HOW TO USE THIS MANUAL This shop manual describes the servicing pro- cedures for the XR6OOR Throughout the manual, the following ab- breviations are used to identify individual models. Follow the Mainterance Schedule recomme- ndations to ensure that the vehicle is in peak operating coudition Throuhout the manual, the following abbre- viations are used to identify the models. CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM CODE ‘AREA (TYPE) — (TYPE) _| CYLINDER HEAD/VALVES 8 Belgium ° U __ Australia w _ CYLINDER/PISTON Sections 1 through 3 apply to the whole | %/ GLUTCH/KICK STARTER 7 motorcycle, while sections 4 through 17 | & describe parts of the motorcycle, grouped ac- RCTERnaT OR cording to location = Find the section you want on this page, then Ce ee turn to the table of contents on page 1 of that, —— poeta TRANSMISSION Most sections start with an assembly or |_ FRONT WHEEL/SUSPENSION/STEERING a system illustration, service information and | —————= _ troubleshooting for the section. The subse- | | REAR WHEEL/BRAKE/SUSPENSION EE quent pages give detailed procedures. g <—<————— ———> |B HYDRAULIC BRAKE If you are not familiar with this motorcycle, = os read section 18, Technical Features REAR FENDER/EXHAUST PIPE If you don’t know what the source of the trou. [a | electrics - ble is, refer to section 19, Troubleshooting. | & |_ ELECTRICAL SYSTEM £ i WIRING DIAGRAM ‘Alinformation, ilustrations, directions and spec | |} — : a fications included in this publication are based on i TECHNICAL FEATURES the latest 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 per HONDA MOTOR CO., LTD. Service Publication Office TROUBLESHOOTING XR6OOR(K) ADDENDUM Date of issue: August, 1988 © HONDA MOTOR CO., LTD.IMPORTANT SAFETY NOTICE ene] Indicates a strong possibilty of severe personal injury or loss of life if instructions are not followed CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not followed. NOTE: Gives helpful information Detailed descriptions of standard workshop procedures, safety principles and service operations are not included It's important to note that this manual contains some warnings and cautions against same specific service methods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda inves. tigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy ‘himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools, selected._1 GENERAL INFORMATION GENERAL SAFETY 1-1 TORQUE VALUES 1-5 SERVICE RULES 1-1 TOOLS 1-7 MODEL IDENTIFICATION 1-2 CABLE & HARNESS ROUTING 1-9 | 1 SPECIFICATIONS 1-3 GENERAL SAFETY Ifthe engine must be running to do some work, makesure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead todeath. Inhaled asbestos fibers have been found to cause respiratory Gasoline is extremely flammable and is explosive under ce- disease and cancer. rain conditions. Do not smoke or allow flames or sparks in ‘Never use an air hose or dry brush to clean breake or clutch as- the work area or where gasoline is stored. semblies. SERVICE RULES ‘© Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that do not meet HONDA’s design specifications may damage the motorcycle. © Use the special tools designed for this product. © Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling. © When torquing a series of bolts or nuts, begin with the larger-diameter or inner bolts first, and tighten to the specified torque diagonally, unless a particular sequence is specified. © Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before re- assembly. © After reassembly, check all parts for proper installation and operation. © Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners, The use of incorrect tools and fasteners may damage the motorcycle. © Route all electrical wires as shown on pages 1-9 through 1-12, Cable and Harness Routing, and away from sharp edges and areas where they might be pinched between moving parts. 1-1GENERAL INFORMATION MODEL IDENTIFICATION ‘The engine serial number is stamped on the lower left side The frame serial number is stamped on the right side of the of the crankcase. steering head. a, ‘4 | ‘The carburetor identification number is on the right side of ‘The color code label is attached to the left frame tube the carburetor body. under the seat. When ordering a color coded part, always specify its designated color code. 1-2GENERAL INFORMATION ae SPECIFICATIONS TEM SPECIFICATION DIMENSIONS | Overallengih 2,160 mm (@5.01n) Overall width 900 mm (35.5 in) (B model) 980 mm (35.4 in (U model) Overall height 1.210 mm (48.0 in) (8 mode) 1.220 mm (48.0in}(U model Ground clesrance 335 mm (13.2 in Wheelbase 1.480 mm (87.5 in} (8 mode) 1,455 mm (57.3 in) (U modcl) Seat height 940 mm (37.0) Foot peg height 418 mm (16.5 in) (L)/420 mm (16.5 in) (R) Dry weight Curb weight 120.5 kg (26.5 by/190.8 kg (287-5) FRAME Type ‘Semi double cradle Front suspension, travel Telescopic 280 mm (1.0in) Raar suspension travel Prosink 280 mm (11.01) Tire size (B model) T (U model) Front 80/100-21 61M 3.00-21-4°R | Rear 110/100-18 64M 450-18-4PR Tire pressure Front 15 Psi (100 kpa, 1.0 kg/cm?) Rear 15 Psi (100 kpa, 1.0 kg/cm?) Front brake, swept area Dise, dual piston caliper Rear brake, swept orea Drum, leading traling shoes Fuel capacity 1001it(2.7 US. gal. 2.3 imp oa) Fool reserve capacity 2.01i(0.5 US. gol.0.4 Imp gah Caster 62" Trail 118 mm (4.6 in) Front fork olcapacty 643 ¢0(21.8 on) ENGINE Tyee Gasoline, air-cooled 4 stroke SOHC Cylinder arrangement Single evinderincined 18" Bore and stroke 87 X BO mm(3.82 X 3.15 in) Displacement 891 cc (36.1 cuin) Compression ratio 80°1 Valve train 4-valve, single chain driven SOHC, RFVG Otlcepacity 2.3it(24US. at, 2.0Imp at) Lubrication system Forced pressure andy sump | Air fitration systom Oiled polyurethane foam Cylinder compression 500 # 100 kPa = 1 kg/em, 71.1 + 14.2 ps) De compressor effected Intake valve. Opens 5° (BTCD) at 1 mm lift Closes 40° (ABDC) at 1 mmilift Exhaust valve Opens 45" (BBDG) a | mmf Closes 5 (ATOC] att mit Valve clearance intake 0:10 mm (0.004 in) Exhaust. 0.12 mm (0.005 in) CARBURETOR | Type Piston valve LB rurnber POBAA ‘Main jet #165 (B model), #135 (U model) | Pilot screw 2-5/8 turns out Float level 14.5 mm (0.57 in) Idle speed 1,300 + 100 min (rpm)GENERAL INFORMATION TEM SPECIFICATION DRIVE TRAIN Clutch ‘Wet multi-plate Transmission 8-speed constant mesh Primery reduction 2.188 (70/32) Gear ratio | 2.385 (31/13) Gear ratio i 1.647 (28/17) Gear ratio il 1.260 (28/20) Gear ratio lV 1.000 (23/23) Gear ratio V 0.840 (21/25) Final reduction 3.571 (50/14) Gear shift pattern Left foot operated return system (1-N—2—3—45) ELECTRICAL, Tanition col Ignition timing Initial 6° BTDC at 1,300 + 250 min (rpm) (F mark) Fulladvance | 31 + 2°BTDC at 4,000 min" (rpm) Alternator ‘AC generator 150 W/5,000 min (rpm) Spark plug DPRBEA-9 (NGK) or eee X24EPR-U9 (ND) For extended high | DPR9EA-9 (NGK) or speed riding X27EPR-US (ND) Spark plug gap 0.8-0.9 mm (0,031—0.038 in) Headlight 12/35 W (8 model 12.V/25 WU model) Tail/Stop ight 12/18/21 W(B model) Turn signal light Speedometer light High beam indicator light Position light 12.V/18/ 5 W(U model) 12.V/10 WU model only) 12v/ 3W 12V/ 2W 12V/ 4W 1-4GENERAL INFORMATION TORQUE VALUES ENGINE hem Ow] omy |__ Ta tom Remarks Spark pa 7] — | eae1a Crankoase drain plug i 2512.5, 18) Ot iter cover bat 3| 6 310.7 Vane edusting tock a a] oa 25.2.5, 10) Cylinder head bot a] 8 36 3.8, 26) Com sprocket bot 2; 7 20 (2.0, 18 Gyinder ead cover bot teem) = | | 8 3312.3,10 mm | 1!) 6 1211.29) temmsw) | 12, 6 1011.0, 71 Rocker arm she a] a | 28.2.8, 20) Bubvocker orm shaft a] 44 28 2.8, 20 eX a] 1 2312317 Cylinder bot a] 19 5015.0, 30) Guten tock nt 1) ts 170 (11.0, 80) Dive gear lock nut i) is 10 11.0, 80) Flywheel bolt 1) 12 | 125 (12.5, 90) Gears drum bot i} 6 12112, 8) Shift rum stopper arm bok i] 8 25125, 18) Gears return sng in i) 8 ba 2.4, 17) Shit fork sot bot fal 3 155.10 Keck starter stopper plte 2) 8 25.2.5, 18 rankease bol in ea) 8 12(42,9) Grankease cover bot s| 6 | 2029 FRAME 1 tom are] imead, | Tose nim tae es) | ean Down tube drain pag 7] 10 40 (40,28) Of staner i| a 35 (8.5, 40) il inlet pipe flare nut (lower) 4 18 40 (4.0, 29) toe | 18 4018.0, 28) Oi outlet hose fae nut pa) te 40 18.0, 28) Side stond pivot bol ji} 49 18.0 29) Fort tank mounting bot 2) 3 10140, 7 Engine hanger bolt (10 mm) | 5 | 10 50 (5.0, 36) (8mm! 3 | 27127, 20) Exhaust pipe jin nut a| 2 21127, 20) | Exhaust pipe Samo 2] 8 2713.7 20 Exhaust muflor mount bot 2 | 8 700.0. 60 Fight fotpeg bot 2 10 165,47 Handlebar holder bot a) le 212.7 20 Front one +] 2 516.5, 47 Front axe holder nt 2| 6 121129) | Front epoke —— toa a Front whe! sim lock 1 | 8 1343.9) / Fork upper inch bot a} 3 33188 28) Fork lower pinch bok a] 8 | 3318.8, 24 Fork cop 2) — 232.3, 18) Fork bottom bolt 2| 8 36 (3.5, 25) ‘Apply LOCTITE® | BEE equivalent Throttle pulley pivot screw Lij os 4.3 0.43, 3) l 1-5GENERAL INFORMATION Item Steering bearing adjusting nut Steering stem nut Front brake dise Brake master cylinder bleeder screw Rear axle nut Rear spoke Rear wheel rim lock Final driven sprocket Rear shock absorber upper mount Rear shock absorber lower mount ‘Swingarm pivot nut ‘Shock arm-to-swingarm bolt ‘Shock arm-to-shock link bolt Shock link-to-frame bolt Rear shock spring adjuster lock nut Rear shock hose joint bolt Rear shock hose lock nut, Rear shock piston rod end nut Brake pedal pivot bolt Brake caliper bolt Brake caliper bleeder screw Brake pad pin Fuel valve Gearshift pedal Kick starter arm Brake hose joint bolt ory | Thread Dia. (mm) 26 24 6 8 16 10 10 10 14 12 10 10 50 10 12 12 10 Torque Nem (ka-m, ft-lb) Remarks 3 (0.3, 22) 118 (11.8, 85) 15 (1.5, 11) 6106, 4) 95 (9.5, 69) 410.4, 3) 13.1.3, 9) 46 (4.6, 33) Apply oil 45 (4.5, 33) 30 (3.0, 22) | 90 19.0, 65) 45 (4.5, 33) 45 (4.5, 33) 70 (7.0, 51) 90 (9.0, 65) | 30 (3.0, 22) | 30 (3.0, 22) 38 (3.8, 27) Apply LOCTITE® 242 or equivalent 40 14.0, 23) 27 (2.7, 20) 6 (0.6, 4) 18 (1.8, 13) 1011.0, 7) 1011.0, 7) | 27 (2.7, 20) 35 (3.5, 25) I dard torque values below. Torque specifications listed above are for the most important tightening points. If a specification is not listed, follow the stan- STANDARD TORQUE VALUES Hem Nem (kg-m, ftlb) tem Nem tkgem, ft-lb) 5 mm bolt and nut 6 (0.6, 4) 5 mm screw 40.4, 3) 6 mm bolt and nut 10 (0.1, 7) 6 mm screw and 6 mm bolt 9(0.9, 7) 8 mm bolt and nut 22 (2.2, 16) with small (8 mm) head 10 mm bott and nut 35 (3.5, 25) 6 mm flange bolt and aut 12.(1.2, 9} 12 mm bolt and nut 55 (5.5, 40) 8 mm flange bolt and nut, 27 (2.7, 20) 10 mm flange bolt and nut 40 (4.0, 29)GENERAL INFORMATION TOOLS SPECIAL DESCRIPTION TOOL NUMBER, | neren To secrion Bearing puller catch Knock pin puller set — Remover weight — Slider shaft Tensioner holder Valve guide reamer Bearing remover set Spindle — Remover handle Remover weight Bearing remover, 15 mm Remover handle Remover weight Crankcase assembly tool = Collar — Thread adapter ~ Shaft puller Oil seal driver attachment Ball race remover Slider weight Fork seal driver attachment Steering stem nut wrench Compression gauge attachment Steering stem driver Bearing driver Damping valve wrench Bearing driver base Spherical bearing driver Needle bearing remover Snap ring pliers Slider guide, 14 mm Piston ting sleeve Slider guide attachment 07931 —MK20100 07936—MA70000 077410010201 07936—MA70100 07973—-MG30003 07984~5510000 07936~3710001 07936~3710600 079363710100 077410010201 07936-—KC10500 (07936—MK50100 07741—0010201 07931—KF00000 07931 —KF00100 07931 —kF00200 07931 —ME40000 07GAD—sD40101 07953—MJ1000 07947—KA50100 07947—KA40200 07916-KA50100 07908~-KK60000 07946-4300101 07946—MJ00100 07920—-KA30001 (07HMF—KS60100 07946-KA30200 (07931—MA70000 07914~3230001 (07974—KA40000 07974—KA30201 07974—KA30100 10 Je 6 6 10, 13 10 10 10 10 10 12 12 12 12 12 13 13 13 13 13 14 13 13 13GENERAL INFORMATION COMMON DESCRIPTION TOOL NUMBER REFER TO SECTION Wrench, 10 x 12 mm 077080030200 3 Adjusting wrench A 077080030300 3 ‘Spoke wrench, 5.8 x 6.1 mm 077010020300 3 Float level gauge 074010010000 4 Valve guide driver, 6.6 mm 07742-0010200 6 Valve spring compressor 077570010000 6 Wrench, 17 x 27. mm 077160020300 8 Extension bar 077160020500 8 Attachment, 32 x 35 mm 07746-0010100 8, 12,13 Pilot, 20 mm. 077460040500 8, 10, 13 Pilot, 40 mm 07746 0040300 10 Primary gear holder 077240010100 8 Clutch center holder 077240050001 8 Driver 07749-0010000 8, 10, 12, 13 Flywheel holder 07725-0040000 9 Rotor puller 07733-0020001 9 Attachment, 2 x 55 mm 07748-0010400 10 Attachment, 62 x 68 mm 077460010500 10 Attachment, 72 x 75 mm 07748-0010600 10 Pilot, 17 mm 077460040400 10, 13 Attachment, 42 x 47 mm 07746-0010300 10, 12, 13 Pilot, 25 mm 07748-0040600 10 Pilot, 35 mm 077480040800 10 Wrench, 30 x 32 mm. 07716-0020400 12 Pilot, 15 mm. 07746 0040300 12 Remover head, 15 mm 077460050400 12 Remover shaft 07748-0050100 12, 13 Remover head, 17 mm 07746-0050500 13 Remover head, 20 mm 07746-0050600 13 Retainer wrench A 077100010100 13, Retainer wrench body 07710~0010401 13 Attachment, 24 x 26 mm 07748-0010700 13 Driver 07748-0020100 13 Attachment, 20 mm 1.0 077460020400 13 Attachment, 37 x 40 mm 077460010200 10, 13 VALVE SEAT CUTTER DESCRIPTION TOOL NUMBER REFER TO SECTION 38.5 mm flat cutter 07780-0012400 40 mm seat cutter 07780-0010500 35 mm seat cutter 07780-0012300 6 37.5 mm intake cutter 07780-0014100 6.6 mm cutter holder 07781-0010201GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire hamesses: © A.loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. © Do not squeeze 2 wire against a weld or the end of its clamp. © Secure wires and wire harnesses to the frame with their spective bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harneses. © Route harnesses so they are not pulled taut or have exces sive slack. © Protect wires and hamesses with electrical tape or tubing where they contact a sharp edge or corner. Clean the at- taching surface thoroughly before applying tape. © Do not use wires or hamesses with damaged insulation. Repair by wrapping them with protective tape or replace them. ‘© Route wire harnesses so as to avoid sharp edges or corners. © Avoid the projected ends of bolts and screws. © Keep wire harnesses away from the exhaust pipes and other hot parts. © Be sure grommets are seated in their grooves properly. © After clamping, check each harness to be certain that it is, rot interfering with any moving or sliding parts. © After routing, check that the wire harnesses are not twisted or kinked, © Wire harnesses routed along the handlebar should not be pulled taut, have excessive slack, or interfere with adjacent (r surrounding parts in any steering position. © Do not bend or twist control cables. Damaged control cables will net oper stick or bind. fe smoothly and may O x Sad XD (©: CORRECT x: INCORRECTGENERAL INFORMATION (1) FRONT TURN SIGNAL LIGHT WIRE (Umobel only) (3) FRONT BRAKE LIGHT SwiTcH WIRE (Bmodel) (Umodel) (2) ENGINE STOP ‘SWITCH WIRE (6) BRAKE HOSE (7) (Bmodel) (8) (Umodel) 1-10GENERAL INFORMATION (IGNITION COIL, (2) MAIN WIRE HARNESS. (9) IGNITION COIL (10) MAIN WIRE HARNESS (11) CARBURETOR AIR VENT TUBE (4) AC REGULATOR (3) CARBURETOR: AIR VENT (5) CDI UNIT (12) CDI UNIT (15) SPARK, (8) SPAR} PLUG CAP F (14) CLUTCH weap ICLUTCH CABLE (ALTERNATOR | (HA)CLUTEM 5g terwaron ine anness (16) CRANK CASE BREATHER | TUBES (17) CARBURETOR OVERFLOW TUBE 1-11GENERAL INFORMATION (1) TAIL/BRAKE LIGHT WIRE (4) (Bmodel) (3) TAIL/BRAKE LIGHT WIRE (5) (Umodel)LUBRICATION HOTOL + COOLOL => (a)encine on (7) OIL FILTER (CREEN FILTER (6) OIL PUMP DRIVEN GEAR 2-0LUBRICATION SERVICE INFORMATION 2-1 OILCOOLING SYSTEM 24 TROUBLESHOOTING 2-1 ENGINE OIL STRAINER CLEANING 26 ENGINE OIL LEVEL CHECK 2-2 OILSTRAINER NUT 2-6 ENGINE OIL CHANGE 2-2 OILPUMP 2-6 ENGINE OIL FILTER REPLACEMENT 2-3 LUBRICATION POINTS 2-14 OIL PASS PIPE 23 SERVICE INFORMATION GENERAL. ‘© This section describes inspection and replacement of engine oil and the oll filter. Also, the cleaning of the strainer and ser- ing oil pump, oil pass pipe and cooling system. CAUTION + Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, itis still advisable to thoroughly wash your hands with soap and water as soon as possi- ble after handling used oil. “OIL VISCOSITIES SPECIFICATIONS Oil capacity 2.3 liters (2.4 U.S. at., 2.0 Imp gt) at engine assembly 1.9 liters (2.0 U.S. at., 1.7 Imp qt) at oil change 1.95 liters (2.06 U.S. qt., 1.72 Imp qt) at oil and oil fitter, Single change. grade Recommended oil Use Honda 4-Stroke Oil or equivalent. API Service Classification: SE or SF. VISCOSITY: SAE 10W—40 or 20W—80 NOTE a Sr Multi + Use SAE 10W—40 oil when the outside temperature is aaa below 0°C (32°F). e Other viscosities shown in the chart may be used when the av. ‘erage temperature in your riding area is within the indicated 199 10 20 30 Ae range. F400 20 1007 ITEM STANDARD SERVICE LIMIT _Oil pump tip clearance ___0.15 mm (0.006 in) max. 0.20 mm (0.008 in) Oil pump body clearance 0.15~0.21 mm (0.006—0.008 in} 0.26 mm (0.010 in) Oil pump end clearance 0.02—0.08 mm (0.001 9.003 in} 0.12 mm (0.008 in) Oil pump delivery Pump A 7.5 liters (7.9 U.S. qt)/min. at 6,300 min” (rpm) Pump B 10.0 liters (10.6 U.S. qt}/min. at 5,300 min: (rpm) TORQUE VALUES fankease drain plug 25 Nem (2.5 kg-m, 18 ft-lb) Downtube drain plug 40 Nem (4.0 kg-m, 29 ft-lb) Strainer nut 55 Nem (5.5 kg-m, 40 ft-lb) Oil inlet hose joint nut 40 Nem (4.0 kg-m, 29 ft-lb) Oil outlet hose joint nut 40 Nem (4.0 kg-m, 29 ft-lb) Oil fiter cover bolts. 9.Nem (0.9 kg-m, 7 ftb) Oil Level Too Low Low oil pressure + Normal oil consumption + Faulty oll pump + External oil leaks + Oil pump drive gear broken + Worn piston rings Oil Contamination + Oil not changed often enough + Faulty head gasketLUBRICATION ENGINE OIL LEVEL CHECK (1) UPPER LEVEL (2) OI FILLER cAP/DIPSTICK ; Support the motorcycle upright on lave ground. i \ Start the engine and let it idle for a few minutes. a Stop the engine then chock th of vel with te ofl cap! dipstick by inering tin until the treads touch te ler neck Do not screw the cap in when making this check Ifthe ailovels below the lower mark on the diptck, fil 10 the upper level mark with the recommended ol a ENGINE OIL CHANGE (a) LOWER LeveL a NOTE + Change the engine oil with the engine warm and the motor- cycle on its side stand to assure complete and rapid drain ing Remove the oll filler cap and drain plugs on the frame down ‘tube and the left crankcase. CAUTION > \ + Used engine oil may cause skin cancer if repeatedly left in con- tact with the skin for prolonged periods. Although this is unlikely untess you handle used oi! on a daily basis, itis still ihe advisable to thoroughly wash your hands with soap and water a (1) DOWN TUBE DRAIN PLUG 4s soon as possible after handling used oil. \ ‘After the oil has drained, check that the drain plug sealing ‘washers are in good condition, then install the plugs. TORQUE Crankcase drain plug: 25 Nom (2.5 kg-m, 18 ftb) Downtube drain plug: 40 Nem (4.0 kg-m, 29 ftlb) NOTE + If maintenance is also scheduled for the oil fiter and the strainor nut, do these before filing the frame oil tank with oil + The engine takes about 1.9 liters (2.0 U.S. gt, 1.7 Imp at (1) crankéAase DRAIN PLUG at oll change, But since only a portion of that oil is held in the frame's oll tank, you cannot add the full amount initially Pour one liter (1.06 U.S. qt) of recommended oil (page 2-1) into the oil tank. Install the oil filler cap/dipstick. Start the engine and let it idle for a few minutes. Stop the engine and add the recommended oil up to the upper level mark with the motorcycle upright.LUBRICATION CRANKCASE OIL CHECK BOLT NOTE ‘+The crankcase oil level check bolt is useful when checking the lubrication system; the oil pump adjusts the oil level so that the crankcase is always kept at the proper level. If this check shows otherwise, some portion of the lubrication system is not working properly. The crankcase oll level is correct if the oil is flush with the bottom of the check bolt hole. 1) OL CHECK PLUG ENGINE OIL FILTER REPLACEMENT NOTE + Change the oil filter before filing the frame oil tank with oi Remove the oil filter cover from the right crankcase, then remove the filter element. Discard the ol filter element. 11) O-RING. {2) OIL FILTER ELEMENT ‘Chock that the O-ring on the oil fiter cover is in good condi- i tion. % @ Install the spring, new oil fiter element and ol fiter cover. Tighten the cover bolts. \ ‘TORQUE: 9 Nem (0.9 kg-m. 7 ft-lb) s \ (3) SPRING Fillo the upper level with the recommended cil. nm (5) BOLTS (4) “OUT SIDE” MARK (1) PIPE BOLT OIL PASS PIPE iB Bence soi Ts “Seb: pom REMOVAL, Remove the pipe bolts and copper washers. Loosen the pipe bracket bolts and remove the oil pass pipe. CAUTION + Do not bend the oil pass pipe. (ia) BRACKET BOLT oe PRR) corre viasnensLUBRICATION INSPECTION (1) PIPE BOLTS: Check the oil pass pipe for damage, bends or clogging and replace if necessary. Check the pipe bolts for clogging and damage. . If the parts are clogged, clean them with non-flammable or high flash point solvent. INSTALLATION Ui PIPE BOLT)Vi2) BRACKET BOLTS (i)PIPE BOLT) Install the oil pass pipe and loosely tighten the bracket bolts. Tighten the pipe bolts with new copper washers. ‘TORQUE: 12 Nem (1.2 kg-m, 9 ft-tb) Tighten the bracket bolts. (4) BRACKET BOLT (3) COPPER WASHERS OIL COOLING SYSTEM Check the oil pipe and hose for damage or leaks. REMOVAL. Remove the fuel tank (page 4-3). Remove the skid pipe (page 6-3). Remove the oil drain bolt at the frame down tube to drain the oll (page 2-2) Loosen the oil inlet hose and outlet pipe joint nuts. Remove the oil pipe clamp. (3) OL PIPED (4) on ner HOSE CuaMeLUBRICATION Remove the wire band. Loosen the oil inlet and outlet hose set plate bolts. Remove the inlet hose and outlet hose. = INSPECTION Check the oil outlet and inlet hose for damage, bends, or clog- ging and replace if necessary. Check the O-ting is in good condition. (1) SET PLATE E Sa ee (3) OIL OUTLET PIPE (5) O-RINGS, 7 ae OL INLET HOSE INSTALLATION Install the O-rings on the pipe and hose. Install the set plate bolts with washers. Tighten the set plate bolts securely. ‘Secure the hoses and pulse generator wire with the wire band ‘as shown. Connect the oil inlet and outlet pipe. Tighten the joint nuts. TORQUE: INLET 40 N-m (4.0 kg-m, 29 ft-lb) OUTLET 40 Nem (4.0 kg-m, 29 ft-lb) Install the oil pipe clamp and tighten the screw securely, Install the skid pipe and fuel tank. 4) On ANTET HOSE| (3/1 PIPE CLAM 2-5LUBRICATION ENGINE OIL STRAINER CLEANING NOTE + Perform this maintenance before filing the engine with oil. Remove the right crankcase cover (page 8-3). Remove the oil strainer and clean it. Install the oi strainer. Install the right crankcase cover (page 8-17) Fill the crankcase with recommended cil OIL STRAINER NUT NOTE + Clean the screen on the oil strainer nut before filling the frame oil tank with oil. Remove the oil drain bolt at the frame down tube to drain the oll Remove the skid pipe (page 5-3). Loosen the oil joint nut and disconnect the hose from the oil strainer nut. Remove the oil strainer nut from the frame down tube. PCR GRAM Fon, Clean the screen on the oil strainer nut in solvent and bi with compressed ai. senenv onan (1) SCREEN heck thatthe O-ring is in good condition, Reinstall the ol strainer and tighten, TORQUE: 55 Nem (6.5 kgm, 40 fb) Reconnect the oil hose and tighten its nut. ‘TORQUE: 40 Nem (4.0 kg-m, 29 ft-ib} Reinstall the skid pipe. (2) OIL STRAINER NUT (3) O-RING Fill the oil tank to the upper level with the recommended oil. OIL PUMP REMOVAL Remove the clutch (page 8-4). Remove the oil pump driven gear. (1) OWL DRIVEN GEARLUBRICATION Remove the bolt and nut attaching the oil pipe and then the oil dirty iro PPE WTO BOLT pipe : - Remove the collar and O-ring. Remove the bolts attaching the oil pump and then the oil pump from the right crankcase. . (5) OW PUMP 14) COLLAR AND O-RING Remove the oil orifice and O-ring from the right crankcase, Check that the oil orifice in the crankcase is clean by blowing through with compressed air. a (1) OW ORIFICE AND O-RING DISASSEMBLY (1) Screws Remove the oll pump screws. Remove the oil pump body B. Remove the inner and outer rotor Bs from the check valve housing. (3) INNER ROTOR 8 | MAIZ) OUTER ROTOR & 2-7LUBRICATION Remove the lock pin from the oil pump shaft. ‘Separate the check valve housing from oll pump body A. Remove the dowel pins, pump shaft, and inner and outer rotors from the pump A body. INSPECTION Measure the tip clearance between the inner and outer B rotors SERVICE LIMIT: 0.20 mm {0.008 in) Measure the clearance between the outer rotor B and the pump B body. ‘SERVICE LIMIT: 0.25 mm (0.010 in) (1) LOCK PIN (2) Ol. PUMP SHAFT NE HOUSING (1) CHECK VALVE HOUSIN (2) PUMP SHAFT (6) OUTER ROTOR #141LUBRICATION Wipe oil from the rotors and put a piece of plastigauge across them as shown, Install the oil pump body B and tighten the oil pump screws. Remove the oil pump body B and measure the width of the plastigauge. ‘The widest thickness determines the pump end clearance. SERVICE LIMIT: 0.12 mm (0.005 in) Measure the tip clearance between the inner and outer A rotors SERVICE LIMIT: 0.20 mm (0.008 in) ~ Oe es oN ~ 2 Ol PUMP BODY 8LUBRICATION Measure the clearance between the outer rotor A and the pump A body. ‘SERVICE LIMIT: 0.25 mm (0.010 in) Measure the end clearance of pump A. SERVICE LIMIT: 0.12 mm (0.005 in) CHECK VALVE Remove the cotter pin, washer, spring and check valve from the check valve housing, Inspect the valve and check valve bore for scoring or contami- nation, Clean, or replace, as necessary. (1) COTTER PIN WEF) cHeck vanve HOUSING aa 12) CHECK Val WASHER, (5) COTTER Pins 2-10LUBRICATION ASSEMBLY (7) OlL PUMP BODY B (6) OUTER ROTOR 8 (4) CHECK VALVE HOUSING i nant (5) INNER ROTOR B 8 mm thick (3) INNER ROTOR A 6 mm thick (2) OUTER ROTOR A 6 mm thick (1) OIL PUMP BODY A (8) Ol PUMP SHAFT ‘e Install the check valve, spring, and washer with @ new cotter = we - 1) CHECK VALWE io : < (1) CHECK VALVE HOUSING (2) PUMP SHAFT Install the inner and outer rotor As into the oil pump body A. ~ / CAUTION + The inner and outer rotor As are thinner than the rotor Bs. Do not interchange the rotors A and B when assembling. Press the lock pin in the pump shaft, then slip the pump shaft into place. Install the check valve housing. aA 13) LOCK PIN (6) OUTER ROTOR AQia) INNER ROTOR A MMLUBRICATION Press the second lock pin in the pump shaft. Install the inner rotor B aligning the cutout in the inner rotor with the lock pin. Install the outer rotor B, dowel pins and oil pump body B. Tighten the two oil pump screws. INSTALLATION Install the orifice and a new 0-1 1g onto the right crankcase. {Install the oil pump and tighten the oil pump bolts. Before installing the oil pump, pour the clean engine oil into the oil pass hole in the oil pump body B until the oil flows ‘out of the oil pass hole in the check valve housing side as turning the pump shaft counterclockwise. 1) INNER ROTOR 8 (2) SECOND. LOCK PIN (1) O1L PUMP BODY 8 (2) DOWEL PINS. { J | ah * (2) O-RING 1) SHAFT 2 T o B) ou (5) PUMP BODY B (6) INTO (4) CHECK VALVE HOUSING 2-12LUBRICATION Coat the new O-rings with engine oil and install them on the oil pipe. Install the oil pipe. Tighten the oil pipe bolt and nut. Install the oll pump driven gear over the oll pump shaft. Install the clutch (page 8-7), NOTE After installation, support the motorcycle upright on firm, level ground and start the engine and let it idle for a minute. Loosen the oil pipe bolt on the right crankcase cover and check that the oil flows out. Tighten the oil pipe bolt to the specified torque. TORQUE: 12 N-m (1.2 kg-m, 9 ft-lb) j 11) OIL PUMP DRIVEN GEAR (1) OUL PIPE BOLT (2) OIL FILTER COVER 2-13LUBRICATION LUBRICATION POINTS Unless otherwise specitied, use general purpose grease. Apply oil or grease to any other sliding surfaces not shown here. CONTROL CABLE LUBRICATION Periodically disconnect the throttle and clutch cables at their upper ends. Clean the cable end mount in the throttle and clutch lever, then oil the cable ends and reinstall. It is not necessary to oil the cables: if a cable begins to bind, it must be replaced. + MULTIPURPOSE GREASE NLG1 No. 2 [MOLYBDENUM DISULFIDE ADDITIVE} Sam WHEEL BEARINGS Grease new wheel bearings and dust seals before installation. Do not reinstall used wheel bearings or seals. Apply 2 paste grease with 40% or more molybdenum disulfide to the * mark components (2, 3 and 10 below). NOTE Some sources of MoS2 paste grease with 40% or more molybdenum are: + Molykote® G-n Paste manufactured by Dow Corning, USA + Honda Moly 45 (U.S.A. only) + Rocol ASP manufactured by Rocol Limited, U.K + Rocol Paste manufactured by Sumico Lubricant, Japan: Any other manufacturer's paste grease equivalent to the above may also be used. (S) THROTTLE CABLE ROLLAR sy (2) THROTTLE GRIP 8 1)" REAR SHOCK ABsORBOR \ Uppen MOUNT SPHERICAL BEARING:DUST SEALS. ‘SAE #80 0R #80 * GEAR OIL ~ DRIVE CHAIN SH (11) HEEL BEARINGS — DUST Seals. aan" 19 BUST SEALS/COLLARS (OISIDE STAN! PIvoT ‘SHOCK ARM PIVOT NEEDLE BEARINGS ‘SHOCK LINK PIVOT NEEDLE BEARING! (a) BRAKE PEDAL (#)SRAREICLUTCH LEVER PIVOT BOLTS STEERING HEAD, BEARINGS BOTTOM SEAL (6) TRIPMETER GEARY (7) SWINGARM PIVOTIDUST SEALSICOLLARI NEEDLE BEARINGS \ a vor 2-14MAINTENANCE ‘SERVICE INFORMATION 3-1 MAINTENANCE SCHEDULE 3-3. DRIVECHAIN 3.10 COMPETITION MAINTENANCE BRAKE FLUID 3-12 eee 34 BRAKE SHOE/PAD WEAR 3-12 Ignition timing tnitial Full advance Spark plug Spark plug gap Valve clearance IN ex Idle speed Cylinder compression : Decompressor effected Decompressor not effected Manual decompressor lever free play 6° BTDC at 1,300 = 250 min" (rpm) (F mark) 31° 2° BTDC at 4,000 min" (rpm) ‘Standard For extended high speed riding DPRBEA-9 (NGK} X24EPR-US (ND) DPR9EA-9 (NGK) X27EPR-US (ND) 0.80.9 mm (0.03—0.04 in) 0.10 mm (0.004 in} 0.12 mm (0.005 in} 1,300 = 100 min" (rpm) 500 + 100 kPa (5 + 1 kg/cmé, 71.1 + 14.2 psi) 1,400 + 100 kPa (14 1 kg/cm®, 200 + 14.2 psi) 5-8 mm (3/16—5/16 in)MAINTENANCE Front brake lever free play Throttle grip free play Front fork air pressure Rear brake pedal free play Clutch lever free play Drive chain slack Tire pressure Front Rear Tire size Front Rear Tire tread depth TORQUE VALUES Rear axle nut ‘Spoke nipple Rim lock Valve adjusting screw lock nut TOOLS ‘Common Wrench ,10 x 12 mm Adjusting wrench A Special Compression gauge attachment 0.8—8 mm (0.02—0.3 in) 2-6 mm (1/8—1/4 in) 0 kPa (0 kg/em?, 0 psi) 20~30 mm (3/4—1-1/4 in} 10-20 mm (3/8—3/4 in) 35—45 mm (1-3/8—1-3/4 in) 15 psi (100 kPa, 1.0 kg/cm’) 15 psi (100 kPa, 1.0 kg/em) 80/100—21 51M. 110/100—18 64M 3: mm (1/8 in) Min, 95 Nem (9.5 kg-m, 69 ft-lb) 4.Nem (0.4 kg-m, 3 ft-lb) 13 Nem (1.3 kgm, 9 ft-lb) 25 Nem (2.6 kg-m, 18 ft-lb) 07708 -0030200 Bre a0 200 or valve acusting wrench 078083230000 07908—Kk60000 3-2MAINTENANCE MAINTENANCE SCHEDULE REGULAR MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner's Manual at every maintenance period. Is INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY : CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE BREAK REGULAR SEAVICE FREQUENCY MAINTENANCE SeINTERVAL Fst week of Every 30 REFER rem operation operating days To every _| (about 200 mi, 350 km | (about 1000 mi, 1600 km) | PAGE + | FUEL LINE ' 35 +) FUEL STRAINER SCREEN 7 c 26 * | THROTTLE OPERATION 35 TAR CLEANER NOTE c ps6 [SPARK PLUG t 37 + | VALVE CLEARANCE - tt 1 “37 [ENGINE O1L _ A R 22 ENGINE OIL FILTER = a 23 ENGINE OIL STRAINER SCREEN ¢ oe IN DOWN TUBE | = | MANUAL DECOMPRESSOR ; ae LEVER * | CARBURETOR IDLE SPEED _ 1 39 I bevery 10 DRIVE CHAIN NoTE 1 ue operating days 310 {about 300 mi, 500 km) DRIVE CHAIN SLIDER 1 a BRAKE FLUID NOTE 2 _ 1 312 _| |_| BRAKE SHOE/PAD WEAR - i 312 [ Brake system 1 313 * | HEADLIGHT AIM Z ! 