3_ MAINTENANCE ‘SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE FUEL STRAINER SCREEN THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER CRANKCASE BREATHER, SPARK PLUG VALVE CLEARANCE CARBURETOR IDLE SPEED RADIATOR COOLANT COOLING SYSTEM CYLINDER COMPRESSION 34 33 34 34 34 35 35 36 36 3-6 3-9 39 3-10 3-10 DRIVE CHAIN DRIVE CHAIN SLIDER BRAKE FLUID BRAKE SHOE/PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND, SUSPENSION NUTS, BOLTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARINGS 341 312 312 3.13 3.13 34 314 314 3.18 316 3-16 217 348 SERVICE INFORMATION GENERAL + Ifthe engine must be runing to do some work, meke sure the area is well venilice. Never rin ihe engine In an enclosed area, The exhaust canta Nore For engine oil and ol Hite SPECIFICATIONS, Throttle ann tree olay: Valve clearance: IN EX. Cynder compression: poisonous carbon monaxide ras that may cause fess of consciousness ant leat co death. 0.8-0.9 mm (0.031-0.035 in} 0.23 £0.03 mm 0.099 = 0.001 in! (03 mm (6.009 = 0.001 in 100 som 16.0 1.0 kgiom!, 3-1MAINTENANCE Drive chain slack 25-88 mm () ~7-3/8 19) Drive chaia slides depth limit 3.0 mm 10.12 Fear brake pedal tree play 20—30 mmm (3/4— 1-1/4 inn Clutch lever tee play 10-20 mm (3/8—3/4 in) cont Rear Tue size aan '90/100-19 BEP Tube typel 190-16 69P ube type Cold tre pressuce | Driver onl 190 17.90, 22) I 150 11.50, 22) MPa tkgiem psi) Driver end one passe 150 11.59. 22) 175 (1.75, 251 Tire brand DUNLOP BRIDGESTONE T Minimum tre treae depah Fron ‘mim (0,06) Fear: 2.0 mm (0.08 tn TORQUE VALUES Spatk phag 12 Nora (1.2 ha-mm, 9 Fb) Rave axle nut 95 Nem (9.6 ko-m, 69 ft} ke 3.8 Neo (0.38 kgm, 2.7 ‘oko resorvait cover ecrew $.5.Nem (0.15 harm, 4.1 feb TOOL Common Spoke wrench, 6.8 x 6.2 mm 077010020300 3-2MAINTENANCE rt MAINTENANCE SCHEDULE rior the PRE-RIOE INSPECTION in the Quacer’s Manual at wach schertulad meantenance periad “cy a NOTES = THRGTTLE OPERATION [+ Teameureon cHoKe SPARK PLUG = | vawve = | caneuneton Die SPEED { naotaTon GOOLANT 7 feooune s¥sTem | [ome sean ieee [Ste stave 1 t i suseewson lee | wuts, Ts, FASTENER nove T an r WHEEL s-TineS INOTE 4) ififaia vi weap aeaRNGS Sully sone ty a aunOTEA HOOISG, ws We Bore HS he “* tn the interest of safety, we tecommend t Nores 19 be serviced only by an authorized Honda desler established here 1. At righer odometer readings, 1 he frequency intervl 2. Service mere frequently when riding in unusually wat ar dusty a 3. Service mere frequently when riding in roia or at full rattle 4. Service more frequently shen ring OFF-ROAD. 58. Replace every 2 years, or ar the indicated odometer intervet, whichever comes fist Replacement requires mechanical shit 3-3MAINTENANCE FUEL LINE Chock the fust tne for detedovaion, damage or leakage. Roniaco tha fue! ae if necessary. FUEL STRAINER SCREEN _ fasoline is extremely flammable and ix explosive under cera conditions, Work in a well ventilated area sith che engine ‘Stepped. Do not smoke or allow flames or sparks in the work cerca or shere gasoline is stored. (3) SCREEN Turn the fuel valve OFF, Rorrove tho fue! cup, O-ring and stainer and pour tha contents of the fob cup into 2 suitable container ‘Wash the soraen and cup in clean non-flammable or high flash point solvent Roinetall the strainer, O-ring and fuel cup into the fuel valve body, moking aura that the O-ring ie in piace: Tighton the Tusk eup securely (FUER CUP note + Be nat aver tg nthe fal eup. After installing, rafil the tank and turn the fuel velve ON and tcheck thot thete aro no loake. THROTTLE OPERATION Chace the trots atip for smooth operation: complets oper: ing and automatic closing in al steeting positions. Make sure thate