_1_GENERAL INFORMATION [Generar sareTy 1-1 TORQUE VALUES 15 | SERVICE RULES 4-1 TOOLS 1-7 | ooeL eninicaTion 12 CABLES HaRNess ROUTING vo | | speciricaTioNs 13 Le GENERAL SAFETY rer [foke engine must be eurening (0 to sorce work, rouke sure the svea i well-verilated. Never run the englae i an enclosed. The exhaust coaiaing potsonous carbon monoxide gas that may cause loss of contelousness and leat 10 deh, ‘sar vei eal eer ne! ae SERVICE RULES 1. Use genuine HONDA or HONDA design cpasifioations may dame; 0 the erotoreycia 5. Use only matric tools when servicing this mot fasteners 44 Install new gaskets, O-n When tight nally in ‘cotter pins, ane! lock ple any sliding surfaces batore Lae somnbly. wehen + ing bo'ts or nuts, begin with the larger diameter or inner baits Fist. Then tightan ta the ep tops, unleza 2 particular sequence ie specifi. Cleon parte in non llaewoable o¢ high flash point solvent upan disassornbly Inhiaied asbestos fibers have been found to ceuse respiratory disease and cancer. Never usean air hose or dry brush v0 sloan drake assemblies. Gasoline i extremely flammable and is explosive under certain conditions work ina well ventilaced arco with the engine stop: ‘ed. Do noe smoke o7 allow flartes or sparks in the work area fr where gasoline is stored. caution see enzine of may cause skin cancer ifropeaiey tet incon tact with the skin for profenged periods. Akhough ths i nlikely unless vou handle used ot on a day basis, io stil saeviseble ro thoroughly wash sour keds with soap and water (25 coon ax possible after handling used oil omnended parts and lubricants or their equivalants, Parts that don’t meat HONDA’s Use the snecial tools designed for this product to avold damage and incorrect assembly. royce. Metric Bos, nuts, anc screws are not interchangeable with English ssembling. iad eorque diag After raassembly, check all parts for proper installation and operation. 1-1GENERAL INFORMATION MODEL IDENTIFICATION 2) CARBURETOR IDENTIFICATION NUMBER \ ‘cerbureto" iontfieation umber ie on tho right ede of, rotor body, (a) Coun wage, S$ Z “The frame cori number ie stamped on the right sie of the stooring hand The engine serial number Io stamped cn the right side of tho erankesse 1-2(GENERAL INFORMATION SPECIFICATIONS DIMENSIONS | Overa® lena [ Overae wiath Averat neiont Wheelnase Sround cieerance Ory weight curs Tyee Front suspension, travel el | Drives oniy | | cod tee Driver and one passenger Front brake, ining ewept area Roar brake, lining swept aren | Fuel reserve capacity Caster angle Fork fork cil eapenty NINE Type | cvinder arrangement Bore and stroke Displacement Compression ratio | ot eapaciey Coolant capacity Labiieation eye Cylinder compression Intake valve | exnaust volve | valve etesrance (Cold) Incake Ile speed SPECIFICATIONS 2,088 mm {82.1 in) ND, G. GHl types: 2.088 mm 805 mm (31.7 in) 1.120 mm (44.1 in) 1.350 mmm (83.1 1) 250 mm (9.8 118 kg (260 Ibs) ize 82.5 10 Diamonds = | Telescopic fork, 220 mm (8.7 in) { Swingarm, 200 roma (7.8 in) [60 011.60 balers 150 kPa {1 60 kgien 2 psi 180 kPa (1.80 kgicm, 22 sid [128 kPa. 78 kglews, 26 | ‘Single dige, 306 cm? (47.4 69 in} Intrnlexparng shoe, 108.6 er (18.1 ain) Sloteare 98 U8 ga, 1.88 ip oa 118 leere (0.42 US ga 0.38 trp sl 2ees0" 88 rm (8.8 Aid om 13.9 US Uister cooled én Sole cyte acne’ 188 trom vata 700% oA 8 mim (218 x 2.56 0) Faye: 8 510 Ba 8 men (2. 