IMPORTANT SAFETY NOTICE REE reticares. s strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates v possibility Of personal injury or equipment damage Uf instructions are mot followed, NOTE: Gives helpful information, Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to Note that thia manual contains some warnings and cautions against some specific service mathods which could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Pisase 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 passibly hazardous consequences of each conceivable way, nor could Honda investigate such ways, Anyane using servi WHF OF NOt recemmended by Honda, rest satisty Min: thoroughty that neither personal s be jeopardized by the service methods ar toals selected ty Nor vehicle safetyHOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency and Califor- Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial! wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 18 describe parts of the motorcycle, grouped ac- cording to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section, Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subse- quent pages give detailed procedures. If you don’t know the source of the trouble, go to section 20, Troubleshooting, All information, llustrations, directions and spect fications included in this publication are based on the latest product information available at the "@ of approval for printing. HONDA MOTOR CO., LTD. teserves the right to make changes at any time without notice and without incurring any obligation whatever. No part of this publ may be reproduced without weit ritten permission. HONDA MOTOR CO., LTO ‘SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM | COOLING SYSTEM ENGINE REMOVAL/INSTALLATION me fo} CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/STARTER CLUTCH ENGINE CYLINDER HEAD/VALVES CYLINDER/PISTON CRANKSHAFT/TRANSMISSION r FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION a o i} cuassis | HYDRAULIC BRAKES BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER ELECTRICAL LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING EEE g Me Date of Issue: September, 1988 © HONDA MOTOR CO., LTD.1. GENERAL INFORMATION GENERAL SAFETY 1-1 TOOLS 7 SERVICE RULES 1-1 CABLE & HARNESS ROUTING 19 MODEL IDENTIFICATION 1-2 EMISSION CONTROL SYSTEMS 1-16 SPECIFICATIONS 1-3 EMISSION CONTROL INFORMATION TORQUE VALUES qs; LABELS: TAR GENERAL SAFETY om = Ifthe engine must be runing todo some work, make sue the Gasoline is exremely flammable and fi explosive under cetain dvea is weliventlted. Never ram the engine in an enclosed conditions work in 0 well venlated arce with the engine ares. The exhaust contains polsonous carbon monoxide gas ‘hat may: couse lass of consciousness and lead to death. The battery generates hydrogen gas which can be highly explo- sive. Do not smoke or allow flames or sparks near the battery, especially while charging it Inhaled. asbestos fibers have been found co cause respiratory disease and cancer. Never use an air hose or dry brush (o clean brake assemblies. Use an OSHA-approved vacuum eleaner or ‘alternate method approved by OSHA designed 10 miniize the hazard caused by airborne asbestos fibers. + Therear shock absorber contains nitrogen under high pres- sure. Do not allow fire or heat near the shock absorber. + Before disposal of the shock absorber, release the nitrogen. SERVICE RULES stopped. Do not smoke or allow flames or sparks in the work ‘area or where gasoline is stored. The battery electrofste contains sulfuric acid. Protect your eyes, skin and clothing. In ease of contact, flush thoroughly with water and call a doctor if electrolyte gets in your eyes Do not