314 cLuTcH svsTem t rp ea SIDE STAND 1 315 = [ SUSPENSION _ ut 3:15 + [ NUTS, BOLTS, FASTENERS t 1 317, =| WHEELS TYRES 1 1 317 ==] STEERING HEAD BEARINGS 1 1 3.17 + SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS THE PROPER TOOLS AND IS MECHANICALLY QUALIFIED. ‘++ IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTE: 1. Service more frequently when riding in wet or dusty conditions. 2. Replace every 2 years. Replacement requires mechanical skillMAINTENANCE COMPETITION MAINTENANCE SCHEDULE Check all items before each race. Refer to the REGULAR MAINTENANCE SCHEDULE (page 3-3) for regular inon-competition use) service intervals. TEMS INSPECT FOR ‘ACTION AS REQUIRED | REFER TO PAGE ‘ALL PRE-RIDE INSPECTION ITEMS NOTE 2 ENGINE OIL __| Contamination Change 22 FUEL LINE Deterioration, damage or leakage | Replace 35 | VALVE CLEARANCE Correct clearance Adjust a7 CARBURETOR IDLE SPEED Correct idle speed Adjust 39 CARBURETOR CHOKE [Proper operation _ — 33 MANUAL DECOMPRESSOR MECHANICS Proper tae play Adjust 38 CLUTCH DISCS Proper operation see NOTE 1 Replace AIR CLEANER ELEMENT ___| Contamination or tears Clean or replace arena Tightness, proper heat range, and | Tighten, replace or AA | high tension terminal security secure Z ‘STEERING HEAD ee ee eee Adjust or tighten 347 steering stem nut tightness. ‘Smooth operation, no oil leaks, FRONT SUSPENSION ‘good boot condition, air pressure | Replace or adjust 315 | and oil volume ‘Smooth operation, oil leaks and REAR SUSPENSION ; ean Replace or adjust 315 ‘SWINGARM BEARINGS ‘Smooth operation. : Replace 3:16 REAR SUSPENSION LINKAGE REARINGE! Wear Replace | 346 BRAKE SHOES/PADS ‘Wear beyond service limit Replace [32 . Length: | DRIVE CHAIN: MAX, LENGTHIPINS | 4720 mm (70.0 ini/111 pins max, _| Replace 3410 ‘SPROCKETS Wear and secure installation Replace or tighten 31 SEAT Security Tighten 16-2 HEADLIGHT Proper beam aim Adjust 314 ‘Smooth operation, kinks and cor- 214 ‘CONTROL CABLES Saeainioa Lubricate or replace oan ENGINE MOUNTING BOLTS Tightness: Tighten 56 NOTE 1: Competition use necessitates more frequent service. NOTE 2: Refer to the Owner's Manual PRE-RIDE INSPECTION. 3-4MAINTENANCE FUEL LINE Check the fuel line and replace any cracked, damaged or leak- ing parts. STRAINER SCREEN) FUEL STRAINER SCREEN peeeeriay (2 Turn the fuel valve to OFF and disconnect the fuel line at the carburetor. Tun the fuel valve to ON then RES, and drain the fuel into a clean container. = ~ + Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. Remove the two bolts attaching the fuel valve to the fuel tank then remove the fuel filter. Clean the fuel strainer screen. Make sure the O-ring is in good condition and install the fuel valve. Tighten the bolts securely and reconnect the fuel line After filing the fuel tank, check for leaks. THROTTLE GRIP FRE PLAY: 26 mm (1/8—1/4 THROTTLE OPERATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. Make sure there is no deterioration, damage, or kinking in the throttle cables, and that the throttle grip free play is 2—6 mm (1/8—1/4 in) at the throttle grip flange. Throttle grip free play can be adjusted at either end of the throttle cable. Replace any damaged parts before beginning this adjustment, Minor adjustments are made with the upper adjuster. ‘Adjust free play by loosening the lock nut and turning the ad- juster after sliding the rubber cover off, Tighten the lock nut and recheck throttle operation. (2) ADJUSTER (3) LOCK NUMAINTENANCE Major adjustments are made with the lower adjuster on the carburetor. Remove the.seat. ‘Turm the fuel valve to OFF, disconnect the fuel line and remove the fuel tank, ‘Adjust free play by loosening the lock nut and turning the ad- juster. Tighten the lock nut. Recheck throttle operation. Replace any damaged parts. Install the fuel tank and seat. AIR CLEANER Unhook the three fasteners and remove the frame left side cover. NOTE + If the inlet duct cap is attached, remove the seat and inlet duct cap. Release the air cleaner element clamp and remove the element with the holder. Soparate the element from the holder. Wash the element in non-flammable or high flash point sol- vent, and let it dry. Soak the element in gear oll (SAE #80—90) and squeeze out the excess. Install the removed parts in the reverse order of disassembly. (2) ADJUSTER FLEMENT CLAMP (5) - &5,. = a 2 WASH IN SQUEEZE OUT Gear on SQUEEZE SOLVENT SOLVENT — (SAE #80— OUT. THOROUGHLY ‘90) EXCESS OIL|MAINTENANCE SPARK PLUG Disconnect the spark plug cap and remove the spark plug. 0.8-0.9 mm (0.03~0.04 in) Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. Measure the spark plug gap with a wire-type feeler gauge. Adjust the gap by bending the side electrode carefully. ‘SPARK PLUG GAP: 0.8—0.9 mm (0.03—0.04 in) RECOMMENDED SPARK PLUG: Standard X24EPR-UD (ND) L DPR8EA-9 (NGK) For extended high X27EPR-U9 (ND) speed fae DPROEA.9 (NGK) Ti) Tag WOLF cara eo Make sure the ling washer is in good condition. Install the spark plug, tighten it by hand, then use a spark plug wrench for the final tightening. Connect the spark plug cay VALVE CLEARANCE NOTE + Inspect and adjust valve clearance while the engine is cold (below 35°C/95°F). + Make sure the decompressor valve lifters have some free play during this maintenance. Remove the seat. Turn the fuel valve to OFF, remove the tank. lisconnect the fuel line, and Remove the crankshaft and timing hole caps. Remove the valve adjuster covers. Rotate the flywheel counterclockwise to align the ‘’T"’ mark is a4 with the cutout on the left crankcase cover. 4 ow Make sure the piston is at TDC (Top Dead Center) on the com- 11 FEELER GAUGE © ee pression stroke Check the clearance of the left exhaust, and left and right intake valves by insorting a feeler gauge between the adjusting screw and the sub-rocker arm. NOTE + When checking the clearance, slide the feeler gauge from the inside out in the direction of the arrow. . VALVE CLEARANCE: Intad 0.10 mm (0.004 in) Left Exheust: 0.12 mm (0.005 in) 3-7MAINTENANCE Adjust by loosening the lock nut and turning the adjusting (]} ADJUSTING WHENCH A] screw until there is a slight drag on the feeler gauge. ey Hold the adjusting screw and tighten the lock nut. ¢ Toots: WRENCH, 10 x 12 mm 07708-0030200 ADJUSTING WRENCH A 07708-0030300 VALVE ADJUSTING WRENCH 07908~3230000 TORQUE: 25 Nem (2.5 kg-m, 18 ftb) (4) WRENCH, 10.x12mm (3) LOCK NUT Adjust the manual decompressor free play. IGHT EXHAUST VALVE Tajcorour Right exhaust valve: NOTE + Special care must be taken when measuring valve clear- ance at right-hand, exhaust valve. As the Half-decompressor cam slightly lifts the right-hand, ‘exhaust valve when the crankshaft position is before com- pression TDC, correct valve clearance cannot be obtained if, the crankshaft is positioned at this range. Therefore it is necessary to position the crankshaft where there is no valve lift in order to obtain correct valve clearance. CAUTION + (Fit passed the “T” mark (aligning mark), rotate the crank- Shaft counterclockwise again and align it with the “T?” mark. This should be made to prevent the one-way decompressor system from functioning and to obtain the correct valve clear- Adjust the manual decompressor free play. DECOMPRESSION SYSTEM MANUAL. 5-8 mm (3/16-5/16 in) NOTE + Always adjust the manual decompressor linkage after ad- justing the valve clearance (page 3-7). Measure the free play at the tip of the manual decompressor lever. FREE PLAY: 5—8 mm (3/16—5/16 in) ‘Adjust by turning the manusl decompressor adjuster at the gine. After adjusting, tighten the lock nut. Recheck free play at the lever. 3-8MAINTENANCE CARBURETOR IDLE SPEED NOTE * Inspect and adjust the idle speed after all other engine ad- justments are within specifications. + The engine must be warm for accurate idle inspection and adjustment, Ten minutes of stop and go riding is sufficient. Warm up the engine, shift to NEUTRAL, and hold the motor- cycle upright. Connect a tachometer. ‘Turn the throttle stop screw to obtain the specified idle speed. IDLE SPEED: 1,300 + 100 mint (rpm) CARBURETOR CHOKE Check choke lever operation. If the choke lever moves stiffly, clean and lubricate the pivot. After cleaning, recheck the lev- er’s movement. CYLINDER COMPRESSION ‘Warm up the engine. ‘Stop the engine and remove the spark plug. Connect a compression gauge. Open the throttle grip all the way. Operate the kick starter pedal several times and check the gauge reading. NOTE ‘+ Check that there is no leakage at the gauge connection. TOOL: COMPRESSION GAUGE ATTACHMENT 07908—KK60000 UILTHROTTLE sTop screw (1) CHOKE LEVER, é&q") COMPRESSON COMPRESSION (DECOMPRESSOR EFFECTED): Sauce 500 + 100 kPa (5 + 1 kglcm?, 71.1 + 14.2 psi) at 20°C/ 68°F High compression can be caused by + Incorrect vavie clearance + Faulty decompressor If the compression is below than the standard, loosen the right exhaust valve locknut and turn the adjusting screw with care 80 that the valve does not interfere with decompressor cam. Operate the kick starter pedal several times again. NOTE * Before measuring the compression, broaden the right ex- hhaust valve clearance to at least 0.82 mm (correct clear- ance 0.12 mm + 0.7 mm) to release the half decompressor system. COMPRESSION: 1,400 + 100 kPa (14 + 1 kglem?, 200 + 14.2 psi) at 20°C/ 68°F Low compression can be caused by: + Improper valve adjustment + Valve leakage + Leaking cylinder head gasket + Worn piston ring or cylinder Disconnect the compression gauge. ‘Adjust 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 nut. 3-9MAINTENANCE DRIVE CHAIN Turn the engine off. Raise the rear whee! off the ground by placing @ work stand or box under the engine. Shift the trans- mission into neutral. a Measure the slack in the higher drive chain run midway be- tween the sprockets. ii SLACK: 3545 mm (1-3/8—1.3/4 in) STANDARD SLACK: 35—45 mm (1-3/8—1-3/4 in) Adjust as follows: Loosen the rear axle nut and chain adjuster holder nuts, then turn both adjusters equally until the chain slack is correct. CAUTION + Be sure the same adjuster index marks align with the stopper pins on both sides of the swingarm. Tighten the axle nut. TORQUE: 95 Nem (9.5 kg-m, 69 ft-lb) Tighten the chain adjuster holder nuts on both sides. Recheck chain slack and free wheel rotation. When the drive chain becomes extremely dirty, it should be re- moved and cleaned prior to lubrication. Remove the drive’ sprocket cover. Remove the chain retainer clip carefully. Remove the master link and remove the drive chain. é CAUTION + Be careful not to lose the O-rings when the clip and master link are removed. Clean the drive chain with a non-flammable or high flash point solvent that will not damage the O-rings and wipe dry. caUTION x + Do not use a steam cleaner or high pressure washers as these {11 KEROSENE wil damage the O-rings (2) WIPE DRY : age 3 nh Ea ae 90 cocscacKS OR SAE #80 (3) LUBRICATE eae 3-10MAINTENANCE Inspect the drive chain and O-rings for possible wear or dam- age. Replace the chain, if it is worn excessively or damaged. Measure the drive chain length with the chain held so that all links ace straight. 111 PINS LENGTH: STANDARD: 1,762 mm (69.4 in) SERVICE LIMIT: 1,780 mm (70.0 in) Lubricate the drive chain with SAE #80 or SAE #90 gear oil Inspect the sprocket teeth for excessive wear or damage. Replace if necessary. NOTE + Never install a new drive chain on worn sprockets or a worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly. Install a new drive chain. Install the master link with O-rings and chain retaining clip. Install the drive sprocket cover. Adjust the drive chain (page 3-10). CAUTION + Do not assemble the drive chain without the four master link O-rings. + Be sure that there is no space between the master link and the ‘chain retainer elip. CHAIN SLIDER/SLIPPER/GUIDE SLIDER Check the chain slider for wear. CAUTION + If the chain slider becomes worn down to the swingarm, the chain will begin 10 wear against the swingarm, Inspect the chain slipper and replace it if the depth of the chain groove leaves less material than specified. SERVICE LIMIT: 2 mm (0.08 in) (1) SERVICE LIMIT: 1,780 mm (70.0 in) (2) Measure a span of 111 pins x | carmean x / (1) DAMAGE | 4 ° (3) NORMAL, (1) MASTER LINK F (2) (wo spacey / 5) OUT oe (3) CHAIN RETAINER CLIP (4) O-RINGS: (1) CHAIN SLIDER (2) CHAIN SLIPPER 3-11MAINTENANCE Inspect the chain guide slider for wear and replace it if you can see the chain through the wear limit opening. BRAKE FLUID Check the front brake fluid reservoir level. If the level is near the lower level mark, remove the cover and diaphragm. Fill the reservoir with DOT-4 Brake Fluid, CAUTION + Donor remove the cover until the handlebar has been turned so that the reservoir is level + Avoid operating the brake lever with the cap removed. Brake fiuid will squirt out if the lever is pulled. + Do not allow dirt or other contaminants to get into the reser- If the level was low, check the entire system for leaks. Rofer to section 14 for the brake bleeding procedure. Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. BRAKE SHOE/PAD WEAR BRAKE PAD WEAR Check the brake pads for wear Replace the brake pads if the wear line on the pads reaches the ledge of the brake disc (page 14-5), CAUTION + Always replace the brake pads as a set to ensure even dise pres- BRAKE SHOE WEAR Replace the brake shoes if the arrow on the brake arm aligns with the ““A” reference mark on the brake panel when the brake is applied. (1) WEAR LINES, 3-12MAINTENANCE BRAKE SYSTEM FRONT BRAKE LEVER FREE PLAY Measure the front brake lever fr play at the tip of the lever. FREE PLAY: 0. 8.0 mm (0.02—0.3 in) To increase free play, loosen the lock nut and turn the adjuster counterclockwise. To decrease free play, turn the adjuster clockwise. If the brake lever free play exceeds 8 mm (0.3 in} and the clear- ance between the adjuster and the frant brake master cylinder piston ("A") is less than 1.4 mm (0.06 in), there is probably ait in the brake system and it must be bled (page 14-3}. + Never use any adjusters other than those designed for this ‘motorcycle. Install a new adjuster from the lever side with the Jock nut under the head of the adjuster. BRAKE PEDAL HEIGHT To adjust: Loosen the lock nut and adjust the pedal height by turning the stopper bolt. Tighten the lock nut. Adjust the brake pedal free play. BRAKE PEDAL FREE PLAY NOTE + Adjust the brake pedal free play after adjusting the brake pedal height, Measure the brake pedal free play. FREE PLAY: 20—30 mm (3/4—1-1/4 in} If adjustment is necessary, turn the rear brake adjusting nut. (1) PISTON (2) ADJUSTERMAINTENANCE HEADLIGHT AIM Bmodel) || (Wimode {8 model) ‘Adjust the vertical beam by turning the headlight mounting bolts (U model) Adjust the vertical beam by turning the adjusting screw on the headlight cover. ADJUSTING SCREW CLUTCH Measure the clutch free play at the lever end. FREE PLAY: 10-20 mm (3/8—3/4 in) Adjust as follows: (1) LOCK NUT i2) AbuUSTER Minor adjustments are made with the upper adjuster. 4H Pull the cover back. Loosen the lock nut and turn the adjuter. Tighten the lock nut and install the cover. ry Major adjustments are made with the lower adjuster. |f major adjustment is required, turn the upper adjuster all the way in and back out 1 turn, Loosen the lower lock nut and turn the adjusting nut, Tighten the lock nuts. Check the clutch operation. 3-14MAINTENANCE SIDE STAND Check the side stand spring for damage and/or loss of tension. Check that the side stand assembly is not bent and that it moves freely. Tighten the pivot bolt if necessary TORQUE: 40 N-m (4.0 kg-m, 29 ftb) SUSPENSION FRONT Check the action of the fork by compressing the suspension several times. Check the entire fork assembly for signs of leaks or damage. Replace any components which are unrepairable, Torque all nuts and bolts. ow + Do not ride a vehicle with faulty suspension. Loose, worn, or damaged suspension parts may affect stability and rider con- tol. Check the fork air pressure when the fork is cold. Lift the front wheel off the ground by placing a work stand or box under the engine. Remove each air valve cap and measure the air pressure. STANDARD AIR PRESSURE: 0 kPa (0 kg/cm’, 0 psi) For air pressure adjustment, see the Owner's Manual REAR Place the motorcycle on a work stand or box to raise the rear wheel off the ground. Move the rear wheel sideways with force to see if the swing arm bearings or wheel bearings are worn. Replace if excesively worn. Check the entire rear suspension to be sure everything is se- curely mounted and not damaged or distorted. Torque all nuts and bolts. 3-15MAINTENANCE Bounce the rear of the motorcycle up and down to check for proper operation. Check the entire rear suspension to be sure everything is se- curely mounted and not damaged or distorted. Torque all nuts and bolts to their specified values (pages 1-5 and 3-2), Pump grease into the swingarm, pivot bearings through the ‘grease fitting on the swingarm. Grease the linkage bushings through the grease fittings on the linkage pivots. (1) GREASE FITTINGS SPARK ARRESTER CLEANING Remove the muffler lid. Start the engine and increase rpm to blow carbon out of the exhaust pipe while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel. Repeat until carbon stops coming out. WM + Do not perform this operation while the exhaust sytem Is hot - Perform this operation in a well-ventilated area, free from fire hazards. Use adequate eye protection. "i = (1) GASKET (2) MUFFLER LID) After cleaning the spark arrester, install the muffler lid and gasket and tighten the bolts. Be sure that the muffler lid and gasket are in good condition CAUTION Be sure that the spark arrester screws are securely in place, 3-16NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their cor- rect torque values (section 1) at the intervals shown in the ‘ Maintenence Schedule (pages 3-3, and 3-4). e - Check all cotter pins, safety clips, hose clamps and cable : stays. * EEL SEOKES FT SPOKE NIPPLE WRENCH Mar) TIRE PRESSURE 5.8 x 6.1 mm x is NOTE ~ ‘The pressure should be che Tire pressure: Front: 15 psi (100 kPa, 1.0 kg/em’) Rear: 15 psi (100 kPa, 1.0 kg/cm?) Tire size: B model U model ] Front | 80/100-2151M | 3.00—21—4PR_|/ Rear | 110/100-1864M | 4.50—18—4PR Check the tires for cuts, embedded nails or other sharp ob- — jects. Check the tire cleat depth. SERVICE LIMIT: imum (1/8 in) Tighten the wheel spokes and rim lock. ‘TORQUE VALUES: ‘SPOKE NIPPLE: 4 Nem (0.4 kg-m, 3 ft-lb) RIM LOCK: 13.Nem (1.3 kg-m, 9 ftlb) STEERING HEAD BEARINGS Raise the front wheel off the ground and check that the | handlebar rotates freely. Check that the control cables do not interfere with handlebar rotation. if the handlebar moves une- venly, binds, or has vertical movement, adjust the steering | head adjusting nut (page 12-21). 3-17FUEL SYSTEM 4-0FUEL SYSTEM ‘SERVICE INFORMATION 41 CARBURETOR DISASSEMBLY 47 ‘TROUBLESHOOTING 4-2 CARBURETOR ASSEMBLY 410 FUEL TANK 4-3 CARBURETOR INSTALLATION an AIR CLEANER CASE 4-4 PILOT SCREW ADJUSTMENT 412 CRANKCASE BREATHER 4-5 TEMPERATURE AND ALTITUDE CARBURETOR REMOVAL 46 ADJUSTMENT a12 SERVICE INFORMATION GENERAL + Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. CAUTION 7 + Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. ‘© When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. ‘© The carburetor float bow! has a drain screw that can be loosened to drain residual gasoline. SPECIFICATIONS Fuel tank capacity 10 lt (2.6 U.S. gal, 2.3 imp gal) Reserve capacity 2'lt (0.5 U.S. gal, 0.4 Imp gal) Carburetor = Type Piston valve <> FUmodel Identification number PDBAA Jet needle setting 3rd groove Float level 14,5 mm (0.87 in) Pilot screw opening 2.5/8 turns out Main jet #165 ¢#135> #60 1,300 100 min (rpm) 390 mm Hg Throttle grip free play 2=6 mm (1/8—1/4 in) TOOL Common Float level gauge (074010010000 44TROUBLESHOOTING Engine Cranks But Won't Start + No fuel in tank + No fuel to cylinder + Too much fuel getting to cylinder + No spark at plug (ignition malfunction} + Air cleaner clogged + Decompressor malfunction Engine Idles Roughly, Stalls, or Runs Poorly + Idle speed incorrect + Ignition malfunction + Low compression (Section 3) + Rich mixture + Lean mixture + Air cleaner clogged + Air leaking into manifold + Fuel contaminated + Decompressor does not operate Lean Mixture + Carburetor fuel jets clogged + Fuel cap vent blocked + Fuel filter clogged + Fuel ine kinked oF restricted + Float valve faulty + Float level too low Rich Mixture + Choke stuck closed + Float valve faulty + Float level too high + Carburetor air jets clogged + Sticking float + Dirty air cleaner FUEL SYSTEM 4-2FUEL SYSTEM FUEL TANK ci gour (2) TANK BAND 4 FUEL TANK REMOVAL Remove the seat. ‘Tum the fuel valve to OFF and disconnect the fuel line. Remove the tank band, bolts and tank, = + Keep gasoline away from flames or sparks. + Wipe up spilted gasoline at once. Check that fuel flows out of the fuel valve freely. If flow is restricted, clean the fuel strainer (page 3-5). FUEL TANK INSTALLATION Install the fuel tank with the two mounting bolts and tank band. Connect the fuel tube. NOTE + After assembling, make sure there are no fuel leaks. + Do not overtighten the fuel valve screws. Install the seat. SEAT INSTALLATION Be sure to hook the seat onto the fuel tank and frame, as shown. (7) FUEL TANK CAP. {8) FUEL TANK CAP PACKING (9) TANK BAND (10) FUEL COCK (1) FUEL TANK (2) TANK SETTING. 5 mrsaantne oP gy om RUBBER Meo . ae (4) TANK PLATE’ (5) RUBBER A 43FUEL SYSTEM. AIR CLEANER CASE 1) SEAT REMOVAL Remove the seat and side covers. Remove the mud guard mounting bolts and the mud guard. Unfasten the wire bands on the air cleaner case. | Remove the duct from the air clearner. (U model only). (1) DUCT m2) BOLTS Loosen the air cleaner connecting tube clamps. Weal Remove the air cleaner mounting bolts then remove the air (1008s ‘cleaner from the left side. (a) CONNECTING TUBE CLAMP 4-4FUEL SYSTEM INSTALLATION Install the air cleaner in the reverse order of removal. (1) Duct CaP (U model only) (2) AIR CLEANER ELEMENT A caner (5) COVER SEAL 7 (6) AIR, (4) ELEMENT SETTING (7) CARBURETOR wy TATE] INSULATOR BAND CRANKCASE BREATHER Route the crankcase breather tube as shown. (1) CRANKCASE BREATHERFUEL SYSTEM CARBURETOR REMOVAL SIDE COVER Remove the seat and fuel tank. Remove the side covers. Loosen the carburetor clamps. Loosen the drain screw and drain the fuel into a suitable con- tainer. Wm + Keep gasoline away from flames or sparks, wipe up spilled gas- line at once. Pull the carburetor away from the engine through the right side. Disconnect the throttle cables and remove the carburetor.FUEL SYSTEM CARBURETOR DISASSEMBLY FLOAT, FLOAT VALVE, AND JETS H SCREWS: Remove the overflow tube, drain tube and air vent tube. Remove the three float chamber screws and the float cham- ber. Measure the float level with the float tang just contacting the float vaive. Tool: FLOAT LEVEL GAUGE 074010010000 a ‘SPECIFICATION: 14.5 mm (0.57 in) Adjust the float level by carefully bending the float tang. (1) FLOAT. Remove the float pin, float and float valve. A UELOAT (2) FLOAT VALVE (3) FLOAT PIN. (1) FLOAT VALVE Inspect the flost valve and its seat for grooves, nicks, or con- tamination. Inspect the operation of the float valve. Check the float for deformation and the presence of fuel.FUEL SYSTEM Remove the main jet, needle jet holder, edlejetandsiow jet. (4) por (2) SLOW (3) MAIN JET SCREW JET Turn the pilot screw in and carefully count the number of turns it seats lightly. Make a note of this to use as o reference installing the pilot screw. CAUTION + Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. Remove the pilot screw and inspect it. Replace i itis worn or is) NEEDLE » damaged. SET (4) NEEDLE Hower Jer Check each part for wear or damage. Blow open all jets with compressed air. 5 (i) NEEDLE JET FLOAT CHAMBER ASSEMBLY ,; (4.\_ (2) NEEDLE JET HOLDER ‘Assemble the float chamber components in the reverse order of disassembly i“ (3) MAIN Jet ~~ (5) PLOT SCREW (4) SLOW JeT THROTTLE VALVE (1) SCREWS Remove the two screws attaching the carburetor top cover, land the body. (1) SCREW (2) THROTTLE Remove the link arm set screw, the throttle drum assembly, Teaine the plastic washer and throttle valve assembly from the throt- tle bore. 14) PLASTIC WASHER Se 2) THROTTLE VALVEFUEL SYSTEM. Remove the two screws attaching the link arm to the throttle 1? SCREWS. valve and separate the link arm from the throttle valve. ‘ . 12) LINK ARM ae Remove the jet needle set spring and jet needle (1) THROTTLE VALVE (3) JET NEEDLE CLIP Check the throttle valve and jet needle for wear, nicks or other damage. Assemble the throtle valve in the reverse order of disassem- by. Nore ea a, Gy + Install the jet needle clip on the jet needle (2) JeT NEEDLE ts STANDARD: 3rd groove ° + Align the hole in the link arm with the threaded hole in the link arm shat and install the set screw PI CUTORRVALYE (1) CHOKE LEVER (2) SETTING PLATE (3) SCREW Remove the choke lever setting plate and the lever. Remove the two screws attaching the air cut-off valve cover ‘and the cover. 4-9FUEL SYSTEM (1) DiapHRaGN Remove the spring, diaphragm and O-ring e Check the diaphragm for pin holes or other damage, 2) SPF Assemble the air cut-off valve in the reverse order of disas- PNG sembly. - \ [sso * Install the O-ring with its flat side toward the carburetor i body. a CARBURETOR ASSEMBLY Blow open all passages with compressed air before installing jets and valves. Reassemble the carburetor in the reverse order of diassembly.FUEL SYSTEM Install the O-ring securely. Install the new cover gasket and cover and tighten the screws securely. Inspect throttle operation as described below: + Open the throttle slightly by pressing on the throttle link- ‘age. Then release the throttle. + Make sure that there is no drag when opening and closing the throttle. Connect the tubes as shown. CARBURETOR INSTALLATION Properly (page 1-10). Perform the following inspections and adjustments. + Throttle operation (page 3-5I. + Idle speed (page 3-9). 