no deterioration, damage, or kinking in the ttle cables. Ruplace any dacayed parts LLutricate the throttle cables ipage 2-7} if throttle operation is Measure throttle erip fee play at the shrotde giip fl FREE PLAY: 2~6 mm (1/8—1/4 fal Throttle atip Hee play can be adjusted at either end of the throttle cable ‘Minor adiustments are made with the upper edius the lock nut and tun the adjuster je netease oF ders 3-4 \ se res (LOCK NUT (2) UPPER ADJUSTER.MAINTENANCE Major acjustmants ara mato with tha iower adjuster, seat and eft side fairing 19 the lock nuts and turning the CARBURETOR CHOKE Check for smooth upper choke laver operation, Lubricate the choke cable if the operation in not smooth, AIR CLEANER Remove tha tive noite attaching the ak Cleaner cat replace the at cleaner (1) cHoKE and install the air claaner cate |MAINTENANCE CRANKCASE BREATHER Remove the drain plug from the tube and drain the deposits Rainstal the drain plug. NOTE + Service more frequently when 1 aden in rain, or st ful throttle cy pran eLug” 7 SPARK PLUG (2) SIDE ELECTRODE 0.8-0.9 mm {0.031 0.035 in RECOMMENDED SPARK PLUGS See T__Nax not Stanaara cAgEH uazreno | Disconnect the spark play cap and clean any dirt from around the spark plug base, Remove and discard the spark plug. Measure the new spaik plug gap using a wire-type fecler gauge, ‘SPARK PLUG GAP: 0.8--0.9 mm (0.031—0.035 int ‘Adjust the gap if necessary by bending the side electrode carefully and install the plugs. TORQUE: 12.N-m (1.2 kg-m, 9 feb] Connect the spark plug caps VALVE CLEARANCE INSPECTION _ ; ay TiMING HOLE CA NOTE % Inspect and adjust valve (below 35°C/95°F) jarance while the engine is cold sove the cylinder hood cover Ipoge 9-3). Remove the crankshaft hole cap and timing hole cap. te the ciankshalt coumtereockwise and align the rrark on the lytheel with the index mark on the left crankcase sure the piston is at TDC {Top Dead Center) on the com (4) CRANKSHAFT HOLE CAPMAINTENANCE Check the valve clearance by inserting a feeler gauge between the cam lobe and vaive fitter. VALVE CLEARANCE: Intake ond Exhaust: 0.23 + 0,03 mm (0.009 « 0.001 ia) the clearance is no: coreect Remove the camshatts age 9:3). Remove the valve ters anc shims. Nore De 0% allow to fall shiny into crankcase The shimis) may occasionally stick to the titer ark all itters and shims co ensure correct reassembly. It fs easy to remove the vaive lifter with a valve lapping too! or magnet. + Hemave the shims Ciean the valve retainers with compressed air Measure the ahim thickness with a micrometer and recerdit Js0 the chart on tho following page to select the shims neadad to bring the valve claaanoes within speciticstion Note Sixty: five shims are avaliable in thickness intervals of 0.025 mm. The thinnest is 1.200 mm the thicket #8 2.800 mm. To conten your shim choice, you may use the following a=b-c+d 1; new shim thickness recorded valve elaarance Cc snecilied valve clearainoe 4 old shim thickness oxomple: recorded valve clearance: 0.18 ram bid shim thickness: 1.750 mm specitind valve clearance: 0.23 em 9-018 0.29 +1.760 a7 now shim thickness = 1.700 mm nore 1.200 mm 1.225 mm 1.250mm 1.275mm | If the requited thickness of the new shim is more than 2.800 mm, tho valve eeat i probable heavily carbone, lace the seat, racheck value clesrance and taselac! theyrs MAINTENANCEMAINTENANCE valve retainers, aac 4) VALVE LIFTER Lifide 08 to the valve lifters Jnstall the shims on Apply molybdenum Install the valve lifters into valve lifter holes. nore + Replacement Hifters come in four different thickness. Be @ to recheck valve clearance whenever a iter is r= he shinis and valve titers in their origina! positions, Install