remove the radiator eap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine must be cool before servicing the cooling system, CAUTION: Used engine aif may cause skin cancer if repeatedly left in con tact with the skin for prolonged periods. Although this is un- likely unless you handle used oi on a daily basis, it is still ‘adviseable to thoroughly wask your hands with soap and ‘water as soon as possible after handling used vil 1. Use genuine HONDA or HONDA-recommendod parts and lubricants or thelr equivalants. Parts that don’t meet HONDA’s design specifications may damage to the vehicle. 2. Use the special toals designed for this product to avoid damage and incorract assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts, and screws are not interchangeable with English fas: reners. 4, Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. ‘5. When tightening bolts or nuts, begin with the larger-diameter or inner bolts first, Then tighten to the specified torque diag: ‘nally in 1-5 steps, unless a particular sequence is specified Clean parts in non-flammable or high flash point solvent upon disassembly, Lubricate any sliding surfaces before re ion and operation. 6 assombly, 7. After reassembly, check all parts for proper inst 8. Route all wires as shown on pages 1-9 through 1 14. Cable and Harness Routing, 1-1GENERAL INFORMATION MODEL IDENTIFICATION "88 SHOWN: After '88 Similar: “The vehicla identification oumber {VIN} is ettached to the right side of the down tube. a, (2) FRAME SERIAL NUMBER ‘The frame serial number is stamped on the right side of the. The engine serial umber is stamped on the right erank- steering head ccase below the rear cylinder. (4) CARBURETOR IDENTIFICATION NUMBER ‘The carburetor identification numbers are on the carbure- The color label is attached to the rear fender under the tor body intake side. seat. When ordering a color coded part, always specity its desig ated color cade, 1-2GENERAL INFORMATION SPECIFICATIONS ITEM ‘Overall length Overall width Overall height Wheelbase Seat height Foot peg height Ground clearance DIMENSIONS ‘SPECIFICATIONS 2,085 mn (82.1 in) 750 mm (29.8 in) 1075 mm (42.3 in) 430 mm (58.3 in) 778 mm (30.6 in} 355 mm (14.0 in) 185 mm (6.1 in} Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Oi capacity + after disassembly with ol fi after drairing Coolant change Total system Coolant capacity Lubrication system Air filtation Cylinder compression Intake valve Opens: Closes: Exhaust valve Opens Closes, Valve clearance (cold) intake exhaust Engine weight Idle speed Dry waight 168 kg (370.3 1b) Curb weight 184 kg (405.6 Ib) FRAME Type Twin tube diamond, alminium Front suspension, travel Telescopic fork, 130 mm [5.12 in) Rear suspension, travel ‘Swingarm, 120 mn (4.72 in) Gross vehicle weight rating 291 kg (642 Ib) Maximum weight capacity 158 kg (345 Ib} Front tire size 110/80—17 57H Tubeless type Rear tire size 150/017 69H Tubeless typo Cold tire | Up 10 90 kg Front | 225 kPa |2.25 kafem?, 33 psit pressure | (200 Ib) load Rear -225 kPa 2.25 kglem’, 33 psi) Up to maximum | Front | 225 kPa (2.25 kglem’, 43 ps) | weight capacity Rear 250 kPa [2.50 kg/em’, 36 psi Front brake, lining swept area Hydraulic single disc, 262 x 2 cm? (40.6 x 2 sq in} Rear brake, lining swept area Hydraulic single disc, 200 x 2 cm? (31.0 x 2 sq in} Fuel capacity 12.0 lt (3.18 US gal, 2.64 Imp gal) Fuel reserve capacity 2.0 Im {2.10 US at, 1.76 Imp qt Caster angle 27° Trail length 171 mm (4.37 in) Fork oil capacity ‘88: | 497 ce (16.8 US 2, 17.4 Imo 02) ‘After ‘BB: | 502 ce (16.9 US or, 17.6 imp 02) Fork oil level ‘a8: | 133 mm (5.2 in) After ‘88: | 128 mm (5.0 in) ENGINE Type Water cooled twin, 4-stroke SOHC (Single