the slider bushin \ | Ri h the slider bushing aD ‘ BUSHING Note + Remove the burrs from the slider bushing mating surface being careful not to peel off Its taflon coating, / (3) OL SEAL (4) GUIDE BUSHING ‘Cost the slider bushing and guide bushing with recommended (1) FORK TUBE fork oil and install the fork slider into the fork tube ae a (2) FORK SLIDER RIDE RED 11-37FRONT WHEEL/SUSPENSION/STEERING Hold the ail egal cage using the seal case holder as shown Drive the guide bushing into the fork tube with the backup | (1) OIL SEAL DRIVER fing, using the oil seal driver Drive a new oll seal until the stop ring groove is visible, using the oil seal driver Install the stop ring into the oil seal case groove. | 1 ousr seat |_-(a) STOP RING. | Install a new dust seal (5) OIL SEAL (6) BACK UP RING 07KMD~—Kz30100 PS redise Oil seal case holder ‘07KMB—K230200 q \ BUSHING IS (2) SEAL CASE HOLDER Install the fork piston into the fork slide: wOPORREUEES: Toavoid damaging the fork dust seal and quide bushing, install the fork slider spacer. (1) FORK SUDER, SPACER (2) FORK TUBE Hold the axle holder of the fork slider in the vise with the shop towel or soft jows cauTiON + Do not overtighten the axle holder. (4) FORK SLIDER (3) oust seau (1) CENTER BOLT Install the center bolt with anew sealing washer and tighten it uw ‘TORQUE: 40—50 Nem (4.0~8.0 kgm, 29~36 ft-b) , sa Note If the center bolt turns together with the fork damper, tem Dporarily install the fork spring and fork cap and tighten the center bolt. a 11-38 RIDE REDFRONT WHEEL/SUSPENSION/STEERING Wipe off eny oil from the spring guide. Install te spring guide with the oll holes tacing up. JL LOCK NUE Temporarly install the lock nut with the small diameter end ae ws facing down. (2) OL HOLE PS (3) SPRING GUIDE caumion +The fork slider spacer must be used 10 maintain correct ol eel = and to prevent dst sea! damage = (1) FORK SUDER SPACER, Four the half amount of recommended fork ail into the fork CAUTION * Do not pull up the fork tube more than 300 mm (11.8 in) from the axle holder to extend the fork. The fork oil wil spilt out ‘from oil hole in the fork slider (1) 300 mm Bleed the air {com the Fork as follows: iin 1. Extend the fork, cover the top of the fork tube with your hhand and compress the fork slowly. Repeat the above procedure 2 3 times. 2. With the piston rod fully pushed in, pour the recommended fork oil Pro Honda Suspension Fluid SS-7M, U.S.A. only or ipsret equivalent) into the piston rod until a litle oll lows out from the piston rod end. 2, Pump the fork tube ond piston rod slowly 8 10 times. 4. Pour the recommended fork cil to the specified capacity and repeat step 3 Compress the fork tube fully and leave it for 8 minutes to wow settle the oil vel HOLE RIDE RED 11-39FRONT WHEEL/SUSPENSION/STEERING Measure the oll level from the top of the fork tube. RECOMMENDED OIL: Pro Honda Suspension Fluid 55—7M (U.S.A. only) or equivalent STANDARD OIL CAPACITY: (Per fork leg) 651 cm? (22.9 Imp o2, 22.0 US 02) STANDARD OIL LEVEL: 107 mm (4.21 in) he oil level is the same in both fork slider. (1) OL LeveL Waximar 38mm B74) | Siohily atiferas ol lovel 655 cm? iteart fl eepacity (23.3mp 02, 22.5 | compression Minimum | 124mm (4.88 in) | Slightly softer as pi level 631 em? ie nears fl apacity (22.1 imp o2, 21.8 | compression. US