12) GASKET 1) O-RING ‘ He Coverl 4-11FUEL SYSTEM PILOT SCREW ADJUSTMENT Turn the pilot screw clockwise until it seats lightly and then back it out to the specification. INITIAL OPENING: 2-5/8 turns out CAUTION + Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. ‘Warm the engine up to operating temperature. Stop the engine and connect a tachometer. Startthe engine and adjust the idle speed to 1,300 + 100 min"! (rpm) with the throttle stop screw. Check that the engine speed increases smoothly by turning the throttle grip. ‘Turn the air screw until the highest idle speed is obtained. Reset the idle speed to 1,300 + 100 min” (rpm) with the thro- tle stop screw. TEMPERATURE AND ALTITUDE ADJUSTMENT Use the chart on the right to determine if carburetor adjust ments are necessary because of changes in temperature and altitude. Draw a line straight up from your temperature to your altitude. Where those lines intersact, draw a horizontal line straight to ‘the left. Where that line meets the left edge of the chart is your correction factor. To adjust the main jet size, multiply the standard main jet size by your correction factor. Hf the correction factor is 0.95, or below, raise the jet needle clip by one position and turn in the pilot screw 1/2 turn. Hf the correction factor is above 0.95, adjustments to the jet needle and pilot screw are not necessary. For example: Ata temperature of 30°C (86°F) and an altitude of 3,000 m (9840 ft), carburetor recommendations are as follows: + Main jot 125 x 0.92 = 115 + Jet needle 3rd groove from top minus 1 + Pilot screw opening 21/4112 = 1-3/4 tums out 2nd groove from top Standard Carburetor Setting: retor Sorting: (1: U model Mainjet #165 (+135) Jot needle sett 3rd groove Pilot screw opening 2.5/8 tums out (1) PiLoT Screw ‘CTHROTTLE STOP SCREW Boal Lit fo | 4 e HE Po ifsc tecamssareasal (2) Temperature ALANNN her a Sai! JET NEEDLE 4-12ENGINE REMOVAL/INSTALLATION ro 27 Nem (2.7 kg-m, 20m) \ | 27 Nem (2.7 kg-m, 20 ftb) 40 Nem (4.0 kg-m, 29 ftb) 40 Nem (4.0 kg-m,” 29 ft-lb) 40 Nem (4.0 kg 29 ft-lb) oe = ~ do num 4.0 kom, 29 fb) "40 Nem (4.0 kg-m, x 29 ft-lb} ‘9. Nem (0.9 kg-m, 7 ftlb) 2) 20 ft-lb) 5-1ENGINE REMOVAL/INSTALLATION ‘SERVICE INFORMATION 5-2 ENGINE INSTALLATION 5-6 ENGINE REMOVAL 5-3 SERVICE INFORMATION GENERAL ‘© During removal and installation, support the motorcycle with a work stand or box. © A jack or adjustable support is required to maneuver the engine. © Parts requiring engine removal for servicing: Crankshaft Section 10 Balancer Section 10 Transmission Section 11 SPECIFICATIONS Engine weight 43.5 kg (96.0 Ib) Oil capacity 2.3 lit (2.4 U.S. qt, 2.0 Imp qt) TORQUE VALUES Engine hanger bolts: 8 mm bolt 27 Nem (2.7 kg-m, 20 ft-lb) 10 mm bolt 40 Nem (4.0 kg-m, 29 ft-lb) Foot peg nut 27 Nem (2.7 kg-m, 20 ft-lb) Exhaust pipe clamp 27 Nem (2.7 kg-m, 20 ft-lb) Exhaust pipe joint nut 27 Nem (2.7 kg-m, 20 ft-lb) Rear axle nut 95 Nem (9.5 kg-m, 69 ft-lb) Oil hose joint nut 40 Nem (4.0 kg-m, 29 ft-lb) Oil pipe flare nut 40 Nem (4.0 kg-m, 29 ft-b} 5-2ENGINE REMOVAL) ENGINE REMOVAL Drain the oil from the engine and cil tank (page 2-21. Remove the following: — seat and fuel tank. = side covers. — engine skid pipe. — kick starter arm. — right foot peg. — brake pedal — exhaust pipe. ISTALLATION (4) FOOT PEG (3) BRAKE PEDAL (2) ENGINE SKID PIPE Disconnect the alternator connectors. (1) ALTERNATOR CONNECTORS 7 Remove the carburetor (page 4-6). Disconnect the clutch cable.ENGINE REMOVAL/INSTALLATION Remove the spark plug cap. Disconncet the oll tank breather tube at the cylinder head. Disconnect the manual decompressor cable from the valve lifter lever. Disconnect the pulse generator wire coupler. Remove the drive sprocket cover and drive chain protector. Loosen the rear axle nut and turn the drive chain adjusters to loosen the chain Remove the drive sprocket and the drive chain. Disconnect the crankcase breather hose from the crankcase (1) OIL TANK BREATHER, Tey LSP ARK PLUG CA aENGINE REMOVAL/INSTALLATION Loosen the oil inlet hose and outlet pipe joint nuts. - Disconnect the oil outlet pipe and hose and the oil inlet hose, [bmao!NT. NUT Ro or from the frame. Loosen the oil inlet and outlet hose set plate bolts, Remove the oil pipe clamp and oil pipe. Remove the rear engine bracket. Remove the upper and front engine brackets. Remove the front and rear engine hanger bolts. Remove the engine from the right side. = (| (@LERONT ENGINE BRACKET) 5-5ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION j SF (Ta rm BOLTS™ following: Replace any damaged or leaking exhaust pipe gaskets. [018 mm BOLTS: ¢ Perform the following inspections and adjustiments. \ . Throttle grip free play (page 3-5) om me Check all electrical equipment. TORQUE: 8 mm BOLTS: 27 Nem (2.7 kg-m, 20 ftb) 10 mm BOLTS: 40 Nem (4.0 kg-m, 29 ft1b)CYLINDER HEAD/VALVES 10 Nem (1.0 kgm, 7 feioy 33 Nem (2.9 kgm, 17 feb) 12 Nom (1.2 kgm, 9 fb) oN 20 Nem (2.0 kg-m, 14 ft-lb)CYLINDER HEAD/VALVES SERVICE INFORMATION 6-1 VALVE SEAT INSPECTION TROUBLESHOOTING 63 ANDREFACING coe CYLINDERHEADCOVERREMOVAL 6-4 CYLINDER HEAD ASSEMBLY eis SATInER TEA BIeauen CYLINDER HEAD INSTALLATION 6-17 DISASSEMBLY 65 CAMSHAFT INSTALLATION 6-18 CAMSHAFT REMOVAL 67 CYLINDER HEAD COVER ASSEMBLY 6-19 CYLINDER HEAD REMOVAL 6-10 CYLINDER HEAD COVER CAM CHAIN TENSIONER REMOVAL —6-10._'NSTALLATION cet CYLINDER HEAD DISASSEMBLY 6-11 SERVICE INFORMATION GENERAL «This section covers maintenance of the cylinder head, valves, camshaft and rocker arm. @ Service covered in this section can be done with the engine installed in the frame, € Pour clean engine ol into the oll pockets in the cylinder head to lubricate the cam. unit: mm (in) TEM STANDARD SERVICE LIMIT Compression | Decompressor 800 + 100 kPa (5 * 1 kg/cm?, _ effected That £ 14.2 psi Decompressor does | 1400 = 100 KPa (14 2 1 kglom?, _ not effect | "200 2 14.2 psi) Camshaft | Carn it NW 34-165— 81.316 (1.2266—1.2928) | _31.05 (1.222) x 31,001—31.251 (1.2241—1.2904) | _31.0011.220) _ Runout 0.40 (0.016) Rocker am shaft OD. 11.466—11.484 (0.4514—0.4521) | _11.41 10.449) ‘Sub-rocker arm shaft | 0.0 N 7,972-7.967 (0.3137-0.9139) | __7.92 10.312) x 6.972 6.969 (0.2744-0.2745) | __6.92 (0.272) Rocker arm 1D. 11.500—11.518 (0.4528 0.4535) | _11.55 (0.455) Sub-rocker arm LD. INN) 8,000-8.015 (0.3150-0.3155) | __8.05 (0.317) __ EXIA,B) | 7.007.016 0.2756-0.2761) | __7.05 (0.277) Sub-rocker anm-to-shaft clearance 0.033=0.043 (0.0013-0.0017 | _0.08 (0.003) _| Rocker arm shaft-to-arm clearance ~0.016-0.052 (0.0006-0,0020) (0.006) Valve spring Free length | Inner 36.1 (1.240) 34.1 (1.34) Outer 36.0 (1.417) 35.0 (1.38) Preloadength | Inner 6.14204 kg (13.5 = 0.88 bY) _ 2800.1) : Outer 11.8 = 1.0 kg (26.0 = 2.21 by _ 31.5 (1.24)CYLINDER HEAD/VALVES Unit mm in ve STANDARD SERVICE MT [ave | Siemo.b. [ON “6.875 ~6.500 (0.26600.2608) | 6.56 (0.287) 6.560~6.575 0.2682 —0,2689) | 6.55 0.268) Guide 1B. [IN 6.600-~6.615 10.2698-0.2421) | 6.6310.261) | x 6.600-6.615 10.2598-0,2421) | 6.6310.261) Stem-to-guide |_IN 0.010—0.040 (0,0004—0.0016) | 0.065 (0.0026) _| clearance Ex _|_9.025-0.055 (0.0010-0.0021) 0.008 (0.0031) _| Votve face [IN 1.20 1.85 (0.087-0.07 2.6 (0.10 width EX 0.9—-1.7 (0.04—0.67) 2410.09) _| Cyngor hood Warpeoe a 0.10 0.004) Vat seat | INEX 12-146.08-008) | 2.00.08) width TORQUE VALUES Cylinder head bolt Cam sprocket bott Cylinder head cover 6 mm (SH) 6 mm bolt 8 mm bolt Rocker arm shaft Sub-rocker arm shaft IN EX Valve adjuster lock nut TOOLS Special Knock pin puller set = Slider shaft — Remover weight Valve guide reamer Cam chain tensioner holder Common Valve guide driver, 6.6 mm Valve spring compressor 36 Nem (3.6 kg-m, 26 ftlb) 20 Nem (2.0 kg-m, 14 ftb) 10 Nem (1.0 kg-m, 7 ft-b) 12 Nem (1.2 kg-m, 9 ft-lb) 23 Nem (2.3 kg-m, 17 ftlb) 28 Nem (2.8 kg-m, 20 ft-lb) 28 Nem (2.8 kgm, 20 ftlb) 23 Nem (2.3 kg-m, 17 ftb) 25 Nem (2.5 kg-m, 18 ftb) (07936 —MA70000 (07936 —MA70100 07741 -0010201 079845510000 07973-MG30003 077420010200 or 079426570100 077570010000 or 079573290001CYLINDER HEAD/VALVES TROUBLESHOOTING Engine top-end problems are usually performance-related and can usually be diagnosed by a compression test. Engine noises can usually be traced to the top-end with a sounding rod or stethoscope. Low Compre + Valve — Incorrect valve adjustment — Burned or bent valves — Incorrect vaive timing ~ Broken valve spring + Cylinder head ~ Leaking or damaged head gasket — Warped or cracked cylinder head + Cylinder and piston (Refer to Section 7) ion High Compression + Excessive carbon build-up on piston head or combus- tion chamber + Decompressor does not operate or damaged Excessive Noise + Incorrect valve adjustment + Sticking valve or broken valve spring + Damaged or worn rocker arm or camshaft + Loose or worn cam chain + Worn or damaged cam chain tensioner + Worn cam sprocket teeth Poor Idling + Compression too low + Manual decompressor out of adjustment Kick Starting Difficult + Manual decompressor out of adjustment + Decompressor does not operateCYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL Remove the seat and fuel tank (page 4-3). — oo Remove the carburetor (page 4-6). (1) CARBURETOR Disconnect the oil tank breather tube. (1) BRACKET BOUTS Mg St On TA Loosen the decompressor cable lock nut and remove the cable || SNACKE® POLTSMByis) OU Tae Snes Tien TUSK from the valve lifter lever and cable holder. Remove the oil pipe = bracket bolt, oil pipe bolts, sealing washers and oll pipe. ay oy) Bout Remove the crankshaft hole cap and timing hole cap. ‘Turn the crankshaft and align the ‘“T”" mark on the generator rotor with the index notch on the left crankcase cover at com- pression stroke. SOR CABLE Remove the three bolts attaching the insulator to the cylinder ™ head and remove the insulator. VN — = (2) BOLTS. Remove the upper hanger plate rubber cap, then remove the (HANGER PLATE RUBBER CAP hanger plate. (21 UPPER HANGER PLATECYLINDER HEAD/VALVES Remove the cylinder head cover bolts. NOTE + Loosen the bolts indicated by arrow. Remove these bolts after removing the cylinder head cover. Slide the cylinder head cover to the intake side and remove it. Remove the bolts. Remove the dowel pins and head cover gasket. CYLINDER HEAD COVER DISASSEMBLY Remove the dowel pin with the knock pin puller. Toots: KNOCK PIN PULLER SET 07936—MA70000 — SLIDER SHAFT 07936—MA70100 ~ REMOVER WEIGHT 077410010201 ' (1) KNOCK PIN PULLER SET 6-5CYLINDER HEAD/VALVES (11 gprs VALVE LIFTER LEVER Remove the valve lifter lever and spring. Remove the sub-rocker arm shafts, sealing washers, wave (1), SUB-ROCKER ARMS, washers and sub-rocker arms from the cylinder head cover. “ (2) SUE-ROCKER %. ARM SHAFT (3) SUB-ROCKER ARMS Remove the rocker arm shafts, copper washers, rocker arms eN wb Z from the eylinder hes 1) ROCKER ARMS: ROCKER ARM INSPECTION Inspect the rocker arms and the sub rocker arms for wear or damage. NOTE + Ifany rocker arms require servicing or replacement, inspect the cam lobes for scoring, chipping or flat spots. Measure the ID of the rocker arm and sub-rocker arm. SERVICE LIMITS: ROCKER ARM: 11.55 mm (0.455 in) ‘SUB-ROCKER ARM IN: 8.05 mm (0.317 in) EX: 7.05 mm (0.277 in) 6-6CYLINDER HEAD/VALVES ROCKER ARM SHAFT INSPECTION Inspect the rocker arm and sub-rocker arm shafts for wear or damage. Measure the rocker arm shaft OD. SERVICE LIMIT: 11.41 mm (0.449 in) ‘Measure the sub-rocker arm shaft OD. ‘SERVICE LIMIT: IN_7.92 mm (0.312 in) EX 6.92 mm (0.272 in} Calculate the rocker arm-to-shaft clearanc ‘SERVICE LIM : 0.14 mm (0.006 in} Calculate the sub-rocker arm-to-shaft clearance. SERVICE LIMIT: 0.08 mm (0.003 in) CAMSHAFT REMOVAL Remove the cam chain tensioner shaft screw. Sot the tensioner holder on the tensioner shaft. ‘Turn the crankshaft and remove the cam sprocket bolts. CAUTION + Be careful not to drop the bolts into the crankcase. TOOL: CAM CHAIN TENSIONER HOLDER 07973~MG30003 Pull the cam sprocket off the cam sprocket holder shoulder ‘and remove the cam chain from the sprocket. ‘Suspend the cam chain with a piece of wire to keep it from fall- ing into the crankcase, Remove the camshaft and sprocket holder. Remove the tensioner holder. 6-7 (2) CAM SPROC} KET BOLT!CYLINDER HEAD/VALVES Remove the set pins. (1) SET PINS CAMSHAFT BEARING INSPECTION ‘Turn the outer race of each bearing with your finger. The bear- ings should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the camshaft. If the outer races do not turn smoothly and quietly, replace the bearings. Remove the camshaft ball bearings from the camshaft. CAMSHAFT INSPECTION Check each cam lobe for wear or damage. ‘Measure the cam lobe height. SERVICE LIMITS. INTAKE: 31.05 mm (1,222 in) EXHAUST: 31.00 mm (1.220 in) Check camshaft runout with a dial indicator. Support both ends of the camshaft with V-blocks. ‘Actual runout is 1/2 of the total indicator reading. ‘SERVICE LIMIT: 0.04 mm (0.002 in)CYLINDER HEAD/VALVES DECOMPRESSOR SYSTEM DISASSEMBLY Press the cam sprocket holder off of the camshaft. Remove the thrust washer, one way clutch, reverse decom- pressor cam and decompressor cam (with spring). NOTE + Do not confuse the cam spring with the clutch spring. INSPECTION Check the one way clutch outer, rollers and springs for wear or damage. Check both decompressor cams for wear or damage, replace if necessary. Inspect the cams’ sliding surface on the camsheft for scoring or wear, DECOMPRESSOR SYSTEM ASSEMBLY Lubricate both decompressor cams, one way clutch, and the thrust washer with oil, then install the decompressor cam, with its spring, onto the camshaft. Install the reverse decompressor cam and the one way clutch with a pin Install the thrust washer. Press the cam sprocket holder onto the camshaft after aligning the indentation on the camshaft with the lug on the cam sprocket holder, {iy SPRING vt (2) DECOMPRESSOR CAM {31 REVERSE DECOMPRESSOR Lites (7) CAMSHAFT (4) ONE WAY CLUTCH 4771) CAM SPROCKET Oy o HOLDER, (6) THRUST on (1) OUTER (3) ROLLERS [2) SPRINGS (7) SPRING _ (2) REVERSE DECOMPRESSOR CAM '3) ONE WAY CLUTCH (4) ROLLER/SPRING — | oT == (6) DECOMPRESSOR CAM__ 15) PIN. (1) INDENTATION (2) LUGCYLINDER HEAD/VALVES Be sure that the one way clutch outer rotates in one direction only. CYLINDER HEAD REMOVAL Remove the exhaust pipe (page 15-3). Remove the cylinder head cover (page 6-4). Remove the camshaft (page 6-7). Remove the two cylinder head nuts. Remove the five cylinder head bolts. NOTE + Loosen the bolts in @ crisscross pattern in two or more steps. (1) DOWEL PINS q Remove the cylinder head. “ CAUTION + Be careful not to damage the cylinder head mating surfaces. Romove the cylinder head gasket and dowel pins. CAM CHAIN TENSIONER REMOVAL Remove the tensioner shatt. Remove the camchain tensioner and spring. (3) TENSIONER SHAFT 6-10CYLINDER HEAD/VALVES CAM CHAIN TENSIONER INSPECTION (1) CAM CHAIN TENSIONER (2) TENSIONER SHAFT \ h Insert the tensioner shaft into the tensioner and inspect the tensioner by turning the shaft. - ‘The tensioner shaft should turn clockwise freely and should ot turn counterclockwise. . Check the tensioner lifter and tensioner shaft for excessive or abnormal wear or damage. CYLINDER HEAD DISASSEMBLY Remove the valve spring cotters, retainers, springs, and valves with a valve spring compressor. TOOL: VALVE SPRING COMPRESSOR 07757—0010000 or 07957—3290001 CAUTION + To prevent loss of tension, do not compress the valve springs ‘more than necessary to remove the cotters. NOTE + Mark all parts to ensure that they are reassembled in thei original ls Remove the spring seats and valve stem seals. Remove any carbon deposits from the combustion chamber. Carefully clean any gasket material from the cylinder head ‘mating surfaces. CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a straight edge and a feeler gauge. ‘SERVICE LIMIT: 0.10 mm (0.004 in) VALVE SPRING INSPECTION ‘Measure the free length of the inner and outer valve springs. ‘SERVICE LIMITS: INNER: 34.1 mm (1.34 in) OUTER: 35.0 mm (1.38 in)CYLINDER HEAD/VALVES. VALVE/VALVE GUIDE INSPECTION Inspect each valve for trueness, burning, scratches or abnormal stem wear. Check the valve movement in the guide. Measure and record each valve stem 0.D. SERVICE LIMIT: INTAKE: 6.56 mm (0.257 in) EXHAUST: 6.55 mm (0.258 in) ‘Measure and record each valve guide 1.0. using a ball gauge or inside micrometer. checking the valve guide I.D. ‘SERVICE LIMIT: INTAKE: 6.63 mm (0.261 in) EXHAUST: 6.63 mm (0.261 in) Calculate the stem-to-guide clearance. VALVE STEM-TO.GUIDE CLEARANCE ‘SERVICE LIMITS: INTAKE: 0.065 mm (0.0026 in) EXHAUST: 0.080 mm (0.0031 in} NOTE + Ifthe stem-to-guide clearance exceeds the service limit, de- termine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace guides as necessary and ream to fit. If stem-to-guide clearance still exceeds the service limit when new guides are installed, replace the valves. NOTE + Roface valve seats whenever new valve guides are in- stale 6-12CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the replacement guides in the freezer for about an hour. Heat the cylinder head to 100°—150° ¢ (212°—300° F) with a hot plate or oven. + To avoid burns, wear heavy gloves when handling the heated eolinder head. CAUTION + Do not use a torch to heat the cylinder, it may cause warping. ‘Support the cylinder head and drive out the old guides from the ‘combustion chamber side of the cylinder head, CAUTION + Avoid damaging the cylinder head. Place a new O-ring on the new valve guide. Drive in the guide from the top of the head. Inspect the vaive guide for damage. TooL: VALVE GUIDE DRIVER, 6.6 mm 07742—0010200 or 07942—6570100 Ream the new valve guides after installation, NOTE Use cutting oil on the reamer during this operation. + Always rotate the reamer in the same direction. Clean the cylinder head thoroughly to remove any metal parti les. Reface the valve seats (page 6-14) TOOL: VALVE GUIDE REAMER 07984—5510000 VALVE SEAT INSPECTION AND REFACING Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to each valve face. Lap each valve and seat using a rubber hose or other hand-lapping tool, CAUTION + Valves cannot be ground. If the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve, TT VALVE GUIDE DRIVER 6.8 mm a = tS - * 4 Le La (1) VALVE GUIDE DRIVER 6.6 mm = Se 1) VALVE GUIDE REAMER f = é ce cy “1 et ——— b= . 