HOW TO USE THIS MANUAL ‘This service manual describes the service procedures for the CMX250C. Follow the Maintenance Schedule (Section 3) recom- mendations to ensure that the vehicle is in peak oper- ating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency and California Air Resources Board. Perfarming the first scheduled maintenence is very important. {t compensates for the initial wear that ‘occurs during the break-in period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removaV/installa- tion of components that may be required to perform service described in the following sections. Section 4 through 18 describe parts of the motorcycle, grouped according to location, Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illus- tration, service information and troubleshooting for the section. The subsequent pages give detailed pro- codure, 4 you don’t know the source of the trouble, go to sec- tion 20 Troubleshooting. ALL INFORMATION, ILLUSRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LAT- EST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING, HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF ‘THIS PUBLICATION MAY BE REPRODUCED. WITHOUT WRITTEN PERMISSION. THIS MAN- UAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTE- NANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS. HONDA MOTOR CO.,LTD. SERVICE PUBLICATION OFFICE Date of Issue: August, 1995 @ HONDA MOTOR CO., LTD. CONTENTS FUEL SYSTEM Ei ENGINE REMOVAL/INSTALLATION KE 7 | CYLINDER HEAD/VALVES Bg CYLINDER/PISTON Ej [ cuutcH/cearsHieTunkace = ALTERNATOR/STARTER CLUTCH | CRANKSHAFT/TRANSMISSION a [| BRONT WHEEL/SUSPENSION/ STEERING ENGINE AND DRIVE TRAIN 2 a @ | REAR WHEEL/BRAKE/SUSPENSION EE 2 eee a ° | HYDRAULIC BRAKE Ea — [ IGNMONSYSTEM ELECTRIC STARTER [17° LIGHTS/METER/SWITCHES Ei WIRING DIAGRAM E El | TROUBLESHOOTING BE INDEX Ei I ELECTRICALSYMBOLS ‘The symbols used throughout this manual show specific service procedures. If supplementary information is required pertaining to thase symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one|s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum oil solution (mixture of the engine oll and molybdenum grease in a ratio of 1: 1), Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalenth. Example; Molykote® BR-2 plus manufactured by Dow Corning, U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide grease (containing more than 3% molybdenurr disulfide, NLGI #2 or equivatent). Example: Molykote® 8R-2 plus, manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S-A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan ARSE | Use silicone grease. Pym | rpivatocking agent. Use Bal pad ad middle strength locking agent unless other specified. Apply seatant Use brake fluid, DOT 4, Use the recommended brake fluid, unless otherwise specified. Use Fork ar Suspension Fluid.1. GENERAL INFORMATION GENERAL SAFETY WW SERVICE RULES 12 (MODEL IDENTIFICATION 13 SPECIFICATIONS 14 TORQUE VALUES 1412 TOOLS 114 LUBRICATION & SEAL POINTS 1-16 CABLE & HARNESS ROUTING 1-18 EMISSION CONTROL SYSTEMS 1-26 EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLY) 1-28 GENERAL SAFETY CARBON MGNOXIDE Ifthe engine must be running to do some work, make sure the area is woll ventilated. Never run the engine an enclosed area. Wm + The exhaust contains poisonous carbon monoxide gax that ‘can cause lass of consciousness and may lead to death. Run the engine in an open area or with an exhaust evac- uation system in an enclosed area, GASOLINE Work in @ well ventilated area. Keep cigarettes, flames ‘or sparks away from the wark area or where gi stored. WM + Gasoline is extremely flammable and is explosive under cer- tain conditions, KEEP QUT OF REACH OF CHILDRE! HOT COMPONENTS: Wm + Engine and exhaust system parts become very hot and remain het for some tine after the engine is run, Wear insu- lated gloves or wait until the engine and exhaust system have coated before handling these parts. USED ENGINE Oil, CO © Used engine ail may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is uuntikely unless you handle used oit on a daity basis, itis still advisable to thoroughly wash your hands with soap and ‘water as soon as possible after handling used oll. KEEP OUT OF REACH OF CHILDREN. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. Use an OSHA-approved vacuum cleaner oF alternate method approved by OSHA, designed to mize the hazard caused by airborne asbestos fibers. i * Inhaled asbestos fibers have been found to cause respiratory disease and cancer. BRAKE FLUID CAUTION + Spilling fluid on painted, plastic or rubber parts witl damage them. Place 0 clean shop towel over these parts whenever the system is serviced, KEEP OUT OF REACH OF CHILDREN. 1-1GENERAL INFORMATION BATTERY HYDROGEN GAS & ELECTROLYTE i + The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. + The battery contains sulfuric acid (electrolyte). Contact with skin ‘or eyes may cause severe burns, Wear protective clothing and a face shield. — If electrolyte gets an your skin, flush with water. — If electrolyte gets in your eyes, flush with water for atleast 15: minutes and eall a physician immediately + Electrolyte is poisonous. — If swallowed, drink large quantities of water or milk and fol- low with milk of magnesia or vegetable oil and calle: physi- cian. KEEP OUT OF REACH OF CHILDREN. SERVICE RULES 1, Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don't meet HONDA’s design specifications may cause damage to the motorcycle. 2. Uso the special tools designed for this product to avoid damage and incorrect assembly, 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners, 4, Install new gaskets, O-rings, cotter pins, and lock plates when reassembling, 5, When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. Alter reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as show on pages 1-18 through 1-25, Cable and Harness Routing,GENERAL INFORMATION MODEL IDENTIFICATION '96 = 2000 shown; After 2000 similar: (1) The frame serial number is stamped on the right side of the steering head. s (2) VEHICLE IDENTIFICATION NUMBER (STENGINE SERIAL NUMBER (2) The vehicle identification number {VIN) is attached (3) The engine serial number is stamped on the lower fn the left side af the down tube as shown. loft side of the crankcase, (5) COLOR LABEL IDENTIFICATION NUMBER) (4) The carburetor identification numbers are stamped (5). The color label is attached to the air cleaner housing on the left side of the carburetor body. cover as shown. When ordering color-coded parts, always specify the designated color code. 1-3GENERAL INFORMATION SPECIFICATIONS ;- GENERAL rem SPECIFICATION DIMENSIONS | Overall length 2,115 mm (3.3 in) Overall wiath £835 mm (32.9 in) Overall height 1089 mm (42.5 in) Wheelbase 3,450 mm (57.1 Seat height 675 mm (26.6 in) Footpeg height 300 mm (11.8 in) Ground clearance 180mm (639 in) Dry weight 141 kg (311 Ibs) Curb waight 150 kg (331 tbs) Maximum woight Except Canads type | 156 kg (345 ths) capacity Canada type 181 ka (955 tbs) FRAME Frame type ‘Semi double cradle Front suspension Front whoe! travel 116 mm (4.8 in) Rear suspension ‘Swingarm Rear wheal travel 74 men (2.9 én} Front tre size 3.00~ 18.47 Rear tire size 130/90 - 15M/C 66 Tire brand (Bridgestone) | Front: L303 Rear: G508 (Duniop) "Rear: K627 Front brake Hydraulic single brake Rear brake Internal expanding shoe Gaster angle 30°40" Trail length 113 mm (4. in) Fuel tank capacity 10.0 liter (2.64 US gal, 2.20 mp gal) Fuel tank reserve capacity 2,7 liter (0.77 US gal, 0.59 Imp gal) ENGINE Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system ump tye Cooling system Air filtration | Crankshaft type Engine dry weight | Cylinder arrangement 59x89 mm (2.1 x27 in} 234 crn? (14.3 cu-in} 92:1 Chain drive and OHC with rocker arm =8" BTDC 35" ABDC 35° BEDC 5° ATDC Forced pressure and wet sump Trochoid Aircooled Paper fitter ‘Assembled type 38.5 kg (84.9 Ibs) Vertical twin, paralietGENERAL INFORMATION ;- GENERAL (Cont'd) Tem SPECIFICATION CARBURETOR | Carburetor type Constant velocity single carburetor Throttle bore 26 mm (1.0 in) DRIVETRAIN | Clutch system Muiti-plate, wet Clutch operation system Mechanical type Transmission Constant mesh, 5-spesd Primary reduction 3.631 (69/19) Final reduction 2.957 (33/14) Gear ratio ast | 2.846 (97/23) and. | 1.777 (92/18) ard | 1.933 (28/21) 4th | 1.083 (26/24) Sth | 0.913 (21/23) Gearshift pattern Left foot operated return system, 1-N-2-3-4-5 ELECTRICAL | Ignition system AC-CDI Starting system Electric starter motor Charging system Triple phase output alternator Rogulator/rectifior SCR shorteditriple phase full wave rectification Lighting system Battery 1-5GENERAL INFORMATION Unit: mm tin) ;- LUBRICATION SYSTEM. ITEM STANDARD SERVICE LIMIT Engine oll capacity ‘At draining 15 liter (1.6 US qt, 13 Imp at = At disassembly 18 titer (1.8 US qt, 1.8 imp at) — Recommended engine oil HONDA GNG éstroke oll or | equivalent motor oil API service classification SF or SG | Viscosity: SAE 10W ~ 40 il pump rotor Tip clearence 0.15 (0.006) (0.20 (0.008) Body clearance 0.15- 0.21 (0,006 - 0.008) (0.25 (0.010) End clearance 0.05 ~ 0.13 (0.002 ~ 0.005) 0,14 (0.008) > FUEL SYSTEM (TEM ‘SPECIFICATION Carburetor identification number 49 states type ME35C_ California type VES6B CM type vessD Main jet #108 Slow jot #38 Pilot screw initial opening 23/8 turns out High altitude setting 2/8 turns out Float level 185 mm (0.73 in} Idle speed 1,400 + 100 rpm Throttle grip free play 2= 6mm (1/12 - 1/4 in) 1-6GENERAL INFORMATION — CYLINDER HEAD/VALVES ll TEM ‘STANDARD ‘SERVICE LIMET ‘ylinder compression 1,100 KPa (11.2 ker, 188 psi) at __ 600 rpm Cylinder head warpage I —= 0.10 (0.008), Valve and valve | Valve clearance INFEX | 0.06 0.10 (0.002 - 0.004) —=— guide | Vaive stem 0.0. IN| 5.480 5.465 (0.2146 - 0.2762) 5.42 (0213) EX | 5.430 — 5.445 (0.2738 0.27.44) 5.40 (0.218) Valve gui IN __| 5.475 — 5.485 (0.2156 0.2158) 5.50 (0217) [Ex ]5.475~ 5.485 (0.2186 - 0.2158) 5.50 (0.217) ‘Stem-to-guide clearance IN | 0.010 - 0.035 (0.0004 - 0.0014) 0.08 (0.003) EX | 0.030 0.058 (0.0012 ~ 0.0022) 0.10 10.008) Valve seat wiath IN/EX | 3.0 1.7 (0.039 - 0.083) 78 (0.07) Valve spring | inner INEX | 29.8 (1.181 29.07.14) free fenath, Outer INFEX | 38.2 (1.50) 37.0 (1.46) Rocker arm Rocker arm LD [iNrex |"70.000 = 10.015 (0.3937 - 0.3943) 10.10 (0.388) Rocker arm shaft 0.D | IN/EX | 9.972 - 9.987 (0.3926 - 0.3932) 9.91 40.390) Rocker arm-to-shaft clearance (0.013 — 0.045 (0.0005 - 0.0077) 0.05 ¢0.002), Camshaft Com lobe height IN__| 27.383 27.549 (1.0781 1.0844) 27.24.07) [ex 27.209 — 27.368 (1.0712 - 1.0775) 27.0 (1.06) Runout — 0.05 (0.002) Journal 0.0. 19.967 — 19.980 (0.7861-0.7866) | 19.92 (0.788) Bushing 0. 20.063 20.083 (0 7808-0.7907) | 20.20 (0.795) - 16 Saini BIE TON Unit: mm din) rem ‘STANDARD SERVICE LIMIT Cylinder 1D. 153.000 — 63,010 (2.0886 - 2.0870) 53.10 (2.097) Out of raund — 0.05 (0.002) Taper — 0.08 (6.002), Warpage — 0.05 £0,002) Piston, piston | Piston mark direction IN" mark facing toward the intake side | ___—— ona Piston 0.0. 52,970 - 52.990 (2.0854 - 2.0862) 52.90 (2,083) Piston 0.0. measurement point 10-mim (0.4 in) from bottom of skirt —— Fiston pin bore 1D. 115.002 ~ 16.008 (0.6806 - 0.5803) 16.06 (0.593) Piston pin 0.0. 14.894 16.000 (0.5903 — 0.5808) 74,98 (0.590) Pistor-to-piston pin clearance (0,002 — 0.074 (0.0007 — 0.0008) 0.07 (0.003) Piston ringto-ring | Top 0.015 — 0.048 (0.0006 - 0.0018) 0.10 (0.004) | Grooveclesrancs | Second (0.015 — 0.050 (0.0008 - 0.0020) 0.10 (0.004) Piston ring end gap | Top (0.15 ~ 0,30 (0.006 -0.012) 0.45 (0.078) Second | 0.30~0.45 (0.012-0.018) 0.60 (0.028) Oil side rail) | 0.2-0.7 (0.07 0.03) (0.90 (0.038), Gylinder-to-piston clearance 0.070 - 0.040 (0.0008 — 0.0016) 0.10 (0.008) Connecting rod small end |. 15.016 16.034 (0.5912 0.5919) 15.08 (0.594) Connecting rod-to-piston pin clearance 0.016 — 0.040 (0.0008 — 0.0076) [6:10 (0.008) 1-7GENERAL INFORMATION (— CLUTCH/GEARSHIFT LINKAGE Unit ram to} Trem ‘STANDARD SERVICE LIMIT Ciach lever foe play 10-20 (08-3) | Clutch spring free length 37.8 (1.49) 36.0 (1.42) Clutch diss thickness 2.92-3.08 0.116-0.121) 2.6 (0.10) Ciutch plate warpage — 0.20 (0.008) Clutch outer. 36.000 26.001 (10838 — 1.0240) 26.04 (1.026) Bish vwaeaiile Te 70.0007 20021 (07874 0.7682) 70:05 (0.789) [oo. 26.969 26.980 (1.0220 1.0728) 26.90 (1.020) Unit: mm ind > ALTERNATOR/STARTER CLUTCH TEM ‘STANDARD SERVICE LIMIT Siarer driven sprocket 1D 22.010 22,022 (08668 - 0.8670) 72.08 (0.889) Boss 01D, | 96.975 ~37.000 (1.4567 - 1.4567) 36.90 (1459) [- CRANKSHAFT/TRANSMISSION etme iat TEM ‘STANDARD ‘SERVICE LIMIT Crankshaft] Connecting rod big | Side clearance | 0.10-0.40 (0.004 -0.016) 0.60 10.024) end Radial clearance | 0.004 - 6.012 (0.0002 - 0.0005) 0.05 (0.002) Runout Atbothends | — 0.03 0.001) ‘At bearing hoider | = (0.05 (0.002) "Tranamiasion Ms | 20.030 ~ 20.081 (0.7882 — 0.7680) 20.08 0.791) ct 20.020 20.041 (0.7882 - 0.7890) 20.08 (0.799) C4 | 20.020 20.041 (0.7882 - 0.7690) 20.08 (0.791) ct | 19.979 — 20.000 (0.7866 - 0.7874) 19.93 (0.785) Ci | 16516 16.594 (0.6502 - 0.6500) 76.58 (0.653) Gearto-bushing clearance | Ct | 0.020- 0.062 (0.0008 - 0.0024 0.30 0.008) Mainsheft 0.0. ‘M5. 19.959 — 19.980 (0.7858 ~ 0.7866) 19.91 (0.784) Countershatt OD. Ci | 16.466 16.484 (0.6675 0.6490) 76.47 (0.646) ce 19.959 — 19.980 (0.7858 - 0.7866) 19.91 (0.784) Gear-to-ahatt clearance MS | 0.040 6.082 (0.0016 ~ 0.0032) 0,10 (0.008) cA 0.040 - 0.082 (0.0016 ~ 0.0032) 0.10 (0.004) Bushingto-shaft clearance | C1_| 0.082 0.068 (0.0018 0.0027) 010 (0.004) Shift fork, | Fork LD. 12.000 — 12.018 (0.4724 - 0.4731) 12,05 (0.474) shaft Claw | 4,83 — 5.00 (0.194 - 0.197) 4,80 (0.189) | Fork shett O.. 11.976 — 11.994 (04724-04731) 71.93 0.470) 1-8GENERAL INFORMATION -— FRONT WHEEL/SUSPENSION/STEERING Unit: min in TEM STANDARD SERVICE LIMIT Minimum tre weed depth 15 (008) ‘Cold tire pressure Up to 90 kg (200 Ibi load —_| 200 kPa (2.00 kgf/cm’, 28 psi) [ — ee mum welaht | 200 kPa (2.00 kate? 28 pel {| = ‘Axle runout — 0.20 (0.008) _| ‘Wheel rim runout Radi — 2.00.08) ‘Axial [__2.040.08) ‘Wheel hub-to-rim distance 3075411121 20.08 -_—_| Fork spring free length 546.0 (21.50) 35 207) Fork tube runout (0.20 (0.008), Recommended fork fluid Pro Honda Suspension Fluid 55-6 — Fork fid level 129 (5.4) | Fork fluid capacity 234 gan? (7.9 US on, 8.2 Imp oz) = ‘Steering head bearing preloed 17.04 — 1.59 kg (2.29 -3.37 Ibe) — Unit: rom (in) [- REAR WHEEL/BRAKE/SUSPENSION TEM STANDARD SERVICE LIMIT Minimum tre tread depth 2.00.08) Cold tire pressure Upto 90 kg (200 ib)load | 200 KPa (2.00 katiem?, 29 pai) — ete maximum weioh | 299 ura 2.00 kgton?, 28 ps) a axle runout — 0.20 (0,008) Wheel rim runout [Radial — 2.00.08) ‘Axial — 2.00.08) Wheel hubstevim distance 2.8 £1 (0.85 40.08) — Brake pedal free play __ tI (wa — 1-174) Brake drum 1.0. 720.0 (5.12) 431182) Brake lining thickness 45 (0.18) 2.00.08) — HYDRAULICBRAKE Unit: mm Cin) eM | ‘STANDARD SERVICE LIMIT Specified brake fuld [DOT gare Brake dise thickness £01016) 35 (0.14) Brake dise runout I — 0:30 10.012) Master cylinder Cylinder .D. | 12.700 - 72.743 (0.5000 - 0.5077) 12.755 (0.5022) Piston 0.0. 72.087 — 12.684 (0.4889 — 0.4984) 12.645 (0.4878) Brake caliper Cylinder LD. 25,400~ 25.405 (1.0000 ~ 1. [25.480 (7.0020) Fiston 01D. 25,353 25,368 (0.9981 —| 25.300 (0.8967) 1-9GENERAL INFORMATION (— BATTERY/CHARGING SYSTEM TEM ‘SPECIFICATION Battery Capacity 12V—6 An Current leakage mA max, Voltage Fully charged 13.0-132V (20"G/68"F) Needs charging Below 12.3 V Charging ur | Normal OB AON ent Quick 3.0 A/1.0h Alternator Capacity - 190 W/5,000 rpm Charging coil resistance 02-060 agulatarFocorrequlted vorage | "95~2000 18.5— 14.0 V/5,000 rpm [ear 2000 14.6 16.6 V/6,000 rpm [- IGNITION SYSTEM TM ‘SPECIFICATION Spark plug NGK DENSO Stenderd CREHSA U20FSRU For cold climate (below 5°6/41°F) CREHSA UierSRU For extended high speedrriding | GRTHSA UZFSRU ‘Spark plug gap I 0.6 — 0,7 mm {0.02 - 0.03 in} {gnition coil peak voltage 100 V minimum ‘Alternator exciter coil peak voltage | 100 V minimum larition pulse generator peak voltage I 0.7.¥ minimum Ignition timing — | “F* mark 1 10° BTDC/1,400 rpm. Full advance | 25° BTDC Unit: mm fin) j- ELECTRIC STARTER TEM STANDARD SERVICE LIMIT Starter motor brabh spring tension 780=7,060 9 [ase Starter motor brush length 125— 13.0 (0.49-0.51) [ 851033) 1-10GENERAL INFORMATION [- UGHTS/METER/SWITCHES ire SPECIFICATION Bulbs Headlight "962000 12-3655 W (Highviow beam) | After 2000 72-6055 W Tailibrake light TRV = 282 op (7/27 Wi License light 12V—4 0p (6W) Front tum signal light 12 V=32 cp (28 Wi Reeer turn signal light 32 V-32 ep (28 W) Tnstrament light T2V-34W “| High beam indicator 12V-34W _| Turn signal indicator V-34W Neutral indicator 2V-3W ‘Side stand indicator (96 - 2000) 12V-2W Fuse Main fuse 20 ‘Sub fuse WAN? 1-11GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TYPE ier ato RAR FASTENER TYPE gi area BR ‘Smm hex bolt and nut (05,36) | Smmecrew 410.4, 29) 8mm hex bolt and nut 10(1.0,7) | 6 mm screw 8 (0.8, 65) 8mm hex bolt and nut 22(2.2, 16) | 6 mm flange bolt (8 mm head) 8 (0.9, 65) 10 mm hex bolt and nut 3413.5, 25) | 6mmflange bolt {10mm head) and nut | 12 (1.2, 8) 12mm hex bolt and nut 54(65, 40) | 8 mm flange bolt and nut 26 (2.7, 20) 10 mm flange bolt and nut 39 (4.0, 28) ‘+ Torque specifications listed betow are for important fastanors. + Others should be tightened to standard torque values listed above, NOTES: 1. Apply a locking agent to the threads. 