a: Clean the fork spring with high flash point or non flammable solvent and then install it into the fork sider with tapered side facing up, Use the underside of the fork cap as @ gauge to determine which end of the fork spring is tapered, Only the tapered end wil ft into cap Attach 9 600 mm (24 in} length of mechanic’s wire to the lock nut on the piston rod Feed the mechanic's wire up through the fork spring and hola the lock valve. Remove the mechanic's wire from the pistan rod. Thread the lock nut onto the piston rod with its threaded end up. Continue turning the lock nut by hand until it seats. + 14mm | (0.88 in (1) Lock NUT’ Inotalll the opring eet onto the fork epring. Apoly the recommenced fork oil to @ new O-ring and install it onto the fork can, Screw the fork cap on the piston rod. Hold the lock nut and tighten the fork cap. TORQUE: 20—24 Nem (2.0-2.4 kg-m, 14—17 ftlb) Temporarly install the fork cap into the fark tube yur SS (1) sPaING 2) WIRE %3) lock NUT | (1) SPRING (3) LOCK (4) FORK CAP ‘SEAT 481808 (2) SPRING| 11-40FRONT WHEEL/SUSPENSION/STEERING INSTALLATION (86, '87, '88) Ty ove (3) TOP 4) FORK CAP Install the fork tubes in the steering stem and bridge, rotating them as you push them up. Note + Align the groave of the fork tube with the uoper edge of the fork top bridge ('86, °87:) + Align the tops of fork tubes and top bridge ('88:). (6) FORK (6) TOP BRIDGE TUBE i {121 TOP BRIDGE, Tighten the foik tube pinch bolts bottom) (1) PINCH BOLTS TORQUE: 18-25 Nem (1.8—2.5 kg-m, 13—18 fro) Tighten the fork cops. iG FORK Boor clamp |W yl i| TORQUE: 15-30 Nem (1.5—3.0 kg-m, 1122 fb) Tighten the fork tube pinch bolts (top! TORQUE: 18-25 Nem (1.82.8 kg-m, 13-18 feb) Push the fork boots up until they just touch the bottom of the bottom fork brage, then tighten the clamps. Install the brake calipar (page 13:13) Tighten the breke hose clamp bos Install the front whee! (page 11-13). Hf fork air prossure is desired, ne cure the front wheel Is ‘suspended above the ground befare adding ar (page 3-14) Standard fork sir pressure is O kPa (0 kalem®, 0 psi. 39kPa (0.4 kglem?, 6 psil is the maximum, cauTion ‘Use a fow-volume low-pressure pump 10 charge the fork legs with ar. Too much pressure will damage the oil seul ao (2) BRAKE CALIPER, RIDE RED 11-41FRONT WHEEL/SUSPENSION/STEERING INSTALLATION ('89, ’80) Install the fork leg aligning its index groove with the upper sur- face of the top bridge Tighten the lower pinch bolts TORQUE: '89: 18—25 N-m [1.82.5 kgm, 13-18 feb) "90: 2430 Nem |2.4—3.0 kgm, 17—22 ft-lb) cAUTION + Overstightening the pinch bolts can deform the fork tubes. Deformed fork tuber must be replaced. Tighten the fork caps. ‘TORQUE: 30—40 Nem (3.0—4.0 kg-m, 22—29 ft-lb) NOTE + Fork height is adjustable, see page 11-43 and 44 for fork height adjustment. Tighten the upper bricge pinch bolts TORQUE: '89: 18-28 Nem (1.8—2.8 kgm, 13—18 Feb} "90: 30-34 Nem (3.0—3.4 kgm, 22—25 ft-lb) Install the fork protector and tighten the bolts. TORQUE: 12—14 Nem (1.2—1.4.kg-m, 9-10 ft Install the front brake caliper on the left fork leg and tighten the ols NOTE + The longer caliper bolt is for the upper position. ‘TORQUE: '89: 32—36 N-m |3.2—3.6 kg-m, 23-26 ft-lb) "80: 24—30 Nem [2.43.0 kom. 17—22 ft-lb) ‘CAUTION * Do not twist the brake hose when attacking