Over Head Camshaft) engine 2 Cylinders 52° V 79.0 x 66,0 mm (3.11 x 2,60 in) 647 co (38.4 cu-in} 94:1 Silent, mult-ink chain drive and OHC with rocker arms 2.8 lit (2.94 US qt, 2.46 imp qu) 2.3 lt (2.43 US at, 2.02 imp at) 2.2 lit (2.32 US qt, 1.84 imp qn) 4,6 lit (1.81 US qt, 1.41 Imp at) 2.2 iit (2.32 US qt, 1.94 Imp qt) Forced pressure and wet sump Paper filter 1,324 + 196 kPa (13.5 + 2 kg/cm, 192 + 28 psi) 10° atoc 40° ABDC 40° BBDC —} 10° aToc (0.15 = 0.02 mm (0.006 = 0.0008 in) 9.20 = 0.02 mm (0.008 = 0.0008 1) 80 kg (176 tb) 1,200 + 100 rm Lat 1 mm tift Fest iore aT £25901 dmercan Hands Mater Co, ne Al Rights Reserved Mev se11 1otog) 2091 NTGEO 1-3GENERAL INFORMATION aA OR AON [_ 1: California model rem | ‘SPECIFICATIONS CARBURE- | Carburetor type Constant Velocity dual carburetor TION | Identification number VOGKA [VDGLA} Pilot screw initial setting See page 414 Float level 9.2 mm (0.36 in) DRIVE TRAIN. | Clutch Cable operating, multi-plate, wet ‘Transmission S-speed Primary reduction 1.888 (36/68) Final reduction 2.750 (16/44) Gear ratio | 2.769 (13/36) Goar ratio Il 1.982 (17/32) Gear ratio Il 1.450 (20/29) Gear ratio IV 3.174 (23/27) Gear ratio V 0.965 (29/28) Gear shift pattern Left foot operated return system, 1-N-2~3-4—5, ELECTRICAL | Ignition Digitaized full ransistor ignition Ignition timing "“F" 10° BTDC at idle Full advance 31° BTDC at 7,000 + 200 rpm Starting system Starter motor Alternator 240 W/5,000 rpm | Battery capaci 12V8.Ah _ MF Batt Spark plug ae ——e | Standard DPRBEA-S X24EPR-US For cold lima (Below 5°C, 41°F) DPATEA-S X226PR.US Ry ean an eae rues. peereue - Spark plug aap (0.80— 0,90 mm (0.031 0.036 ini Firing orasr Front— (232°) — Rear ~(488°)—Front Fuse/Main fuse OA x8, 15Ax1/30A [usaTs: Headlight (high/low beam] 12 V—601s5 W Tailrakelight 12. V—-2/32 ep x2 SAE No. 1187 | Front tur signal/running light 12V—32/3 cp SAE No. 1034 Rear turn signal light 12. V-32 ep SAE No. 1073 | Instrument light 12.V-3.4W x1, 1.7 Wx2 il pressure warning light 12V-3.0W High beam indicator 12V-3.0W ‘Turn signal indicator 12V-3.0Wx2 Neutral indicator 12 V-3.0W 1-4GENERAL INFORMATION TORQUE VALUES ‘The torcue specifications listed under Engine’ and Frame" are for specific tightening points. a specification is not listed, follow the standard torque values below. STANDARD TORQUE VALUES | TYPE TORQUE N-m (kg-m, ft-lb) TYPE TORQUE Nery (kg-m, ft-ib) 5 mm bolt, nut 6 (0.60, 9.6) ‘5 mm screw 4 (0.40, 2.9) 6 mm bolt, nut 10 1.0, 7.2) 6 mm screw, 6 mm 8 mm bolt, nut 22 (2.2, 16) bolt with 8 mm head 910.9, 6.5) 10 mm bolt, nut 35 (3.5, 25) 5 mm flange bolt, nut 12.(1.2, 9) 12mm bolt, nut 55 (5.5, 40) 8 mm flange bolt, nut 27 (2.7, 20) l 10 mm flange bolt, nut 40 (4.0, 29) ENGINE Thread dia. | Torque on Oty | mm) Nem ¢kg-m, fib} Fee ‘Spark plug 4 12 14 (1.4, 10) Cylinder head cover bolt 4 6 10(1.0, 7.2) | Special bolt Camshaft holder bolt 6 a 2312.3, 17) nut 2 8 23:(2.3, 17) 6 mm bolt 4 6 10 (1.0, 7.2) Cylindar head nut | 8 10 48 (4.8, 35) bolt 4 8 23 12.3, 17) 8 mm nut 4 8 23:(2.3,17) 6 mm bolt 2 6 10 (1.0, 7.21 Socket boit Camshaft sprocket bolt 4 - 2312.3, 17) | NOTE Clutch lock nut q 18 130 13.0, 94) Staked nut Right crankcase cover bolt 15 6 10 (1.0, 7.21 Left crankcase cover bolt 9 6 10 (1.0, 7.21 Oil filter cartridge 1 20 10 (1.0, 7.2) | Apply clean engine oil to the Oring Oil drain bolt a 14 35 (3.5, 25) Neutral switeh l 10 12:(1.2, 9) il pressure switch 1 ~ 12(1.2,9) | NOTES Primary drive gear bolt 4 12 9019.0, 65) | UBS bolt, NOTE 2 Flywheel bolt 1 2 130 (13.0, 94) | Left hand threads, NOTE 2 Storier one way clutch 6 8 30 (3.0, 22) | Torx bolt, NOTE 1 Oil control bolt 1 10 23:(2.3, 17) Gil pipe bait 2 7 10(1.0, 7.2) | Special bolt Connecting rod cap nut 4 8 34 (3.4, 25) Crankcase bolt 14 8 27 (2.7, 20) | NOTE2 6 6 12(1.2,9) | NOTE2 Shift drum stopper plate bolt 1 6 26 (2.6, 19) | NOTE1 Insulator band screw. 