2. Left hand thre 3. Stake, 4, U-nut 5, ALOC bolt: replace with # new one, eae THREAD DIA, | TORQUE i ome (inn) | Ne tcgt, toe) | REMARKS Lubrication System: Oil pump mounting scrow 3 6 10(1.0,7) Cylinder Head/Valves: ‘Spark plug 2 10 12.1.2, 9) Valve adjuster lack nut \ 4 5 101.0, 7) Cylinder head/camshatt holder nut 8 8 23123, 17) Gylinder head bot 3 6 121128) Cam sprocket bolt 2 7 20120, 14 | Note 1 Cylinder head caver bolt 2 6 70 (1.0, 7) Clutch/Gearshift Linkage: Clutch lifter bolt 4 6 12012,9) Clutch conter lock nut 1 16 74(7.5,64) | Note 2 Shift drum stopper arm boit 1 6 32112,9) Gearshift return spring pin 1 8 25(25, 18) | Note 1 Primary drive gear lock nut 1 16 53 (6.4, 39), Crankease/Crankshatt: Drive sprocket bolt 2 | 8 12112,9) Oil drain bolt 1 2 25 (25, 18) Crankshaft mounting bolt 5 8 23123, 17) Crankshaft mounting nut 1 6 420.2.9) Oil passage plate mounting screw 3 6 10(1.0.7) | Note 1 Alternator/Starter Clutch: Flywheo! bolt {4 10 59 (6.0, 43) Startor clutch mounting screw 3 6 9 (09,65) | Note 1.2 Stator mounting bolt 3 5 8 (06, 4.3) ‘Stator wire clamp bolt 1 5 610.6, 4.3) Ignition pulse generator mounting bolt 2 8 10(1.0,7) Starter motor terminal nut 1 8 1-12GENERAL INFORMATION (eee THREAD DIA, | TORQUE oem om tem) | Nem kgm, beet) | REMARKS Frame/Body Panols/Exhaust System: | ‘Steering lock mounting screw 2 6 Note1 Gearshift pedal pivot cap nut i 8 Gearshift pedal link adjuster lock nut (front) 1 6 Note2 Gearshift pedal link adjuster lock nut 1 6 Side stand pivot bolt 1 10 10(1.0,7) Side stand pivot nut 3 10 2913.0, 22) | Notes Fuol vaive tock nut 1 8 26 (2.7, 20) Engine Mounting: Engine front mounting nut 1 10 6216.3, 48) Engine rear mounting nut 2 10 88 (9.0, 65) Front Wheel/Suspension/Steering: Steoring stem nut 1 2 74 (7.5, 58) ‘Steering stem bearing adjusting nut Joa 2 310.3, 22) Fork top pinch bolt 2 7 11.1.8) Fork bottom pinch bolt 2 8 3418.5, 25) Front axle bolt 1 2 6216.3, 46) Brake dise mounting bolt 6 8 396.0, 28) | Note Wheel spoke 36 BC 32 410.4, 28) Tire valve nut 1 ev! 310.3, 22) Fork cap 2 28 2212.2, 16) Fork socket bolt 2 8 2012.0, 14) | Noto 1 Rear Wheel/Brake/ Suspension: | Rear axle nut 1 “ 88(9.0,65) | Notes Whee! spoke 38 C32 40.4, 29) Tire vaive nut 1 8v1 30.3, 22) Driven sprocket mounting nut 4 10 6416.5, 48) | Notes Shock absorber mounting bolt (upper) 2 8 26 (2.7, 20) (lower) 2 10 42(4.3, 31) Swingarm pivot nut 1 “ 88 (8.0,65) | Note 4 Drive chain slider mounting self tapping screw 3 5 30.3, 2.2) Drive chain adjuster lock nut 2 6 10(1.0,7) Hydraulic brake: Caliper pin bolt 1 8 22(2.2, 16) Caliper pin bolt A 1 8 18 (1.8, 13) Caliper bleed valve 1 7 6 (0.6, 4.3) Pad pin | 2 10 18 (1.8, 13) Pad pin plug 2 10 2 (0.2, 1.4) Caliper bracket mounting bolt 2 8 30(3.1, 22) | Notes Brake hose bolt | 2 10 34 (3.5, 25) Master cylinder holder bolt | 2 5 229) | Master cylinder reservoir cap screw 2 4 110.1,07) | Brake lever pivot bolt 1 6 6 (0.6, 4.3) Brake lever pivot nut 1 6 8 (0.8, 4.3) Brake switch mounting screw 1 4 110.1,07) | Brake Mose clamp bolt 2 8 12(1.2.9) Lights/Meter/Switches: Headlight bracket mounting nut 1 10 34(3.5,25) | Note 4 Tall light unit mounting nut 2 8 710:7,5.1)_| 1-13GENERAL INFORMATION TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2, Not available in U.S.A. 2. Alternative tool. 07936 ~ 3710200 DESCRIPTION TOOL NUMBER REMARKS | _ FEF. SEC. Carburetor float level gauge ‘07404 — 0070000 3 Wheel spoke wrench 07010020300 | NOTE 2 12,13 Valve adjuster wranch 8 7708 0030800 | NOTE 3: 3 07908 - KE90200 Timing cap wrench 7703 - 0910001 3 Lock nut wrench, 20 x 24 mm 07718 - 0920100 8 Extension bar 07716— 0020500 | NOTE1 9 Gear holder 07724— 0010200 8 Flywheel holder 07725 — 0040000 10 Flywhes! pulier 907733 - 0920001 10 Valve guide driver, 85mm 0742 - 0010100 7 Attachment, 32 x35 mam 07746 - 0010100 113 Attachmant, 37 x 40 mam 07746 - 0010200 2 ‘Attachment, 42 x 47 mam 7748 — 0010300 14,12 Attachment, 62 x55 mm 07748 — 0010400 " Attachment, 62 x 68 mm | 07746 - 0010500 " Pilot, 18 mm 07746 — 0040300 11, 12,18 Pilot, 20 mm | 07746- co40500 " Pilot, 25 mm | 07748- oo4o600 " Pilot, 22 mam 07746 - 0041000 " ‘Bearing remover head, 15 mm_ | 07746 - 0050400 12,13 Bearing remover shaft 07746 - 0060100 12.13 Oil seal driver 07747 - 0010100 12 Oil seal driver attachment 07747 - 0010501 ” Driver 07749 - 0010000 31,12,13 Valve spring compressor 07787 - 0010000 7 Valve seat cutter NOTE 1 | ‘Seat cutter, 24.5 mrn (45° IN} 7780 - 0010100 7 Seat cutter, 22 mm (48° EX) 07780 - 9910701 7 Flat cutter, 25 mm (32° IN) 07780 — 0012000 7 Flat cutter, 21.5 mm (32° EX) 07780 - 0012800 7 Interior cutter, 30 mm (60° IN/EX) 07780 - 0014000 7 Cutter holder, §.5 mm 0761- 0010101 | NOTE 7 Plot screw wrench 07808 - 4220201 5 Snap ring pliers: 07814 - 3230001 1“ Steering stem socket 07816 - 3710101 2 Bearing remover set | 97936 - 3710001 3 — Remover handle 07936 - 3710100 aring remover set (07936 3710600 — Romover weight o7741— 0910201 | NOTES: 07896 - 3710200 Bearing remover set, 16 mm 07996-Kc10000 n — Remover shat, 15 mm 07998 -KC10100 " — Remover head, 15 mm 07896 -KC10200 i — Remover weight o774i— 0910201 | NOTES: " 1-14GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Ball race driver (07944 - 1750007 2 ‘Stem beering driver 97948 -GC40000 2 Needle bearing remover 07946 - KA50000 13 Piston base ‘07958 - 3000000 8 Valve guide reamer, 5.885 mm. 07984 -0880001 | NOTE 7 (07984 — 0980000 (U.S.A. only) Clutch center holder o7GMB - KT70101 9 Peak voltage adaptor O7HGJ-0020100 | NOTE 3: 16 | Imrie diagnostic tester (model 625) Drive chain tool set O7HMH-MRt0108 | NOTE 3 O7HMH ~ MR10104 (U.S.A, only) Analog tester (SANWA} SP-16D -NOTE1 46,17, 18 Analog tester (KOWA) TH-5H —! | 16,17, 18 1-15GENERAL INFORMATION LUBRICATION & SEAL POINTS -— ENGINE LOCATION MATERIAL REMARKS Rocker arm and shaft sliding surface Cam chain ‘Transmission gear teeth and bushings Piston pin hole Piston pin surface ‘Connecting rod small end Each bearing Piston ring sliding surface Piston ring and ring groove Crankshaft big end Shift fork claw and pivot inner surface: Shift drum grooves Clutch disc Engine oll Valve stem (valve guide sliding surface) Valve guide (valve stom sliding surface) Camshaft bushing inner surface Cam lobes M3, 4 gear spline C1 gear, C1 bushing sliding surface M4, C3, C5 shift fork grooves Molybdenum disulfide il (a mixture of 1/2 ‘engine oll and 1/2 molybdenum disulfide gresse) Oil passage plate screw threads Starter clutch outer bolt threads Gearshift stopper plate bolt threads Locking agent 1-16GENERAL INFORMATION [ FRAME 7 LOCATION MATERIAL REMARKS Steering stem bearing ores Multi purpose grease Front whee! dust see! lips Rear wheel hub dust seal lips Speedometer gear inside Wheel axle outer surface Rear wheel O-ring Driven flange dust seal lips Rear brake anchor shaft Brake cam Rear brake pedal pivot shaft Swingarm pivot shaft outer surface Swingarm pivot dust sea! lips Swingarm pivot bushing | ‘Throttle pipe inner surface Side stand pivot | | Gearshift pedal pivot | Clutch lever pivot bolt ‘Steering lock mounting screw threads Tosking agent Drive chain case mounting bolt threads Helmet holder mounting bolt threads Fork oll seal lips Pro-Honda suspension Fork cap bolt O-ring fluid SS-8 or equivalent Brake master cylinder piston and cups DOTS or DOT 4 brake Caliper piston and piston se fluid Caliper piston dust seais Silicone grease Front brake lever pivot bolt Handlebar grip inner surface Honda Bond A or Honda Hand Grip Cement (US A.only) 1-17GENERAL INFORMATION CABLE & HARNESS ROUTING (7) LEFT HANDLEBAR SWITCH WIRE (8) CLUTCH CABLE (4) THROTTLE CABLES (3) RIGHT TURN SIGNAL WiRE (2) BRAKE HOSE} (10) LEFT TURN SIGNAL WIRE (11) SPEEDOMETER CABLE (1) MAIN WIRE HARNESS: 1-18GENERAL INFORMATION (3) IGNITION SWITCH WIRE (2) INDICATOR PANEL WIRE (1) RIGHT HANDLEBAR SWITCH WIRE Sy (4) SPEEDOMETER WIRE FT HANDLEBAR SWITCH WIRE ( ya (9) RIGHT TURN SIGNAL WIRE (8) MAIN WIRE HARNESS (12) 6P (NATURAL) CONNECTOR (6) LEFT TURN SIGNAL WIRE (7) HEADLIGHT WIRE Install the grommets into the connector box.GENERAL INFORMATION (3) REGULATORIRECTIFIER {2)IGNITION CONTROL MODULE (ICM) 7 (8) CLUTCH CABLE 1-20(GENERAL INFORMATION (2) REGULATOR/RECTIFIER 4P CONNECTOR (1) MAIN WIRE HARNESS (3) REGULATORIRECTIFIER 2P CONNECTOR (4) IGNITION COIL PRIMARY WIRE CONNECTORS (5) IGNITION CONTROL MODULE (ICM) (8) SPEEDOMETER CABLE 1-21GENERAL INFORMATION (3) REGULATOR/RECTIFIER CONNECTORS (3) CLUTCH CABLE (2) CHOKE CABLE (4) FUEL TANK BREATHER TUBE (7) ALTERNATOR/IGNITION PULSE GENERATOR/NEUTRAL SWITCH WIRE (11) BioDE 1-22GENERAL INFORMATION (4) REGULATOR/RECTIFIER (3) CARBURETOR AIR VENT TUBE (1) BATTERY NEGATIVE CABLE ¢ (11) CRANKCASE BREATHER TUBE _ (5) CARBURETOR OVERFLOW TUBE 7) AIR CLEANER HOUSING DRAIN TUBE (6) CRANKCASE BREATHER SEPARATOR DRAIN TUBE 1-23GENERAL INFORMATIONGENERAL INFORMATION EMISSION CONTROL SYSTEM ROUTING (California Type Only} (1) EVAPORATIVE EMISSION (EVAP) CANISTER —__—— ZZ cr evaronanve emssion PURGE CONTROL VALVE (6) EVAP CANISTER DRAIN TUBE (No. 3) (4) AIR VENT TUBE (5) VACUUM TUBE (No. 11) (7) AIR TUBE (No. 2) 1B) Alf TUBE (No. 5) (15) AIR TUBE (No. 8} (14) CARBURETOR. DRAIN TUBE (3) VACUUM TUBE (No. 11) (13) FUEL TANK BREATHER TUBE (10) AIR TUBE (No. 4) (12) AIR VENT TUBE (11) FUEL TANK BREATHER TUBE (Na. 1) 1-25GENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘The US. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motoreyeles built after January 1, 1983 comply with applicable noise emission standards for one. year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and main tained according to the instructions provided. Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the omissions system warranty in effect. SOURCE OF EMISSIONS The combustion process. produces carbon monoxide and hydrocarbons, Control of hydrocarbons is very important because, nder certain conditions, they react to form photochemical smog when subjected to sunlight. Carban monoxide does nat react, inthe same way, but itis toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro- carbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made ‘except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system, CRANKCASE EMISSION CONTROL SYSTEM ‘The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into. the combustion chamber. 41) CARBURETOR (2) AIR CLEANER (3) CRANK CASE BREATHER SEPARATOR 1-26GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM {California type only) This vehicle complies with California Air Resources Boart: evaparative emission regulations Fuel vapor from the fuel tank and carburetor is directed into the evaporative emission (EVAPI canister where itis absorbed and stored while the engine IS stopped. When the engine is running and tha evaporative emission (EVAP) purge control valve is open, fuel vapor in the EVAP canister is drawn into the engine through the carburetor, (1) FUEL TANK (4) CARBURETOR (2) EVAPORATIVE EMISSION PURGE CONTROL VALVE (EVAP PURGE CONTROL VALVE) (3) EVAPORATIVE EMISSION (EVAP) CANISTER, | Rear [13080 - 15MiC 66P Cald tire | Up to 90 ka (200 Ibs) toad Front | 200 kPa (2.00 kg/cm, 29 psi) pressure | Rear | 200 KPa (2.00 kalomt, 29 psi) Up to maximum weight capacity Front | 200 kPa {2.00 kg/em?, 28 psi) [Rear | 200 KPa (2.00 ka/em:, 28 psi) Minimumn tire tread depth Front_| 1.5 mm (0.08 [Rear | 20mm (0.08 in) TORQUE VALUES Spark plug. Valve adjuster lock nut Cylinder head cover bolt Oil drain Bott Rear axle nut Wheel spake Tire valve nut TOOLS Valve adjusting wrench B Timing cap wrench Drive chain cutter — Link plate holcier Wheel spoke wrench 3-2 12 Nem (1.2 kam, 8 IDE 10 Nem (1.0 kgf. 7 IDF) 10 Nem (1.0 kgm, 7 bff) 25 Nem (25 kgtm, 18 IDFA) 88 Nem (9.0 kgm, 65 Ibft) 4Nm (04 kgfm, 2.9 bff) 3.Nem (0.3 kgf, 2.2 bf) (07708 - 0030400 or 07908 ~ KE90200 (07708 - 0010001 (O7HMH - MR10103 O7HMH ~ MR10130 07701 ~ 0020300 Not available in U.S.A.MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. I:Inspect end Clean, Adjust, Lubricate or Replace if necessary, C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical information and tools, Consult their authorized HONDA dealer. FREQUENCY | NOTE ODOMETER READING (NOTE 1) Oy [Ruaoonafes| «Ta [a [ow [a [ae] ITEMS: X10Gkm | 10 | 64 | 128/ 192 | 256 | 320 | 344 * | FUEL LINE 1 1 | 34 + | THROTTLE OPERATION i i Tl se S |* | CARBURETOR CHOKE o im t| 36 E | [Ain CLEANER [_NoTE2 aR a 35 |_| CRANKCASE BREATHER NOTES ele[cjc{[clc| 36 3 |_| spank pLuc TpRltiR{t[R| 38 ale VALVE CLEARANCE 1 I 1 1 1 1 1 37 5 |_| encine on. RlalaAlRialalr| 39 8 ** | ENGINE OIL STRAINER SCREEN c c c 310 & | = [ENGINE IDLE SPEED Tote a = | APORATEEMESION NOTE 4 ' 1) an DRIVE CHAIN 342 |_| BRAKE FLUID 315 E BRAKE SHOE/PAD WEAR 316 |__| BRAKE SYSTEM 316 EE = | arake Lisi swe 37 = [> [HeaoucHT Aim 27 3 (CLUTCH SYSTEM 318 |_| SIDESTAND a8 3 | * | SUSPENSION a9 2 | * | NUTS, BOLTS, FASTENERS if 319 17) WHEELSTRES 320 STEERING HEAD BEARINGS 3-20 * Should be serviced by an authorized HONDA dealer, unless the owner hes proper tools and service data and is mechanically qualified. ‘** Inthe interest of eatety, we recommend these items be serviced only by en authorized HONDA dealer. NOTES: 1. At higher odometer reading, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas, 3. Service more frequently when riding in rain or at full throttle. 4. California type only. 5. Replace every 2 years, or at indicatad odometer interval, whichever comes first. Replacement requires mechanical skill. 3-3MAINTENANCE FUEL LINE - (1) FUEL TUBE » Chock the fue! lines for deterioration, damage or leskage. Replace the fuel line if necessary, THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the thrattle cabios and replace them if they are deter orated, kinked or damaged. Lubricate the throttle cables, if throttle operation is not smooth, Measure the free play at the throttle grip flange. FREE PLAY: 2-6 mm (1/12- 1/4 in) Throttle grip free play can be adjusted at elther end of the throttle cable. Minor adjustment are made with the upper adjuster. Remave the dust cover from the adjuster. ‘Adjust the free play by loosening the lock nut and turning the edjuster.. (ADJUSTER (2) LOCK NUT Major adjustments are made with the lower adjusters. Adjust the free play by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nuts securely. Rechack the throttle operat Replace any damaged parts, if necessary. 3-4MAINTENANCE CARBURETOR CHOKE The choke system uses a tus! enrichment circuit controlled by a starting enrichment (SE} valve. | The SE valve opens the enrichment circuit via a cable when the choke lever on the handlebar is pulled back. (1) CHOKE LEVER Check for smooth choke lever operation and lubricate the choke cable if required. Inspect the cable for cracks which could slow moisture to enter. Replace the cable it necessary. AIR CLEANER Remove the left side cover (page 2-2). Romove the screws and air cleaner housing cover. Disconnect the breather tube from the air cleaner, Pull out the air cleaner setting plate, then remove the air cleaner from the housing. Discard the air cleaner in accordance with the maintenance schedule. Install the breather tube to the new air cleaner. Install the new air cleaner and secure it by compressing the setting plate as shawn STEW Ala CLEANER] Install the removed parts in the reverse order of removal, 2) BREATHER TUBE)MAINTENANCE CRANKCASE BREATHER Remove the drain plug from the breather tube to empty any deposits Reinstall the drain plug and clip. NOTE + Service mora frequently when riding in rain or at full throttle, SPARK PLUG Disconnect the spark plug caps and remove the spark plugs. NOTE + Clean around the spark plug bases with compressed air before removing, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plug and inspect or replace as described in the maintenance schedule, INSPECTION Check the following and replace if necessary (recommended spark plug: page 3-1) + Insulator for damage + Electrodes for wear + Burning condition, coloration; — dark to light brown indicates good condition, — excessive lightness indicates malfunctioning ignition ‘system or lean mixture. — wot or black sooty deposit indicates over-rich mixture. REUSING A SPARK PLUG Clean the spark plug alectrodes with wire brush or special plug cleaner. Chack the gap between the center and side electrodes with ‘a wire-type feeler gauge. Ht necessary, adjust the gap by bending the side electrode carefully. ‘SPARK PLUG GAP: 0.6 - 0.7 mm: (0.02 -0.03 in) (2) SIDE ELECTRODE (3) INSULATOR 0.6 - 0.7 mmn 3-6MAINTENANCE CAUTION - (2) SPARK PLUG CAP + To prevent damage to the cinder heud, hand-tighsen the spark lig before using a wrenct to tighten to the specie torque Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification, TORQUE: 12 Nem (1.2 kgf, 9 Itt) REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type fester ‘gauge (see above). CAUTION + Do not overtighten the spark plug. Install and hand tighten the new spark plug, then tighten it about 1/2 of a turn after the sealing washer contacts the seat of the plug hole. VALVE CLEARANCE NOTE + Inepect and adjust the valve élearance while the engine is cold (below 35°C/95°F). Remove the fuel tank (page 2-3. Remove the spark plug cap and ignition colls, Remove the bolts and cylinder head cover. Remove the spark plug (page 3-6) Remove the crankshaft and timing hole cap using the spe- cial 1001, TOOL: Timing cap wrench 07708 - 0010001MAINTENANCE Turn the crankshaft clockwise, and align the “T* mark on the flywhool with the index mark on the left crankcase ‘Make sure the No. 1 or No. 2 piston is at TOC an the com pression stroke, Inspect the intake and exhaust valve clearances of the cylin- der at TDC by inserting a feeler gauge between the adjust- ing screw and valve stem. VALVE CLEARANCE: 10 mm (0.002 ~ 0.004 in) Adjust if necessary by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge, Hold the adjusting screw and tighten the lock nur. Too: Valve adjusting wrench 8 07708 --0030400 or 07908 - KE90200 TORQUE: 10 Nem (1.0 kgf-m, 7 Itt) Recheck the valve clearance, Turn the crankshaft counterclockwise ane full turn (380 degrees) and align the “T” mark on the flywheel with the index mark on the left crankcase cover. Check the valve clearance of the ather cylinder. VALVE CLEARANCE: IN/EX; 0.08 — 0.10 mm (0.002 - 0.008 in) 3-8MAINTENANCE ‘Check that the cylinder head cover packing is in good condi tion, replace if necessary. Install the cylinder head cover. Install the mounting rubbers and bolts, then tighten the bolts to the specified torque, TORQUE: 10 Nem (1.0 kafim, 7 Ub) Check that O-rings are in good condition, and install the timing hole cap and crankshaft hole cap. Install the removed parts in the reverse order of removal. ENGINE OIL OIL LEVEL INSPECTION Place the motorcycle on level ground. Check the oil levet using the oil filler cap/dipstick by placing itinto the filler hole without screwing it in. If the oll level is below oF near the lower fevel line on the dipstick, add the recommended oil up to the upper level. RECOMMENDED ENGINE OIL: Honda GN4 4-stroke oil or equivalent API service classification: SF or SG Viscosity: 10W ~40 NOTE Other viscosities shown in the chart may be used when the average tempersture in your riding area is within the indicated range. Reinstall the dipstick,MAINTENANCE ENGINE OIL CHANGE i + Uf the engine must be ranning to do some work, make sure the area is wellventitated. Never runt the engine in an enclosed area, The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death Warm up the engine. NOTE + Change the engine oil with the engine warm and the motorcycle on level ground to assure complete draining, Remove the oll filler cap/dipstick and drain bolt, CAUTION + Used engine oll may cause skin cancer if repeatedly lft tn contact ith the skin for prolonged perlods: Although this is unlikely unless you handle used oil on a daily bass, itis still advisable to thor ‘ouighly wask your hands with soap and water as soon as possible after handling used ol Drain the oll completely. Check that the sealing washer on the drain bolt is in good condition, and replace if necessary, Install and tighten the drain bolt. TORQUE: 25 Nem (2.5 kgm, 18 IbFt) Fill the crankcase with recommended engine oll OIL CAPACITY: 15 liter (1.8 US gt, 1.3 Imp qt) after draining Install the oii filler cap/dipstick. Start the engine and let it idle far 2 to 3 minutes Stop the engine and check that the oil level is at the upper level line om the dipstick. Make sure there are no oil leaks. ENGINE OIL STRAINER SCREEN Drain the engine oil Remove the oil pump (paige 4-2. Remove the engine oil strainer screen from the oll pump. Ciean the strainer scraen by washing it in clean solvent and blowing it dry with compressed air. Reinstall the oil fitter screen onto the oil pump. Install the oi! pump (page 45) Fill the crankcase up to the proper level with recommended oll 3-10MAINTENANCE ENGINE IDLE SPEED x= + If the emgine must Be running to do come wark, make sure the ‘area is well ventilated. Never ran the engine in an encloved area. The exhaust contains poisonous carbon monaxide gas that may ease loss of comsciousmess and lead to death. NOTE + Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specitications. + The engine must be warm for accurate idle speed inspec tion and adjustment. 41) THROTTLE STOP SCRE ‘Warm up the engine for about ten minutes, Turn the throttle stop screw as required to obtain the spaci- fied idle speed. IDLE SPEED: 1400 + 100 rpm EVAPORATIVE EMISSION CONTROL SYS- (1) EVAP PURGE CONTROL VALVE TEM (CALIFORNIA TYPE ONLY) } Cheek the tubes between the fuel tank, EVAP canister, EVAP purge control valve and carburetor for deterioration, dam- age or loose connections, Check the EVAP canister for cracks or other damage. Refer to the Vacuum Hose Routing Diagram Label and Cable & Harness Routing (page 1-25) for tube connections.MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION EI + Never inspect and adjust the drive chain while the engine is ran- ning. ‘Tum the ignition switch OFF, place the motorcycle on its side stand and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets, CHAIN SLACK: 15 ~25 mm (5/8 ~1 in} CAUTION + Excessive chain slack, 30 mm (2 in) or more, may damage the frame. Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically for use with O-ring chains. Wipe off the excess chain lube. ADJUSTMENT Loosen the rear axle nut. Loosen both lock nuts and turn both adjusting nuts until the correct drive chain slack is obtained. Make sura the index marks on the both adjusters are aligned with the rear edges of the axle slots in the swingarm. Tighten both lock nuts. Tighten the rear axle nut to the specified torque. ‘TORQUE: 88 Nem (9.0 kgfim, 65 Ibft) Recheck the drive chain slack and free whee! rotation. Lubricate the drive chain with Pro Honda Chain Lube or equivatent chain lubricant designed specifically for use with O-ring chains. Wipe off the excess chain lube. Check the drive chain wear indicator label. If the arrow mark of the chain adjuster reaches the red zone on the label, replace the drive chain with a new one (page 3- 13), CLEANING AND LUBRICATION Clean the chain with non-flammable or high flash point sal- vent and wipe it dry. Be suro the chain has dried completely before lubricating, Inspect the drive chain far possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprocket as necessary. a (2) INDICATOR LABEL, ie \ | (@) NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT. : (1) CLEAN, (2) WIPE AND DRY 3-12MAINTENANCE Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically for use on O-ring chains. Wipe off the excess chain lube. SPROCKETS INSPECTION Inspect the drive and driven sprocket teeth for wear or dam- age, replace if necessery. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the new replecement chain will wear rapidly. Check the attaching bolts and nuts on the drive and driven sprockets. Hany are loose, torque them. REPLACEMENT This motorcycle uses a drive chain with a stakad master link, Loosen the drive chain (page 3-12), ‘Assemble the special tool as shown, TOOL: Drive chain tool set 07HMH - MR10103 or O7HMH - BARIO100 (USA. only) NOTE + When using the special tool, follow the manufacturer's instruction. 1) LUBRICATE (2) PRO HONDA CHAIN LUBE OR EQUIVALENT (1) WEAR_ (@) DAMAGED PORN (1) DRIVE CHAIN TOOL SET 3-13MAINTENANCE Locate the crimped pin ends of the master link from the out side of the chain, and remove the link with the drive chain cutter. TOOL: Drive chain tool set O7HMH ~ MR10103 oF O7HMH —MA1010A (U.S.A. only) Remove the drive chain, Remove the excess drive chain links from the new drive chain with the special tool. NOTE + Include the master link when you count the drive chain inks. STANDARD LINKS: 108 Tinks REPLACEMENT CHAI DID: 520VC5 RK: 520MOZS CAUTION ever rewse the ol dre dain, master Tink, master Wink place and Orrings: Install the new drive chain, ‘Assemble the new master link, O-rings and plate. CAUTION + Tnsert the master link from the inside of the drive chat nd install ‘he plate withthe identification mark facing the ouside Assemble and set the spacial tool. TOOL: Drive chain tool set ‘O7HMH —MR10103 oF ‘O7HMH —MR1010A (U.S.A. only! Make sure that the master link pins are installed properly. Measure the master link pin length projected from the plate, ‘STANDARD LENGTH; DID: 1.15 - 1,55 mm (0.045 - 0.061 in) 1.2 ~ 1.4 mm (0.05 - 0.06 in} Stake the master link pins. 3-14 (1) MASTER LINK (2) DRIVE CHAIN TOOL SET (3) MASTER Ll UNK (4) DRIVE CHAIN TOOL SET (1) STANDARD LENGTHMake sure that the pins are staked properly by measuring the diamoter of the staked area using a slide caliper, DIAMETER OF THE STAKED AREA: DID: 5.5 mm (0.22 in) RK: 5.65 mm (0.222 in) After staking, check the staked area of the master link for cracks, If there is any cracking, reptace the master link, O-rings and plate. CAUTION +A drive chain with «elip-ype master tink must not be used BRAKE FLUID ‘CAUTION + Donat mis diferent types of fluid, ax they are not compatible wih each other + Do not allow foreign material to ender the ssitem when filing the + Avoid spilling uid on painted, plastic or rubber parts, Place a ra ‘over these parts whenever the system ts serviced. NOTE + When the fluid level is low, chack the brake pads for wear (see next page). A low fluid level may be due ta Wear of the brake pads. If the brake pads are worn, tha caliper piston is pushed out, and this accounts for a low reservoir level. + ithe brake pads are not worn and the fluid level is tow, ‘check entire system for leaks {see next page). Check the brake reservoir level through the sight glass, lf the level is near the lower level mark, check the brake pad ‘wear (see next pagel. MAINTENANCE (3) SLIDE CALIPER 3-15MAINTENANCE BRAKE SHOE/PAD WEAR FRONT BRAKE PADS Chack the brake pad for wear: Replace the brake pads if either pad is worn to the bottom ‘of wear limit groove. Refer to page 14-4 for brake pad replacement. REAR BRAKE SHOE Replace the brake shoes if the arrow on the brake arm aligns with the reference mark “A” whan the rear brake pedal Is applied, Refer to page 19-9 for brake shoe replacement. Tin) ARROW BRAKE SYSTEM FRONT BRAKE 700) BRAKE Hose Firmly apply the brake lever, and check that no air hes entarad the system, Ifthe lever feels soft or spongy when operated, bleed the air from the system. Inspect the brake hose and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required, Refer to page 14-3 for brake bleeding procedures. BRAKE PEDAL FREE PLAY Check the brake pedal free play. FREE PLAY: 20 - 30 mm (3/4 ~ 1-1/4 in} 3-16MAINTENANCE ‘After adjusting the brake pedal free play, check the reer ht switch operation and adjust if necessary. BRAKE LIGHT SWITCH NOTE + Perform the rear brake switch adjustment after adjusting the brake podal free play. +The front brake light switch does not require adjustment. Adjust the brake light switch so that the brake light will come on when the brake pedal is depressed 20 mm (3/4 in), and brake engagement begins. Hold the switch body and turn the adjusting nut, Do not tum the switch body. HEADLIGHT AIM = ‘An improperly adjusted headlight may blind oncoming drivers, or ‘it may fail light the road fora safe distance. NOTE + Adjust the headlight beam as specified by local laws and regulations, Place the motorcycle on @ level surface. "96-2000: ‘Adjust the headlight beam vertically by loosening the head- light adjusting bolt, ‘Aiter 2000; ‘Adjust vertically by turning the vertical adjusting screw. ‘Adjust horizontally by turning the horizontal adjusting serew, ADJUSTMENT VERTICAL ADJUSTMENT 3-17MAINTENANCE CLUTCH SYSTEM Measure the clutch free play at the end of the clutch lever. FREE PLAY: 10-20 mm (3/8 -3/4 in) Minor adjuistment are made with the upper adjuster at the (1) Logk NUT (2) ADJUSTER clutch lever. ‘ Loosen the lock nut and turn the adjuster. CAUTION + The adjuster may be damaged ft is positioned 100 far out, leaving ‘minimal thread engagement. Hf the adjuster is threaded out near its limit and the correct free play cannot be obtained, turn the adjuster all the way in and back out one turn. Tighten the lock nut and make a major adjustment as described below. Major adjustment is performed at the clutch arm, Loosen the lock nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening tha lock ut If proper free play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch (see section 9), SIDE STAND Support the motorcycle on a level surface. ‘Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement ‘and lubricate the side stand pivot if necessary. Check the side stand ignition cut-off system: — Sit astride the motoreyele and raise the side stand, — Start the engine with the transmission in neutral, then shift the transmission into geer, with the clutch lever 41) SIDE STAND squeezed, y — Move the side stand full down, — The engine should stop as the side stand is lowered. If there is @ problem with the system, check the side stand switch (section 18), 3-18MAINTENANCE SUSPENSION == Lote, worn or damaged suspension parts impair motarcyclexta- bidity ond control. Repair or replace any damaged components before riding. Riding 2 motoreycle with faulty suspension Increases your risk of an accident and possibie éajury. FRONT ‘Check the action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire assembly for signs of feaks, damage or loose fasteners, Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to section 12 for fork service, REAR Support the motoreyele securely and raise the rear wheel off the ground. Check for worn swingarm bushings by grabbing the rear Wheel and attempting to move the wheel side to side, Replace the bushings if any loaseness is noted. Cheek the action of the shack absorbers by compressing them several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired, Tighten all nuts and bolts. Refer to section 13 for shock absorber service. NUTS, BOLTS, FASTENERS Check thet all chassis nuts and bolts are tightened to their correct torque values (page 1-121. Check that all cotter pins, safety clips, hose clamps and cable stays are in place and property secured.MAINTENANCE WHEELS/TIRES ira pressure should be checked when the tires are coup. RECOMMENDED TIRE PRESSURE AND TIRE SIZE: Unit: kPa (kgtiem’, psi) SS FRONT REAR Cold | Up to 90 kg tire | (200 Ibs) load Pres" "Up to maximum, sure | weight capacity 200 (2.00, 23) | 200 (2.00, 23) 200 (2.00, 28) | 200 (2.00, 29) 130/80 -15 Tire size 300-1847 | Mie gap Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness (refer to soc- tion 12 end 13). Measure the treed depth at the center of the tires. Replace the tires when the tread depth reaches the follow- ing firnits, MINIMUM TREAD DEPTH: FRONT: 1.5 mm (0.06 in) REAR: 2.0 mm (0.08 in) Tighten any loose spokes. TOOL: Wheel spoke wrench 97701 - 9020300 Not available in USA, TORQUE: 4 Nem (0.40 kgf-m, 2.9 Ibfft) STEERING HEAD BEARINGS NOTE + Check that the control cables do not interfere with han- dlebar rotation. (1) STEERING HEAD BEARINGS Support the motorcycle securely and raise the front wheal off the ground, ‘Chack that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has vertical ‘movement, inspect the steering head bearings (section 12) 3-20MEMOLUBRICATION SYSTEM. LUBRICATION SYSTEM DIAGRAM (1) CAMSHAFT (8) CRANKSHAFT ) Aap gu Tou ma (8) COUNTERSHAFT (6) OIL STRAINER SCREEN 4-04. LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM 40 TROUBLESHOOTING “1 SERVICE INFORMATION 41 OILPUMP a2 SERVICE INFORMATION GENERAL + Used engine oll may cause skin cancer {f repeatedly left in contact with the skin for prolonged periods, AUhowgh this i unlikely waters ‘you handle used oll on w daily basis, iis stl advisable 0 thoroughly wash your hands with soap and water ax soon as possible after handling used ot SPECIFICATIONS Unit: rae Cin) TEM ‘STANDARD SERVICE LIMIT Engine oll capacity [ At draining 15 liter (1.6 US gt, 1.3 Imp qu) — ‘At disassombly 1B liter (1.8 US qt, 1.8 Imp at) — Recommended engine oil Honda GNé &-stroke oil or equivalent mator oil API sarvice classification SF or SG Viscosity: SAE 10W — 40 Oi pump rotor Tip clearance [ 0:15 (0.008) 020 (6.008) Body clearance [e:t8-021 (0.006 ~0.008) 0.25 (0.010) Side clearance | 0.95 - 0.13 (0.002 - 0.005) 0.14 (0.008) TORQUE VALUES Oil drain boit 25 Nam (2.5 kgm, 18 IbF‘t) il pump mounting screw 10.Nem (1.0 kate, 7 IBF) Engine oll level too low - high oil consumption Engine oil contamination + External oil leaks + Oil not changed often enough + Worn piston rings + Head gasket faulty + Gil not changed often enough + Worn piston rings Faulty head gasket 4-1LUBRICATION SYSTEM. OIL PUMP REMOVAL Drain the engine oll (page 3-10}. Remove the right crankcase cover (page 9-3) and crankshaft hole cap. Rotate the flywheel counterclockwise until the holes in the oll pump gear aligns with the oil pump attaching screws, Remove the three screws and oil pump assembly. Remove the O-ring. DISASSEMBLY Remove the oll strainer screen and clean it. (1) STRAINER SCREEN Remove the screw and oll pump cover, dowel pin and gas- ket, Remove the inner and outer rotors. (2) PUMP COVER (1) SCREW Remove the bolts and gear cover. (1) BOLTS (2) GEAR COVER 4-2LUBRICATION SYSTEM Remove the pump gear and pull the pump shaft out of the 2) PUMP SHAFT. pump body. i ‘Thoroughly clean all the components. (1) PUMP GEAR INSPECTION ‘Temporarily install the oil pump shaft. Install the outer and inner rotors into the oil pump body. Measure the tip clearance. ‘SERVICE LIMIT: 0.20 mm (0.008 in} Measure the pump body clearance. ‘SERVICE LIMIT: 0.25 mm (0.010 in} Measure the side clearance using a straight edge and fesler ‘gauge. ‘SERVICE LIMIT; 0.14 mm (0.006 in}LUBRICATION SYSTEM. ASSEMBLY (4) O1L PUMP COVER (3) OlL PUMP BODY (Ss oY (2) DRIVEN GEAR (5) OUTER ROTOR (6) INNER ROTOR, (7) STRAINER SCREEN (8) GEAR COVER (2) PUMP GEAR Install the oil pump shaft and pump gear into the oll pump body. NOTE + Align the cut-outs between the pump shat (1) PUMP SiRAFT ‘and gear. Install the gear cover and tightan the bolts. (2) BOLTS (1) GEAR COVER 4-4LUBRICATION SYSTEM Install the inner and outer rotors. NOTE + Align the cut-outs between the pump shaft and inner rotor. (1) INNER ROTOR Install the dowel pin. Install the oil pump cover and tighten the screw. Install the oil strainer screen to the oll pump body. INSTALLATION Apply cil to the new O-ring. Install a new O-ring into the crankcase. Install the oil pump and tighten the three screws to the specified torque. TORQUE: 10 Nem (1.0 kgf, 7 tht) Install the right crankcase covar (page 9-12) and crankshaft hole cap. Fill the crankcase with recommended engine oil (page 3-9).FUEL SYSTEM. 5-05. FUEL SYSTEM ‘SERVICE INFORMATION 5-1 CARBURETOR INSTALLATION 5-11 TROUBLESHOOTING 5-3 PILOT SCREW ADJUSTMENT 5-12 CARBURETOR REMOVAL 5-4 HIGH ALTITUDE ADJUSTMENT 5-13 CARBURETOR DISASSEMBLY 5-4 AIR CLEANER HOUSING 5-14 CARBURETOR ASSEMBLY 57 SERVICE INFORMATION + Gasoline i extremely flammable and is explash + Uf the engine must be running fo do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The ‘exhaust contains poisonous carbon monoxide gas that can cause toss of consciousness and may lead to death, Rum the engine in an ‘open area or with an exhaust evacuation system in an enclosed area. + Bending or ewisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss af vehicle control. + Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can ‘eause a fire or explosion. CAUTION Bare 10 Pee IW Cphrap ifreCloag Gi ond fil plnbgea Wh Geapreive @D- TMF Wapiti rag be aap NOTE + Hthe motorcycle is to be stored for more than one month, drain the float chamber. Fuel lef cause clogged jets resulting in hard starting or poor driveability. the float chamber may + Before disassembling the carburetor, place an approved gasoline container under the carburetor drain screw, loosen tthe screw and drain the carburetor. + When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. + After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to prevent any foreign material from dropping into the engine. Be sure to remove the cover when reinstalling the carbu- retor. 5-1FUEL SYSTEM SPECIFICATIONS TEM ‘SPECIFICATION Carburetor identification number 49 states type VEC California type E368 Canada type \vEasD Main jet #0 Siow jot #35 Pilot screw Initial opening 2.3/4 tums out High sititude setting 2-1/4 tums out Float level 48.5 mim (0.73 in) | Idie speed 7,400 + 100 1pm Throttle grip free play 26 mm (1712-14 in) TORQUE VALUES Fuel valve lock nut 26 Nem (2.7 kgf, 20 Ibftt) TOOL Carburetor float level gauge ‘97401-00100 5-2FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start No fuel to carburetor Engina flooded with fuel No spark at plug {ignition system faulty) Clogged air cleaner lake air leak Improper choke operation Improper throttle operation Engine idtes roughly, runs poorly or stalls, Improper choke operation Ignition: maifunction Fuel contaminated Intake air leak Incorrect idle speed Incorrect pilot screw adjustment Low cylinder compression ‘Starting enrichment {SE} valve stuck open Damaged starting enrichment (SE) valve seat Rich mixture Lean mixture Clogged carburetor Misfiring during acceleration + Ignition system faulty + Lean mixture Afterburn during acceleration + Ignition system faulty + Lean mixture Poor performance (driveability) and poor fuel economy + Fuel system clogged + Ignition system faulty + Aircleaner clogged Afterfiring + Ignition system malfunction + Carburetor malfunction + Lean mixture + Rich mixture Lean mixture * Clogged fuel jets + Faulty fioat valve + Float level too low + Blocked fuel fill Clogged fuel str Restricted fuel line Clogged air vant tube Intake air joak Vacuum piston stuck closed Worn jet needle or needie jet Faulty flost valve: Starting enrichment (SE) valve stuck open Damaged starting enrichment (SE) valve seat Clogged + Float level too high jet Incorrect fast idle speod + Incorrect choke cable operation + Starting enrichment (SE) vaive stuck or damaged 5-3FUEL SYSTEM. CARBURETOR REMOVAL Loosen the starting enrichment (SE) valve nut and remove the SE valve from the carburetor, Remove the thrattie cable holder screws and disconnect the throttle cables from the throttle drum. CAUTION + Boot kink or twist the throne cable. Iwill not operate smoothly ‘and may stick if it is Kinked or twisted, Loosen the connecting tube band screw. Remove the carburetor mounting nuts and carburetor. Disconnect the air vent tube and overflow tube. CARBURETOR DISASSEMBLY STARTING ENRICHMENT (SE) VALVE Disconnect the choke cable end from the SE valve and remove the valve spring. - enc \” Check the valve for nicks, grooves or other damage, Check the walve seat for wear. 5-4FUEL SYSTEM DIAPHRAGM/VACUUM PISTON. 1@ diaphragmivacuurn piston can be removed without remaving the float chamber. Remove tha vacuum chamber cover and air vent tube guide by removing the four screws. (1) SCREWS" Remove the compression spring and diaphragm/vacuum (1) SPRING piston, Inspect the vacuum piston for wear, nicks, or other damage. Make sure the piston moves up and down freely in the chamber. Push the jet needle holder down and turn it counterelock- wise 90 degrees with a screwdriver. Then remove the nee- die holder, spring, jet neadie and washer from the dia- phragm/vacuum piston. Inspect the jet needle for excessive wear at the tip or other damage. Check for a torn diaphragm or other deterioration. FLOAT AND JETS Remove the three screws and accelerator pump diaphragm cover. (2) DIAPHRAGM COVER 5-5FUEL SYSTEM Remove the spring, diaphragm and boot ® (3) BOOT (2) DIAPHRAGM (1) SPRING Remove the accelerator link bolt, collar and washer. (1) LINK BOLT, (2) SCREWS Remove the four screws and the float chamber, Remove the following: (3) FLOAT CHAMBER, — Float pin —Float a reais (1) FLOAT. (2) FLOAT VALVE Inspect the float vaive for grooves and nicks, and repiace if necessary, Inspect the operation of the valve. Remove the following: — Main jot (3) MAIN JET — Needle jet holder — Needle jet 4) SLOW JET — Slow jot (ws PLoneeeer " ‘Turn the pilot screw in and record the number of turns before it seats lightly, Use this as 2 reference for reinstalla ton. CAUTION + Diamage ao the pilor screw sear will occur ifthe pilot sevew is ight ened against the seat Remove the pilot screw. Inspect the pilot screw and each jet and replace them if they are worn or damaged. Blow open all carburetor body openings with compressed al, 5-6FUEL SYSTEM CARBURETOR ASSEMBLY (8) VACUUM CHAMBER COVER (6) JET NEEDLE HOLDER (ayJeT NEEDLE \ isyvacuum psrowpirnag & ase -N (1) ACCELERATOR \ S69 i PUMP LINK ai fe (7) SLOW JET @. ww 5a — (8) ACCELERATOR PUMP cM rr © (9) NEEDLE JET (10) NEEDLE JET HOLDER (11) MAIN JET (12) FLOAT VALVE (13) FLOAT CHAMBER 5-7FUEL SYSTEM FLOAT AND JETS (3) NEEDLE JET HOLDER] sa (4) MAIN JET = Needle jt = Needle jet holder = Main jet ” CAUTION Ee neatly be scored or sratched eo mstowseT gg \ (5) PILOT SCREW: Handle al Inatal the pilot a0row and return it to ita original position as noted during removal Perform pilot screw adjustment if # new pilot screw is installed (page 6-12) (2) MAIN JET (1) PILOT SCREW Pag (3) SLOW JET Install the float and float valve in the carburetor body, then install the float arm pin through the body and float FLOAT LEVEL INSPECTION With the fost vaive seated and the float arm just touching the valve, measure the float level with the special tool as shown, Float level: 18.5 mm (0.73 in} TOOL: Carburetor float level gauge 074010010000 The float cannot be adjusted. Replace the float assembly if the float Jevel is out of specifi cation. 