the brake caliper, ar the brake hose may damaged. all the front wheel (page 11-13) Wf fork alt pressure is desired, be sure the front wheel is suspended above the ground before adding air (nage 3-14), ‘Standard fork air pressure Is 0 kPa (O kg/cm, 0 psi ‘39 kPa (0.4 kg/em?, 6 psi is the maximum. CAUTION + Use a low-volume low-pressure pump 10 charge the fork legs with air Too much pressure may damage the oil seas, (1) GROOVE ‘ ‘ 2 ‘CALIPER 11-42 RIDE REDFRONT WHEEL/SUSPENSION/STEERING INSTALLATION (After '90) Insert the fork tube into the fork bottom bridge, clamp it et the position approx. 100 mm [3.9 In} above the standarc clamping, position and tighten the fork cap TORQUE: 30~40 N-m (3.0— 4.0 kg-m, 22~29 feb) Loosen the bottom pinch bolts and insert the fork tube into the fork top briage. ‘Standard position: Align the top surface of the top biidge with the groove 10 mm (0.40 in) below the top of the fork tube. For slterrate positions, see page 1143 and a4. Tighten the fork top pinch bolts. TORQUE: 30-34 (3.0—3.4 ka-m, 22-25 ftlb) Tighten the fork bottom pinch bolts TORQUE: 24—30 (2.4—3.0 kg-m, 17-22 ftlb) CAUTION + Overtightening the pinch bolts ean deform the fark tube Deformed fork tubes must be replaced. Return the compression damping adjuster to ite original posi ton as noted during removal. Apply a locking agent to the caliper mounting bolt threads, Install the fork protector and brake caliper ‘Torque, Fork protector: 12— 14 Nem (1.2—1.4 kg-m, 9—10 ft-lb) Brake caliper: 24-30 Nem (2.4—3.0 kgm, 1722 ft lo) Install the front wheel (oage 11-13) FORK HEIGHT/ANGLE ADJUSTMENT (After ‘88) ‘The position of the fork tubes in the fork bridges is adjustable. ‘The standard position aligns the Index groove with the upper surface of the top bridge STANDARD POSITION: ‘89, ‘90: 6 mm (0.2 in) ‘After ‘90: 10 mm (0.4 in} (at first index groove) NOTE ‘+ Measure from the top of the fork tube. Do not include the fork cap thickness, or the chamfered edge of the tube inthe height measurement. (1) Fork PINCH, BOLTS BA ytd 100 mm (3.9in) A i os PAZ) ECTTON BRIDGE | 41) BRAKE HOSE CLAMP: s iy (3) BRAKE CAL (2) PROTECTOR seams 85 / (gerne nla (1) FORK TUBE (2) INDEX GROOVE POSITION I; 4) STANDARD. RIDE REDFRONT WHEEL/SUSPENSION/STEERING (On long. fast trecks where there are few turns, consider an alternate position with the top of each fork tube flush with the ‘top bridge upper surface. ('88, “89) On long, fast tracks where these ore few turns consider en altenate position with the upper surface of the top bridge pos tioned with § mm (0.2 in) below the top of the fork tube. (After 90) FAST TRACK POSITION: ‘88, ‘BS: 0 mm (0 in} "90: 5 mm (0.2 in) (On tracks where there are many tuene ex poor traction, con sider an alternate position with the upper surface of the top bridge positioned within ’89, ‘90: 12 mm {0.87 in), After ‘90: 17mm (0.87 inl below the top of the fork tube, NOTE + Never position the upper surface of the top bridge more than 12 mm (0.87 in} : '89 and '80 or 17 mm (0.67 in) After ‘90 below tha top of the fork tube. TIGHT TRACKS! POOR TRACTION POSITION: "89, ‘90: 12 mm (0.47 in) 90: 17 mm (0.67 in} STEERING STEM REMOVAL Remove the handlebar (nage 11-6), Remove the front wheel (page 118), Remove the front fender mounting bolts and collars, Remove the front fender. Attor ‘87: Remove the front brake hose guide. 