7002.55 i) aadernns) F rye! 238 em 1146 evn) iro Chain dive DOC Te tear (1.69 US et 1.41 imp at ater assembly 13 see 1°27 US oe 1.44 imp a ter eon 1.8 Iter 1.08 US et, 088 Impet ee eas tod ee 160.2 D5 KPO 16.02 1.0 koem 228.414 pal | lovers | {be abe | | age ea0c | rele se atoc | 0.23 mm (0.009 int | 0.23 mm (0.009 int 1,300 + 109 msn“! pen) |TEM {ABURETOR | Carburetor type/venturi dia, | Idensitication number Pict serew apering {rive TRAIN | Cuter Transmission Primary recuction Final reduction Gear ratio 1 { 1 | w | Gear shite pattern ELECTRICAL, Titian ignition timing ij Atternator Battery capacity Spark olug Soark pug op | Main fuse | Heaaiant tuentow beam Position tighe | Tain sige ight Taibrake eons instrument tate | newreat nateata High beam indi | Tuin signal indicator invnat Fu asvance GENERAL INFORMATION SPECIFICATIONS KEIMIN/Q2 mm (7.3 fn | 20 spa F typo: PD 6BC Gil type: PD 6eB 112 Gil tyoe: 2.58 V4 rv 10.88 in | Wet mult-place ‘-spaad constant mach | 2.7272 ieor22 | 3.1838 (4113) 2.8461 (97/23) [12777 e2n@) 1.393 (28/21) 0816 (26/24) | opsas (23/255 | 0.7e87 22/2) Left foot operated return 5 co ‘8° STDC at sale 30° BYDC at 4.500 min lpm) = CRIEN-9 - {6.8—0.9 mm (0.637 0.036 in) 208 OMx3, 16A81 12V 60 vise W vaw vziw iv 8 wi2IW ViTWwe 1Zv34W virw Zv34w 1-4GENERALINFORMATION TORQUE VALUES | my | treed | __ TORQUE : Cylinder head cover bol | 8 6 4211.2, 9 Samsha‘t hele Dok 6 | 6 | waza inden eas cap 2 | 10 | 405 331 ankoase vover bot 13 6 | 1019.0.71 ‘yaied bat 1 | 12 | 110109.0, a0) i Pamary drive dee ut 1 | 12 | 95085, 60) | Gluten center lock rt 1 | 16 | cowo.4) i Oi rain bot + | 22 | 2525.19) i ‘Spark plug 1 1000 | 1241.2, 8) i Crane boi 12 6 | azo i Campiate bel \4 6 | 1a2e Stoner rt bolt 1 & | 1214.25) Appiy locking agont ro the thraads Ot soe bot 1 7 | reav2.9) 2 & | taia to wate 0 \4 7 | waz | starter etch outer bol los & | 1611'5.12) | Appty locking agent to the throods Temperature sensor } 4 = 10 14.0, 7) Apply sealant FRAME ory | Theed TORQUE 5 | as QTY | ia een) Shem gr, penn Sicering stom [a | 24 TB ite 88) | Steering bearing adjustment nut 1 | 26 510.5, 4) lear hole bolt a 8 taiD8 37 | Sooke nm | 3.8 10.38, 2. | Fort exe + | 2 | 65165,47 | Front ane Holder a 4 € | tain29) | Reor one xt + | a i959) | | Shock absorber mounting bolt {Low 1 10 45 14,5, 33) | | Wopen | 1 10 6516.5. 47 | Fore top pinch tote [4 8 93.13.3241 | | Fovk bottom pinch bok ¢ 8 33103,24 Smingerm pivot bo 1 1% oio.es| | Shock tinkering bolt +) 42.) 305 110.5, 75) Snovk lnkto-shack erm bot + | 42 | 1050.8, 75) Shock arta frame bel + 42 1058008, 78 Brake hove of bol 3) 40 | (355, 25 Boke hose fort ester cyireer side) | 1 «| 109.5, 25) fbroke howe side) 1) 40 | 44a, 39) 2 to | taato; | ! Brake pipe nut 1-5GENERAL INFORMATION Thread TORQUE | rreM Y j REMARKS | Catiper mounting bolt 2 Master cylinder cover screw 2 3 4 Brake lever pivot nut 5 Front brake light switch screw 4 Brake pedal bolt + 3 8 8 2 catver nt |For ska bin on | ro amore [a siterip nae i [AoW # locking agent tothe reads Thermostatic switch 1 ss Srake caliper bleed va “Torque specificavons Fisted above are for specific lahtenina poi values below a specification Is ot fisted folfow the standard torque STANDARD TORQUE VALUES TORQUE Nom tkqvn, feb TYPE TORQUE Nem tko-m, 1b) | Smeidor mur | 510.60, 3.6) 410.40, 23) 8 mm bott. nut 8 mm bof, nur bok with 8 mm head — | 9 (0.8, 6.5) 0 mn Bott, wu 35 (3.5, 25) ‘8 mm flange bart, nu! 12,9) | 2 mov bolt, nut 5515.5. 