111) FLOAT LEVEL GAUGE 5-8FUEL SYSTEM Install a new O-ring in the float chamber. Install the four float chamber screws Install the aceslerator link, washer catlar and link bolt Set the boot and install the accelerator pump shafticia- phragm, NOTE + Align the diaphragm tabs with the grooves of the float chamber. Install the diaphragm spring and cover. CAUTION + Do not pinch the diaphragm under the cover: Tighten the diaphragm cover screws. (2) FLOAT CHAMBER (3) LINK BOLT, (2) SCREWS (1) FLOAT CHAMBER ® XN nyacor a ae Aw, 2) (2) DIAPHRAGM, (4) SPRING (1) DIAPHRAGM COVER 5-9FUEL SYSTEM DIAPHRAGM/VACUUM PISTON (1) DIAPHRAGM/VACUUM PISTON Install the jet needie, spring and jet needle holder to the vacuum piston Push the jet neadia holder in and turn it 90 degrees clock: fs wenn Install the diephragm/vacuum piston in the carburetor body, (4) CHAMBER COVER aligning the diaphragm tab with the groove of the carbure- tor body. Hold the vecuum piston up to almost full open so the dia- (3) SPRING——_ phragm is not pinched by the chamber cover. Install the chamber cover with the spring, aligning its tab with the hole in the carburetor, and secure with at least two scraws before releasing the vacuum piston. (1) DIAPHRAGM Install the remaining vacuum chamber cover sorews, (2) TUBE GUIDE Bai) CHAMBER COVER the diaphragm under the chamber cov STARTING ENRICHMENT (SE) VALVE Install the spring over the choke cable and connect the cable end to the SE valve. “ Move the choke lever all the way up and down and make ‘sure that the SE valve operates properly (31 SE VALVE 5-10FUEL SYSTEM CARBURETOR INSTALLATION [2 O-RING Connect the overfiow tube and air vent tube, Install the new gasket onto the insulator. ‘Check that the O-ring is In good condition, replace if neces: sary. Install the carburetor into the frame. Install and tighten the carburetor mounting nuts. Tighton the insulator band screw. Connect the throttle cables to the throttle drum, then install and tighten the thrattle cable guide screws. Install the starting enrichment (SE) valve to the carburetor body, and tighten the nut securely. Route the overflow tube and air vent tube correctly (page 1 128), Adjust the throttle grip free play (page 3-4) Install the removed parts in the reversa order of removal.FUEL SYSTEM PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE i + Af the engine must be running to do some work, make sure the ‘area is well-ventilated. Never rum the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gax that may ‘cause loss of consciousness and lead to death. NOTE + The pilot screw is factory pre-set. Adjustment is not nec: essary unless the carburetor is overhauled or s new pilot screw Is installed. + Use a tachometer with graduations of 59 rpm change, 1. Turn the pilot scraw clockwise until it seats lightly, and then back it out to the specification given. This is an Ini tial setting prior to the final pilat seraw adjustment. CAUTION + Damage tothe pitot screw seat will occur if the pilen screw i tight ‘ened against the seat INITIAL OPENING: 2-3/4 turns out 2. Warm the engine up to operating temperature. ‘Stop and go riding for 10 minutes is sufficient. 3, Stop the engine and connect a tachometer according to the tachometer manufacturer's instructions. 4, Start the engine end adjust the idle speed with the thro tle stop screw. IDLE SPEED: 1,400 + 100 rpm 5, Turn the pilot screw in or out slowly to obtain the highest engine speed. 6. Readjust the idle speed with the throttle stop screw. 7. Turn the pilot screw in until the engine speed drops 50 'pm. 8 Readjust the idle spaed with the throttle stop screw. 9. Apply Loctite 601 or equivalent to the inside of the limiter cap. Place the cap over the pilot screw so that it can be turned clockwise only, This will prevent adjustment in the coun- terclockwise direction which richens the fuel mixture. NOTE Be careful not to turn the pilot screw when installing the lirniter eap. — fel {THROTTLE STOP SCREW, (1) PILOT SCREW (2) STOPPERS: 5-12FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT When the vehicle is ta be operated continuously above 2,000 m (6,500 feet), the carburetor must be readjusted as follaws to improve driveability and decrease exhaust emis~ sions. Warm up the engine to oparating temperature. Stop and go riding for 10 minutes is sufficient. ‘Tum the pilot screw clockwise 1/2 turn. Adjust the idle spesd to 1,400 + 100 mpm with the throttle stop screw. HIGH ALTITUDE SETTING: 1/2 turn In from Initial setting NOTE + This adjustment must be made at high altitude to ensure proper high altitude operation. Attach a Vehicle Emission Control Information Update Label ‘on the left side of the air cleaner housing as shown in the label position illustration. NOTE ‘Do not attach the label to any part that can be easily removed from the CAUTION ‘Sustained operation at an altitude lower than 5,000 feer (1,500 m) ‘with the carburetor adjusted for high alviude sortings may cause cenigine co idle roughly and stalin eraffc. It may also cause engine damage due to overheating. When the vehicle is to be operated continuously below 5,000 feet (7,500 m), turn the pilot screw to the Low Altitude Setting specified below. LOW ALTITUDE SETTING: 1/2 turn out ‘Adjust the idle speed 1,400 + 100 rpm with the throttle stop screw. Be sure to make these adjustments at low altitude. Remove the Vehicle Emission Control Information Update Label that is attached on the left side of the air cleaner hous: ing. ty PILOT SCREW (1) PILOT SCREW 5-13FUEL SYSTEM AIR CLEANER HOUSING REMOVAL Remove the following: — Rear fender (page 2-4) — Side covers (page 2-2) — Reear wheel (page 13-3) —Baitery (page 15-4) Disconnect the rear brake light switch connector. Remove the starter relay switch from the battory tray Remove the bolts and battery tray. Disconnect the crankcase breather tube from the breather separator. Loosen the connecting tube band screw. (3) BATTERY TRAY _ (4) BREATHER TUBE Remove the air cleaner housing mounting bolts. Pull and remove the air cleaner housing backward. (1) BOLTS | (1) AIR CLEANER HOUSING |FUEL SYSTEM INSTALLATION. Installation Is in the reverse order of removal. (2) BATTERY TRAY 5-15ENGINE REMOVAL/INSTALLATION 88 Nem (8.0 kgf, 66 IF) 82 Nem (6.3 kgtm, 46 Ib) 6-06, ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 61 ENGINE INSTALLATION 64 ENGINE REMOVAL 62 SERVICE INFORMATION GENERAL + The following components require engine removal for service. — Cylinder head/valves (Section 7) — Cyliner/pistun (Section: 8) — Crankshaft (Section 11) — Transmission (Section 11) ‘+ The following components can be serviced with engine installed in the frame. — Camshatt (Section 7) —Cluteh (Section 9) — Gearshift linkage (Section 9) —Cartouretor (Section 5) — Oil pump (Section 4) SPECIFICATIONS 1TEM ‘SPECIFICATION Engine oil capacity | At draining 16 liter (1.6 US at, 1.3 Imp ath __[Atéisessembiy | (1B liter (1.9 US at, 1.6 Imp atl Engine weight 38.5 ka (84. Ibs) TORQUE VALUES Exhaust pipe joint nut 14 Nom (1.4 kgf, 10 Ibe) Engine rear mounting nut 83 Nem (8.5 kgfm, 61 Ibf-ft) Gearshift pedal pivot nut 22 Nem (2.2 kam, 16 Ibfft) Drive sprocket bolt 12.Nem (1.2 kati, 9 Ioffe) 6-1ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL (1) CARBURETOR] Support the motoreyele using a safety stand or a hoist. Turn the ignition switch OFF and disconnect the battery negative (-) wire from the terminal Drain the engine oil (page 3-10) Remove the follow! — Carburetor (page 5-4) — Seatfuel tank (page 2-2, 3) — Exhaust system (page 2-4) Disconnect the spark plug caps. Disconnect the clutch cable from the bracket and clutch arm. Remove the nut and startar motor cable from the starter moter. Remove the boit and engine ground wire. Disconnect the crankcase breather separstor tube from the crankcase. Disconnect the follawing connectors: — Alternator connector — Neutral switch connector — Exciter coil connector — Ignition pulse generator connector a (3) IGNITION PULSE a CONNECTOR ST Remove the gearshift pedal link pinch bolt. Remove the left footpeg mounting bolts and footpeg/gesr- shift linkage assembly, (2) BOLTS: 1) GEARSHIFT PEDAL LINK. 6-2ENGINE REMOVAL/INSTALLATION Remove the bolt and side stand switch. Remave the bolts and starter matar cable clamp, Remove the bolts and left crankcase rear cover. Remove the fixing plate bolts, fixing plate and drive sprocket. UPPER HANGER! BRACKETI Remove the upper engine hanger nut and bolt. for Remove the nuts, bolts and upper engine hanger bracket Remove the front engine hanger nuts and bolts, Remove the nut, bolt and front engine hanger bracket. Remove the rear engine mounting nuts and bolts, then remove the engine from the left side of the frame. Note the direction of the engine hanger plate, bracket and hanger bolts.ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION | o UPPER AER Inatll the engine into the tram fe Temporarily install the reat engine hanger bolts and nuts. Install the front engine hanger bracket, than temporarily install the hanger bolts and bracket bolt. Install the upper engine hanger plate, then temporarily install the hanger plate bolts and hanger bolt. First tighten the rear engine hanger nuts to the specified torque, TORQUE: 88 Nim (9.0 kgfm, 65 lb-ft) Tighten the front engine hanger bracket bolt to the specified torque. TORQUE: 62 Nem (6.3 kgm, 46 IbFft} Tighten the upper engine hanger plate nuts and hanger nut, securely. Install the drive sprocket and fixing plate to the counter shaft Install and tighten the fixing plate bolts to the specified torque. TORQUE: 12 Nem {1.2 kgtm, 9 IDF‘) Install the left crankcase rear cover and tighten the bolts. Route the starter motor cable and secure it with the cablo clamps and bolts. Route the side stand switch wire properly (page 1-18). Install the side stand switch aligning the switch pin with the side stand hole and the switch groove with the return spring holding pin ‘Seoure the side stand switch with a new bolt. TORQUE: 10 Nem (1.0 kgm, 7 bt) (2) SIDE STAND SWITCH 6-4 (2) CABLE CLAMPENGINE REMOVAL/INSTALLATION Install the left foctpeg/gearshift linkage assembly, and install and tighten the mounting botts. Install the gearshift arm to the spindle aligning the punch marks. Install and tighten the pinch bolt to the specified torque. TORQUE: 10 N-m (1.0 kgtm, 7 tbttt) Connect the following connectors: — Ignition pulse generator connector — Exciter coil connector — Neutral ewitch connector — Alternator cannector Connect the crankcase breather tube to the engine. Install the engine ground wire and tighten the bolt. Connect the clutch cable to the clutch arm and bracket. Install the spark plug caps. (2) GROUND WIRE Install the following: (2) CARBURETOR — Exhaust system (page 2-8) — Carburetor (page 5-11) — Seat/fuol tank (page 2-2, 3) the crankcase with the recommended engine oil [page 3-9. Adjust the clutch lever free play (page 2-18). ae 6-5CYLINDER HEAD/VALVES: 2Nm ga kgf-m, 17 IbFf0) 10.Nem (1.0 kg, 71bEY é \ Zé F oo (1.2 kgm, 9 IDF 10 Nem (1.0 kgm, 7 IbF-A) 7-07. CYLINDER HEAD/VALVES ‘SERVICE INFORMATION TROUBLESHOOTING (CYLINDER COMPRESSION TEST CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSPECTION ROCKER ARM/CAMSHAFT REMOVAL VALVE GUIDE REPLACEMENT 7-10 VALVE SEAT IINSPECTION/REFACING 7-11 CYLINDER HEAD ASSEMBLY 14 CYLINDER HEAD INSTALLATION 15 CAMSHAFT/ROCKER ARM INSTALLATION 7-16 SERVICE INFORMATION GENERAL + This section covers service of th + Rlocker arms and camshaft can be serviced with the engine installed in the frame. The engine must be removed for servicing the cylinder head and valves. + When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. + Clean all disassembied parts with cleaning solvent and dry them by blowing them aff with compressed air before inspection. + locker arm lubricating oi is fed through oll passages in the cylinder head, Clean the oll passages before assembling ‘cylinder head and rocker arm holder. + Be cereful not to damage the mating surfaces when removing the cylinder haed cover and cylinder head. SPECIFICATIONS Unit: mm find Tem | STANDARD SERVICE LIMIT Cylinder compression 7/100 kPa (11.2 kg/em?, 159 psi) at _— 600 rpm [Cylinder head warpage — 10.10 (0.008) Vaiveand Valve clearance INIEX | 0.06-0.10 (0,002 - 0.004) — ‘valve gulde: Valve stem 0.0. IN 5.450 ~ 5.465 (0.2146 - 0.2152) §.42 (0.213) EX 5.430 - 5,445 (0.2138 - 0.2144) 5.40 (0.213) Vaive guide tb. IN| 5.475 5.485 (0.2186 - 0.2169) 550(0.217) | ex 5.476 — 5.485 (0.2156 - 0.2159) 5.50 (0.217) ‘Sterm-to-guide clearance IN | 0.700.035 (0.0004 - 0.0014) 10.08 (0.003), {ex 0.030 — 0.085 (0.0012 - 0.0022) 0.10 (0,004) Valve seat width [iwex | 7.0- 1.1 (0.039 - 0.049) 181007) | Inner | IN/EX | 28.9 (1.18) 29.0 (1.18) freelensth | outer Linvex | 38.2 (7.50) — 37.0 (7.46) Rocker erm | Rocker arm ID. IN/EX | 70.000 — 10.016 (0.3987 — 0.3943) 70.10 10.398) Rocker arm shaft OD, IN/EX | 9.972 ~ 9.987 (0.3926 - 0.3932) [981 (0.380) [Rocker arm-to-shaft clearance | IN/EX | 0,013 ~0.043 (0.0005 - 0.0017) [0.05 (0.002) | Camshe | Cam lobe height iN ‘77383-27543 (10781-10848) | 27.2 (1.07) | [ex | 27.209-27.369(1.0712— 1.0775) | __27.0(1.06) Runout | 0.08 (0.002) | Journal 0. _ _19.967 ~ 19.980 (0,7861 - 0.7866) 19.92 (0.784) | Bushing |. D. 20.063 ~ 20.083 (0.7893 --0.7907) 20.20 (0.795) 7-1CYLINDER HEAD/VALUES TORQUE VALVES \Velve adjuster lock nut Cylinder head/camshaft holder nut Cylinder head bolt Cam sprocket bolt Cylinder head cover bolt TOOLS (07708 - 0910001 (07742 -0010100, Timing cap wreneh Valve guide driver, 6.6mm Vaive guide reamer, 5.685 mm Valve spring compressor Velve seat cutters Seat cutter, 24.5 mm (48° IN/EX) Flat cutter, 25 mm (32° IN) (07787 - 0010000, (07780 - 0010100 (07780 ~ 0012000, Flat cutter, 25 mm (32° EX) (0780 --0012601 Interior cutter, 28 mm (60° IN/EX) (0780 - 0014500, Cutter holder, 6.5 mm. 07781 - 0010101 TROUBLESHOOTING 10.Nem (1.0 kgf, 7 Ibéf) 23 Nem (2.3 kgf, 17 IDF) 12.Nem (1.2 kgm, 9 Ibéft) 20 Nem (2.0 kgfm, 14 Ibf-f) Apply @ locking agent to the threads 10 Nem (1.0 kgfim, 7 Ib) (07984 ~ 0380000 or 07984 — 0980000 (U.S.A. anly) —these are commercially available in U.S.A. + Engine top-end problems usually affect engine performance. These problem can be diagnosed by @ compression test or by tracing angine noises to the top-end with sounding rod stethoscope. + If the performance is poor st low speeds, check for white smoke in the crankcase breather tube. If the tube is smoky, check for a seized piston ring (Section 8). Low compression + Valves: — Incorrect valve adjustment — Burned or bent valve — Incorrect valve timing — Weak valve spring + Cylinder head: — Leaking or damaged head gasket — Warped or cracked cylinder head + Worn cylinder, piston or piston rings (section 8) High compression Excessive carbon build-up on piston crown or on combustion chamber Excessive smoke + Worn valve stem or vaive guide + Damaged stem seal + Worn eylinder. piston or piston rings (section 8) Excessive noise + Incorrect valve adjustment + Sticking valve or broken valve spring + Worn rocker arm andor shaft Rough idle. + Low cylinder compression + Intake air leak Overheating + Excessive carbon build-up on the piston head or combustion chamber Knocking or abnormal noise ‘+ Excessive cartoon build-up + Worn piston and cylinder (section 8) 7-2CYLINDER HEAD/VALVES CYLINDER COMPRESSION TEST Wm + If the engine must be running to do some work, make sure the ‘rea is well-ventilated. Never rum the engine in an enclosed area. The exhaust contains poisonous carbon monozide gas that may ‘cause loss of consciousness and lead 0 death. Warm up the engine. Stop the engine and remove the spark plugs. Install a compression gauge. Open the throttle all the way and crank the engina with the starter motor until the gauge reading stops rising, COMPRESSION PRESSURE: 1,100 kPa (11.2 kg/em®, 159 psi) at 600 rpm Low compression can be caused by: — Blown eylinder head gasket — Improper vaive adjustment = Valve leakage — Worn piston ring or cylinder High compression can be caused by: —Carbon deposits in combustion chamber or on piston head ROCKER ARM/CAMSHAFT REMOVAL Riel -eite Romove the fuel tank (page 2-3). s Remove the spark plug caps. Remove the ignition calls. Remove the bolts and cylinder head cover. Remove the cylinder head caver packing, Remove the crankshaft and timing hale caps using the spe cial tool. TooL: Timing cap wrench 07709 - 0010001 (1) CRANKSHAFT HOLE CAP|CYLINDER HEAD/VALVES. Turn the crankshaft counterclockwise and align the “T* mark on the flywheel with the index mark on the left cramk- case cover. Loosen the camshaft holder nuts and cylinder head bolts in ‘sequence shown in 2-3 steps. Remove the nuts and camshaft holders and dowel pins. ‘Thread a 5 mm screw into the rocker arm shaft and! pull the rocker arm shaft aut of the camshaft holder. ‘= > ee (1) 5mm SCREW Remove the rocker arms and rocker arm springs. (3) SPRING (2) ROCKER ARM NOTE Sy + Mark and store the disassembled parts to ensure that they are reinstalled in their original locatior (1) ROCKER ARM SHAFT 7-4CYLINDER HEAD/VALVES Pull the wedge A of the cam chain tensioner straight up while holding the wedge 8 down to release the cam chain tension. Secure wedge A with 3 2 mm pin as shown. (3)2mm PIN Romove the cam sprocket bolt. ‘Tum the crankshaft counterclockwise one turn, and remove the other cam sprocket bolt. NOTE + Be careful not to drop the cam sprocket bols into the crank Slide the cam sprocket off the camshaft flange and remove the cam chain from the sprocket. Remove the camshaft from the right side and remove the cam sprocket. Hang the cam chain with piace of wire to prevent it from falling into the crankcase. Remove the snap ring, spacer and bushing from the cam- shaft. NoTE + The snap ring and spacer are installed on the left side ony. ~T (a) BusHINGS f (2) SPACER 7-5CYLINDER HEAD/VALVES INSPECTION Inspect the rocker arms for wear or damage to the camshaft contact surface and for a plugged oil hole. NOTE + IF the camshaft contact surface of the rocker arm is dam- aged or abnormally worn, check the cam lobes for dam 290. Measure the |.D. of each rocker arm. [SERVICE LIMIT: 10.10 mm (0.398 in) Inspect the rocker arm shafts for wear or damage. Measure the 0.0, of each rockar arm shaft SERVICE LIMIT: 9.91 mm (0.290 in} Calculate the rocker arm-to-shaft clearance ky SERVICE LIMIT 0.05 mm (0.002 in) Insect the camshaft bushings for wear or damage. Measure the LD. of each bushing. ‘SERVICE LIMIT; 20.20 mm (0.795 in) ‘Support both ends of the camshaft with V-blocks and mea- sure the camshaft runout with a dial gauge. SERVICE LIMIT: 0.05 mm (0.002 in) 7-6CYLINDER HEAD/VALVES Measure the camshaft journal 0.0. ‘SERVICE LIMIT: 19.92 mm (0.784 in) Measure the height of each cam lobe, ‘SERVICE LIMIT: IN: 27.2 mm (1.07 in) EX: 27.0 mm (1.06 in) CYLINDER HEAD REMOVAL Remove the engine from the frame (section 8). Remove the camshaft (page 7-3). Remove the nuts and intake manifold. Remove the cam chain tensioner upper bolt and loosen the lower bolt. 7-7CYLINDER HEAD/VALVES. Remove the cylinder head bolts, nut and the cylinder head. (1) BOUTS __ lia} CYiinDeR Head NOTE + Be careful not to left the front cylinder head bolt fall into the cylinder. CAUTION ‘Do nut strike the cylinder head fis to remove the cylinder head. Remove the dowel pins and cylinder head gasket. CYLINDER HEAD DISASSEMBLY Remove the spark plugs from the cylindar head. Remove the valve spring cotters, retainers, springs and valves using the special tools as shawn. TOOL: Valve spring compressor 07787 - 0010000 CAUTION + To prevent loss of tension, do nor compress the vaive springs mare than necessary to remove the coters. NOTE + Mark all parts during disassembly so they can be placed Remove the valve stem seals and valve spring seats. (2) OUTER SPRING (1) RETAINER 2 eee wserncsear | Fg. (@) INNER SPRING 7-8CYLINDER HEAD/VALVES CYLINDER HEAD INSPECTION (3) COMBUSTION CHAMBERS CYLINDER HEAD Remove carbon deposits from the combustion chambers, Check the spark plug hole and valve areas for cracks. NOTE + Avoid damaging the gasket surfac + Gasket will come off easier if sosked solvent. Cheok the cylinder head for warpage with a straight edge and feeler gauge. ‘SERVICE LIMIT: 0.10 mm (0,004 in} VALVE SPRING Measure the free length of the inner and outer valve springs. SERVICE LIMITS: Inner: 29.0 mm (1.14 in} ‘Outer: 37.0 mm (1.46 in) Replace the springs if they are shorter than the service lim- its, VALVE/VALVE GUIDE Inspect each valve for bending, burning or abnormal stem wear. Check valve movement in the guide, measure and record each valve stem 0.0. ‘SERVICE LIMITS: IN: 5.42 mm (0.213 int EX; 5.40 mm (0.213 in}CYLINDER HEAD/VALVES Ream the guides to remove any carbon deposits before checking clearances. Ingart the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. Too: Valve guide reamor, 5.485 mm 07984 - 0880000 or 07984 - 0880000 (U.S.A. only) Measure and record each valve guide 1D. SERVICE LIMIT: IN/EX: 5.50 mm (0.217 in) Subtract each vaive stom 0.0. from the corresponding guide LD. to obtaiin the stem-to-guide clearance. ‘SERVICE LIMITS: IN: 0.08 mm (0.003 in} EX: 0.10 mm (0.004 in) If the stem-to-guide clearance exceeds the service limits, determine if a new guide with standard dimensions would bring the clearance within tolerance, If so, replace any guides 4s necessary and ream to fit. If the stem-to-guide clearance exceeds the service limits with new guides also, replace the valves and guides. NOTE + Reface the valve seats whenever the valve guides are replaced (page 7-11), VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 100 — 160°C (212 ~ 300°F) with a hot plate or oven, Gi + To avoid burns, wear heavy gloves when handling the heated eplinder head. CAUTION ‘Do not use-a torch to heat tl ojlinder head: it may cause warping ‘Support the cylinder head and drive out the valve guides from the combustion chamber side of the eylinder head, TooL: Valve guide driver, 55mm —_07742-0010100 (1) VALVE GUIDE REAMER | (1) VALVE GUIDE DRIVER 7-10CYLINDER HEAD/VALVES Install a naw O-ring on the new valve guide. (1) VALVE GUIDE DRIVER Drive in the guide from the top of the head. . i TOOL: Valve guide driver, 5.5mm 077420010100 Inspect the valve guide for damage. Roam the new valve guide after installation. Insert the reamor from the combustion chamber side of the head end also always rotate the reamer clockwise. TOOL: Valve guide reamer, 5.485 mm 07984 - 0980000 or ‘7984 - 0980000 (U.S.A. only) NOTE reamer during this operatior Use cutting oll ont Clean the particies, Reface the valve seat (see below). VALVE SEAT INSPECTION/REFACING Clean the intake and exhaust vaivas thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve seats. Lap the valves and seats using rubber hose or other hand- 19 tool, jemove and inspect the valves. jer head thoroughly to remove any metal CAUTION + The valves cannot be ground. If a valve face is burned or badly worn or if ir contacts the seat unevenly, replace the valve Inspect the width of each vaive seat. STANDARD: — 1.0~1.1 mm (0.039 ~ 0.063 in} SERVICE LIMIT: 1.8 mm (0.07 in} + If the seat is too wide, too narrow or has low spots, the seat must be ground. \Z (1) SEAT WIDTH 7-11CYLINDER HEAD/VALVES VALVE SEAT REFACING Valve seat cuttors/arindors or equivalent vaive seat refacing equipment are recommended to correct worn vaive seats. NOTE + Follow the refacing manufacturer's operating instruc: tions. Use 2 45 degrees cutter to remove sny roughness or irregu- larities from the seat. NOTE + Reface the seat with @ 45 degrees cutter whenever @ valve uide is replaced, Use 2 92 degrees cutter to remove the top 1/4 of the exist- Us seat. Remove the cutter and inspect the area you have refaced. cutter to remove the bottom 1/4 of the old 8 60 degre (1) ROUGHNESS: (1) OLD SEAT WIDTH (1), OLD SEAT WIDTH 7-12CYLINDER HEAD/VALVES Install 8 45 degrees finish cutter and cut the seat to the proper width. Make sure that all pitting and irregularities are removed, Refinish if necessary. 