4 s 410.4, 2.9) | NOTE2 Timing hole cap 1 14 10 (1.0, 7.2) | NOTES. Crankshaft hole cap 14 30 15(1.5,11] | NOTES Oil pump driven sprocket bolt 1 6 15(1.5,.11) | NOTE1 Valve adjusting screw lock nut 6 Zz 2312.3, 171 Cylinder stud bolt 8 mm. Zz 8 20-30 |2.0~3.0, | NOTE 1, Refer section 10. 14-21 10 mm 8 10 30-50 (3.0-5.0, | NOTE 1, Refer section 10. 22-36) NOTE 1: Apply a locking agent to the threads. NOTE 2: Apply clean engine oil to the threads. NOTE 3: Apply molybdenum disulfide grease to the threads. NOTE 4; Apply sealant to the threads. 1-5GENERAL INFORMATION FRAME Torque it Nem (harm, fh Ramer Fareapeions 2) 8) eaezn | Front engine mounting bot 1} 10 404.0, 29) | Roar upper engine mounting bolt 1} 10 40 (4.0, 29) | Note 2 mounting bolt lock mut 1 | 2 55 (55,40) | — mounting bolt adjusting bolt 1] 2 nate | Gearshit arm bolt 1 6 wza2s) | “Thermostatic switch 1 4 16 yei1@,13) | NOTES Exhaust pipe joint nt 4 8 27 (2.7, 20) Muffler band bolt 1 8 2712.7, 20) | Imustler mounting bolt | 2 8 27 (2.7, 20) Fuel tank mounting bolt: Front 1 6 1200.2. 9) Re 1 a 22 (2.2, 181 Fuel fter bracket bolt 1 6 22 (2.2, 161 Front brake master cylinder holder 2 6 12(0.2,9) Brake cil boit 4] 10 | 30¢0,22) Broke reservoir sc 4 4 | 150.2,14 Bleed valve 2 7 | (6106,4.3) Front caliper mounting bolt 2 8 27 12.7,20) | Flange bot Front caliper pin bolt 2| 10 | 28128, 20) Pad pin 2| 10 1710.7, 121 Pad pin plug | 2) 10 | 2500.25.10 Front broke disc retaining bolt \ 6 e 4016.0.29) | NOTE Rear brake reservoir mounting screw 1 6 910.9, 6.5) Roar brako diac retaining batt 4 e 3513.5, 25) retaining bot lock nut 4 e 90.9, 7) Roar caliper mounting bolt | 2 8 2712.7, 20) Rear calpor pivot bolt 1 e 22(2.2,16) Brake toraue rod bolt z| 10 3513.5, 25 Hendlebar pinch belt 2 8 2712.7, 20) | Janition switch mounting bolt 2 e 2512.5, 18) Fork pinch bolt (upper 2 7 4100.1,8) Fark pinch bolt (lower) 2\ 10 5016.0,36) | NOTE2 Fork tube cap 2| — | a3a3.10 Fork socket bolt 2 @ 470.7,12) | Nore Steering bearing adjustment nut 1 | 26 20 (210,14) | NOTE2 Steering stem nut + | 24 | 108110.8, 76) | Flange nut Front axie bot 1} 44 60 (6.0, 43) Front axle pinch bolt ‘ a 222.2, 16) Fear whee! nut + | 18 | 1201120, en Eecenie besring cartier lock nut 1 | 35 | 165 (16.5, 120) | Staked nut Shack absorter upper mounting bolt + | 12 65 16.5,47) Flange bot Shack absorber lower mounting bolt 1 | 10 45 (4.5.33) | Cap rut Shock absorber domper roc lock nut 1} 62 (62,45) | NOTE Swingarm adjusting belt 1] 26 1511.5, 11) Swingarm adjusting bolt lock nut 1] 26 85 (65, 47) Swingarm pivot aut 1 | 44 8516.5, 47) Eceniic bearing carrer pinch bolt 1] 16 7517.5, 54) Sprocket mounting bolt 6 a 43183, 31) Foot peg bracket bolt 4 a 27 (2.7, 20) Sub-frame mounting bolt 4| 10 40 (4.0, 29) Side stand pivot bolt 1) 10 38 (3.8, 27) Side stand bracket bolt 2 8 2 (2.8, 20) Centar stans mounting bolt 2 | 10 | 55065,40) | Using 2 box wrench, Ignition switch mounting bolt 2 8 | 28iz5.18 | Tore bot NOTE 1: Apply a locking agent to the threads. NOTE 3: Apply sealant to the threads, NOTE 2: Apply clean engine oll to the threads. 