40) 8 mm ange Dat nu! 2.7, 20) { L {oe [10 mm ange 4c }GENERAL INFORMATION TOOLS SPECIAL DESCAITION Valve hole procectoy Driver base Dever shat Fork sea anver Shap ring pers | Guten cemer notte | Needle beanng verover Searing removes, 15 mm remover shaft, 15 mm Bal race remover | = caver nanaie sorber compressor attachment Crankcase assambly toot = collar assembly thueated shart | Guests oa mer. 4.5 mm New for this model 1-7 TOOL NUMBER O7HMG —MR7O008 07947—KR 10109 07947—KR10000, 07947-37010 07631—0070000 07914—323000 97916—KA50100 07923-KE 10000 (0793) —MA70000 (07936 —KC 10000 07936 -KC 10500 107936-KC 10100 07936 KC 10200 07741—0010201 ‘O7HNM—MLo0 100 07946-4300101 07948—MJ00100 (07983 -Myi 0000 Myio100 NJ10200 = 11510000 =KN30101 (07965 — vn100000 (07868 —vmoo100 o7g68— vmoz00 (o765— vm00300 O7HMH—MiLCO100 (07808—4730001GENERAL INFORMATION DESCRIPTION Ft tevel gauge Tock rut wrench, 20 x 24 mm 0020700 Gear holder (010200 | etainer wwrencts body 0010401 Retainer wrench 3 0010200 Flywheel hoicer ‘6.40000 Frotor puller 002000 | (0010200 steachment, 32 » 35 mm fatcachment. 37» 40 sy | ‘steachment, 42 x 47 mm ‘pitachment, 52 x 55 mm ‘attachment, 62 » 08 mm 0010500 ‘attachment. 24 5 26 mr (0010700 0040300 040400 —0040s¢o Pos. 22 carn Flot, 28 an 07746 -0041100, 07746 —cos0400 07746 -cos0 100 07746 —o0s0s00 ¢7747-0010100, 077470010600 077490010000, 077570010000 (07GME—001000 (o7Gme—0019100 07701 -0020300 (07411 -0020000, THsk 07308--002000 eating remover head, 15 son Bening remover shat Bearing remover head, 17 Fark seal drives body Fark seal devas attachment bri ave spring compressor ‘Shock absorber compr ‘Spoke wrench, 5.8 x 6.1 rm Digital muttimeter ie tester [KOWA) ic tester | SANWA VALVE SEAT CUTTER DESCRIPTION Too NO Seat cuter, 24.5 mm \aS® EX 07780-0010100 Seat etter, 27.8 rom la" 07780-0010200 ] Fit cutter, 28 mm 122° EX 07780-00120 | |) Rat cuter, 28 me £22" BI 07780 -0012:00 19 | nero ete. 30 rem (60° 17 07780-0014000 i | intair eutter, 26 ren (6D? EX) 07780-0012500 Cater noir &§ mn 07781 ~0010800 18GENERAL INFORMATION CABLE & HARNESS ROUTING ting cates and wite harnesses: vwve robo surentisseages O x ‘hire harnesses sway trom the exhaust pipes and hot parts sommes ere seated in their grooves properly er clamping, check 28 nol Interfere with long the handlebars ahouid not be laut, have excessive slack, be pi ]acent oF surrounding parts * be stick oF bind 0: CORRECT +: INCORAECT 1-9GENERAL INFORMATION (1) FRONT TURN, :2) FRONT TURN SIGNAL WIRES SIGNAL WIRE '3) SPEEDO. acter cage (12) WIRE BANOS (13) CLUTCH CABLE (6) G, Git, NO type: (7) RIGHT HANDLEBAR SWITCH WIRE Nee x (8) IGNITION ‘SWITCH WIRE (36) TaRorTe CABLES (18) SPEEDOMETER ABLE tro) eaake Host P | TH CLUTCH (9) SPEEDOME CABLE CABLE 1-10GENERAL INFORMATION G1, ND type: (1) HORN i UGHT SWITCH S (8) REGULATOR) LECTIFICR ~ a) STARTER,GENERAL INFORMATION (1) stanTeR RELAY [Letras 6 peo FUSE BOX CONNECTOR 151 9 PARED) FUSE SOX CONWECTOR cn (es REGULATCR 4 Br. | conectan RPT BSS // | ‘\ SH f \. (starter Motor NS Af DRAGE7 (12) ENGINE BREATHER DRAIN TUBE