1.2:mm (0.05 in) Apply a thin costing of Prussian Blue to the valve seat. Prose the valve through the valve guide and onto the seat to make a clear pattern. NOTE Nia) ‘+ The location of the valve seat in relation to the valve face OLD. SEAT WIDTH very important for good sealing. ifthe contact arse is too high on the valve, the seat must be 32 (1) CONTACT TOO HIGH lowered using a 32 degrees flat cutter. {tthe contact area is too low on the valve, the seat must be 41) CONTACT TOO LOW raised using # 60 degrees inner cutter. “A (2) OLD SEAT WIDTH Refinish the seat to specifications, using @ 45 degrees finish cutter. After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. After lapping, wash all residual compound off the cylinder head and valve. NOTE + Do not allow lapping compound to enter the guides.CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY (1) VALVE COTTERS. (2) SPRING RETAINER_>S (3) OUTER VALVE SPRING —+" (4) INNER VALVE SPRING: (9) ExHaUST VALVE Install the valve spring seat and a new stern seal. Lubricate the vaive stems with molybdenum disulfide oil ‘and insert the valve into the valve guide. To avoid damage to the stem seal, turn the valve slowly when inserting. Install the valve springs with the tightly wound eoils facing the combustion chamber. + 4 (1) FACING TO THE COMBUSTION CHAMBER 7-14CYLINDER HEAD/VALVES Install the valve spring retainers and cotters using the spe- fi) VALVE SPRING COMPRESSOR cial tool as shown. a3 ee To prevent loss of tension, do not compress the valve spring more than necessary. TOOL: Valve spring compressor 07787 — 0010000 Tap the valve stems gently with two plastic hammers as shown to seat the cotters firmly. CAUTION Support the cylinder head abowe the work bench surface to prevent possible valve damage, CYLINDER HEAD INSTALLATION Clean the gasket material off the mating surface of the cylin- der head. Make sure that the cam chain guide is installed properly. Install the dowel pins and @ new cylinder head gasket as shown, Install the cylinder head. (1) CYLINDER HEAD (2) TENSIONER UPPER Install the cam chain tensioner upper bolt and sealing washer. Tighten the cam chain tensioner bolts, 7-15CYLINDER HEAD/VALVES: Temporarily install the cylinder head mounting bolts and ‘nut, but do not tighten them. Install the O-rings into the groove In the inteke manifold and install it onto the cylinder head. Install the spark plugs, CAMSHAFT/ROCKER ARM {01 CAMSHAFT — (2) SFRING (3) ROCKER ARM ROCKER ARM HOLDER ASSEMBLY sft Lubricate the rocker arm and rocker arm shaft with clean cngine oil Install tho rocker arms and springs in the camshaft holder, {and install the rocker arm shafts with the threaded end fac: (4) ROCKER ARM SHAFT Apply molybdenum disulfide oil to the inside of the cam- (1) CAMSHAFT shat bushings. Install the comehaft bushings onto: both: ends of the:cam= @ =W0, (2) BusHINes 7-16CYLINDER HEAD/VALVES Install the spacer by placing its tab into the groove in the (2) ALIGN loft end of the shaft and secure it with the snap ring. CAMSHAFT INSTALLATION ‘Turn the crankshaft counterclockwise and align the “T” mark on the flywheel with the index mark on the left crank- case cover. Pass the camshaft through the cam chain end sprocket and install it in the cylinder head. NOTE + Install the cam sprocket with the timing marks (index lines) facing toward the lett side. Position the dowel pins of the camshaft bushings into the grooves in the eylindar head,CYLINDER HEAD/VALVES Align the timing marks (index lines) on the cam sprocket (7) CAM SPROCKET) with the top of the cylinder head and install the cam chain f over the sprocket. Install the cam sprocket on the camshaft flange and align the cam sprocket bolt holes in the sprocket and camshaft Apply a focking agent to the threads of the cam sprocket bolts. Install and tighten the sprocket bolt. Turn the crankshaft counterclockwise one full turn (360°) and install and tighten the other bolt Make sure: that the timing marks on the sprocket align with the top of the cylinder head when the “T” mark on the fly- whee! aligns with the index mark on the left crankcase Remove the 2mm pin from the chain tensioner wedge. (02 mm PIN CAMSHAFT HOLDER INSTALLATION Ingtall the dowel pins into the cylinder head 7-18CYLINDER HEAD/VALVES Loosen the valve adjusting screws fully and install the camshaft holders with the “F* mark toward the front. Install the cylinder heed washers and nuts. Tighten the nuts and bolts in the sequence shown In 2~3 steps. ‘TORQUE: Nut: 23 Nem (2.3 kgm, 17 It) Pour fresh oil into the oil pockets in the cylinder heed until the cams are submerged. Adjust the valve clearance (page 3-7). Inspect the cylinder head cover packing for damage or dete- rioration and replace with # new one if necessary.CYLINDER HEAD/VALVES Install the cylinder head cover and tighten the bolts. TORQUE: 10 Nem (1.0 kgf, 7 Ibe) {install the ignition coils and cornect the connectors. Install the spark plug caps to the spark plugs. ‘Check that the O-rings of the crankshaft and timing hole cap are in good condition, replace if necessary, Install and tighten the crankshaft and timing hole caps using the special fool, TooL: ‘Timing cap wrench 0708 - 0010001, Instatl the fuel tank (page 2-3). 7-20MEMOCYLINDER/PISTON 8-08. CYLINDER/PISTON ‘SERVICE INFORMATION 81 CYLINDER/PISTON INSPECTION a3 ‘TROUBLESHOOTING 82 GYLINDER/PISTON INSTALLATION 8-6 (CYLINDER/PISTON REMOVAL 83 SERVICE INFORMATION GENERAL + This eeetion cavers earvics of the eylinder and piston, + Cylinder head lubricating oil is fed through an ail passage in the cylinder. Be sure this oil passage is not clogged end ‘that the O-rings and dowel pins are in place before installation. + When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tions. + Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. + Refer to section 11 for the cam chain tensioner ramoval and inspection. SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD [SERVICE LiMTT Cylinder 1D. 153,000 — 63,010 (2.0866 - 2.0870) 53.10 ¢2.091) Out of round — [0.05 (0.002) Taper — [0.05 10-002) Warpag 0.05 ¢0.002) iston, pis. | Piston mark direction "IN" mark facing toward the Intake __ ton ring side Piston 0.0. 52.970 — 62.980 (2.0864 - 2.0862) 152.90 (2.083) Piston 0.D. measurement point 10 mm (0.4 in) from bottom of skirt — Piston pin bore LD. 116.002 — 16.008 (0.5806 - 0.5808) 16.05 (0.593) Piston pin 0.0. | 14.984 76.000 (0.5903 - 0.6906) 14.98 (0.590) | Pistor-to-piston pin clearance 10.002 — 0.014 (0.0001 — 0.0006) 0.07 (0.003) | Piston ring-to-ring | Top (0.015 0.045 (0.0006-0.0018) | _—0.100.004) | groove clearance | Second {0.015 ~ 0.050 (0.0006 - 0.0020) (0.10 (0.004) Pistonringend | Top 0.15 - 0.30 (0.006 - 0.012) 0.45 (0.078) gep “Second __—_—*| 0.300.485 (0.012-0.018) 0.60 (0.024) Oil (side rail) 0.20.7 (0.01 - 0.03) 0.90 (0.035) Cylinder-to-piston clearance 0.010 - 0.040 (0.0004 0.0016) 0.10 (0.008) Conneeting rod smail end LD. 15.016 - 16.034 (05912-05919) | 15.08 (0.594) Connecting rod-to-piston pin clesrance 0.016 - 0.040 (0.0008 - 0.0078) 0.10 10.008), TOOL Piston base 107968 - 3000000CYLINDER/PISTON TROUBLESHOOTING Low compression + Worn cylindar oF piston rings Excassive smoke piston or piston rings installation of piston rings + Scored or scratched piston or cylinder wall Overheating + Excessive carton build-up on the piston head or com- bustion chamber Knocking or abnormal noise + Worn piston and cylinder + Excessive carbon build-up 8-2(CYLINDER/PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL (7) CAM CHAIN TENSIONER LOWER BOLT Remove the following: — Cylinder head (page 7-7) — Cam chain tensioner lower bolt (page 7-7) — Cam chain tensioner guide — Cylinder Remove the dowel pins and cylinder gasket. PISTON REMOVAL Remove a piston pin clip with pliers. NOTE + Do not let the clip fall into the crankcase. Press the piston pin out of the piston and remove the pis- ton, CAUTION + Abways support the piston when pressing out the piston pin to pre vent damage tothe big-end bearing CYLINDER/PISTON INSPECTION CYLINDER INSPECTION Inspect the top of the cylinder for warpage. SERVICE LIMIT: 0.05 mm (0.002 in}CYLINDER/PISTON Inspect the oylinder bore for wear or damage. Measure the cylinder I.D. in X and ¥ axis at three levels. ‘Take the maximum reading to determine the cylinder wea ‘SERVICE LIMIT: 63.10 mm (2.094 in} Calculate the taper and out of round at three levels in X and Y axis, Take the maximum reading to determine them. ‘SERVICE LIMIT: ‘Taper: (0.05 mm (0.002 in) (Out of round: 0.05 mm (0.002 in) The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded, ‘Tha following oversize pistons are available: (0.25 mmm (0.010 in) (0.50 mm (0.020 in) The piston to cylinder clearance for the oversize piston must be: 0.01 ~ 0.04 mrn (0.0004 - 0.0016 in). PISTON INSPECTION " Remove the piston ring. NOTE + Do not damage the piston rings during removal Remove any carbon deposits from the piston ring grooves, using an ald piston ring as shown, 8-4\CYLINDER/PISTON ‘Temporarily install the piston rings to their proper posi with the mark facing up. Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves. ‘SERVICE LIMIT: ‘Top: _ 0.10 mm (0.004 in} ‘Second: 0.10 mm (0.004 in) Inspect the piston for wear or damage. Insert the piston ring squarely into the bottom of the cylin- der and measure the ring end gap. NOTE + Push the rings into the cylinder with the top of the piston to be sure they are squarely in the cylinder. ‘SERVICE LIMIT: Top: 0.45 mm (0.018 in) Second: 0.80 mm (0.024 in) Oil (side rail): 0.90 men (0.035 in) Measure the diameter of the piston at 10 mm (0.4 in) from the bottom and 90 degrees to the piston pin hole, SERVICE LIMIT: 52.90 mm (2.083 in} Calculate the piston-to-cylinder clearance. ‘Take 2 maximum reading to determine the clearance. SERVICE LIMIT: 0.10 mm (0.004 in) Measure the piston pin bore. ‘SERVICE LIMIT: 15.05 mm (0.593 in) 8-5CYLINDER/PISTON ‘Measure the 0.0. of the piston pin. SERVICE LIMIT: 14.98 mm (0.590 in) Calculate the piston-to-piston pin clearance. SERVICE LIMIT: 0.07 mm (0.003 in} Measure the connecting rod small end LD. SERVICE LIMIT: 15.08 mm (0.594 in} CYLINDER/PISTON INSTALLATION PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install the ton rings, NOTE ‘Apply oll tothe piston rings. + Avoid piston and piston ring damage during installation. Install the piston rings with the marking (N) facing up. + Do not mix the top and second rings: the top ring is nar- rower than the segand ring in with, Do not align the gaps in the oil rings {side rails) Space the piston ring end gaps 120 degrees apart. After installation, the rings should rotate freely in the ring grooves. Bed lo we ae (1) TOP RING Eros (3) SIDE Fs RAILS (4) SPACER 8-6CYLINDER/PISTON PISTON INSTALLATION Clean off any gasket mater crankcase upper surface. | from the cylinder base and Apply 8 thin coat of clean engine oll to the connecting rod small ends and piston pins. Cover the opening into the crankcase with a rag. Install the pistons and piston pins, using new piston pin clips. Remove the rag. NOTE + Install the piston with its “IN” mark facing the intake side. + Do not align the piston pin clip’s end gap with the piston cut-out. + Do not let the clip fall into the crankcase. Install the dowel pins end @ new gasket. Cost the cylinder bores and pistons with engine oll. Place the piston bases under the pistons, compress the pis- ton rings and slide the cylinder over the pistons. TOOL: Piston base (07958 - 3000000 Remove the piston bases.CYLINDER/PISTON, Install the cam chain tensioner guide. Install the cylinder head (page 7-15) 8-8 (2) CAM CHAIN TENSIONER LOWER BOLT/ SEALING WASHER \, 2MEMOCLUTCH/GEARSHIFT LINKAGE9. CLUTCH/GEARSHIFT LINKAGE ‘SERVICE INFORMATION 9-1 PRIMARY AND OIL PUMP DRIVE TROUBLESHOOTING a2 GEARS ae RIGHT GRANKCASE COVER GEARSHIFT LINKAGE 910 REMOVAL 9-3 RIGHT CRANKCASE COVER cuuTes 94 INSTALLATION’ 912 SERVICE INFORMATION GENERAL + This section covers removal and installation of the clutch, primary drive gear, oll pump drive gear and gearshift link- age. These services bbe performed with the engine installed in the frame. SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD SERVICE LIMIT Clutch lever free play 10-20 (ae —3y4) — Clutch spring free length 37.8 (7.49) 36.0 (7.42) ‘Cluteh dise thickness 2,92 - 3.08 (0.115 -0.121) 2.60.10) Clutch plate warpage — 0.20 (0.008), Clutch outer 0. 26.000 ~ 26.021 (1.0236 - 1.0244) 26.0 (7.025), Clutch outer guide 1D. 20.000 ~ 20.021 (0.7874 ~ 0.7882) 20.05 (0.789) OD. 25.959 — 25.980 (7.0220 ~ 7.0228) 25.90 (1.020) TORQUE VALUES Clutch lifter bolt Clutch center lock nut Shift drum stopper arm bolt Gearshift return spring pin Primary drive gear lock nut TOOLS Clutch center holder Gear holder Lock nut wrench, 20. 24 mem Extension bar 12. Nem (1.2 kgm, 9 Ib) 74 Nem (7.5 kg, 4 IbFh) 12. Nem (1.2 kgtn, 9 Ib) 25 Nem (2.5 kgf, 18 lb-ft) Apply a locking agent to the threads 53 Nem (6.4 kgf, 39 IBF) 07GMB- KT70101 077240010200, 07716- 0020100 07716 ~ 0020500 or equivalent commercially available in U.S.A. 9-1CLUTCH /GEARSHIFT LINKAGE TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the fr ‘Clutch lover hard too pull in Damaged, kinked or dirty olutch cable Improperly routed clutch cable Damaged clutch lifter mechanism. Faulty clutch lifter plate bearing Clutch will not disengage or motorcycle craeps with clutch disengaged + Too much clutch levar free play + Clutch plate warped + Check for oll additive Clutch sips © Clutch her sticking Worn clutch dises Weak clutch springs No clutch lever free play Check for oll additive Hard to shift Misadjusted clutch cable Damaged or bent shift fork Bent shift fork shaft Incorrect engine oil viscosity incorrect gearshift spindle assembly ‘Damaged shift drum cam grooves 9-2 Qil level too high, improper oil viscosity, or additive used play. ‘Transmission jumps out of gear + Worn shift drum stopper arm Wear or broken gearshift spindle return spring Bent shift fork shaft Damaged shift drum cam grooves: Worn gear dogs or siots Goarshift pedal will not return + Weak or brokan gearshift spindle return spring + Bent gearshift spindleCLUTCH/GEARSHIFT LINKAGE (2) FOOTPEGBRACKET / = RIGHT CRANKCASE COVER REMOVAL bf Drain the engine ail (page 3-10). Remove the bolts and right footpeg bracket. Disconnect the clutch cable from the clutch arm. Remove the bolte and right crankcase cover. Remove the gasket and dowel pins. CLUTCH LIFTER REMOVAL/INSTALLATION Remove the clutch lifter rod.CLUTCH/GEARSHIFT LINKAGE Remove the lifter spring from the end of the clutch arm. (3) OW SEAL Check the clutch arm, lifter rod and spring for wear or dam: age. o Check the oil seal for damage. (2) LIFTER ARM Apply grease to the oil seal lip and insert the clutch arm into Sy reese inal te iterate Nn \ (1) LIFTER SPRING Slightly turn the clutch arm clockwise and install the lifter rod into the right crankcase cover. CLUTCH creo ys REMOVAL Remove the clutch lifter plate bolts, plate and clutch springs. NOTE + Loosen the clutch lifter plate bolts in a crisscross pattern in 2-3 steps. Unstake the clutch lock nut with a drill or grinder. CAUTION + Be careful not to damage the mainshapt threads 9-4CLUTCH/GEARSHIFT LINKAGE Remove the clutch center lock nut using the special tools. (7) CLUTCH CENTER HOLDER TooLs: Clutch center holder O7GMB ~KT70101 Lock nut wrench, 20 x24 mm Extension bar Remave the following: —Ciuteh center — Spring seat —Judder spring — Clutch dises and plates — Pressure plate — Spline washer —Clutch outer (6)PRESSURE — Outer guide (6) CLUTCH DISCS PLATE — Thrust washer (4) CLUTCH PLATES (3) JUDDER SPRING (1) CLUTCH CENTER INSPECTION Clutch lifter bearing Turn the lifter bearing rollers with your finger. The bearing should turn smoothly and freely without excessive play. if necessary replace the bearing. Clutch spring Measure the clutch spring free length. SERVICE LIMIT: 36.0 mm (1.42 in} 9-5CLUTCH/GEARSHIFT LINKAGE Clutch conter Check the grooves of the clutch center for damage or wear caused by the clutch plates, Replace if necessary. Clutch dise Replace the clutch discs if they show. signs of scoring or dis- coloration. Measure the disc thickness of each disc. ‘SERVICE LIMIT: 2.6 mm (0.10 in) Clutch pate Check each disc plate for warpage on a surface plate using a feeler gauge. ‘SERVICE LIMIT: 0.20 mm (0.008 in) Clutch outer/elutch outer guide Check the slots of the clutch outer for damage or wear caused by the clutch discs, Roplace if necessary. Measure the clutch outer .D, ‘SERVICE LIMIT: 28.04 mm (1.025 in) Measure the 0.0. and LD. of the clutch outer guide. SERVICE LIMIT: 0.D.: 25.90 mmm (1.020 in) LD. 20.05 mm (0.789 in) 9-6CLUTCH/GEARSHIFT LINKAGE INSTALLATION (4) PRESSURE PLATE (2) Lock NUT 74 Nem (7.5 kgm, Bd Ib) (1) LIFTER PLATE (5) CLUTCH OUTER ‘ AQ (8) CLUTCH CENTER 12Nen (1.2 kgtm, 9 bE) Install the thrust washer and clutch outer guide onto the mainsheft, ToTsuST WASTER . aS (2) OUTER GUIDE! Install the clutch outer and spline washor. NOTE + Note the lirection of the spline washeCLUTCH/GEARSHIFT LINKAGE lata he spring eet nd judo sping ont the catch con SERN Assemble the clutch pressure plate, discs, plates and clutch (2) CLUTCH DISCS center, and install them in the clutch outer. SS Coat new clutch discs with clean engine oil. ISS (8) SPRING SEAT Stack the discs and plates alternately. NOTE ee + Note the direction of the judder spring. (1) SPRING SEAT 7 (4) JUDDER SPRING (2) JUDDER SPRING (o) CLUTCH CENTER + Stack the discs and plates alternately. Install the lock washer with its “OUT SIDE” mark facing out. Attach the clutch center holder using the clutch Install 8 new lock nut, then tighten it to the specified torque using the special toots, TooLs: Clutch center holder 07GB — KT70101 Lock nut wrench, 20x 24mm 0716~ 0020100 Extension bar 07716 - 0020500 or equivalent commercially available in U.S.A. TORQUE: 74 Nem (7.5 kgfm, 54 Ibtft) Stake the end of the lock nut into the groove of the mail shaft with a punch, 9-8CLUTCH/GEARSHIFT LINKAGE Install the clutch springs and lifter plate. Install and tighten the lifter plate bolts to the specified torque. crisscross pattern in 2 — ‘TORQUE: 10 Nm (1.0 kgfm, 7 thf) Install the lifter plate bearing if it was removed. Install the right crankcase cover (page 9-12) REMOVAL jove the right crankcase cover (page 9-3). Remove the oll pump (page 4-2). Remove the oil through and spring from the erankshatt. Attach the gear holder between the primary drive and dre ven gear as shown. TOOL: Gear holder 07724 -0010200 Remove the lock nut and washer. Remove the clutch assembly (page 9-4) Remove the oll pump drive gear and primary drive gear. INSTALLATION Install the primary drive gear and oll pump driven gear on the crankshaft NOTE Install the clutch assembly (page 9-7). Install the lock washer with its "OUTSIDE" mark facing out.CLUTCH/GEARSHIFT LINKAGE ‘Attach the gear holder betwoen the primary drive and dri- ven gear as shown Too: Gear holder 07724- 0010200 Install the drive pin into the crankshaft hole. Install and tighten the lock nut to the specified torque. TORQUE: 53 Nim (6.4 kgm, 39 Ibé#t) Install the oll through and spring. Install the following: — Oil pump (page 4-8) — Right crankcase cover (page 9-12) (1) OIL THROUGH! =| a (2) GEARSHIFT PEDAL ie GEARSHIFT LINKAGE DISASSEMBLY Remove the following: — Right crankcase cover (page 9-3) — Oil pump (page 4-2) — Clutch assembly (page 8-4) Remove the bolt and gearshift pedal link. Pull the gearshift spindle out of the crankcase, 9-10CLUTCH/GEARSHIFT LINKAGE Remove the following: — Stapper arm bolt — Stopper arm Return spring — Shift drum stopper plate bolt — Stopper plate — Dowel pins (3) STOPPER PLATE ASSEMBLY Install the return spring and shift drum stopper arm and tighten the bolt to the specified torque. TORQUE: 12 Nem (1.2 katie, Itt) Install the dowel pins into:the shift drum holes. Hold the stopper arm using the screwdriver and install the shift drum stopper plate by aligning the dowel pins with the holes in the stopper plate. Install and tighten the shift drum stopper plate bolt Install the gearshift spindile into the crankcase, so that the return spring pin is positioned between the spring ends. Install the gearshift pedal link by aligning the punch marks: Check the operation of the gearshift linkage, Install the following: — Oil pump (page 4-8) —Clutch assembly (page 9-7) — Right crankoase cover (see naxt page)CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER INSTALLATION Clean off any gasket material Install the dowel pins and new gasket NOTE Be careful not to damage the gasket mating surface. Install the right crankcase cover and connect the clutch cable to the cluteh arm. Sot the clutch cable guide and tighten the right crankcase cover bolts. Install the right footpeg bracket and tighten the botts. Adjust the clutch (page 3-18). Fill the crankcase with the recommentied engine oll {page 3-3) Start the engine and check the clutch for smooth operation. Be sure there are no oil leaks. (a) BOLTS 9-12MEMO:ALTERNATOR/STARTER CLUTCH 10-010. ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 40-1 STARTER CLUTCH 10-3 TROUBLESHOOTING 10-1 ALTERNATOR INSTALLATION 10-7 |_ ALTERNATOR REMOVAL 10-2 SERVICE INFORMATION GENERAL + This section covers the removs clutch + afer to section 16 for alternator inspection, and to section 16 for ignition pulse generator inspection, SPECIFICATIONS ‘end installation of the flywheel, alternator, ignition pulse generator, and sterter Units mm tin) (TEM ‘STANDARD SERVICE MIT ‘Starter driven sproket Lo. 22.010 ~ 22.022 (0.8665 — 0.8670) 22.08 (0.869) Boss 0.0. 36.975 — 37.000 (1.4557 — 1.4567) 36.90 (1.453) TORQUE VALUES Flywheet bolt 58 Nem (6.0 kgf, 43 IbFf) Starter clutch mounting screw 9 Nem (0.9 kgém, 6.5 Itt) Apply @ locking agent to the threads ‘Stator mounting screw 8Nem (0.6 kgtm, 4.3 loft) Stator wire clamp screw Nem (0.6 kom, 4.3 Ib) Ignition pulse generator screw 10 Nem (1.0 kgm, 7 IbFtt) TOOLS Fiywhee! holder 0725 - 0040000 Rotor puller 0733~0020001 Engine does not turn + Faulty starter one-way clutch 10-1ALTERNATOR/STARTER CLUTCH ALTERNATOR REMOVAL FLYWHEEL REMOVAL Remove the bolts and left foatpeg bracket. Romove the bolt and gearshift pedal link. Romove the fuel tank (page 2-3). Disconnect the alternator, exciter coil and ignition pulse generator wire connectors. (1) IGNITION PULSE é GENERATOR CONNECTOR), (7) BOLTS JaMR2) LEFT CRANKCASE REAR COVER] Remove the bolts and left crankcase rear cover. Remove the alternator wire grommet from the left crank- case groove, Remove the bolts and left crankcase cover. Cr (3) LEFT CRANKCASE COVER! 10-2ALTERNATOR/STARTER CLUTCH Hold the flywheel using the special tool, then remove the flywhea! bolt. TOOL: Flywheel holder 0725 ~ 0040000 Remove the washer, Remove the flywheel using the special tool Too: Rotor puller 0733 ~ 0020001 STATOR REMOVAL Remove the following: — Socket bolts and ignition pulse generator (3) STATOR — Socket bolts and wire clamp — Socket bolts and stator 2) WIRE CLAMP. STARTER CLUTCH REMOVAL Remove the bolt and starter driven sprocket setting plate. Remove the starter drive gear, driven gear and drive chain fs en assembly Remove the following: — Left crankcase cover gasket — Dowel pins — Side spacer — Side spacer gasketALTERNATOR/STARTER CLUTCH ‘Temporarily install the starter driven gear, and check the operation of the one-way clutch by turning the driven sprocket, You should be able to turn the driven sprocket count clockwise smoothly, but the sprocket should not turn elock- wise. DISASSEMBLY Remove the rollers, spring caps and springs from the clutch outer. (1) ROLLER, ogee < (2) SPRING cap” (3) SPRING Remove the clutch outer mounting screws using an impact (1) IMPACT DRIVER driver. Remove the starter clutch outer, side plate and dowel pin. INSPECTION (3) OIL SEAL ‘Check the starter driven gear for abnormal wear or damage. Chock the starter drive gear and driven gear teeth for wear or damage. Check the oil seal of the driven sprocket for wear or dam- age. (2) DRIVEN GEAR (1) DRIVE GEAR 10-4ALTERNATOR/STARTER CLUTCH ‘Measure the starter driven sprocket |. and 0.D. Check the rollers, spring caps and spring for wear, damage or deformation. Check the rotor contact area of the clutch outer for wear or damage. ASSEMBLY oN 0.9 bgt, 65 04 Na (7) ROLLER (5) STARTER CLUTCH OUTER 10-5ALTERNATOR/STARTER CLUTCH (2) CLUTCH OUTER Install the dowel pin into the fiywhe Install the sterter clutch outer aligning its hole with the dowel pin. E (1 DOWEL PIN Apply # locking agent to the starter clutch outer mounting [ili serew threeds. Tighten the screws to the specified torque. TORQUE: 9 Nem (0.9 kgf-m, 6.5 Ibf-t) fa screws ‘Stake the screws into the groove of the starter clutch outer. (3) STARE (4) CLUTCH OUTER Install the springs, spring caps and rollers clutch oute! Install the starter driven sprockot into the clutch outer. (1) ROLLER = (2)SPRING CaP” a) serine 10-6ALTERNATOR/STARTER CLUTCH STATOR ASSEMBLY (1) WIRE CLAMP 6 Nem (0.6 kgm, 4.3 Ibéft) (2) IGNITION PULSE GENERATOR (2) STATOR 10.Nem (1.0 kgfem, 7 bff} 6. Nem (0.6 kgm, 4.3 tot) Install the following: (3) IGNITION PULSE GENERATOR — Stator and socket bolts — Wire clamp and socket bolts i — Ignition pulse generator and socket bolts NOTE + Install the ignition pulse generator wire grommet into the left crankcase cover groove securely. ALTERNATOR INSTALLATION Install the dowel pins, naw side plate gasket and side plata. (2) SIDE PLATEALTERNATOR/STARTER CLUTCH Install the new left crankcase cover gasket. Install the starter drive sprocket, driven sprocket and drive chain as an assembly, Install the starter driven sprocket setting plate and tighten the bolt securely. FLYWHEEL INSTALLATION Clean any oil from the crankshaft taper. 1) CRANKSHAFT] Install the flywheel aligning the key way in the flywheel with B1) FLYWEEEL HOLDER] the dowel pin on the crankshaft. Install the washer and flywheel bott. Hold the flywheel using the special tool, then tighten the bolt to the specified torque. TooL: Flywheel holder 07725 = 0040000 TORQUE: 59 Nm (6.0 kgfm, 43 Ibtt) LEFT CRANKCASE COVER INSTALLATION Install the teft crankcase cover and tighten the bolts, NOTE + At left crankcase cover installation, install the starter ‘motor cable into the guide in the left crankcase cover. + Install the alternator wire grommet into the left crankcase groove securely. (1) LEFT CRANKCASE COVER] 10-8ALTERNATOR/STARTER CLUTCH Install the left crankcase rear cover and side stand switch wire clamp, and then tighten the bolts. Install the gearshift peds! by aligning the punch marks, then tighten the bolt. Install the left footpeg bracket and tighten the bolts. Connect the alternator, exciter coil and ignition pulse gener- ator connectors. Install the fuel tank (page 2-3) (1) IGNITION PULSE. GENERATOR CONNECTOR 10-9CRANKSHAFT/TRANSMISSION. 23m (2.3 kgm, 17 bE) 11-011, CRANKSHAFT/TRANSMISSION ‘SERVICE INFORMATION 11-1 CRANKSHAFT 11-8 “TROUBLESHOOTING 11-2. CRANKCASE BEARING 11-11 | CRANKCASE SEPARATION aig REPLACEMENT ee TRANSMISSION 114 CRANKCASE ASSEMBLY 11-13, GENERAL + For crankshaft and transmission repair, the crankcase must be seperated + The following parts must ba removed before separating the crankcase. — Altornator/etarter clutch (Section 10) 2 oylinderpiaton (Section 8) — Clutch/gearshift linkage (Section 8) — Engine (Section 6) — Ghinder head (Section 7) = oil pump (Section 4 SPECIFICATIONS Lier in ITEM STANDARD ‘SERVICE LIMIT Crankshatt | Connecting rod big end side clearance | 010-040 (0.004—-0.0%6) 0.60 (0.024) Radial lesrance 0.004-0.012(0.0002-0.0008) | 0.06 0.002) Runout ‘At both ends — [0.08 (0.001) At beating holder — 0.05 (0.002) Tranariasion | Gear 1D. M5__| 20:020~ 200041 (0.7882 - 0.7890) 20.08 (0.79) Ct__| 20.090~ 20.041 (0.7882 ~0:7890) 20.08 (0.79%) A __| 20.020 20.041 (0.7862 -0.7890) 20.08 (0.791) Gear bushing OD. Ct__| 19.979 20.000 (0.7866 -0.7874) 19.53 (0725) ‘Gear bushing LD. a 76.516 - 16.534 (0.6502 — 0.6509) 16.58 (0.653) Geer-io-bushing clearance | C1 | 0:020~0,062 (0.0008 -0.0028) 0.10 0.008) Mainshaft 0.0, M5 19,959 - 19,980 (0.7658 — 0.7866) 19,91 (0.784) ‘Countershaft 0.D. ct 16,466 - 16,484 (0.6475 — 0.6490) 16.47 (0.646) ca 19.959 = 19.980 (0.7858 ~ 0.7666) 19.91 (0.784) Geartoshafichearance | MS | 0.040 0.082 (0.0016 - 0.0032) 0.100.004) ca 0.040 - 0,082 (0.0016 - 0.0032) 0.10 (0.004) Bushing-to-shaft clearance cr 0,032 = 0.068 (0.0013 - 0.0027) 0.10 (0.004) Shiftfork, | Fork [io. 12,000 - 12.018 (0.4724 -0.4737) 42.08 (0.474) shot Claw thickness: 4.93 - 5.00 (0.194 - 0,197) 4,80 (0.189) Fork shaft 0.D. 11,976 ~ 11.994 (0.4724 — 0.4731) 11.93 (0.470) TORQUE VALUES Crankshaft mounting bolt Crankshaft mounting nut Oil passage plate: mounting screw 23 Nem (2.3 kgtm, 17 lb) 42.Nem (1.2 kgf, 8 Ibftt) 10.Nim (1.0 kgfim, 7 IbFft) Apply a locking agent to the threads 11-1CRANKSHAFT/TRANSMISSION TOOLS Bearing remover, 15 mm 07936 - KC10500 Remover weight 07741 - 0010201 or 07936 - 3710200 Attachment, 32 x 35 mm 07746~ 0010100 Attachment, 42 x 47 mm 07746 ~ 0010300, Attachment, 52 x 58 mm 07748 - 9010400 Attachment, 62 x 68 mm (07748 - 0010500, Pilot, 20 mm 07748 - 0040500 Pilot, 22 mm 07748 ~ 0041000, lot, 25 mm. 07748 - 0040600, TROUBLESHOOTING Crankshaft noisy + Worn connecting red big end bearing + Bent connecting rod + Worn crankshaft main journal bearing ‘Transmission jumps out of gear + Worn gear dogs or slots + Bent fork shaft + Worn or bent shift forks + Broken shift drum stopper + Broken shift linkage return spring Herd to shift Improper clutch operation Incorrect clutch adjustment Incorrect engine oil viscosity Bent shift fork Bent shift fork shaft Bent shift fork claw Damaged! shift drum cam grooves Bent shift spindle 11-2CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION a rae Tee EUTRAT Src “d Romove the bolt, neutral switch set plate and neutral switch. Remove the two laft crankcase bolts. Remove the seven right crankcase bolts. Place the left crankcase facing down and separate the right and left crankcase halves.CRANKSHAFT/TRANSMISSION Remove the gasket and dowel pins. TRANSMISSION REMOVAL/DISASSEMBLY Remove the shift fork shaft, shift forks and shift drum. Remove the mainshaft and countershatt as an assembly from the left crankcase. Disassemble the transmission. INSPECTION Chock the shit fork and fork shaft for wee or damege Monsuistho iO. of he aie foe SERVICE LIMIT 12.05 mm (0.474 in) 4 Measure the shift fork claw thickness, ‘SERVICE LIMIT: 4.80 mm (0.189 in) 11-4‘Measure the O.D. of the shift fork shaft SERVICE LIMIT: 11.93 mm (0.470 in) Ingpect the shift drum grooves for wear or damage. Check the gear dogs, dog holes and teeth for abnormal wear cr lack of lubrication. Measure the LD. of each gear. .08 mm (0.791 in) Measure the |D. and 0.D. of C1 gear bushing. SERVICE LIMIT: ‘0.D.: 19.83 mm (0.785 in} 16.58 mm (0.653 in) Calculate the gear-to-gear bushing clearance, SERVICE LIMIT: 0.10 mm (0,004 in) Check the shift fork groove of the shifter gears for excessive ‘wear or damage, Measure the 0.D. of the mainsheft and countershatt SERVICE LIMIT: M5, clutch outer: 19.91 mm (0.788 in) cr: 16.41 mm (0.646 in) ca: 19.91 mm (0.784 in) Calculate the gear bushting-to-shaft clearance. SERVICE LIMIT: 0.10 mm (0.004 in) CRANKSHAFT/TRANSMISSION Ms (1) CLUTCH OUTERCRANKSHAFT/TRANSMISSION ASSEMBLY (1) €1 GEAR (377) 42) C3 SHIFTER GEAR (287) (6) C5 SHIFTER GEAR (217. (7) M4 SHIFTER GEAR (247) Se (5) COUNTERSHAFT (11) MAINSHAFT/M1 GEAR(137) (10) M3 GEAR (217) 11-6CRANKSHAFT/TRANSMISSION Assemble the transmission gear and shafts, (1) SHIFT FORK GROOVES Coat each gear with clean engine ail and check for smooth movernent. Apply molybdenum disulfide oil to the shift fork grooves in the Ms, C3 and C5 gear. INSTALLATION Install the mainshaft and countershaft es an aseemble Into the laft crankcase, Install the shift drum into the crankcase. Align the neutral switch rotor teb with the neutral ‘switch hole in the loft crake: Install the shift forks and shift fork shaft NOTE + Install the shift forks into the shifter gear grooves with their marks facing dawn.CRANKSHAFT/TRANSMISSION CRANKSHAFT jaya REMOVAL Separate the crankcase halves (page 11-3). Remove the transmission (page 11-4) Remove the crankshaft mounting bolts and nut, then remove the crankshaft. Remove the B-clips, plain washer and cam chain tensioner. Position the crank balancer weight as shown, Pass the cam chain between the guide insertion part and cerenk balancer weight, then pass it between the cam chain tensioner pin and crank balencer weight. INSPECTION Measure the connecting rod big end side clearance. ‘SERVICE LIMIT: 0.60 mm (0.024 in) 11-8CRANKSHAFT/TRANSMISSION Measure the connecting rod big end radial clearance. ‘SERVICE LIMIT: 0.05 mm (0.002 in) ‘Measure the crankshaft runout at both ends. ‘SERVICE LIMIT: 0.03 mm (0,001 in} Measure the crankshaft runout at the center bearing holder. ‘SERVICE LIMIT: 0.05 mm (0.002 in} ‘Check the cam chain guide and slipper for excessive wear or damage. Inspect the tensioner spring for damage or weakness. sf 4 (2) CAM CHAIN GUIDE 11-9CRANKSHAFT/TRANSMISSION INSTALLATION (1) BALANCER Position the crank balancer weight as shown and install the carn chain in the reverse order af removal. (2) TENSIONER PIN Install the cam chain tensioner and plain washer, and secure (1) CAM CHAIN TENSIONER = them with a Brolip, (21 WASHER 3) B-CLIP Install the crankshaft into the left crankoase. LT. CRANK SHAET jay NuT Tighten the crankshaft mounting bolts and nut to the speci: fied torque. TORQUE: Bolts: 23 Nm (2.3 kgt-m, 17 Ibf-ft) Nut: 121Nm (1.2 kgt-m, 9 ibe) Install the transmission (page 11-7), Assemble the crankcase (page 11-13). CRANK CASE BEARING REPLACEMENT ‘Separate the crankcase halves (page 11-2). Rernove the crankshaft (page 11-8). Remove the transmission (page 11-4), Turn the inner racs of each bearing with your finger. ‘The bearings should turn smoothly and quietly. Also check that the outer race of each bearing fits tightly in the crankcase. 11-10CRANKSHAFT/TRANSMISSION Right crankcase: Drive out the mainshaft and crankshaft bearings. Drive new bearings into the right crankcase using the special tools. Toots: Crankshatt bearing: Driver (07749 - 0010000 Attachment, 62 x68mm 07746-01050 Pilot, 25 mm. 07748 - 0040600, Mainshaft bearing: Driver 97749 - 0010000 Attachment, 62 x58mm 07746-01050 Pitot, 20 mm. 07746 - 0040500 Loft erankease: Remove the crankshaft and countershaft oil seals. Remove the oll passage plate screws and plate,CRANKSHAFT/TRANSMISSION Drive out the counterahaft and crankshaft bearings, \)) BEARING REMOVER Remove the mainshaft bearing using the special tools. Toots: Bearing remover, 15 mm 07936 - KC10500 Remover weight (07741 ~ 0010201 or (07936 - 3710200 (U.S.A. only) Drive new bearings into the left crankcase. TooLs: Crankshaft bearing: Driver 107749 - 010000 Attachment, 62x68mm 07745 ~-0010500 Pllot, 25 mm 07748 - 0040800 Mainshaft bearing: Driver 07749 - 0010000 Attachment, 32%x35mm 07748 -0010100 Countershaft bearing: Driver 07749 - 0010000 Attachment, 42x 47mm 07748-01030 Pilot, 22 mm (07748 — 0041000 Install a new O-ring. Apply @ locking agent to the oil passage piate mounting screw threads. Install the oi! passage plate and tighten the screws to the specified torque. TORQUE: 10 Nem (1.0 kgm, 7 Ibfft) 11-12CRANKSHAFT/TRANSMISSION Install the new crankshaft and countershatt oll seals. CAUTION Do nor drive the countershaft oil seat below the end of case us this will block the of! passage inthe shaft. Install the crankshaft (page 11-10). Install the transmission (page 11-7) (8) CRANKSHAFT (CRANKCASE BEARING LOCATIONS DUST SEAL (1) GEARSHIFT SPINDLE DUST SEAL COUNTERSHAFT (4) MAINSHAFT BEARING (6202) (6) CRANKSHAFT BEARING (6308) —~ BUST SEAL (2) COUNTERSHAFT BEARING. ey Or 10) mS ‘CRANKSHAFT BEARING (6305) (9) COUNTERSHAFT (8) MAINSHAFT NEEDLE BEARING BEARING (6304) CRANKCASE ASSEMBLY Install the dowel pins and new gasketCRANKSHAFT/TRANSMISSION. Assemble the crankcase halves together. (1) RIGHT CRANKCASE BOLTS Install and tighten the elght seven crankcase bolts. NOTE + Tighten the right crankcase bolts in a crisscross pattern in 2-3 steps. Install and tighten the two left crankcase bolts. Install the neutral switch and neutral switch set plate, and tighten the bolt. Install the removed parts in the reverse order of removal. 11-14MEMO.FRONT WHEEL/SUSPENSION/STEERING ‘Nem (6.3 kgm, 46 IFA) 12.Nm (1.2 kafim, 9 Ibe) 80 Nom (3.1 kgf, 22 Ib) 12-012. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 12-1 FRONT WHEEL 128 ‘TROUBLESHOOTING 12:2 FORK 12:13 HANDLEBAR 12:3 STEERING STEM 12-22 SERVICE INFORMATION GENERAL = + A contaminated brake disc o pad reduces stopping power, Discord contaminated pads and clean a contaminated disc with a Wigh quality brake degreasing agent. + When servicing the front wheel, fork or steering stom, support the motorcycle securely with a jack or other support + Refer to section 14 for brake system information. SPECIFICATIONS Unit: men fin) Tem ‘STANDARD SERVICE LIMIT Minimum ure read depth I 75 10.06) Cold fire pressure | 200 kPa (2.00 katfem®, 29 psit — 200 kPa (2.00 katicm:, 29 psil — ‘Axis runout (0.20 (0.008) Wheel rim runout Radial — 2.0 (0.08) _____aiar (2010.08) Wheel hub-to-tim distance 307511121 £0.06) Fark spring free length 546.0 (21.50) 596.1 (21.07), Forktube runout 0.20 (0.008) Recommended fork fad Pro Honda Suspension Fluid S88 — Fork fluid level [29 (6.1) -= Fork fluid capacity | 234 cm? (7.9 US oz, 82 Imp 02) — Steering head bearing preload [1.06 1.53 kg (2.28 3.37 Ibs) = TORQUE VALUES Steering stem nut 74 Nem (7.5 kgm, 64 IDFA Steering stem bearing adjusting nut 31Nim {0.3 kgfim, 2.2 Ib) Fork top pinch balt 11 Nem (1.4 kgm, 8 IbF Fork bottom pinch bolt 34 Nem (3.5 kgm, 25 lot) Front axle bolt 182 Nim (6.3 kgtm, 46 IbFt) Brake caliper bracket mounting bolt 30 Nem (3.1 katim, 22 Ibfft) ALOC bott Brake disc. mounting bott 39 Nem (8.0 kgfm, 29 IDE) ALOC bolt Wheel spoke 4 Nem (0.4 kam, 2.9 Ib} Tire valve nut 3Nm (0.3 kafim, 2.2 bf) Fork cap 22 Nem (2.2 kgm, 16 Ibe) Fork socket bott 20 Nem (2.0 kgf-m, 14 Ibft)Apply-a locking agent to the threads Headlight bracket mounting bolt 34 Nem (3.5 kgm, 25 lft) 12-1FRONT WHEEL/SUSPENSION/STEERING TOOLS Wheel spake wrench Bearing remover head, 15 mm Bearing remover shaft Driver Attachment, 37 x 40 mm Attachment, 42x 47 mm Pilot, 15 mm Oil ses! driver body Oil seal driver attachment Steering stem socket Ball race remover Stern bearing driver TROUBLESHOOTING Hard steering 07701 - 0020300 not available In U.S.A. (07748 - 0050400, 0746 --0050100 97749 ~0010000, (07746 - 0010200 07748 - 0010300 (0746 - 0040300 07747 ~ 9010100, (07747 - 0010501 07916 -3710101 07948 - 1790000 07946 - GC-40000 + Stoering head bearing adjusting nut too tight, + Faulty steering head bearing + Insufficient tire pressure + Faulty tire ‘Steers to one side or does not track straight Bent fork Bent front axle ‘Whoo! installed incorrectly Faulty steering head bearing Bent frame Worn wheel bearings Worn swingarm pivot components ‘Weak front shock absorber Front wheel wobbling + Bent rim ‘+ Worm front wheel bearings + Faulty tire + Unbalanced tire and whee! 12-2 Whee! turns hard + Faulty whee! bearings + Faulty speedometer gear + Bent front axle Soft suspension + Weak springs + Low fork fluid level + Low tire pressure Hard suspension + Incorrect fork fluid viscosity + Bent fork tubes * Clogged fluid passage ‘Suspension nois; + Low fork fluid level + Loose fork fasteners + Lack of grease in speedometer gearFRONT WHEEL/SUSPENSION/STEERING HANDLEBAR (2) REARVIEW MIRRORS. ee REMOVAL Remave the wire bands. Remave the rearview mirrors. Remove the grip end by holding the grip end and removing the (2) SCREW (1) GRIP END Disconnect the olutch switch wires from the switch. Remove the cluteh lever holder bolts, holeler and clutch lever bracket assembly, (0) CLUTEA SWITCH WIRES (2) BOLTS: (4) CLUTCH LEVER BRACKET Remove the left handlebar switch screws. (2) LEFT HANDLEBAR SWITCH (1) SCREWS: 12-3FRONT WHEEL/SUSPENSION/STEERING 2) CHOKE LEVER, Disconnect the choke cable from the choke lever and remove the left handlebar switch. Disconnect the front breke switch wires from the switch (3) HOLDER Remove the master cylinder holder bolts, holder and master’ (4) MASTER CYLINDER eylinder assembly. x [(}) BRAKE SWITCH WIRES Remove the right handtebar switchythrottle housing screws, Disconnect the throttle cables from the throttle pipe and remove the right handlebar switchithrottle housing. 