11-44 "88, ‘89. 1) TOP oF Omm sn TUBE 5mm (0.2 in) (1) INDEX Groove (2) POOR TRACTION POSTION 6, '87 shown: (1) FRONT FENDERRemove the steering stem nut, Remove the fork legs (page 11-15). Remove tho fork top bridge. Remove the staering head adjusting nut and washer. Remove the dust seal, upper besring and steering stem from the head pipe. BEARING REPLACEMENT NOTE + Always replace the bearings and bearing races @s 0 sot + To prevent the steering stem threads fram being damaged, tall the steering stem nut onto the thresds, Remove the lower bearing from the steering stem. FRONT WHEEL/SUSPENSION/STEERING (3) SOCKET WRENCH, 30 x 32. mm 07716-0020400 OR EQUIVALENT - COMMERCIALLY AVAILABLE USS yA g4 (3) EXTENSION BAR My 07716- 0020500 OF (ge EQUIVALENT CONIMERCIALLY AVAILABLE IN USA (2) FORK TOP BRIDGE, (1) EXTENSION BAR 0716 -0020800 of EQUIVALENT COMMERCIALLY AVAILABLE IN USA. (1) SEAL (2, UPPER BEARING (3) STEERING stem aS (1) oust SEAL « ngs @ % (2) LOWER BEARING RIDE RED 11-45FRONT WHEEL/SUSPENSION/STEERING Remove the upper and lower bearing races from the steering (I) BEARING RACE REMOVER 07953— 4250002 OR® head using specal tools, J07953—MJ1000A (U.S.A. ONLY) 9 $0 " bs a - tor 87 @ ‘Aer 87: I eARiNG race remover O7eas-46s0109, Install new bearng race: (1) FIVER NOTE + Ifthe motorcycle has been involved in an accident, examine the area around the steering head for cracks. Driver 07430010000 Attachment, 42 x 47 mm 07746~0010300 Lower race: Driver 077490010000 "B9: Attachment, 42 « 47 mm 077460010300 After ‘89; Attachment, 52 x 55 mm 077460010400 (a) ANYachen oe (1) STEERING STEM DRIVER (079484300101 OR 07946 —MBO0C0O Install the dust seal onto steering stem. AND GN—-HTS4 (U.8.A. onty) 11-46 RIDE REDFRONT WHEEL/SUSPENSION/STEERING INSTALLATION (LOWER REARING RACE. ge (2) LOWER BEARING ~@S > (9 oust SEAL. Pack the upper and lower taper bearings with grease (shell albania €° 2-3 or equivalent) Install the upper taper roller bearing in the stesring head pipe. ~ ‘Slide the steering stem through the steering head pipe form & the bottom, = —(5) UPPER BEARING (6) UPPER BEARING RACE (1) STEERING STEM SOCKET Inctall the stecting hoad adjusting nut and torque with the 3 ss ee 07916—KA50100 » steering stem socket. TORQUE: 1—2.Nem (0.1—0.2 kg-m, 0.71.4 feb) ‘Tum the steering stem lock-to-lock times to sest the bear- ings and tighten the adjusting nut again Temporarily install the fork legs (page 11-41, after “88: (9) EXTENSION BAR 07716—0020500 OR 17-421, EQUIVALENT COMMERCIALLY AVAILABLE INU.S.A. Inctall the fork top bridge end tighten the steering stem rut TORQUE: 95—140 Nem (9.5~14.0 ko-m, 69-101 feb) Tighten the fork pinch bolts (page 11-41, After’BB: 11-42 and 43), Recheck the steering stem adjustment before installing the removed parts. Install the removed parts in the reverse order of removal (2) SOCKET WRENCH, 30 x 32 mm 07716--0020400 (OR EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A, RIDE RED 11-47REAR WHEEL/BRAKE/SUSPENSION a6: 24-30 Nem [2.43.0 ke-m, = 1721 fb) EEN o-109 wn iB0"%0.9%em Sonate 40-50 Nm (4.05. 