the camshafts {pege 9-16) end rotate them by rotating the crankshaft counterclockwise several times. ve clearance. cylinder head cover {page 9-19) CARBURETOR IDLE SPEED NOTE + inspect and adpist idle soeed after ad other engine adh suistments are within specificattons. +The engine must de warm for accurate adhusiment. Ten minutes of st riding 's sufficient. Warm up the endine. Support the motorcycle in an upright position on level ground | and shift the tansmission into neutral | Check the idla speed and ails by turning the throttle stop screw if necessary. IDLE SPEED: 1,300 100 mia-*(tprm) RADIATOR COOLANT | | Check the coolant vel of the reserve tank with the engine runaing 9 normal operating temperature. The lever should be between the “UPPER” and “LOWER” fevel lines. Ve 8 ienecessiry, remove the gle and reserve tork wap then fi the “UPPER” level line with 9 50/50 mixture of distilled ix 3-9MAINTENANCE COOLING SYSTEM Moke sure the hoses are in good condition: they should not show any signs of deterioration Replace any hose thet shows signs of deterioration, Check that all hose clamps are tight, Aemove the right side Faring (page 15-2} and rodioter geile. Check the air passages for etogging or domage Straignten bent fins oF collapsed core tubas and remove in Sects, mud 07 any obstructions with compreseed air or tow water pressure Replace the radiator if the st flow is rostriced over more than 30% of the radiating surfoee For radiator replacement, rafer to page 5-5, CYLINDER COMPRESSION Warm up the engine to ermal oporsting temperature. ‘Stop tho angiro, dleconnsct the spark pig cap and ramove the ‘park plug. Insert the compression gauge. Open the throttle all the way ond crank the engine with the starter motor. Crank the angina ‘unt the gauge reading etope rlaing. The maximum reading 'e usually teached wehin 47 seconds, ‘COMPRESSION PRESSURE: 1,596 = 96 KPa (16.0 = 1.0 kg'em?, 228 + 14 psi) 1 comprension ia high it indicstes thet carton depasite heve sccumulated on the combustion chamber and/or the giston 1 compreasion ig low, pour 3-6 02 (0.10.2 US. o2! of clean engine oil inte the cylinder shrough the spark plug hole and recheck the compression. 1 the comproasin increases from the provieus valua, check tho 10" rings, the same as the previous value, check the valves for leakageMAINTENANCE DRIVE CHAIN un at 1 Never inipect or adjust the drive chain while the engine i ran nt CHAIN SLACK INSPECTION ‘Stop the enging, shift the sransmission into neutral enw sup i) port the motorcycle on its sic Measure the drive chai stack in the lower drive chain run miauvay between the sprockets SLACK: 25-35 mm (1-198 is) CAUTION ain Sack, 40 mun (1-5/8 ir) OF erore, may damage ADJUSTMENT {Loasan tha rear axe nut, then turn bat adlusting muts equally Lunt the chain slack is correct caurion + Mate sure the same index marks on both the teft and right ad- inwsiers alten with te ends of the cut-ouis Tighten the axle ou TORQUE: 96 Nem (9.5 kgean, 89 fib) Check the ehsin siack and tree wheat rotation. Chock the chein weae label. It the rad zona on the labs! aligns ith, orig hayand the arrow mark, the chain must be replaced REPLACEMENT CHAIN: Daido: 0.1.0 870VC 7-102 Takasago: RK52070-1021 Inspect the cfive chain and sprockets for damage or wear. A coriva chain with damaged collers. loose gins, or missing O- ‘rngs must be reaveced. Replace any. sorecket which is Gam= ‘aged or excessively worn. + Never installa new diva chain on worn sprockets or a worn jnive chain on new sprockets. Bott chain anid sprockets must he in goo consdtion or the replac spcockets wilt wea rapidly. (1) oRIVE CHA ~ « curour € END Soma rT I ane ye) aeh ia r ADJUSTING