6-13CYLINDER HEAD/VALVES Remove the valve and measure the face width. SERVICE LIMIT: IN-2.6 mm (0.10 in} EX 2.4 mm (0.09 in} Measure each valve seat width. ‘SERVICE LIMIT: 2.0 mm (0.08 in) If the seat is too wide, too narrow, or has low spots, the seat must be refinished for good sealing, NOTE Follow the refacer manufacturer's opera VALVE SEAT GRINDING Using a 45 degree cutter, remove any roughness or irregulari- from the seat cutter when the valve guide is replaced. (2) VALVE SEAT CUTTER VALVE SEAT CUTTERS 60° t ‘4 \ 6-14CYLINDER HEAD/VALVES Using 2 32 degree cutter, remove 1/4 of th material isting valve seat Use a 60 degree cutter and remove the bottom 1/4 of the old seat. Use @ 45 degree finish cutter and cut the seat to the proper width. NOTE + Make sure that all pitting and irregularities are removed. NOTE + The location of the valve seat in relation to the valve face is very important for good sealing and maximum valve ser- vice. Apply a thin coating of Prussian Blue to the valve seat. Press the valve through the valve guide and onto the seat to make a clear pattern, Remove to inspect the valve If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter. Rofinish the seat to the correct width using a 45 degree finish cutter. 6-15 (1) OLD SEAT WIDTH (1) OLD SEAT WIDTH \ (121.4 mm (0,05~0.06 in) iS (1) CONTACT TOO HIGH - (2) QLD SEAT WIDTH meCYLINDER HEAD/VALVES Hf the contact area is too low on the valve, the seat must be raised using a 60 degree inner cutter. Refinish the seat to correct width, using a 45 degree finish ct ter. (1) CONTACT TOO LOW (2) OLD SEAT WIDTH 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, valve, and valve guide CYLINDER HEAD ASSEMBLY Lubricate each valve stem with oil, then insert the valves into the valve guides Install new valve stem seals. Install the valve spring seats, springs and retainers. The springs’ tightly wound coils should face in toward the f (7) COTTERS combustion chamber. (1) SPRING SEAT oe (2) STEM SEAL (3) INNER a (4) OUTER eae (5) ce (6) RETAINER 1) VALWE SPRING COMPRESSOR Compress the valve springs using the valve spring compres- 4 sor, then install the valve cotters. CAUTION + To prevent loss of tension, do not compress the valve spring ‘more than necessary, TooL: VALVE SPRING COMPRESSOR _07757--0010000 or 07957~3290001 6-16CYLINDER HEAD/VALVES Tap the valve stems gently with a plastic hammer to firmly _ ‘seat the cotters. CAUTION + Support the cylinder head above the work bench surface to pre- vent possible valve damage CYLINDER HEAD INSTALLATION ia Install the spring on the cam chain tensioner as shown. a (2) TENSIONER, Install the cam chain tensioner into the cylinder head. Apply engine cil to a new O-ring and install it in the groove of the cam chain tensioner shaft. Insert the tensioner shaft through the tensioner and into the cylinder head. Hold the tensioner’s lever straight down. Place the tensioner holder tool's pin into the hole in the tensioner which will be facing up. Slowly release the tensioner lever until the tool rests against the cylinder head casting NOTE + Leave the tool in place until the camshaft, sprocket, and chain are installed, (1) TENSIONER SHAFT ~ (1) DOWEL PINS Clean any gasket material from the cylinder surface. Install the dowel pins and new gasket. 2) CYUNDeR HexD GASKET 6-17CYLINDER HEAD/VALVES Install the camshaft bearing setting pins. Install the cylinder head. Tighten the cylinder head bolts in a crisscross pattern in two or more steps. TORQUE: 30 Nem (3.0 kg-m, 22 ft-tb) Tighten the cylinder head nuts. CAMSHAFT INSTALLATION Apply MoS2 grease to the camshaft bearings and install them ‘onto the camshaft; the sealed bearing goes on the sprocket side with the seal facing out. If both bearings are the sealed type, point their seals facing away from the camshaft. NOTE ‘Some sources of MoSz paste grease with 40% or more molyb- denum are: + Molykote® G-n Paste manufactured by Dow Corning, U.S.A + Honda Moly 45 (U.S.A only) + Rocol ASP manufactured by Rocot Limited, U.K. + Rocol Paste manufactured by Sumico Lubricant, Japan. Any other manufacturer's paste grease equivalent to the — (1/ TIMING MARK ] ‘ (2) SEAL FACE above may also be used. TENSIONER HOLDER gal Place the cam sprocket outside the cam chain with its dished face toward the left side. Install camshaft through the sprocket and cam chain. ‘Turn the crankshaft and align the “'T"" mark on the flywheel with the index notch on the left crankcase cover. TOOL: CAM CHAIN TENSIONER HOLDER 07973-MG30003 Align the timing marks on the cam sprocket with the upper sur- face of the cylinder head and install the cam chain over the sprocket without rotating the sprocket. Position the cam sprocket onto the shoulder of the camshaft and install one cam sprocket bolt. Tum the crankshaft and install the other sprocket bolt. Tighten the sprocket bolts to the specified torque. ‘TORQUE: 20 N-m (2.0 kg-m, 14 fb) (2) TIMING MARES Remove the tensioner holder. 6-18CYLINDER HEAD/VALVES ‘Turn the crankshaft and align the ‘‘T"’ mark with the index ™@y)WOER NOTCH” Ti) Inbex NOTCH notch and make sure that the timing marks on the sprocket align with the upper surface of the oylinder head. fa." MARK iia) TIMING MARKS fig ‘Align the hole in the tensioner shaft with the hole in the cylin- | VSORERSCREN {et head while turning the tensioner shaft clockwise and tight- + eee en the screw. (2) TENSIONER SHAFT, CYLINDER HEAD COVER ASSEMBLY -11) MARK A, Bor D NOTE + Each arm is stamped with its letter code a in the location shown. Install properly. Apply MoS2 grease to the rocker arm shafts. Apply liquid sealant to the thread of the rocker arm shaft. Install the rocker arm shafts and copper washers. NOTE Some sources of MoS: paste grease with 40% or more moly>- er aee e + Molykote® G-n Paste manufactured by Dow Corning, U.S.A. - . + Honda Moly 45 (U.S.A. only) (1) ROCKER ARM C; ¢ 2) ROCKER + Rocol ASP manufactured by Rocol Limited, U.K. an + Rocol Paste manufactured by Sumico Lubricant, Japan. Any other manufacturer's paste grease equivalent to the above may also be used. Tighten the rocker arm shafts to the specified torque. TORQUE: 28 N-m (2.8 kg-m, 20 ftb) ee (6) ROCKER ARM (4) ROCKER ARM SHAFT 6-19CYLINDER HEAD/VALVES Install the sub-rocker arms marked A, B and the wave washers in the location shown. Apply engine oil to the sub-rocker arm shatts. Apply liquid sealant to the thread of the sub rocker arm shaft. Install the sub-rocker arm shafts and sealing washers. Install the sub-rocker arms marked "“IN’” and the wave wash ers in the location shown, Apply engine oil to the sub-rocker arm shafts. Apply liquid sealant to the thread of the sub rocker arm shat. Install the sub-rocker arm shafts and sealing washers. Tighten the sub-rocker arm shafts. TORQUE: IN, 28 Nem (2.8 kg-m, 20 ft-Ib) EX. 23 Nem (2.3 kg-m, 17 ft-lb) Install the vaive lifter lever and spring. Align the cutout of the lever shaft with the hole in the cylinder head cover and insert the dowel pin. (2) WAVE WASHERS [1) SUB-ROCKER ARM B/S (3) SUB-ROCKER ARM A o 13) SUB-ROCKER ARM (4) SUB-ROCKER ARM SHAFTS SHAFTS (3) SPRING (1) DOWEL PIN rf (1) (a) PLOT. (2) DRIVER SS (3) ATTACHMENT > Ici) BEARING PLATE 2 ) DRIVER, (3) GEARING DRIVER ATTACHMENT 10-7CRANKSHAFT/BALANCER RIGHT CRANKCASE BEARING REPLACEMENT, Remove the bearing setting plate from the right crankcase. Remove the bearing from the right crankcase with the bearing Install a new bearing in the right crankcase with the driver, at tachment, and pilot. Use the following tools to install and remove the bearing. Mainshaft Bearing INSTALLATION Attachment, 62 x 55 mm. Pilot, 25 mm Driver Countershaft Bearing REMOVAL Bearing removar sot spindle — Remover handle — Remover weight INSTALLATION Attachment, 42 x 47 mm Pilot, 20 mm. Driver Attachment, 37 x 40 mm Balancer Shaft Bearing REMOVAL Bearing remover, 15 mm Remover weight Remover handle INSTALLATION Attachment, 42 x 47 mm Pilot, 17 mm. Driver Crankshaft Bearing INSTALLATION Attachment, 72 x 75 mm Pilot, 35 mm Driver 10-8 (I BALANCER (2) BEARING SETTING PLATE BEARING (3) MAINSHAET BEARING Log (6) RIGHT CRANKSHAFT BEARING BEARING 07746—0010400 077460040600 07749-0010000 07936~3710001 07936-3710600 07936-3710100 077410010201 or 07936—3710200 07746—0010300 07746—0040500 077490010000 07746—0010200 FT Lock wasnen Remove the shift fork shaft, shift drum, and shaft forks. (1) SHIFT FORK SHAFT (3) SHIFT FORKS = (2) SHIFT DRUM (11 COUNTERSHAFT (2) MAINSHAFT \ ; Remove the mainshaft and countershaft as an assembly. E i 11-3TRANSMISSION INSPECTION Disassemble the mainshaft and countershaft. Inspect each gear for wear or damage. Check the gear teeth for wear or damage. Check the gear engagement dogs for w or damage. Check each gear for excessive or abnormal wes Inspect the I.D. of each gear. ‘SERVICE LIMITS: M4 28.10 mm (1.106 in) MS — 28.08 mm (1.105 in) C1 25.10 mm (0.988 in) 325.10 mm (0.988 in) C2 28.10 mm (1.106 in) Measure the I.D. and 0.0. of each gear bushing. SERVICE LIMITS: MS 0.D. 27.90 mm (1.098 in) c10.. 24.93 mm (0.981 in) cL. 20.01 mm (0.791 in) (M4,C20.D. 27.93 mm (1.100 in} M4, C21.D. 25.10 mm (0.988 in) Calculate the clearance between the gear and bushing. ‘SERVICE LIMIT: 10 mm (0.004 in) ‘Measure the 0.0. of the mainshaft. SERVICE LIMIT: M4 24.92 mm (0.981 in) 11-4TRANSMISSION Measure the countershaft 0.0. SERVICE LIMITS: ct 19.94 mm (0.785 in) 2,3 24.92 mm (0.981 in) ‘Measure the I.D. of the shift fork. ‘SERVICE LIMIT: 14.05 mm (0.553 in) Measure the thickness of the shift fork claw. SERVICE LIMIT: 4.5 mm (0.18 in) Measure the 0.D. of the shift fork shaft. SERVICE LIMIT: 13.90 mm (0.547 in) Inspect the shift drum grooves and replace the drums if they are damaged or show excessive we:TRANSMISSION TRANSMISSION ASSEMBLY Check the gears for freedom of movement or rotation on the shaft Check that the snap rings are seated in the grooves. 2 (28T) 1 31T) Of? @ 0 (a!LoWen Boss sive C5 (217) R IDE. a (1) HIGHER BOSS SI C3 (257) (4) STEPPED SIDE (3) CUPPED SIDE Mi (i3Ty @ Doc @ 66@ M2177) 0@ M3 (207) M5 (257) Align the hole in the M5 gear bushing with the hole in the main- shaft when installing. Install the mainshaft and countershaft into the left crankcase together. 11-6TRANSMISSION Install the shift forks between the gears with the marks facing to right. eae (2)"0" MARK, \ "RY MARK Install the shift drum. Install the shift fork shaft into the shift forks and align the center shift fork set bolt holes. (1) SHIFT FORK SHAFT Install a new lock washer and shift fork set bolt Tighten the set bolt and bend up the lock washer tabs against, the bolt head. TORQUE: 15 Nem (1.5 kg-m, 11 ftlb) ‘Assemble the shift spindle as shown.‘TRANSMISSION Align the return spring with the pin bolt and install the shift (1) PIN BOLT 12) SHIFT PLATE spindle while pulling the shift plate = ‘Assemble the crankcases (Section 10). Install the shift cam plate, stopper arm (page 8-16) and gear shift pedal and check the transmission for smooth shifting (3) RETURM SPRING 11-8FRONT WHEEL/SUSPENSION/STEERING 23 Nem (2.3 kg-m, 17 fib) +m (0.2 kg-m, 1 ft-lb) 27 Nem (2.7 kg-m, 20 ft-lb} ‘47 ft-lb) 65 N-m (6.5kg-m, 12-0FRONT WHEEL/SUSPENSION/STEERING ee SERVICE INFORMATION 12-4 FRONT WHEEL 12-6 TROUBLESHOOTING 12-2 FORK 12-11 HANDLEBAR 12-3. STEERINGSTEM 12.18 SERVICE INFORMATION GENERAL © A work stand or box is required to support the motorcycle, SPECIFICATIONS ITEMS ‘STANDARD SERVICE LIMIT Axle runout = 0.2 mm (0.01 in) Front wheel rim runout | Radial — ~ 2.0 mm (0.08 in) ‘Axial — 2.0 mm (0.08 in) Fork spring free length ‘A: 63.0 mm (2.480 in) 62.4 mm (2.487 in) B: 582.8 mm (22.945 in} ~ 877.0 mm (22.717 in) =| Fork tube runout = 0.2 mm (0.008 in} Fork oil level 110 mm (4.3 in) 100—130 mm (3.9-5.1 in) Fork air pressure O kPa (0 kg-m:, O psi) (0-100 kPa (0— 1.0 kgicm?, O- 15 psil Fork oil capacity - (643 cc (21.74 02) 640.5—645.5 cc (21.66—21.83 o7) TORQUE VALUES Steering bearing adjustment nut Steering stem nut Fork upper pinch bolt Fork lower pinch bolt Handlebar holder Front axle Front axle holder Fork cap Spokes Rim lock Brake dise Fork bottom bolt Throttle pulley pivot screw 3. Nem (0.3 kg-m, 2 ft-lb) 118 Nem (11.8 kg-m, 85 ft-lb) 33 Nem (3.3 kg-m, 24 feb) 33 Nem (3.3 kg-m, 24 ft-lb) 27 Nem (2.7 kg-m, 20 ft-lb) 65 Nem (6.5 kg-m, 47 ft-lb) 12 Nem (1.2 kg-m, 9 ft-lb) 23 Nem (2.3 kg-m, 16 ft-lb) 4 Nem (0.4 kg-m, 3 ft-lb) 13 Nem (1.3 kg-m, 9 ft-lb) 15 Nem (1.5 kg-m, 11 ftlb) ‘35 Nem (3.5 kg-m, 25 ft-lb) 4.3 Num (0.43 kg-m, 3 ftlb) 12-1TOOLS Special Steering stem nut wrench Steering stem driver Fork seal driver Fork seal driver attachment Ball race remover ‘Common Wrench, 30 x 32 mm Remover head, 15 mm Bearing remover shaft Attachment, 42 x 47 mm Pilot, 15 mm Driver Attachment, 32 x 35 mm Extension bar 07916-KA50100 07946 -4300101 07947—KA50100 07947—Ka40200 07953—MJ10000 07716-0020400 077460050400 07746-0050100 077460010300 07746-0040300 077490010000 07746-0010100 07716-0020500 TROUBLESHOOTING Hard Steering + Steering stem nut too tight + Faulty steering stem bearings + Insufficient air in front tire Jers to One Side or Does Not Track Straight Bent fork. Bent front axle, wheel misaligned Wheel installed incorrectly Front Wheel Wobbiing + Distorted rim Worn front wheel bearings Loose or broken