1-6GENERAL INFORMATION TOOLS ‘SPECIAL | Refer to Description Tool number | Alternate tool Tool number i : L | | section | Oil pressure gauge (078063000000 -NOTE1 2 Gi pressure gouge ettschment | 075104220100 2 | Ofer wreneh | o7HAn—Pu70100 2 Vecuum oeoge (074040030000 Vacuum gouge | M9378-021-xxxxx | 3 | Valve adjusting wrench 07908~-KE90000 07908—KE90100. | Vecuum/Pressure pump A937X—081—KXXHX LTVacuum pump | ST—AH—2e0-Me7 | 4 | Pressure pump | ST—aH—zs5_mc7 | 4 isp rig a 079149290001 _NoTe't 2.18, 14 Stents sarvavcket 07918-3719100 2 | Glatch enter holder 07923—KE10000 07180010008 7 | Beerng remover sat 07936—3710001 jou —tertaver haved 07836—3710100 | —esene letaver 3k 07936—3710600 | pees er 07741 0010201 — [Cee omesoem | 07943—MF50100 3 Valve guide driver attachment | (EX) 07943—MF50200 a | Valve guide reamer,8.5.mm | 079842000008 | aw | 079842000001 IUS.A. en ° Valve guide reamer, 6.6 mm |, 07984 “220008 | ex 07984~2e20001 8 Steeing stern crver 07348—Ma00000 12 Lock mut wrench 07908 KE99000 2 taney lonarer Gib 67948 -Muc0o00 13 =ilinerhea 07948-Mc0200 ~atier shaft 07945—MJCO100 —_|-Driver handle | 07988--3710001 Sohal bebe vor 07945-ka30200 |_NoTE 2 8 Bal tee remover eet 07948—Kw0001* [Adjustable bear| 07736-Ao1000a | 12 ~dtiver attachment A o7aas—Kmsoicd [Ling puller USA. oni —hier attachment B o7845—Kws0200 | ~ariver shaft assembly 07348—K180360 —bearing remover A 07946—KMg0401" | | Seating famerer 6 (07945—k180500, Sesser nace (07948—K480600, Fotkasal iver 07047—-kAsO100 w dtivar attache 07847 kF09100 Shack absorber compressor | 07967—KE10000 3 Moin bearing ver attachment | O7HMFMN90400 tH Oi eee! drver 07365KEB0100 13 Digital multrester | ks-AHM—92-009 | -U.S.A, only 5 Chris nore charger Mo_ 1012/2 Honda battery tester 076MJ—0010000 "2 New for this model. NOTE 1: Equivalent commercially available in U.S.A NOTE 2: Not available in U.S.A. 1-7GENERAL INFORMATION COMMON Description Tool number Alwernate tool Tool number | Rete to |_ section Float evel gauge 274010010000 | FNOTET 4 lock nut wrench, 17 x 27 mm | 077160020300 1 Gest holder (07724-o010100 note 2 7 Flywheel hold 077250040000 NOTE 8 Tor be (07703010100 818 Rotor puller 077330020001 079332290001 a Valve guide comover, 5.8mm | 077420010100 3 Valve guide remover, 6.6mm | 07742—0010200 8 Bening remover Rees, 20 mm | 077480050600 1 i VALVE SEAT CUTTERS (NOT AVAILABLE IN U.S.A.) Cuter holder, 6.6 mim 077810010201 |_Vaive guide €XCABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: © A loose wire, harness or cable can be a safety hezard. After clamping, check each wire to be sure itis secure. Do not squeeze wires against welds or clamps, © Secure wires and wire harnesses to the frame with thelr re spective wire bands at the designated locations, Tighten the bands so thet only the insulated surfaces contact the wites or wite harnesses, ‘© Route harnesses s0 they are neither pulled taut nor have ex: cessive slack © Protect wires and harnesses with electrical tape or a tubing it thoy contact a sharp edge or corner. Clean the attaching surface thoroughly before applying tape. ‘© Donot use a wire or harness with broken insulation. Rapai by wrapping them with protective tape or replace them, ‘© Route wire harnesses to avoid sharp edges or corners. Also ‘void the projected ends of bolts and screws, © Keep wire harnesses away from the exhaust pipes and other hot parts. ‘© Bo cure grommets aro seated in their grooves properly. © After clamping, check each harness to be certain that it ‘does not interfere with any moving or sliding parts, © After routing, check that the wire harnesses are not twisted or kinked. ‘© Wire harnesses routed along the handlebars should not be pulled taut, have excessive slack, be pinched by or interfore with adjacent or surrounding parts in all steering positions, © De nat bend or twist the control cables. Damaged control cables will not aperate smoothly and may or bind, GENERAL INFORMATION ohh = 0: CORRECT x: INCORRECTGENERAL INFORMATION (2) CLUTCH CABLE | co) err Han (8) nigh HanovéeaR "swircn wie SWITCH WIRE (6) SUBFUSE BOX 1) SUB-FUSE BOX CONNECTOR (9°) (4) METER WIRE CONNECTOR (3) SUB-FUSE BOX CONNECTOR (3) (2) HEADLIGHT CONNECTORGENERAL INFORMATION (2) SIPHON TUBE (THROTTLE (3) CHOKE caaLe pane (4) CRANKCASE BREATHER: Tuse (5) FUEL TUBE INLET LINE (6) FUEL TANK DRAIN CUP (9) THERMOSTATIC SWITCH (8) GROUND POINT (7) ALTERNATOR WIRE (6) PULSE GENERATOR x 4P WHITE CONNECTOR £ F a (1) CLUTCH CABLE (2) FRONT IGNITION COIL (3) PULSE (5) TURN SIGNAL (@) RIGHT HANDLEBAR SWITCH GENERATOR &P WHITE CONNECTOR ‘9? RED CONNECTOR WIREGENERAL INFORMATION (2) CRANK CASE BREATHER 1G) AIR CLEANER CASE DRAIN TUBE (a) FUEL TUBE — sew — het ‘A\\(s) STARTER RELAY SWITCH a (1) AIR TUBE (6 TURN SIGNAL RELAY — (14) SUB.AIR 7 CLEANER (12) FUEL TUBE (11) COOLANT RESERVE TANK OVERFLOW TUBE (10) AIR CLEANER CASE DRAIN TUBEPLUG (9) FUEL TANK DRAIN TUBE (1) REAR IGNITION COIL CONNECTOR (2°) (3) FUEL TUBE (2) FUEL PUMP RELAY . & ze (8] SHOCK ABSORBER (7) FueL BuMe —— DRAIN TUBE RELAY (a) AIR TUBE (8) REAR BRAKE LIGHT SWITCH CONNECTOR 4 AN (7) REGULATORIRECTIFIER , AP BLACK CONNECTOR (6) FUEL PUMP WIRE (5) REAR IGNITION COIL. 1-12GENERAL INFORMATION (1) TAILLIGHT WIRE (2) SPARK UNIT (3) FUEL TANK (4) FUEL TUBE (To Carb.) DRAIN TUBE (5) FUEL FILTER { | TT | | teyearreny | |_| case | \ (10) SHOCK ABSORBER > \ DRAIN TUBE (6) FUEL TUBE (To puinp) (8) Ain CLEANER r CASE DRAIN TUBE (11) RESERVE TANK (OVER FLOW TUBE (7) FUEL PUMP (12) Alp CLEANER CASE DRAIN TUBE (13) FUEL TANK DRAIN TUBEGENERAL INFORMATION CALIFORNIA MODEL ONLY: NOTE +The tobe stow Below re mmbered hay appear onthe Veer oe Ring Diogo Label age 7-1) (1) CARBURETOR (5) SUB-AIR CLEANER (4) @ TUBE (4) © JuBe (3) FUEL TUBE’ view z view ¥ @@ueE AIR CLEANER CASE AIR CLEANER, ‘CASE DRAIN (18) SECONDARY AIR SUPPLY HOSE —_AIR SUCTION VALVE (ASV) (14) AIR CLEANER CASE DRAIN TUBE (20) @ TuBE: sale (19) FUEL TANK DRAIN TUBE SECTION AA 1-14GENERAL INFORMATION CALIFORNIA MODEL ONLY: (2) AiR VENT CONTROL VALVE (AVCV) (1). TUBE (3) @ TUBE (4) GROUND CABLE TO FUEL TAt 1-15GENERAL INFORMATION EMISSION CONTROL SYSTEMS Tho U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during thelr useful life, when cperated and maintained accarding to the instructions provided, and the E.P.A. requires that motorcycles built after January 1, 1983 comply with ap- plicable noise emission standards for one year or 6,000 km (3,730 miles} after the time of sale to the ultimate purchaser, When operated and maintained according to the instructions provided. Compliance with the terms of zhe Distributor’s Limited Warranty for Honda Motorcycle Emission Contra Systems is necessary in order to keep the emissions system warranty in ef- fect ‘SOURCE OF EMISSIONS ‘The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, Linder eertsin conaitions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but itis toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as wall as other systems, to reduce carbon monoxide and hydro- carbons. EXHAUST EMISSION CONTROL SYSTEM Except for California: ‘The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle epeed adjustment with the throttle stop screw. The exhaust emission control system is separate trom the crankcase emission control system. California only: ‘The exhaust emission control system consists of a secondary alr supply system which introducas filtered air into the exhaust {gases in the exhaust port. No adjustments to this system should be made, although periodic inspecton of the components is recommended, The secondary air supply system helps improve emission performance. [1] AIR CLEANER (3) CARBURETOR (4) INTAKE MANIFOLD (8) EXHAUST MANIFOLD 1-16GENERAL INFORMATION CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system which routes crankcase emissions theough th combustion