12-4Remove the handlebar upper holder caps. Remove the upper holder bolts, holders and handleber. Remove the bolts and speedometer/indicator panel assem- bly. Remove the nuts, lower holders, cushion washers and cush- jon rubbers. INSTALLATION Install tha cushion rubbers, washers and lower halders, ‘Temporarily tighten the lower holder nuts. {Install the speedometer/indicator panel assembly and tighten the bolts FRONT WHEEL/SUSPENSION/STEERING (2) SPEEDOMETER (3) SPEEDOMETERFRONT WHEEL/SUSPENSION/STEERING Place the handlebar on the lower holders. Install the upper holders and temporarily tighten the upper holder bolts. Tighten the lower holder nut. Align the punch mark on the handlebar with the top of the fower holders, Install the upper holders on the handlebar with thelr punch marks forward. Tighten the front bolts first, then tighten the rear bolts. (1) PUNCH MARKS| Hf the handlebar grips were removed, apply Honda Bond A or Honda Hand Grip Cement (U.S.A. only) to the inside of the grip and to the clean surfeces af the right and left han- dlabar. Wait 3-5 minutes and install the grip. Rotate the grip for even application of the adhesive. NOTE + Allow the adhesive to dry for an hour before using. Connect the throttle cables to the throttle grip flange, Install the right handlebar switchithrottle housing aligning its locating pin with the hole in the handlebar, (3) LOCATING PIN ed (2) UPPER HOLDERS (2) THROTTLE PIPE 12-6FRONT WHEEL/SUSPENSION/STEERING (WRIGHT HANDLEBAR SWITCH/THROTTLE HOUSING Tighten the forward serew first, then the rear screw. Install the master cylinder aligning the end of the master (1/MASTERCYLINDER (4) PUNCH MARK cylinder with the punch mark on the handlebar, | wower Install the master cylinder holder with the "UP" mark facing fai up. Tighten the upper bolt first, then the lower bolt. TORQUE: 12 Nem (1.2 kghm, 8 Ibi] Connect the brake switch wires, (S)goLTs (G/GRAKE SWITCH WIRES BBIT3)" UP” MARK Connect the choke cable to the choke lever (4) HOLE, (2)CHOKE LEVER Install the left handlebar switch housing aligning its locating pin with the hole in the handlebar. Tighten the forward screw first. then the rear screw. (2)SCREWS 12-7FRONT WHEEL/SUSPENSION/STEERING Install the clutch lever bracket assembly aligning the end of AEEUTCH LEVER BRACKET, the bracket with the punch mark on the handlebar. (4)PUNCH MARK Install the clutch lever bracket holder with the “UP™ mark ; facing up. Tighten the upper bolt first, then the lower bolt. TORQUE: 12 Nem (1.2 kgm, 9 IbFft) Connect the clutch switch wires. & (S)BOLTS —_(3)"UP* MARK] Install the grip end and tighten the screw. (2)SCREW Install the wire bands. (2) REARVIEW MIRRORS Install the rearview mirrors, FRONT WHEEL REMOVAL ‘Support the motorcycle securely usi lent a hoist or equiva- Remove the spsedometer cable setting screw and discon- ect the cable. 12-8FRONT WHEEL/SUSPENSION/STEERING Loosen the front axle pinch batt. Remove the axle and the frant wheel. (1)PINCH BOLT 2) SPEEDOMETER GEARBOX Rernove the side collar from the right wheel hub. Remove the spsedometer gear box from the left whee! hub, INSPECTION ‘Set the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading. ‘SERVICE LIMIT: 0.20 mm (0.008 in) (AXLE ‘Turn the inner race of each bearing with your finger. ‘The bearings should turn smoothly and quietly. ‘Also cheok that the bearing outer race fits tightly in the hub. Remove end discard the bearings if they do not turn ‘smoothly, quietly, or if they ft loosely in the hub. ( ( \ ) NOTE SS Replace the bearings in pairs, Pack new bearings with grease and install them into the hub using the special tools (page 12-11). (WHEEL BEARING 12-9FRONT WHEEL/SUSPENSION/STEERING Check the rim runout by piacing the wheel in a turning stand. Spin the wheel by hand, and read the runout using s dial indi- cator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: Radial: 2.0 mm (0.08 in) ‘Axial; 2.0 mm {0.08 in} DISASSEMBLY Remove the bolts and brake disc. Remove the dust seal and speedometer gear retainer fram the left wheel hub. Remove the dust seal from the right wheel hub, Install the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive the bearing out of the whee! hub. Remove the distance collar and driva out the other bearing, TooLs: Bearing remover head, 15mm 07748 ~ 0050400 Bearing remover shatt 07746 - 0950700 12-10FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY (1) RIGHT DUST SEAL (2) DISTANCE COLLAR (3) LEFT WHEEL BEARING (4) LEFT DUST SEAL (7) RIGHT WHEEL BEARING (5) BRAKE Disc Pack all bearing cavities with grease, CAUTION + Never reinstall an old bearing, once a bearing has been removed, the bearing must be replaced with a new one. Drive in @ new loft bearing squarely with its sealed side facing out, Install the distance collar, then drive in the right side bearing with its sealed side facing out. Toots: Driver 07749 - 0010000 Attachment, 42. 47 mm (07748 ~ 0010300 Pitot, 15 mm (07748 - 0040300 Gm + Do not get greaxe on the brake disc or siopping power will be reduced. Install the brake dise on the wheel hub. Install the tighten the new mounting bolts to the specified torque. ‘TORQUE: 39 Nem (4.0 kgm, 29 Itt)FRONT WHEEL/SUSPENSION/STEERING Place the rim on the work bench. Place the hub with the left side down and begin lacing with new spok ‘Adjust the hub position so that the distancs from the hub left fend surface to the side of rim is 30.75 + 1 mm (1.21 + 0.04 in) as shown. TOOL: Wheel sporke wrench ‘97701 - 0920300 not available in U.S.A. TORQUE: 4 Nm (0.4 kgf'm, 2.9 Ibf#A} Check the rim runout (page 13-10). Install the speedometer gear retainer into the left wheel hhub, aligning its tangs with the siots in the hub, Apply grease to the dust seal fips and install it into the left wheel hub. Fill the speedometer gear box with grease. Install the speedometer gear box in the wheel hub, aligning its slots with the retainer tangs. Apply grease to the dust seal lips and instal it into the right wheel hub. Install the right side collar. INSTALLATION Install the front wheel between the fork Iegs 0 that the brake disc is positioned betweon the pads, being careful not to damage the pads. Install the front axle. Position the lug on the speedometer gear box against the back of the stopper on the left fork leg. 12-12FRONT WHEEL/SUSPENSION/STEERING Install and tighten the axle to the specified torque. ‘TORQUE: 62 Nm (6.3 kgm, 46 Ib) Tighten the axle pinch bot. Connect the speedometer cable and secure it with @ screw. FORK REMOVAL amove the following —Front wheal (page 128) — Brake caliper (page 14-10) Wm + Do not allow the brake catiper to hang from the Brake hose. Remove the bolts and front fender. Loosen the front turn signal bracket boltinut. Loosen the fork top pinch bolt if the fork is disassembled, loosen the fork cap, but do not remave it yet. Loosen the fork bottom pinch bolt and remove the fork tube from the fork top bridge and steering stem, 12-13FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY (1) FORK CAP Remove the fork cap. SSS | +The fork spring is under spring pressure. Use care when removing he fork cap, Remove the fork spring. (2) FORK TUBE (1) FORK SPRING Pour out the fork fluid by pumping the fork tube several times. Hold the fork slicer in a vice with soft jaws ora shop towel, _{1) FORISLIDER Remave the fork socket bolt with s hex wrench, NOTE + If the fork piston turns with the socket bolt, temporarily install the fork spring and fork cap, Remove the dust seal (1) DUST SEAL 12-14FRONT WHEEL/SUSPENSION/STEERING Remove the oll seal stopper ring. (1), STOPPER RING Pull the fork tube out until resistance from the slicer bush- ing is felt. Then move it In and out, tapping the bushing lightly until the fork tube separates from the fork slider. The slider bushing will be forced out by the fork tube bushing, (1) OL LOCK PIECE Remove the ail lock piece from the fork slider. = Remave the stop ring from the fork piston, “Ri (2) FORK PISTON (STOP RING 12-15FRONT WHEEL/SUSPENSION/STEERING. Remove the fork piston and rebound spring from the fork (1) FORK PISTON tube. (2) REBOUND SPRING (7) Ol, SEAL (3) SLIDER BUSHING Remove the oil seal, back-up ring and slider bus the fork tube. (4) FORK TUBE woe , ‘BUSHING + Do not remove the fork tube bushing unless it Is neces- Sary to replace it with new one. (2) BACK-UP RING INSPECTION Fork spring Measure the fork spring free length. ‘SERVICE LIMIT: 535.1 mm (21.07 in} Fork tube/slider/piston Check the fork tube, fork slider, oll lack piece and fork piston for score marks, and excessive or abnormal wear. Chock the fork piston ring for wear or damage. Check the rebound spring for fatigue or damag Replace the components if necessary, 12-16FRONT WHEEL/SUSPENSION/STEERING Place the fork tube in V-blocks and measure the runout. Actual runout is 1/2 the total indicatar reading. SERVICE LIMIT: 0.20 mm (0.008 in) Fork tube bushing Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratch- ing, or ifthe teflon is worn 90 thet the copper surface appears ‘on more than 9/4 of the entire surface. Check the back-up ring: replace it if there is any distortion at the points shown. ASSEMBLY (6) DUST SEAL (3) BACK-UP | RING (2) SLIDER BUSHING (1) FORK SLIDER Om 20 Nem (2.5 kgf, 14 Ibttt) (1) FORK TUBE (2) BACK-UP RING ty) BUSHING (13) FORK TUBE | BUSHING I evourock rece (9) FORK BOLT 22.Nem (2.2 kgm, 16 ibtft) (7) REBOUND SPRING (10) FORK SPRING (11) PISTON RING (12) FORK PISTON 12-17FRONT WHEEL/SUSPENSION/STEERING Before assembly, wash all parts with’ high flash or non-flam- (4) OIL SEAL (2) SLIDER BUSHING mable solvent and wipe them dry. (1) FORK TUBE Install & new fork tube bushing if the bushing has been BUSHING removed. = Install the sliding bushing, back-up ring and a new oil seal. NOTE Install the oil seal with its lip facing down, (3) BACK-UP RING Install the rebound spring and fork piston into the fork tube. (2) FORK PISTON (1) REBOUND SPRING MY (1) FORK PISTON Install the stop ring onto the fork piston, (2) STOP RING Install the oil lock piece onto the fork piston end. (2) . TUBE Ai PIECE (3) FORK'SLIDER {install the fork tube into the fork slider. 12-18FRONT WHEEL/SUSPENSION/STEERING Hold the fork slider in a vise with soft jaws or a shop towel. (FORK SLIDER, Apply @ locking agent to the fork socket bolt threads and install and tighten the socket bolt with @ naw sealing washer into the fork piston. NOTE * Ifthe fork piston turns together with the socket bolt, tem- porary install the fork spring and fork cap. TORQUE: 20 Nim (2.0 kgfm, 14 Ibe} Drive the oil seal in using the spacial toots. (1) OIL SEAL DRIVER BODY Toots: Oil seal driver body 07747 - 0010100, Oil soal driver attachment 07747 - 0010501 (2) OIL SEAL DRIVER ATTACHMENT, Install the stopper ring into the fork slider groove securely. (1) STOPPER BING. Install the dust seal (1) DUST SEAL 12-19FRONT WHEEL/SUSPENSION/STEERING ecified amount of recommended fork fluid into RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-2 FORK FLUID CAPACITY: 234 om: {7.9 US oz, 8.2 Imp o2) Pump the fork tube several times to remove trapped sir from the lower portion of the fork tube. Compress the fork jeg fully and measure the oil level trom the top of the fork tube. FORK OIL LEVEL: 129 mm (6.1 in) (yon LEVEL Pull the fork tube up and install the fork spring with the tightly wound eail end facing down. Install @ new O-ring onto the fork cap. 2 (2) FORK CAP 12-20FRONT WHEEL/SUSPENSION/STEERING INSTALLATION (1) EORK TUBE END Ingtall the fork tube into the steering stem, front turn signal bracket and fork top bridge. Align the top end af the fork tube with the upper surface of the top bridge as shown, (2) TOP BRIDGE Tighten the bottom bridge pinch bolt TORQUE: 34 Nem (3.5 kgfm, 25 Ibt-t) (1) BOTTOM PINCH BOLT (1) FORK CAP (2) TOP PINCH BOLT Tighten the fork cap to the specified torque if it was removed. ‘TORQUE: 22 Nem (2.2 kgf-m, 16 Ibe) Tighten the top fork pinch bolt to the spacified torque, TORQUE: 11 Nim (1.1 kgm, 8 Ib) Install and tighten the front turn signal brecket boltinut, (3) TURN SIGNAL UNIT BOLT/NUT Inetall the front fender with the brake hose stay. (FRONT FENDER Install and tighten the front fender mounting bolts, j Install the front whee! (page 12-12), Install the brake caliper (page 14-12). (a Bolts (2) BRAKE HOSE STAY ar 12-21FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL —Hendiet — Front wheel (page 12-8) —Headlight case — Speedometer (page 18-4) — Ignition switch (page 18-6) Remove the bolts and connector box. Remove the front brake hose clamp bolts, hose clamp and front cover. Remove the nut and headlight bracket Loosen the ste ing stem nut. Remove the fork legs (page 12-13) Remove the stam nut and washer and the top bridge. Remove the steering stem bearing adjusting nut using the special tool. TooL: Steering stem sacket 07936 -3710101 12-22FRONT WHEEL/SUSPENSION/STEERING Remove the upper bearing steering stem, ner race, steel balls (21) and [(1) UPPER INNER RACE @) STEEL BALLS NOTE Be careful not to loose the st is. (STEERING =| BEARING RACE REPLACEMENT NOTE ‘Always replace the bearings and races Ramove the upper and lower bearing outer races using the (07948 - 1780000 (3) DUST SEALWASHER ——_(2) LOWER INNER RACE {install the steering stem nut onto the stem to prevent the threads from being damaged when removing the lower ‘bearing inner race from the stem. Remove the lower bearing inner race with a chisel or equiv- alent tool, being careful not to damage the stem. Remove the dust seal and washer. (1) STEM NUT ae [(3) STEERING STEM DRIVER Install the washer onto the steering stem. Apply grease to new dust seal lips and install it over the steering stem. Install a new lower bearing inner race using @ special tool and a hydraulic press. TOOL: Steering stem driver 07946 - GC40000 (2) LOWER INNER (1) DUST SEALWASHER| 12-23FRONT WHEEL/SUSPENSION/STEERING Drive new bearing outer races into the steering head pipe. (2) ATTACHMENT TOOLS: Driver 07749 - 0010000 Attachment, 37 x 40 mm 97746 - 0910200 (1) DRIVER INSTALLATION (3) BEARING ADJUSTING NUT 3 Nem (0.3 kam, 2.2 IDF) (2) UPPER BEARING STEEL BALL (21) (4) UPPER INNER RACE (1) STEERING STEM (10) LOWER BEARING STEEC BALL (21) (9) WASHER (8) DUST SEAL Apply grease to upper and lower bearing races. Install the: 21 steel balls onto each bearing race. Insert the steering stem into the steoring head pipe, being careful not to drop the steel balls. Install the upper bearing inner race and stem bearing adjust- ing nut. 12-24Tighten the stem bearing adjusting nut to the initial torque. TOOL: Steering stem socket 07916 -3710101 TORQUE: 25 Nem (2.5 kgm, 18 IbFft) Move the steering stem right and left, lock-to-lock, five times to seat the bearings. Make sure that the stoering stem moves smoothly, without play or binding; then loosen the bearing adjusting nut. Retighten the bearing adjusting nut to the specified torque. TORQUE: 3.N-m (0.3 kgm, 2.2 IbFft) Recheck that the steering stem maves smoothly without play or binding. Install the top bridge. Install the fork legs (page 12-21), Install the washer and stem nut Tighten the steering stem nut to the specified torque, TORQUE: 74 Nem (7.5 kgm, 54 Ib) STEERING HEAD BEARING PRELOAD Support the motorcycle using 8 wark stand or box under the engine and reise the front wheel off the ground, Position the steering stem to the straight ahead position. Hook a spring scale to the fork tube and measure the steer- ing head bearing preload. NOTE + Make sure that there Is no cable or wire harne: ence. The preload should be within 1.04 - 1.53 kg (2.29 -3.37 Ib). If the reading does not fall within the limits, lower the front wheel onto the ground and adjust the steering bearing adjusting nut. FRONT WHEEL/SUSPENSION/STEERING (2) STEERING STEM SOCKET (1) ADJUSTING NUTFRONT WHEEL/SUSPENSION/STEERING Install the headlight bracket and tighten the nut. Install the brake hose clamp and tighten the bolts, (3) BRAKE HOSE CLAMP Install the connector box and tighten the bolts. Ke eoUs Install the following: — Ignition switch (page 18-6) — Speedometer (page 18-4) — Headlight case — Front wheal (page 12-12) — Handlebar (page 12-5) 12-26MEMOREAR WHEEL/BRAKE/SUSPENSION 88 Nem (9.0 kgfim, 65 Ib) \ 26 Nem (2.7 kgfim, 20 Ibe) 42 Nem (4,3 kgtm, 31 IbF) 13-013, REAR WHEEL/BRAKE/SUSPENSION ‘SERVICE INFORMATION TROUBLESHOOTING REAR WHEEL REAR BRAKE 13-1 SHOCK ABSORBER 13-2 SWINGARM 13-3 BRAKE PEDAL 13-9 13-12 13-13 13-16 SERVICE INFORMATION GENERAL | ase | + A contaminated brake drum or thoe reduces topping power. Discard contaminated shoes andl clean ai contaminated drum with a high quality brake degreasing agent. + Ajsck or other support is required to support the motorcycle. SPECIFICATIONS Unit: mm (in) TEM ‘STANDARD SERVICE LIMIT Minimum tire tread depth — 2.0 (0.08) Coldtire pressure | Upto 90 kg (200 Ib) load 200 kPa (2.00 kafler, 29 pal — Up fo eases weston 200 kPa (2.00 kaf/em:, 29 psi) = ‘Axle runout — 0.20 (0,008) Wheeirim runout | Radial — 2.0 (0.08) [Axial 2.0 (0.08) Wheel hubtovim distance 2162110852 0.08) — Brake pedal free play 20-30 (3/4— 1-1/4) — Brake drum 10. 