spokes Faulty tire Axle not tightened properly Soft Suspension + Weak fork springs + Insufficient fluid in fork legs + Incorrect fork air pressure Hard Suspension + Incorrect fluid weight in fork legs + Incorrect fork air pressure + Fork tube bent Front Suspension Ni + Slider binding + Insufficient fluid in fork legs + Loose fork fasteners FRONT WHEEL/SUSPENSION/STEERING 12-2FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL (1) CLUTCH LeveR (2) HANDLEBAR SWITCH Remove the headlight (page 16-8) Remove the handlebar switch by removing two bolts (B mod- el) oF two nuts (U model) Loosen the clutch cable adjuster and disconnect the clutch cable. NOTE NOTE _ (4) MANUAL + The clutch lever can be removed with the clutch cable DECOMPRESSOR a connected and the knuckle guard installed, (6) LEFT GRIP LEVER (1) BRAKE MASTER (2) THROTTLE Remove the two screws and clutch lever bracket, CYLINDER BRACKET GRIP. Loosen the pinch screw and slide the manual decompressor lever bracket inside, then pull out the rubber cover and disconnect the decompressor cable. Remove the left grip and manual decompressor lever bracket if necessary. Remove the two screws and separate the throttle body. Remove the throttle pivot screw, pivot cover and roller. Disconnect the throttle cable, then remove the throttle grip. Remove the two screws and brake master cylinder bracket. Remove the wire bands securing the engine stop switch wire. Remove the engine stop switch (3) THROTTLE PIVOT) [4) THROTTLE BODY =” SCREW Remove the handlebar holder bolts and upper holders. {1) BOLTS) Remove the handlebar. (21 PORCH MARR INSTALLATION {Install the handlebar. Align the punch mark on the handlebar with the top edge of the lower holders. Place the upper holders on the handlebar with the punch marks facing forward. Tighten the forward bolts first, then tighten the rear bolts. ‘TORQUE: 26 N-m (2.6 kg-m, 19 ft-lb) 12-3FRONT WHEEL/SUSPENSION/STEERING eee Install the front brake master cylinder with ““UP’” on the brack- (1) PUNCH MARK et facing up. Align the end of the holder with the handlebar punch mark. Tighten the upper bolt first, then the lower bolt. (2) BOLTS (31 “UP MARKBRACKET, Apply a light coating of Honda silicone lubricant or an equiva- [1) THROTTLE GRIP lent to the throttle grip sliding surface and slide the throttle ‘grip over the handlebar. a q Apply grease to the throttle cable ends and the roller. Connect the throttle cable to the grip. Connect the throttle cable to the throttle roller and install the throttle roller on the body. Install the new cover gesket (1 THROTTLE ROLLER (2) COVER GASKET ey (3) ROLLER COVER Align the split line of the throttle body with the punch mark on [1) PUNCH MARK (2) THROTTLE ROLLER the handlebar. COVER! SCREW Tighten the forward screw fst, then the rear screw. Instal the thrtte eller cover onthe throttle body and tighten the serew. TORQUE: 4.3 N-m (0.43 kg-m, 3 ft-lb) : w a (3) SCREWS: 12-4FRONT WHEEL/SUSPENSION/STEERING Install the engine stop switch and terminal by aligning the slit De WITCH of the switch holder with the punch mark on the handlebar. CTE eSNG RESTORS Tighten the screw. Install the manual decompressor lover bracket. (1) BRACKET (2) PUNCH MARK Connect the decompressor cable and install the boot as shown. Align the split line of the manual decompressor bracket with punch mark on the handlebar and tighten the pinch screw se- curely. (3) BOOT Apply Honda Bond A to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe Wait 3-5 minutes and install the grips. Rotate the grips for even application of the adhesive. NOTE + Allow the adhesive to dry for an hour before using, 1) PUNCH (2)D0T MARRE Install the clutch lever bracket with the dot mark on the holder MARK facing up. Align the end of the holder with the handlebar punch mark. Tighten the upper screw first, then the lower screw. 12-5FRONT WHEEL/SUSPENSION/STEERING Install the left handlebar switch by aligning the pin with the hole, and tighten the bolts (B model) or nuts (U model). ‘Adjust the following — the manual decompressor cable (page 3-8) — the clutch (page 3-14) — the throttle cable (page 3-5) FRONT WHEEL REMOVAL \ 11) TRIPMETER caste Ee Raise the front wheel off the ground by placing a box or work stand under the engine. \ Disconnect the tripmeter cable from the speedometer gearbox | at the front wheel. : (2) Screw Remove the axle shaft holder nuts and then remove the front TERESA ALE axle. Remove the front wheel. INSPECTION AXLE Set the axle in V blocks and measure the runout. The actual runout is 1/2 of the total indicator reading, SERVICE LIMIT: 0.2 mm (0.01 in) 12-6FRONT WHEEL/SUSPENSION/STEERING WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not tun ‘smoothly, quietly, or if they fit loosely in the hub. NOTE + Replace hub bearings in pairs. WHEEL Check the spokes and tighten any that are loose, TORQUE: 2.5—5.0 Nem (0.25—0.5 kg-m, 1.8—3.6 ft-lb) Check the rim runout by placing the wheel on a truing stand. Then spin the wheel by hand, and read the runout using a dial indicator, SERVICE LIMITS: 0 mm (0.08 in) 2.0 mm (0.08 in) DISASSEMBLY Remove the tripmeter gear box. Remove the dust seal (1) TRIPMETER GEAR Box 12-7FRONT WHEEL/SUSPENSION/STEERING Remove the tripmeter gear retainer. (1) TRIPMETER GEAR RETAINER Remove the collar and dust seal (2) DUST SEAL; (1) BRAKE DISC - iz Remove the mounting screws and dust cover. Remove the mounting nuts and brake disc. NOTE A + For brake disc inspection, see section 14. Remove the wheel bearings and distance collar from the wheel (1) BEARING REMOVER SHAFT] hub if necessary, NOTE + Never reinstall old bearings: once the bearings have been removed, they must be replaced with new ones. Tools: BEARING REMOVER SHAFT 077460050100 BEARING REMOVER HEAD, 15 mm 077460050400 I2) BEARING REMOVER HEAD, 15 mm 12-8FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY x | + Do not get grease on the brake disc, or stopping power will be reduced. (1) BEARING (2) COLLAR (4) RIM LOCK (6) SEAL Drive in the right bearing first and then press the distance collar into place. 11) DRIVER Drive in the left bearing squarely making sure that itis fully M1) COLLAR Ht, seated and that the sealed side is facing out. 12-9FRONT WHEEL/SUSPENSION/STEERING Install the brake dise onto the wheel hub and tighten the bolts. ~ (1 BRAKE DISC TORQUE: 14—16 Nem (1.4—1.6 kg-m, 10-12 fib) Install the dust cover. Apply grease to the dust seal lip and install the dust seal Install the collar. Apply grease to the tripmeter gear retainer. Install the tripmeter gear retainer into the wheel hub, aligning the tangs with the slots, (1) TRIPMETER Apply grease to the dust seal ip and install the dust seal GEAR Apply grease to the tripmeter gear. Install the tripmeter gearbox into the wheel hub, aligning the tangs with the slots. Clean the brake disc with a high quality degreasing agent. 12-10FRONT WHEEL/SUSPENSION/STEERING INSTALLATION Fit the caliper over the disc, taking care not to damage the brake pads. Clean the axle and hold Install the holder with "UP" facing upwards. Install the axle holder nuts but do not tighten at this time. Align the tripmeter gearbox with the tang on the right fork leg as shown. Tighten the axle to the specified torque. 1a) “UP” MARK TORQUE: 65 Nem (6.5 kg-m, 47 ft-lb) With the front brake applied, pump the fork up and down several times to seat the axle and check front brake operation. Tighten the axle holder nuts: the upper nuts first, then the lower nuts. TORQUE: 12 Nem (1.2 kg-m, 9 ftb) Connect the tripmeter cable to the gearbox. (3) AXLE 12) SCREW i HOLDER NU FORK REMOVAL Remove the following: — the headlight (page 16-8) = the front wheel (page 12-6). = the brake hose clamp bolts. — the caliper mounting bolts and caliper from the left fork leg. — the tripmeter cable clamps from the right fork leg. (3) BOLTS" (a) BRAKE CALIPERFRONT WHEEL/SUSPENSION/STEERING Remove the air valve cap. Depress the air valve and release fork air pressure. Loosen the fork tube cap. Loosen the upper and lower fork pinch bolts and remove the fork tubes. DISASSEMBLY Loosen the fork boot clamp screws and remove the boot. Remove the fork tube cap. CAUTION Uf air pressure is not released before disassembling, the fork tube cap may become a projectile. + The cap is also under spring pressure. Use care when removing ‘and wear eye and face protection. - f > I (1) UPPER PINCH= BOLTS BOLTS (1) FORK BOOT (1) FORK TUBE CAP 12-12FRONT WHEEL/SUSPENSION/STEERING Remove the fork springs and washer. pines 1) SPRINGS Pour out the fork fluid by pumping the fork up and down several times. oie. > th } Remove the dust sesl. QUST SEAL Remove the snap ring. (1) SNAP PING NOTE v + Avoid damaging the inner and outer surfaces of the fork slider when removing the snap ring. 1) BOTTOM BOLT Hold the fork slider in a vise with soft jaws or a shop towel. ‘CAUTION ‘Do not distort the fork slider in the vise. Remove the bottom bolt cover and bottom bolt. 12-13FRONT WHEEL/SUSPENSION/STEERING In quick successive motions pull the fork tube out of the slider. NOTE + The slider bushing is pressed into the slider and the fork ‘tube bushing, on the end of the fork tube, 20 you must force Remove the oil lock piece from the fork slider. Remove the following parts from the fork tube: = fork piston. = oil seal — back-up ring and fork slider bushing. Check the bushings for excessive wear or scratches. I copper appears on more than 3/4 of the entire surface, re- place them. Replace the back-up ring if there is distortion. INSPECTION FORK SPRING Measure the fork spring free length. ‘SERVICE LIM 62.4 mm (2.487 in) B: 677.0 mm (22.717 in) Replace the spring if it is shorter than the service limit. Bottom bolt Check the bottom bolt assembly and washer for damage. Replace the assembly if it shows signs of wear or fatigne. Always use a new washer when reassembling (1) BOTTOM BOLT ASSEMBLY 41) O1L SEAL ae —— 12) BACK-UP ING < -+—— (3) FOAK SLIDER, &, (6) FROK TUBE ¢ BUSHING (5) FORK PISTON (4) OIL LOCK PIECE)! Sie scopeatcidibbatikeisi ly (2) SPRING A (2) WASHER 12-14FRONT WHEEL/SUSPENSION/STEERING Fork piston ring/rebound spring 1) FORK PISTON RING Check the fork piston ring for wear or damage, Check the rebound spring for fatigue or damage, Fork tube/fork sliderifork piston Check the fork tube, fork slider and piston for score marks, ‘scratches, or excessive or abnormal wear. Replace any components which are worn or damaged. FORK TUBE ‘Set the fork tube in V blocks and read the runout. ‘The actual runout is 1/2 the total indicator reading. ‘SERVICE LIMIT: 0.20 mm (0.008 in) ASSEMBLY Clean all parts with non-flammable or high flash point solvent. 10) FORK TUBE (1) VALVE CORE (10) FORK Tu! (12) BOOT UPPER BAND (2) FORK BLT. (5) SPRING SEAT—»@ RING (13) FORK BOOT (19) FORK SLIDER, BUSHING S33 114) oust SEAL (20) FORK SLIDER fe SrnINGE) (16) FORK SEAL (7) PISTON mong 2 7 (8) REBOUND- (17) BACK “Se RING if =, SPRING Ye AXLE o (25) CABLE CLAMP (9) FORK HOLDER by PISTON: eo 22) ‘SPECIAL, WHASHER (1) dILLOCK (18) Boor Cower BAND (23) CENTER PIECE BOLT (24 CUP 12-15FRONT WHEEL/SUSPENSION/STEERING Install the following parts on to the fork tube: = fork piston with piston ring and rebound spring. — fork slider bushing and back-up ring ~ new oil seal applying the ATF to its lip. Install the oil lock piece on the fork piston. Assemble the fork tube and the slider. Hold the fork slider in a vise with soft jaws or a shop towel Install a new sealing washer on the bottom bolt Apply a locking agent to be bottom bolt threads, Tighten the bottom bolt. Drive the oil seal, dust seal and retainer in with the fork seal driver. Install the snap ring into the groove of the slider. TooLs: SLIDER WEIGHT 07947—KA40200 ATTACHMENT 07947—KA50100 Compress the fork assembly all the way and measure the oil level from the top of the tube. Pour in the specified amount of ATF. STANDARD: 643 cc (21.8 oz) NOTE + Be sure the oil level is the same in both fork tubes. ‘STANDARD OIL LEVEL: 110 mm (4.3 in) (1) SUIDER OW SEAL wa — (2) BACK-UP RING +—— (3) FORK SLIDER, BUSHING 1 cm re (8) SNAP WeIchT FING fe Slightly stiffer fork spring effect when fork is charged with standard air pressure. Maximum | 130 mm. oil level (6.1 in) Slightly softer fork spring effect when fork is charged with standard air pressure, Minimum | 100 mm. oil level (3.9 in) 12-16FRONT WHEEL/SUSPENSION/STEERING ‘Wipe all oil from the fork springs and install them into the fork. tube with the narrow coils toward the fork cap. Install the seat washer and springs. Install the O-ring on the fork cap. Install the fork cap but do not tighten it at this time. CAUTION + Be careful not to cross-thread the fork cap. Install the fork boot with its many breather holes towards the outside. INSTALLATION Slip the fork tubes through the fork bridge and steering stem, while rotating them by hand. Align the top of the fork tube with the top surface of the fork bridge. Tighten the upper and lower pinch bolts. TORQUE: Upper: 25—30 Nem (2.5—3.0 kg-m, 18-22 ftb) Lower: 30—35 Nem (3.0—3.5 kg-m, 22—25 ft-lb) Install the tripmeter cable and brake hose clamps. Install the brake caliper (page 14-11). _11) WASHER 15) SPRING 8 (4) SPRING AW 430. a (ah FonK TUBE CaP (1) FORK BOOT CLAMP 2) BREATHER HOLES (1) UPPER PINCH BOLTS (2) LOWER PINCH Bos, oN (1) TRIPMETER — CABLE CLAMP. (2) BRAKE HOSE CLAMP 14) BOLTS (3) BRAKE CALIPER 12-17FRONT WHEEL/SUSPENSION/STEERING 41) FORK BOOT __ CLAMPS Install the front wheel (page 12-11). Push the fork boots up until they just touch the steering stem and tighten the boot clamps, with the clamp screw rearward. TT) FORK CAP BOLT Tighten the fork caps to the specified torque. ‘TORQUE: 23 N-m (2.3 kg-m, 17 ft-lb) P Make sure all weight is off the front wheel and charge the fork with air. e Standard pressure: 0 kPa (0 kg/em®, 0 psi) CAUTION + Use a low-volume low-pressure pump to charge the fork. ( Install the air valve caps. Install the headlight (page 16-9) STEERING STEM FORK BRIDGE REMOVAL (1) BOLTS AND WASHERS! AN Remove the following components: \ — headlight (page 16-8) 5 — instruments (page 16-10) t — handlebar (page 12-3) — front wheel (page 12-6). — front fender. TooL: WRENCH, 30 x 32 mm 07716-0020400 al itoreninds 12-18FRONT WHEEL /SUSPENSION/STEERING Remove the fork tubes (page 12-11), Remove the washer and fork top bridge. Remove the lock washer and discard it. NOTE + Replace the lock washer with a new one whenever it has been removed, Remove the steering head bearing adjusting nut. Toots: EXTENSION BAR 07716-0020500 ‘STEERING STEM NUT WRENCH 07916—KA50100 Remove the seal, upper bearing and steering stem from the head tube. BEARING REPLACEMENT NOTE + Always replace the bearing and bearing races as a set, Remove the upper and lower bearing races from the steering head. TooL: BALL RACE REMOVER 07953—MJ1000 ) waster (1) FORK TOP BRIDGE \ (3) LOCK WASHER ee ot. EXTENTION BAR (SEAL, (2) UPPER