NUT 3-11 j j | iMAINTENANCE sabjication and cleaning: The crive chein on sis motoreycto ie oqvipped with small O rings betwaen the hk plates. The O-rings can be damaged by Zam cleansre, high prescure wachers, and cartain solvents, jan the chain with eoepy water. Wipe éty end tubiicete only sith SAE #80 oF 90 gear ol. Commercial chain lubricants may Contain solvents whieh could damage the rubber O singe DRIVE CHAIN SLIDER Remave the drive sprocket cover Inspect the chain slidar for excessive wear. SERVICE Cit fom upper surface): 2.0 mm (0,12 in} Install the drive sprockat caver SPROCKET! cover BRAKE FLUID [Check the front brake Hid chrough tha eight glaees ifthe love 's wsibla, remove the covar, cat plato ané dophragm. Fill the 0 the upp? level with DOT 4 fluid fram a seated con och the system for lake, cauTIOn “move the recervir cover unl the handlebar has been turned 1 that the reservoir is lee, Afferen: ispos of [Tend a they are not compatible ther. + Do» ow forsian material 10 enter the system when filling A void sting the usd om painted, plastic or rubber parts. Place rag over these ports whenever the system is serowed, 4 for brake blaoding procedures Taghton the ‘ows t0 the spovifiad torque, TORQUE: 1.5 Num (0.15 kgm. 1.1 fib} 3-12MAINTENANCE BRAKE SHOE/PAD WEAR BRAKE PAD WEAR CCheck the biake pads for weer Replace the txake pads if they are worn down to the wea CAUTION Aways replace the Brake pads as a vet to assure even dist pres BRAKE SHOE INSPECTION Replace the bake shoes # the arrow on the br with the reference mark "A" on full applica brace pedal aligns BRAKE SYSTEM roke hoves end fistings for detetioretion, cracks | BRAKE PEDAL HEIGHT To Adlust Loosen the stopper Retighten the lock note + Alter adjusting the brake hight switch and brake 92: adjusting brake pasal tee play FREE PLAY: 20~30 mm (3/4—1-1/4 in) 3-13MAINTENANCE HM adiustiment is swcessary, turn the reae heake adjusting nut NOTE + After adjuating the brake pedal froo play, broke light switch operation and adjust if necessary pais) BRAKE LIGHT SWITCH TZ ADJUSTING NUT (1) REAR BRAKE NOTE N ‘ LIGHT swiTcH 7 Always adjust the reartrake ight ewteh aftor adjusting the Drake: pedal play and height. +The fromt broke light eviteh doos require adjust [Adjust the brake light ewitch 60 thar the breke fight will com fon when the brake pedal ie deptaasad 20 mm [3/4 in}, and broke engagement begine, Hold tha ewitch body and turn the ‘adjusting nut. Do not turn the ewitch body. HEADLIGHT AIM ADJUSTMENT Adivot vertically by turing the vartics! agjueting craw ‘Adjust horizontally by tureing the horizontal adjusting screw. Note © Adjust the hoadight bear as specified by local laws and regulations ng drivers “An improperly adjusted Deslighe may blind one the roi far u safe distance CLUTCH SYSTEM the clutch cauie and clutch lever for loose connections, excessive play, oF oshwr damage, Replace ar repair if neces: sav, Gisconnuct the clutch cable at the upper ene. inspect the cable for kinks oF damage are thoroughly tubricets @ cable and pivot point with a commercelly available cable lubricant to prevent premature wear. instal the cable CLUTCH LEVER FREE PLAY 10-20 mm 384d) M 6 the clutch lever free play at the up of the fever EVER FREE PLAY: 10-20 mm (3/8—S/4 in} 3-14MAINTENANCE iment can be sade with the upper adjuster i ROCK NUT > th foosen the lock nut and \ OECREASE Slide the cubber cover off the edu fadjist the fice play by turning the adjuster 7 tntan the lock nut with a peir of pliers after asjustment Note ‘Do not expose the adjuster threads more then 8 mm 10.32 “~ NAgt a G50 ansusten necessary, « mejor egjustment cen be mede with the tower duster Loosen