730.0 (6.12) 1162) Brake lining thickness 45 (0.18) 2.0 (0.08) TORQUE VALUES Rear axle nut Rear wheel spoke Roar tire valve nut Driven sprocket mounting nut Rear shock absorber upper mounting bolt Rear shock absorber lower mounting bolt ‘Swingarm pivot nut Drive chain slider mounting screw Drive chain adjuster lock nut 88 Nem (8.0 kgfim, 65 Ib) 4 Nem (0.4 kof, 2.9 bff) 3.Nom (0.3 kgf, 2.2 IbFf} A Nem (6.5 kgfom, 37 Ib) 26 Nem (2.7 kgfim, 20 Ibét) 42 Nem (4.3 kgfir, 31 Ib) 88 Nem (8.0 kgfim, 65 ib) 3.Nem (0.3 kgm, 22 IF) 10. Nem (1.0 kgfom, 7 IDF) 13-1REAR WHEEL/BRAKE/SUSPENSION TOOLS Wheel spoke wrench Bearing remover head, 15 mm Bearing remover shaft Driver Attachment, 32 x 35 mm Attachment, 42 x 47 mm Pilot, 15 mim Bearing remover sat — Remover handle — Bearing remover set — Remover weight Neadle bearing remover TROUBLESHOOTING ‘Suspension noise + Weak shock absorber spring + Oil leakage from damper unit + Incorreet suspension adjustment + Low tire pressure 7 adjustment + Bent swingarm pivot + Damaged swingarm pivot bushings + Bent damper unit + High tire pressure 07701 - 0020300 not available in U.S.A. (0748 — 0050400 (07748 - 0050100 07748 ~_0010000 (07746 ~-0010700 (07748 ~ 0010300 (07746 ~ 0040300 (97936 ~ 3770001 (07836 ~ 3710100 (07938 ~ 3710600 07741 — 0010201 or 07996 - 3710200 07936 — KAS0000 ‘Steers to one side or does not track straight + Bent rear axle + Axle alignmentichain adjustment not equal on both sides Roar wheel wobbling » Bont rim Worn rear whee! bearings Faulty tire Low tire pressure Faulty swingarm pivot bushings 13-2REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Suppor the motoreyela securely using 5 hoist or equive- lent. Remove the following: — Cotter pin — Nut, washer, rubber washer — Pivot bolt — Brake panel stopper arm = Adjusting nut — Brake rod, spring Remove the axle nut and washer. ni 2) DRIVE CHAIN, Loosen thé drive chain adjusters. é Push the rear wheel forward. Derail the drive chain, Remove the axle from the left side and remove the rear wheel, Remove the drive chain adjusters. INSPECTION Axle Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading, ‘SERVICE LIMIT: 0.20 mmm (0.008 in) aig) (1) REAR AXLE Wheel Check the rim runout by placing the wheel in a turning stand, Spin the wheal slowly and read the runout using a dial indi ator. ‘Actual runout is 4/2 the total indicator reading, ‘SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.08 in)REAR WHEEL/BRAKE/SUSPENSION Wheel bearing Turn the inner race af each bearing with your finger. Bearings should turn smoothly and quietly. Also check that the bearing outar race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub, NOTE +. Replace the wheel bearings in pairs, Driven sprocket Check tha condition of the final driven sprocket teeth. Replace the sprocket if worn or damaged. NOTE + ithe final driven sprocket requires replacement, inspect the drive chain and drive sprocket. + Never install @ new drive chain on @ worn sprocket or @ worn chain on new sprockets. Both chain and sprocket ‘mnust be in good condition or the replacamant chain or sprocket will wear rapidly. DISASSEMBLY Remove the brake panel assembly from the right wheal hub, Remove the driven flange from the left wheel hub. NOTE + If you will be disassemble the driven flange, loosen the riven sprocket bolts before removing the driven flange from the wheel hub. (1) WHEEL BEARING (1.6000 (2) REPLACE (1) DRIVEN FLANGE 13-4REAR WHEEL/BRAKE/SUSPENSION Driven flange bearing removal Loosen the driven sprocket nuts, Ramove the driven flange from the wheel hub, then remove the driven sprockat nuts and sprocket. (2) DRIVEN SPROCKET Remove the dust seal (() DUST SEAL Ramove the driven flange collar. Drive out the driven flange bearing. Whee! bearing removal Install the bearing remover head into the bearing From the opposite side install the bearing remover shaft and drive the bearing aut of the whee! hub. Remove the distance coller and drive out the other bearing, TooLs: Bearing remover head, 15 mm 07746 ~ 0050400 Bearing remover shaft 0748 - 0050100 U1) BEARING 13-5REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY (1) RIGHT WHEEL BEARING (10) DISTANCE COLLAR (9) DAMPER RUBBER (7) DUST SEAL (8) DRIVEN FLANGE 64 Nem (6.5 kafim, 48 ibtft) ()) DRIVER Whee! bearing installation Pack all bearing cavities with grease. CAUTION + Never reinstall an old bearing, ance a bearing has been remove the hearing must be replaced with a new one Drive in a new left bearing squarely with its sealed side fac- the distance collar, then drive in the right side bear- ing with its sealed side facing out. TooLs: Driver (9748 —0010000 Right side: ‘Attachment, 42 x 47 mm (07748 ~ 0010300 GLORIVER Left side Attachment, 32 x35 mm 07746 ~0010100 @ Pilot, 15 mm 07748 — 0040300 Drive the new driven flange bearing into the driven flange i using the special tools. Toots: Driver 07749 - 0010000 Attachment, 42 x 47 mm 07746 0010300 , lots Terie, O77Ae = OE rm 2) ATTACHMENTIPILOT 13-6Place the rim on the work bench. Place the hub with the left side down and begin facing with new spokes. Adjust the hub position so that the distanee from the hub right end surface to the side of rim is 21.6+ 1 mm (0.85 + 10.04 in} as shown, Toor: ‘Wheel spoke wrench (07741 - 0020300 not available in U.S.A. ‘TORQUE: 4 Nem (0.4 kgf, 2.9 Ib) ‘Check the rim runout (page 13-3) Apply grease to the dust seal lips, then install it into the dri- ‘ven flange. Install the driven flange collar. Install the wheal damper rubbers into the whee! hub, REAR WHEEL/BRAKE/SUSPENSIONREAR WHEEL/BRAKE/SUSPENSION mmm as ‘Do not get grease on the brake drum or stopping power will Be reduced. | Install the driven flange assembly Into the left wheel hub. If the driven sprocket was removed, install the driven sprocket and tighten the nuts. TORQUE: 64 Nem (6.5 kgm, 47 ibf-t) | (7) DRIVEN FLANGE ASSEMBLY Install the feft side collar. (1) SIDE COLLAR, Install the brake drum assembly into the right wheel hub. INSTALLATION Install both drive chain adjusters into the swingarm. Place the rear wheel into the frame and insert the axle through the left drive chain adjuster, rear wheel, right side collar and right chain adjuster. Install the drive chain onto the driven sprocket, Re (1) DRIVE CHAIN ADJUSTER} 13-8REAR WHEEL/BRAKE/SUSPENSION Install the washer and loosely install the axle nut, Install the brake panel stopper arm onto the brake panel, Install the bolt, rubber cushion, washer and nut, then tighten the nut. Secure the nut with a new cotter pin. Install the joint piece to the brake arm and connect the brake rod with the spring. Install the adjusting nut. a (3) SPRING} oe ee oa Adjust the drive chain slack (page 3-12). Tighten the axle nut to the specified torque. ‘TORQUE: 88 Nem (9.0 kgm, 65 Ibé#t) Adjust the rear bral (page 3-16). REAR BRAKE REMOVAL Remove the rear wheel (page 13-3), Remove the brake panel from the rear wheel (page 13-4). INSPECTION Measure the rear brake drum LD, SERVICE LIMIT: 481 mm (6.2 in)REAR WHEEL/BRAKE/SUSPENSION ‘Measure the brake lining thickness. ‘SERVICE LIMIT: 2.0 mm (0.08 in) DISASSEMBLY Remove the brake shoes and springs. Remove the nut, bolt and brake arm, Remove the indicator plate, felt seal and brake cam, 13-10 (2) SPRINGSREAR WHEEL/BRAKE/SUSPENSION ASSEMBLY (3) BRAKE CAM (4) BRAKE SHOES INDICATOR PLA‘ nv erake am (NOI! ne (7) FELT SEAL (6) BRAKE PANEL Apply grease to the anchor pin and brake cam, Install the brake cam into the brake panol. Apply oil to the felt seal and install it onto the brake panel. Install the wear indicator plate on the brake cam aligning its wide tooth with the wide groave on the brake cam. (7 FELT SEAL 13-11REAR WHEEL/BRAKE/SUSPENSION Install the brake arm aligning the punch marks of the arm and the brake cam. Install the brake-arm pinch bolt and tighten the nut securely, Install the brake panel into the wheel hub (page 13-8), (2) SPRINGS Install the rear wheel (page 13-8) (1) BRAKE SHOES SHOCK ABSORBER REMOVAL Support the motorcycle securely using 2 holst or equiva- lent, Remove the upper and lower mounting bolts end shock absorber. INSPECTION Visually inspect the shock absorber for damage, Check the: — Damper rod for bend or damage —Dampar unit for datormatian or oil loaks — Upper and lower joint bushings for wear or damage: Chack smoath damper operation, CAUTION + Do not disassemble the shock absorber. Replace the shock absorber if any component ix damaged. (2) BUSHINGS 13-12REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the shock absorber onto the frame. Install and tighten the upper and lower mounting bolts to the specified torque TORQUE: Upper mounting bolt: 26 N-m (2.7 kgf'm, 20 Ibét) Lower mounting bolt: 42 N-m (4.3 kgfm, 31 Ibtft) SWINGARM * REMOVAL Remove the reer wheel (page 13-3) Disconnect the rear brake pedal return spring Ramove the bolts and drive chain cover. impsocrs| Remove the rear shock absorber lower mounting bolts 1 Remove the swingarm pivot nut, bolt and swingarm. DISASSEMBLY (1) SCREWS (3) STOPPER ARM Remove the following: — Drive chain slider — Rear brake panel stopper arm (2} DRIVE CHAIN SLIDERREAR WHEEL/BRAKE/SUSPENSION Remove the dust seal caps and pivat collars. INSPECTION Chack the pivot bushings and collars for wear or damage. Chack the swingarm for cracks or damage. PIVOT BUSHING REPLACEMENT Remove the outside pivot bushings using the special tools. Too1s: Bearing remover set 07936 ~ 7310001 —Bearing remover handle _-—-(07936- 3710100 — Bearing remover set (07936 - 3710600 — Remover weight 07741 - 0010201 or 07936 - 3710200 Drive out the inside pivot bushings. Apply grease to the inside of the pivot bushings. Drive new bushings into the swingarm. TOOL: Needle bearing remover 07936 ~ KA50000 13-14 % (2) PIVOT COL Fs (7) OUST SEAL CAPS (1) BUSHINGS (2) PIVOT COLLAR, (1) BEARING REMOVER, (1) NEEDLE BEARING REMOVERREAR WHEEL/BRAKE/SUSPENSION ASSEMBLY (5) STOPPER ARM (6) DRIVE CHAIN ADJUSTER (4) SWINGARM. (1) PIVOT COLLAR (7) DRIVE CHAIN SLIDER Grease the pivat collars and install them into the swingarm (2) =—SGmimaH DUST SEAL CAPS pivot. Apply grease to the dust seal lips and install the dust seal caps onto the swingarm pivot, oS. VOT COLLARS 2 S Install the rear brake stopper arm. bol. spring washer. plain (ay screws: (1) STOPPER ARM washer and nut. Tighton the nut securely Install a new cotter pin to secure the nut (Sm Install the chain slider and tighten the screws. (9) DRIVE CHAIN SLIDER 42, gf COTTER PINg 13-15REAR WHEEL/BRAKE/SUSPENSION INSTALLATION IVE CHAIN COVER Install the swingarm inta the frame, and insert the pivot belt from the left side. Install and tighten the pivot nut to the spacified torque, TORQUE: 88 Nim (9.0 kgttm, 65 Ibft) Install the shack absorber lower mounting bolts and tighten them to the specified torque. TORQUE: 42 Nem (4.3 kgtm, 31 Ibftt) Install the drive chain cover and tightan the bolts, a Install the rear brake pedal return spring. Install the rear wheel (page 12-8). BRAKE PEDAL REMOVAL Remove the adjusting nut, brake rod and spring from the ‘ear brake arm. Disconnect the brake pedal return spring from the swing (7) BRAKE PEDAL RETURN SPRING” Disconnect the brake switch spring. 13-16REAR WHEEL/BRAKE/SUSPENSION Ramave the breke pedal plvot pinch bolt anc brake pedal Remove the brake pedal pivot shaft and brake rod as an assembly. Remove the cotter pin and jaint pin, and separate the brake (2) JOINT PIN, rod from the pivat shat (3) BRAKE ROD (1) COTTER PIN (4) BRAKE PEDAL PIVOT INSTALLATION Installation is in the reverse order of removal. NOTE + At installation, aligr and pedal, @ punch marks of the pedal pivot (1) BRAKE PEDALS 13-17HYDRAULIC BRAKE Nem (0.1 kgm, 0.7 tbe) 12. New (1.2 kgm, 9 Ibe) 34 Nem (3.5 kgm, 25 IBF) Oy 34 Nem (3.5 kgm, 25 Ibe) tin (0.8 kgm, 43 bE) | 2Nemm (0.2 kgm, 1.4 [BEF 22 Nem (2.2 kgf, 16 Ibét) 18 Nem (1.8 kgm, 13 Ibfeft) 14-014. HYDRAULIC BRAKE ‘SERVICE INFORMATION 14-1 BRAKE PAD/DISC 144 ‘TROUBLESHOOTING 14-2 MASTER CYLINDER 146 BRAKE FLUID REPLACEMENT/AIR BRAKE CALIPER 14-10 BLEEDING 143 SERVICE INFORMATION GENERAL + A contaminated brake disc or pad reduces sopping power. Discard contaminated pads and clean a contaminated dise with a high ‘quality brake degreasing agent. CAUTION + Avo spilling brake fluid on painted, plastic or rubber parts, Place a rag or shop towel over these parts whenever the gystem is serviced. This section covers maintenance of the front hydraulic brake. ‘Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. Do not allow foreign material to enter the system when filing the reservoi Always use fresh DOT 3 or 4 brake fluid trom @ sealed container when servicing the system. Do not mix different types of fluid ss they may not be compatible. + Always check broke operation before riding the motorcycle, SPECIFICATIONS Unit: mm din} TEM ‘STANDARD ‘SERVICE LIMIT Specified brake fluid DOTSeré i Brake disc thickness 400.18) 35 (0.18) Brake disc runout — 0.30 (0.012) Master cylinder Cylinder 10. 12.700 — 12.743 (0.8000 - 0.5017) [12.755 (0.6022) Piston 0.0. 112.657 — 12.684 (0.4983 - 0.4994) 12.645 (0.497 Brake caliper Cylinder 10. 725.400 — 25.405 (7.0000 - 1.0002) 25.450 ( Piston 0.0. 125,369 — 25.368 (0.9981 - 0.9967) 25.300 (0.9967) TORQUE VALUES Caliper bracket mounting bolt 30 Nem (3.1 kam, 22 Ibfft) ALOC bolt Brake hose oil bolt 34 Nem (3.5 kgf, 25 IbFft) Caliper bleeder valve Nm (0.6 kgm, 4.3 IbFft) Caliper pin bolt 22 Nm (2.2 kgfm, 16 Ibft) Apply a locking agent to the threads Caliper pin bolt A 18 Nem (1.8 kgfm, 13 Ibfft) Apply @ locking agent to the threads Pad pin 18 Nm (1.8 kgm, 13 ibfft) Pad pin plug 2.Nem (0.2 kgm, 1.4 bt) Front brake hose clamp bolt 12.Nem (1.2 kgm, 9 Hof) Master cylinder holder bolt 12 Nem (1.2 kafm, 9 tb) Master cylinder reservoir cap screw 4.Nem (0.4 kgm, 0.7 Ibfft) Brake lover pivot bolt 6 Nem (0.6 kam, 6.3 IDF) Brake lever pivot nut 8Nem (0.8 kgm, 43 IbFA) Brake switch mounting bolt Nem (0,7 kgm, 0.7 tet) 14-1HYDRAULIC BRAKE TOOLS Snap ring pliers 07914 - 3230001 TROUBLESHOOTING Brake lever soft or spongy + Airin hydraulic system * + Leaking hydraulic systam : + Contaminated brake pad/dise : + Worn caliper piston seal . + Worn master cylinder piston cups . + Worn brake padidi + Contaminated cali + Caliper not slicing properly Low brake fluid level : Clogged fluid passage . Warpedidstormed brake disc : Stickinghworn caliper piston . Stickinghworn master cylinder piston Contaminated master cylinder Bent brake lever Brake lever hard + Clogged/restrictad brake system + Sticking/wom caliper piston. + Caliper not sliding properly + Cloggedirestricted fluid passage + Worn caliper piston seal + Stickingiworn master cylinder piston + Bent brake lever ‘Brake grab or pull to one side Contaminated brake padidise Misaligned wheet Cloggedirestricted braka/hose joint Warpedideformed brake disc Caliper not sliding properly Brake drog = Contaminated brake padidise Misaligned wheel ‘Worn brake pad/dise \Warped/deformed brake disc Caliper not sliding properly 14-2BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING CAUTION 5 Do not allow foreign material to enter the system when filing the + Avoid spilling fluid om painted, plasti, ov rubber parts. Place a tay over these parts whenever the system is serviced. With the fluid reservoir parallel to the ground, remove the HL BRAKE LEVER! reservoir cover and diaphragm. Connect a bleed hose to the caliper bleed vetve. Loosen the bleed valve and pump the brake lever, Stop pumping the lever when no mare fluid flows out of the bleed valve, BRAKE FLUID FILLING Fill the reservoir with DOT 3 or 4 brake fluid from a sealed con- tiner. CAUTION + Do not mix diferent types of flail. There are not compatible Connect a commercially available brake bleeder to the bleod valve, Pump the brake bleeder and laosen the bleed valve, adding ‘fluid when the fluid level in the master cylinder reservoir is low. NOTE + Check the fluid level often while bleeding the brakes to prevant air from being pumped into the system. + When using @ brake bleeding tool, follow the manufac- turer's operating inst Repeat the above procedures until air bubbles do not appear in the plastic hose. NOTE + IFair is entering the bieeder from around the bleed valve threads, seal the threads with Teflon tape. + Ifa brake bleeder is not available, fill the master cylinder Close the bleed valve. Next, perform the BLEEDING proce- dure (page 14-4) HYDRAULIC BRAKE 14-3HYDRAULIC BRAKE BRAKE BLEEDING Connect a clear bleed hose to the bleed valve, Pump up the system pressure with the lever until there are ho air bubbles in the fiuid flowing out of the master cylinder and lever resistance is fet, 1, Squeeze the brake lever, open the bleed valve 1/2 turn ‘and then close the valve, NOTE + Do not release the brake lever until the bleed valve has been closed. 2, Release the brake lever after the bleed valve has been closed. Repest steps 1 and 2 until bubbles cease to appear in the fluid coming out of the bleed vaive. Tighten the bleed valve. TORQUE: 6 Nem (0.6 kgm, 4.3 Ibt‘t) Fill the fluid reservoir to the upper lovel. Reinstall the diaphragm and reservoir cover, and tighten the screws. TORQUE: 4 Nem (0.1 kgfem, 0.7 Ibf#t) BRAKE PAD/DISC BRAKE PAD REPLACEMENT NOTE + Always replace the brake pads in pairs to assure even disc pressure, Remove tha pad pin plugs and loosen the pad pins. Remove the caliper mounting bolts and caliper. 14-4HYDRAULIC BRAKE Remove the pad pins and brake pads. ‘Make sure that the pad spring is in place as shown, Install the brake pads. Push the brake pads against the pad spring, then install the pad pins. Push the caliper pistons all the way in to allow installation of new brake pad. NOTE + Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise.HYDRAULIC BRAKE Install the brake caliper to the left fork leg so the disc is post- tioned between the pads. + Be careful not 1o damage the pads Install and tighten the new brake caliper mounting bolts. TORQUE: 30 Nm (2.1 kgfm, 22 Ibft) Tighten the pad pins. TORQUE: 18 Nem (1.8 kgm, 13 tbf-tt) Install and tighten the pad pin plugs. TORQUE: 2 Nem (0.2 kgtm, 1.4 Ibtt) BRAKE DISC INSPECTION ‘Measure the brake disc thickness with a micrometer. SERVICE LIMIT: 3.5 mm (0.14 in} Measure the brake disc warpage with a dial indicator. SERVICE LIMIT: 0.30 mm (0.012 in) MASTER CYLINDER (2) REARVIEW MIRROR (3) PIVOT BOLTINUT REMOVAL Disconnect the brake switch wires. Remove the rearview mirror. Remove the pivot nut, bolt and brake lever. = P(A) BRAKE LEVER OQ (1) BRAKE SWITCH WIRES 14-6HYDRAULIC BRAKE Drain the brake system (page 14-3) (4) MASTER CYLINDER Remove the brake hose ail bolt, sealing washers and brake hose. CAUTION + Avoid spilling fluid on painted, plastic, or rubber parts, Place a rag over these parts whenever the system is serviced. Remove the bolts from the master cylinder holder and remove the master cylinder. (2)soLts DISASSEMBLY (3) SNAP RING PLIERS. (2) SNAP RING Remove the boot. Remove the snap ring from the master cylinder body using tthe special too! as shown. TooL: (1) Boor ‘Snap ring pliers 07914 ~ 3230001 BO Remove the master piston and spring. Clean the inside of the cylinder and reservoir with brake fluid (1) MASTER PISTON INSPECTION Check the piston boot, primary cup end secondary cup for fatigue or damage. Check the master cylinder and piston for abnormal scratches. Measure the master cylinder LD. SERVICE LIMIT: 12.755 mm (0.5022 in) 14.7HYDRAULIC BRAKE Measure the master cylinder piston 0.0. ‘SERVICE LIMIT: 12.645 mm (0.4978 in) *% ASSEMBLY 12.Nem (1.2 kgm, 9 Ib6 ft) 11 Nem (0.1 kgf, 0.7 Ib) 34 Nen (3.5 katm, oe 25 Itt) @ | (6) RESERVOIR CAP (5) PRIMARY CUP S ‘a d (4) MASTER PISTON (7) DIAPHRAGM PLATE (3) SECONDARY CUP, TL (2) SNAP ‘ (1) B00T (6) DIAPHRAGM (9) SPRING 11Nm (0.1 kgm, 0.7 1oF) cAuTION (1) SPRING + Keep the piston, cups, spring, snap ving and boot as set: do not (9) PRIMARY CUP substiute individual parts (4) SECONDARY aaa cur Cost all parts with clean brake fluid before assembly, Dip, the piston in brake flu. install the spring to the piston. install the piston assembly CAUTION _ + When insating the cups, do not allow the lips torn inside ou Q ————— —————— (2) MASTER PISTON 14-8HYDRAULIC BRAKE Ingtall the snap ring. (2) SNAP RING PLIERS (1) SNAP RING CAUTION ‘Be certain the sap ing is firmly seated I the proov Install the boot, (3) BOOT Place the master cylinder on the handlebar. (1) MASTER CYLINDER, (4) PUNCH MARK Install the master cylinder holder with the “UP mark facing up. Align the end of the master cylinder with the punch mark on the handlebar. Tighten the upper bolt first, than the lower bot. TORQUE: 12 Nem (1.2 kgf-m, 9 tft) (3) “UP* MARK. i) Hou Isat brie hose elt with th ol Blt and new sea in cea. ne wasnens Push the brake hose egains the stopper, then tighten the oll bolt tothe specified torque, TORQUE: 34 Nem (3.5 kafom, 25 tft) Ta (1) BRAKE HOSE EYELET Install the brake lever. ‘ First install and tighten the pivot bolt to the specified (3) REARVIEW MIRROR noe : TORQUE: 6 N-m (0.6 kgf-m, 4.3 Iibfft) ag (2) PIVOT BOLT/NUT Hold the pivot bolt and tighten the nut to the specifi torque. TORQUE: 6 Nem (0.6 kgfm, 4.3 Ibi) Connect the brake switch wires. Install the rearview mirror. Fill the reservoir to the upper level and! bleed the brake sys- tom (page 14-3). (1) BRAKE LEVER Wis) BRAKE SWITCH WIRES) 14-9HYDRAULIC BRAKE BRAKE CALIPER REMOVAL Drain the brake system (page 14-3) Remove the oil bolt, sealing washers and brake hose eyelet joint. Remove the caliper mounting bolts and the bre (page 14-4), 2 pads ‘CAUTION + Avoid spilling fluid on painted, plastic, or rubber parts, Place a ‘rag over these parts whenever the system is serviced. DISASSEMBLY Romove the caliper bracket from the caliper body. Remove the caliper pin boot from the bracket. Remove the pad spring and bracket pin boot fram the cali- per body. Place a shop towel over the piston, Position the caliper body with the pistons down and apply ‘small squirts of air pressure to the fluid inlet to remove the pistons. GSI ‘+ Do not use high pressure air or Bring the noztle too close to the inlet, Push the dust and piston seals in and lift them out. CAUTION ‘Be careful not to damage the piston sliding surface, (3) BRACKET PIN BOOT (1) CALIPER BRACKET (4) PAD SPRING (2) CALIPER PIN BOOTHYDRAULIC BRAKE INSPECTION (Check the caliper cylinder for scoring or other damage, Measure the caliper cylinder 1.0. ‘SERVICE LIMIT: 25.450 mm (1.0020 in) Check the caliper pistons for scratches, scoring or other darn- age. Measure the caliper piston 0.0. SERVICE LIMIT: 25.300 mm (0.9961 in) ASSEMBLY (1) PIN BOLT A 22 Nem (2.2 kgf, 16 IDF) (2) PAD SPRING (9) CALIPER BRACKET (3) PAD PINS 18 Nem (1.8 kam, 13 Ibe) (8) PIN BOLT 48 Nem (1.8 kgm, 13 Ib) oy Ge oust seat’ (4) PAD PIN PLUGS 2.Nem (0.2 kgtm, 1.4 tbftt) 14-11