BEARING a fadi=o (4) LOWER BEARING (3) STEERING STEN , (11 OXUL RARE REMOVERS > 12-19FRONT WHEEL/SUSPENSION/STEERING Install new bearing races. NOTE + If the motorcycle has been involved in an accident, examine the area around the steering head for cracks. Toots: DRIVER ATTACHMENT, 42 x 47 mm 07749-0010000 077460010300 Install the bearing adjustment nut on the top end of the steering stem to prevent damage to the threads. Remove the lower bearing race from the steering stem. Replace the dust seal with a new one whenever it is removed, Install the new dust seal. Install the lower bearing using hydraulic press and steering stem driver. TooL: ‘STEERING STEM DRIVER 07946—4300101 or (07946 —MB00000 with GN HTS4 INSTALLATION Pack the bearing cavities with bearing grease. Install the steering stem into the steering head and install the upper bearing and seal. 71) ORvER f (1) LOWER BEARING RACE Be (2) ADJUSTMENT NUT in) STEERING STEM DRIVER, (2) UPPER BEARING Pe o. 2 Sone aca 12-20FRONT WHEEL/SUSPENSION/STEERING Tighten the bearing adjustment nut to 2030 Nem (2,0-3.0 kg-m, 14-22 ft-lb) once. Turn the steering stem lock-to-lock 5 times to seat the bearing and tighten the adjustment nut again. Loosen the bearing adjustment nut. Torque the bearing adjusting nut to specified torque, TORQUE: 3.N-m (0.3 kg-m, 2 fttb) Toots: EXTENSION BAR 077160020500 STEERING STEM NUT WRENCH 07916—KA50100 Install a new lock washer with the locking tab rearward. Install the fork tubes (page 12-17). Install the fork top bridge and washer. Bend the lock washer along the steering stem. Tighten the stem nut. TORQUE: 118 Nem (11.8 kg-m, 85 fb) Recheck the steering stem adjustment (page 3-17) Tool: WRENCH, 30 x 32 mm 07716-0020400 (1) EXTENTION BARI [2) STEERING STEM NUT WRENCH (1) LOCK WASHER (1) WASHER (2) FORK TOP BRIDGE (a) Lock WASHER (1) WRENCH, 30 x 32 mm v 12-21FRONT WHEEL/SUSPENSION/STEERING Install the following parts. front fender front wheel (page 12-11) handlebar (page 12~ instruments (page 16-10) — headlight (page 16-9) 12-22 11) FRONT FENDERREAR WHEEL/BRAKE/SUSPENSION 45 Nem (4.5 kg-m, 33 ft-lb) é (U model) —. Sp We “~“(B model) 30 N-m (3.0 kg-m, 22 ft-lb) 45 Nem (4.5 kg-m, 33 ft-lb) 30 Nem (3.0 kg-m, 22 ft-lb) 13-0REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 13-1 BRAKE PEDAL 13-12 TROUBLESHOOTING 13-2 SHOCK ABSORBER 13-13 REAR WHEEL 13-3. SWINGARM 13-29 REAR BRAKE 13-11 SHOCK LINKAGE 13-32 SERVICE INFORMATION GENERAL © A work stand or box is required to support the motorcycle. © Use genuine rear suspension linkage and shock absorber pivot/mount bolts. © Note installation direction of the bolts. Lubricate swing arm and shock linkage pivot bearings at intervals specified in the m: © The shock absorber has a gas-filled reservoir. + Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a fire or explosion resulting in serious in- jury. + The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. + Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock ab- sorber. © Broke dust may contain asbestos. + Inhaled asbestos fbers have been found to cause respiratory disease and cancer. Never use an ait hose or diy brash to clean brake assemblies. SPECIFICATIONS unit: mm (in) Trem ‘STANDARD SERVICE LIMIT Rear wheel runout Radial _ 2010.10) | _ Axial 2.0 (0.10) Rear axle runout = 0.2 (0.01) Rear brake drum I.D. 110 (4.33) 111.0 (4.37) Rear brake shoe lining thickness 4 (0.16) _ 2.0 (0.09) Rear shock absorber spring free length [ 242.3 (9.64) 240.0 (9.45) Rear suspension damper compression 20.5 (0.81) TORQUE VALUES Rim lock 12.5 Nem (1.25 kg-m, 9 ft-lb} Spokes 3.7 Nem (0.37 kg-m, 3 ftlb) Rear axle nut 95 Nem (9.5 kg-m, 69 ft"b) Final driven sprocket 4d Nem (4.4 kg-m, 32 ft-lb) Rear shock absorber: Upper mount 45 Nem (4.5 kg-m, 33 ft-lb) Lower mount 30 Nem (3.0 kg-m, 22 ft-lb) Hose joint bolt 30 Nem (3.0 kg-m, 22 ft-lb) Hose lock nut 30 Nem (3.0 kg-m, 22 ft-lb) Spring adjuster lock nut 90 Nem (9.0 kg-m, 65 ft-lb) Damper rod end nut 38 Nem (3.8 kg-m, 27 ft-lb) Reservoir damping valve 18 Nem (1.8 kg-m, 13 ft-lb} ‘Swingarm pivot bolt 90 Nem (9.0 kg-m, 65 ft-b)REAR WHEEL/BRAKE/SUSPENSION ‘Suspension linkage: Swing arm-to-shock arm 45 N-m (4.5 kg-m, 33 ftib) Shock link-to-shock arm 45 Nem (4.5 kg-m, 33 ft-lb) 70 Nem (7.0 kg-m, 51 ftb) 40 Nem (4.0 kg-m, 29 ft-lb) 10 Nem (1.0 kg-m, 7 ft-lb) Shock link-to-frame Brake pedal pivot boit Brake arm bolt TOOLS Special Bearing driver base Spherieal bearing driver Damping valve wrench Bearing remover Needle bearing remover Slider guide, 14 mm Piston ring sleeve Slider guide attachment ‘Common Retainer wrench A Retainer wrench body Pilot, 15 mm Attachment, 32 x 35 mm Pilot, 20 mm Pilot, 17 mm. Attachment, 37 x 40 mm Bearing remover shaft Remover head, 17 mm Remover head, 20 mm Driver Attachment, 24 x 26 mm Driver Attachment, 20 mm I.D. Attachment, 37 x 40 mm Attachment, 42 x 47 mm TROUBLESHOOTING Wobble or Vibration in Motorcycle Bent rim Loose wheel bearings Loose or bent spokes Damaged tire Axle not tightened properly ‘Swingarm pivot bearing worn Chain adjusters not adjusted equally Soft Suspension + Weak spring O7HMF—KS60100 07946—-KA30200 07920-—KA30001 (07946—MJ00100 07931—MA70000 07974—KA40000 07974—KA30201 07974—KA30100 077100010100 07710—0010401 077460040300 077460010100 077460040500 07747—0040400 07747—0010200 077460080100 077460080500 077460050600 077490010000 077460010700 077460020100 077460020400 077460010200 07746—0010300 + Improper rear suspension damping or spring preload ad- justment Hard Suspension + Improper rear suspension damping or spring preload ad- justment ‘+ Spring thrust sleeve binding + Bent shock absorber rod + Swingarm pivot bearings damaged ‘Suspension Noise + Faulty rear damper + Loose fasteners ‘+ Worn suspension linkage pivot bushings Poor Brake Performance Improper adjustment Worn brake shoes Brake linings oily, greasy or dirty Worn brake cam Worn brake drum Brake arm serrations improperly engaged Brake shoes worn at cam contact area 13-2REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REAR WHEEL REMOVAL. “ Bes at (2) BRAKE ROD el 4 "8 , Raise the rear wheel off the ground by placing a work stand or box under the engine. Pull the brake arm pin holder forward and disconnect the brake tod from the brake arm. ‘= Loosen the rear axle nut and adjuster holder nuts. ‘Turn both adjusters so the rear wheel can be moved all the way forward for maximum drive chain slack. Move the rear wheel forward. Derail the drive chain from the driven sprocket. Remove the rear axle nut and left chain adjuster. 13) AXLE LE Pull the axle and adjuster away from the stopper plate. Left the stopper plate clear of the pin on the swing arm’s right side. Remove the rear wheel with the rear axle. Remove the rear axle and rear brake panel. Wm + Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. 2) ADJUSTER INSPECTION AXLE ‘Set the axle on V blocks and measure the runout. The actual runout is 1/2 of the total indicator reading, SERVICE LIMIT: ).2 mm (0.01 in) 13-3REAR WHEEL/BRAKE/SUSPENSION Wheel bearings Turn the inner race of each bearing with your finger. The bear- ings should turn smoothly and quietly. Remove and discard the bearings if the races do not turn smoothly, NOTE + Replace wheel bearings in pairs. For bearings replacement, see page 13-5. (1) WHEEL BEARING Wheels Check the spokes and tighten any that are loose. TORQUE: 38 N-m (3.8 kg-m, 28 ft-lb) Check the rim lock for loose and tighten it to the specified torque. TORQUE: 13 Nem (1.3 kg-m, 9 ft-lb) Check the rim runout by placing the wheel on 2 truing stand, ‘Turn the wheel by hand and measure the runout using a dial in- dicator. ‘SERVICE LIMITS: Radial: 2.0 mm (0.01 in} Axia: 2.0 mm (0.01 in} (1) Gooo (2) REPLACE Driven sprocket Check the condition of the final driven sprocket teeth. Replace the sprocket if worn or damaged. + The drive chain and drive sprocket must also be inspected if the driven sprocket is worn or damaged. DISASSEMBLY Remove the collar from the wheel hub. Toots: BEARING REMOVER SHAFT 077460050100 BEARING REMOVER HEAD, 17 mm 07746—0050500 (3) REMOVER HEAD, 17 mm 13-4REAR WHEEL/BRAKE/SUSPENSION Remove the driven sprocket bolts and the sprocket. aa es & it) DRIVEN SPROCKET, aay \ Remove the bearing retainer using the retainer wrench and at- nae In, RETAINER WRENCH A (2) RETAINER WRENCH BODY TooLs: RETAINER WRENCH A 07710-01010 RETAINER WRENCH BODY (077100010401 heel bearings and distance collar, if necessary =, . Remove the wheel bearings and distance collar, if necessary. pmear. j peanmenemoven. 17mm YY | ia} LerT sie BEARING REMOVER, 20 mm NOTE + Never reinstall old bearings; once the bearings are removed, they must be replaced with new ones. Toots: BEARING REMOVER SHAFT 077460050100 BEARING REMOVER HEAD, 17 mm 07746—0050500 BEARING REMOVER HEAD, 20 mm 077460050600 ASSEMBLY NOTE + Mount the tire so that the arrow (if any) on the sidewall point in the direction of rotation. 13-5REAR WHEEL/BRAKE/SUSPENSION (2) BEARING (3) DUST SEAL (4) RETAINER mcouar ©, “is (6) BEARING (5) DRIVEN SPROCKET Drive the left bearing in first. “ (1) DRIVER TooLs: DRIVER 077490010000 ATTACHMENT, 37x 40mm 07747—0010200 PILOT, 17 mm 07747—0040400 yo 2) ATTACHMENT, a 37 x 49 mm Insert the distance collar into place with the ““LH™ mark to the loft 13-6REAR WHEEL/BRAKE/SUSPENSION ae Drive the right bearing in. (1) DRIVER CAUTION / + Drive the bearings in squarely, with the sealed sides facing out, ‘making sure the left bearing is fully seated. Toots: DRIVER 07749—0010000 ATTACHMENT, 42x 47mm 07746—0010300 PILOT, 20 mm 077460040500 a 12) ATTACHMENT. (D PLOT 20m mA 4247 Use the driver and attachment to drive @ new dust seal into the bearing retainer. Apply grease to the dust seal lip. p ta, a Be pT ccsinen Ista te bean etainernto the hu with the arte 4) RETAINER WRENCH A JIB RETAINER WinENC wrench and attachment. BODY [ign TooLs: RETAINER WRENCH A 07710—0010100 RETAINER WRENCH BODY 07710—0010401 Peen the bearing retainer in four places with a center punch. 13-7REAR WHEEL/BRAKE/SUSPENSION Apply engine oil to the threads of the sprocket bolts. Install the driven sprocket onto the hub and tighten the bolts. TORQUE: 30 N-m (3.0 kg-m, 22 ft-lb} Install the collar on to the wheel hub. REAR WHEEL INSTALLATION Install the brake panel in the brake drum. Place the rear wheel into the swingarm, aligning the brake panel slot with the tang on the swingarm. Slip the stopper plate over the pin on the swingarm. Insert the rear axle through the stopper plate and right chain adjuster. (1) DRIVEN SPROCKET Lex \\s Gy TANG AND s.oT [ay STOPPER PLATE ] (aeons (2) PINT (3) REAR AXLE 13-8REAR WHEEL/BRAKE/SUSPENSION Install the drive chain, mote Install the left chain adjuster and axle nut. ln este ‘Adjust the drive chain slack (page 3-10). Typ) onive’ 5° ore Tighten the axle nut. TORQUE: 95 N-m (9.5 kg-m, 69 ft-b) ‘CAUTION + Hold the axle shaft securely to avoid damaging the puller lever with a wrench Connect the brake rod to the brake arm. ‘Adjust the rear brake pedal free play (page 3-13). (2) BRAKE ROD) REAR BRAKE + Brake dost may contain asbestos. + Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. + Wear a protective face mask and thoroughly wash your hands when finished. Remove the rear wheel (page 13-3). Remove the brake panel from the brake drum. INSPECTION Brake deum Measure the rear brake drum 1.D. ‘SERVICE LIMIT: 111.0 mm (4.37 in) Brake lining ‘Measure the rear brake lining thickness. SERVICE LIMIT: 2.0 mm (0.10 in) 13-9REAR WHEEL/BRAKE/SUSPENSION BRAKE PANEL DISASSEMBLY ‘Spread the brake shoes apart and lft them off the anchor pivot and brake cam. NOTE Mark the brake shoes to indicate their original po: before removing them Remove the brake arm and brake cam. Check the brake cam seals for wear or damage and replace if Tirbust necessary. SEALS BRAKE PANEL ASSEMBLY (3) BRAKE CAM (2) THRUST WASHER 10 Nem (1.0 kg-m, 7 ft-lb) a (1) DUST seat, re Ae, (4) BRAKE ARM (5) INDICATOR PLATE 13-10REAR WHEEL/BRAKE/SUSPENSION Install the special washer by aligning its groove with the tab on the brake panel. 41) ANCHOR (2) BRAKE Apply grease to the anchor pins and brake cam, and install the vee cam cam, Wm + Contaminated brake linings reduce stopping power. Keep grease off the brake linings. Wipe any excess grease off the cam. [3 SPECIAL WASHER ‘Align the wear indicator tab with the cutout in the brake cam and install the indicator over the cam. 11) INDICATOR 7 12) BRAKE ARMS) PUNCH PLATE Install the brake arm aligning the punch mark with the cam punch mark. Tighten the brake arm bolt. TORQUE: 10 N-m (1.0 kg-m, 7 ftb) 15) TAB AND CUTOUT Reinstall the brake shoes in their orginal positions. Install the springs. 11) BRAKE SHOES Install the brake panel on the rear wheel and then install the es rear wheel (page 13-8) 12) SPRINGS 13-11REAR WHEEL/BRAKE/SUSPENSION BRAKE PEDAL REMOVAL Pull the brake arm pin holder forward, and disconnect the brake rod from the brake arm. Pull the brake pedal return spring and unhook it rom the swing of arm @ Unhook the brake light switch spring a Pullout the brake pedal pivot bolt lock pin. SWITCH SPRING @ (2) BRAKE LiGHT oe AS (1) Plvor BOLT —_____, .@ ~ (3) RETURIN SPRING Rofl f Go (4) LOCK PIN (8) BRAKE PEDAL INSTALLATION Install the dust seals into the brake pedal Apply grease to the brake pedal pivot hole and dust seals. (1) DUST SEALP (2) PIVOT BOLT Install the pivot bolt, then set the lock pin. (2) BRAKE LIGHT Hook the return spring to the swingarms spring hook and brake light switch spring ‘Set the brake arm pin holder to the brake arm. 13-12REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER REMOVAL (7) RESERVOIR Raise the rear wheel off the ground by placing a work stand or box under the engine. Remove the seat and side cover. Remove the air cleaner (page 4-4), Loosen the reservoir mounting bands and reservoir. [3) BANDS. Remove the CDI unit from the frame. (1 UPPER MOUNT NUT Remove the upper mount nut and bolt. “ , y fJ ‘Sa > Raise the rear whee! until the rear shock absorber lower mount can be removed and then remove the lower mount bolt. Remove the rear shock absorber. oo DISASSEMBLY (1) PIN SPANNER A (2) LOCK NUT i _ \ Loosen the lock nut and adjusting nut. e is \ \ -_—- 13-13REAR WHEEL/BRAKE/SUSPENSION Remove the spring seat stopper and spring seat. Remove the spring. INSPECTION ‘Shock absorber spring. Measure the spring free length. SERVICE LIMIT: 231 mm (9.1 in) Damper Visually inspect the damper unit for dents, oil leaks or other damage. Be sure the damper rod is not bent. Replace the damper unit if necessary. DAMPER DISASSEMBLY Depress the Schrader valve to release the nitrogen from the reservoir. CAUTION + Point the valve away from you when discharging the nitrogen pressure. Wear eye and face protection. + Do not remove the valve core before discharging the nitrogen pressure. (1) SPRING SEAT STOPPER (2) SPRING SEAT 11) CHECK Om LEAKS (2) DAMPER ROD 13-14