0kam, 29-36 trib) 85-108 em & (8.5—10.5 kg-m, S Fal Sen > oh é 7B te / os (ra -2.8 ky, 19—18 tet) P 18-25 Nem (1.8-2.5k9-m, 13-18 fib) 12-0 RIDE RED12. REAR WHEEL/BRAKE/SUSPENSION ‘87, 30-48 Nem (384.3 kg-m, 27-36 fb) 40—50 Nem (4.0-5.0 kg-m, 29-36 ft-lb) 40 80N-m SSS~ torso am, yO ser 85-105 Nem (8,.5—10.5 kg-m, 61-76 fib) (5.5—7.0 kg-m, 40-51 felb) 24-20 Nem (2.4-2.8 kgm, 17-20 fee} 18-28 Nem 0-50 Nem (18-25 kgm, |4.0—5.0 kvm, 13-18 fib) 29-36 fro) RIDE RED 12-1REAR WHEEL/BRAKE/SUSPENSION "88,89: a8: 27-35 feb! 38-48 Nm e ia fom, 8: 40-50 Nem (4.06.0 kg-m, 29-36 fib) “a9: 55—70 Nem (5.5—7.0 kgm, 2 40-51 feb) 18-25 tm (1.8—-25 kon, 13-18 telb) 12-2 RIDE REDREAR WHEEL/BRAKE/SUSPENSION 38-48 Nem (38-48 kg-m, 27-36 feb) 55—70N-m (6.57.0 ko-m, 4-51 feb) 4050 Nem (4.0~5.0 kgm, 28—36 ft-lb) 85-105 Nem (8.5-10.5 kgm, (2.4-2.8 kam, 17-20 fulb) 80—100 Nem 8.0100 kam. 58-72 feb) 13-18 fell) © 12-3REAR WHEEL/BRAKE/SUSPENSION After ‘90: = 38—48 Nem ge S\ 27-35 elo) ey (3.84.8 kam, A S Ss — <7 6G Ne ae? or 76th 76 fe) ge 40-50 Nm (4.08.0 kom, 29-36 fio) 24-28 Nim f BA A talk —> ge Se, 40-81 ft-lb) 80—100 Nem SE 25 Nem (5-7. kgm, (8.0- 10.0 kam, (18-2.5tgm, 40-51 feb) 5872 fe ib} 19-18 feb) 12-4 RIDE REDREAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 12.5 REARBRAKE PEDAL 12.17 TROUBLESHOOTING 127 SHOCK ABSORBER 12-18 REAR WHEEL 12-8 SWINGARM 12-42 REAR BRAKE ('86:) 12-15 SHOCK LINKAGE 12-48 SERVICE INFORMATION GENERAL © A workstand oF box is required to support the motorcycle '@ Use genuine Honda bolts for the rear suspension linkage and shock absorter pivot and mounting; ordinary bolts lack ade- ‘quate strength for these applications, Also take note of the the installation direction of these bolts since they must be in- stalled comectly, © Optional reer wheel sprockets, drive chain, shock springs and shock spring preload pin spanners are available. Rafer to ‘General Infermation, Section 1 ‘© For optimum shock performance, the shock should be disassembled, cleaned and refilled with fresh oll several times @ ‘© For optimum suspension performance and tnkage component service life, the swingarm pivot bearings and shock linkage pivot bearings (along with related collars, seals and bushing} should be disassembied, cleaned, inspected for wear and lubrieated with MoS2 grease each 3 races or 7.5 hours of running, —— 1 The shock absorber contains nirogen cas under high presse. Do not allow fire or heat near the shock absorber. afore lsposal ofthe shock utsorber relewe the altogen by presing the valve core. Then remove the valve from the shock absorber. ‘The shack sbtorber has agas:lled rerrvotr Use only nitrogen to prourize the shack absorber. + The we of an unstable gas can cause «fie or explosion resulting In serious injury. rake dust may contain asbestos. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. ‘Never use an oir hose or dry brash fo elean brake or clutch astemblies, Use an OSHA-approved vacuum cleaner or aliereare ‘merhua approved by OSHA designed to minimize the hazard caused by arbone asbestos fibers. SPECIFICATIONS etn re STANDARD SERVICE uMir ee ae) es 2a) —SS~*~C TT “B7 through ‘90: 260(11.02) 1 277 10.911 ‘aner‘gar [265 (10.48 ———=*d|~—8 210,30) | tae 6 73 (10.78) — spring installed length r a jaa as 267.8 10.80) = 90 267 (10.51) [lake [soe | Rada 20 10.08) ‘eal = [2010.00 | | Rear axle runout _ — 0.2 (0.008) Fea brake drum 0. j= 120.0 612) 781.0 6.16) Tr brake shoe ioe 4.0 0.16) [2000.08 | sori, resus = GBT He [10.0 kalo 142.2 ps = RIDE RED 12-5