chamber. (1) AIR CLEANER, (3) CRANKCASE — FRESH AIR = +: BLOW.BY GAS EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) This model complies with California Air Resources Board evaporative emission requir Fue! vapor from the fue! tank and carburetor is directed into the charcoal canister where itis adsorbed and stored while the engine is stopped. When the engine is running and the purge cantral diaphragm valve is open, fuel vapor in the charcoal canis- ter is drawn into the engine through the carburetor. (3) FUEL TANK (AS (2) PURGE CONTROL VALVE (1) CARBURETORS: (10) INTAKE he MANIFOLDS c C ry (4) DRAIN (9) FLOAT CHAMBERS (6) AIR VENT CONTROL VALVE ==, || (51 CHARCOAL [Fa CANISTER: Es = (7) AIR VENT CONTROL VALVE (@1 70 OPEN [ENGINE STOP) FRESH AIR =: FUEL VAPOR 1-17GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM ‘TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replace: ‘ment, of any device or element of design incorporeted into any new vehicle for the purpose of noise control prior ta its sale or delivery to the ultimate purchaser or while itis in use: or {2) the use of the vehicie after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1, Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2, Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4, Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than thse specified by the manufacturer. EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the rear fender as shown. It contains basic tune-up spscifications. (7) EMISSION CONTROL INEQHMIATION LABEL EMISSION CONTROL INFORMATION UPDATE LABEL ‘After making a high altitude carburetor adjustment (Page 4-15), attach an update label on the lett sub-frame upper pipe Instructions for obtaining the update label are given in Service Letter No. 132. (1) EMISSION CONTROL INFORMATION UPDATE LABELGENERAL INFORMATION VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) ‘The Vacuum Hose Routing Diagram Label is on the air cleaner case cover. Route the vacuum hases as shawn an this label (1) VACUUM HOSE ROUTING DIAGRAM LABELLUBRICATION (1) ROCKER ARM (13) CAMSHAFT: (12) PISTON —_ (11) OW Jet (or cra sHagr L SY yuna ©) Fis =| = A It of Mol WOES ial It oop BE / io enesoune Sees A (6) PRESSURE RELIEF non furen ” YALE (5) OIL STRAINER2. LUBRICATION SERVICE INFORMATION 2-1 OIL PRESSURE CHECK 24 TROUBLESHOOTING 2-2 OIL PUMP/RELIEF VALVE 25 ENGINE OIL LEVEL 2-3 CONTROL CABLE LUBRICATION 210 ENGINE OIL CHANGE 2-3 LUBRICATION POINTS 2.10 OIL FILTER CHANGE 24 SERVICE INFORMATION om _ + If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. ‘CAUTION + Used engine olf may cause skin cancer if repeatedly teft in contact with (he 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 son as possi: bile after handling used oil GENERAL ‘© The oil pump can be serviced after removing the engine from the frame. SPECIFICATIONS Engine oil Oil capacity 2.6 lit (2.94 US at, 2.46 Imp qu after disassembly. 2.3 lit (2.43 US qt, 2.02 Imp qt) at oil filter and oil change 2.2 lit (2.92 US qt, 1.94 Imp at) after draining. i recommendation HONDA 4 stroke oll or equivalent API service classification: SE or SF VISCOSITY: SAE 10W— 40 Ol VISCOSITIES. Other viscosities shown in the chart may || be used when the average temperature in your riding area ie within the indicated || range. | Oil pump rem STANDARD SERVICE LIMIT Roter tip clearance (0.15 mm (0.008 in) (0.20 mm (0.008 ini Pump body clearance — .22 mm (0,006—0.009 in) 0.35 mm {0.014 in} Pump end clearance _ 0,02—0.07 mm {0.001—0.003 in} [0.10 mm (0,004 int Oil pressure 441 kPa (4.5 kgiem?, 64 psi} at 8,000 rpm (80°C/176°F) | — TORQUE VALUES Oil pressure switch 12 Nem {1.2 kg-m, 9 fb) Apply sealant to the threads Engine