the adhuster lock nut at the cite lever anc turn the aduster in completely, Then back it ou! 2 tuins and tighten the Fock Loosen the cable lower acjuster tack mut. Turn the achusting nut to obtain the specified free play. Then tighten the lock mot SIDE STAND Chock the rubber pad for wear or damage Pepiace the rubber pad if wear extengs t0 the wear lina Check the side stand operation The side stand should tower eesly toe Fest stop, then lock 10, suppon the motorcycle 2s the rubber touches the ground, When tha matoreye ig litod upright, the stand should I the sido stand dose not move freely, dieessemble it Gt Type: Support the motorcycle on ite side stond, ‘ation: the side stand should fully you lit the motorcyete upiight I the sige stand does not retract autornaticaliy,lubrica side Replace the side stand pivat bolt or springs, if the side stand dP does nat rewact normally, Move the side stano skteways with force to check if the side stand pivot '$ worn, 3-15MAINTENANCE it SPRING me Pn Remove the rewuen spring at the ratraated position Romove the pivot bolt and remove the sido stand ascombly fro the fame. Check the following parts for waar or damage: inside of the pivot and pivot collar pivot dust seals LLubticate the pivot area with clean grease and reassemble the sid9 stand, cauTon + Anstait the dust seal with its mark side facing tn. Lf | 5 aaah dir eh Ree aor bruni” npr eeas ico | the set ios after installing the pivot colle Recheck the side stand movement SUSPENSION + De not ride a vehicle with faulty suspension. + Loose, warn ar damaged suspension parts impair vehicle stabilly and control FRONT Check the action pf the fork by compressing the suspension CChack the entirg fork assembly for leaks or damage. Replace clamaged components which cannot De repair. Tighten all nurs anc Dots REAR Support the motoreycla securely on level ground Chozk tor wioen swingarm boaringe by grabbing the roar whoo! a3 shown, and attempting ta mova the wheal sida to side. Fi place the bearinge if any loosenoes is noted (page 13-20), ‘Check the ection of the roar shock abserbare by comprossing, thers sovoral tings, [Check entire shook absorber assembly For faake or damege, Alepiace any demoged comporonts which cane: be repaired. Tighton oll puts and bok. NUTS, BOLTS, FASTENERS hook that all chaseie nute ond bets are tightoned to theit cor rect torque values [page 1-6) at the intervals shown jn tho Maintenance Schedule (page 3-2 Chock all cotter pins. safety clips, hose clamps and cable 3-16MAINTENANCE WHEELS/TIRES TIRE PRESSURE NOTE + Tipe presaure should be checked when ties are COLD. Check the tire pressure, aecording to the table below, [Check the tirae for evte. imoadded nae, or other damage Check the front and rear whaels far raeness (Rafer to sections 12 and 13) Measive the teoad depth at the canter of the ties. Roplace the tras when the trond depth roaches the following Minimum tread depth: Front: 1.5 mm {0.08 fa) Raat: 2.0 mm (0.08 in) > Inepset the whee! rime and spokes for damage. Tighten any loose spokes. TORQUE: 3.8 Nien (0.38 kg-em, 2.7 fet) Foot Spoke wronch, 5.8x6.1.mm 077010020300 Check wheel rim runout faage 12-8, 13-4, 1) SPORK WRENCH Recommandad tire prassures and tire sizes: a 1 Front ear Five ize | 90/100-19 SEP (Tube type) | 120/80-16 63P (Tube type! | Cold tie pressure | Onver onty 399 11.80. 22) 190 (1.50, 22) Kea ikgtem?. pst Jae ae fl [eriocestone 3-17MAINTENANCE STEERING HEAD BEARINGS the contral cables ca not interiere with handle: ‘ont whpal off the around: the fork moves freely from side to side. Ifthe fork moves unevenly, bines, of tearing head hearings (Section 12) 8 vertical movernant, inspect the 3-18