oil drain bolt 36 Nem (3.5 kg-m, 25 fib) Oil filter 10 Nem (1.0 kg-m, 7.2 fe1b)LUBRICATION TOOLS Speciat it filter wrench Oil pressure gauge il pressure gauge attachment TROUBLESHOOTING Oit level to0 low + Norra! oil consumption, External oll leaks + Worn piston rings il contamination + Oil not changed often enough + Faulty head gasket + Worn piston rings Low oil pressure + Faulty oll pump. + Clogged oil strainer + Oil level low + Faulty pressure reliet valve + Oilleaks High oil prossure + Faulty pressure relief valve + Clogged oi titer or oll orifica No oi pressure + Oillevel too low Broken oll pump diive or driven sprockets Broken oil pump drive chain + Faulty oil pump + Oil feaks ‘O7HAA~PJ70100 (07505—3000000-ror equivalent commercially available in U.S.A. 075104220100)LUBRICATION ENGINE OIL LEVEL Place the motorcycle on its center stand and shift into neutral & FILLER/DIPSTICK, Start the engine and let it idle for @ few minutes remove the oll filer cap/dipstick and wipe it Check the oil level with the oil filer cap/dipstick by inserting it F (2) upper without screwing it in NOTE ee (3) LOWER: + Do not screw the cap in when making this check. If the oil level is below the lower level mark on the dipstick, fill to the upper level mark with the recommended oi. Check the O-ring for damage. ENGINE OIL CHANGE NOTE + Change the engine oll with the engine warm and the motor: cycle on its sida stand to assure complete and rapid drain: ing. Remove the oil filer cap/dipstick and drain bolt. With the engine stop switch OFF, start the starter motor for few seconds ta drain any oil which may be left in the engine, NOTE (1) DRAIN BOLT + Do not operate the motor for more than few seconds. ‘After the oil has drained, check that the drain bolt sealing Y washer is in good condition, and install the bolt. TORQUE: 35 Nem (3.5 kg-m, 25 ftb) Fill ho crankcase with the correct quantity of the recommend: ed cil ‘ol capacity: 2 2.8 lit (2.94 US qt, 2.46 Imp qt) after disassembly (2) SEALING WASHER, 2.3 lit (2.43 US gt, 2.02 Imp at) at ol fitter and oil change 2.2 lit (2.32 US at. 1.94 Imp at) after draining RECOMMENDED OIL: Honda 4-stroke oil or qeuivalent API service classification: SE or SF VISCOSITY: SAE 10W—40 Install the oil filler cap/dipstick. Start the engine and let it idle for 2—3 minutes. Stop the engine and wait a few minutes, then check that the oil favel is at the upper level mark. Check that there are no ol leaks. 2-3LUBRICATION OIL FILTER CHANGE Drain the engine ol page 2-3) CAUTION : + Do not replace the ol ler when the exhaust ysiom hot. Remove the drive sprocket cover (page ®-2) Remove the ol fiter with after wrench TOOL: Ss On fiter wrench o7Haa—P470100 Apply oil to the new oil filter O-ring and install the new oil itr. Tighten the oil filter with a filter wrench. TORQUE: 10 Nem (1.0 kg-m, 7.2 ft) Fill the engine with recommended oil (page 2-3) OIL PRESSURE CHECK Warm the engine up to normal operating tempersture (approxi mately 80°C/176°F) Stop the engine. +f engin mast bering 10 do soma work, mak are the = area is well-ventilated. Never run the engine in an enclosed es (2) O-RING The exhaust contains poisonous carbon monoxide gas that may ‘cause loss of consciousness and lead ro death Remove the oil pressure switch cover and disconnect the switch wire (i) Oit PRESSURE SWITCH ae Remove the ol pressure switch and connect on oi pressure Gauge attachment and gauge 1 the pressure switch hole Check te ol eve Tools: (i pressure gauge attachment 075104220100 or equivalent commarcilly avaliable in U.S.A . 07506 3000000 or @/ \ ‘equivalent commercially ) COVER (2) swiTcH SCREW available in U.S.A. ei Oil pressu ‘Start the engine and check the oll pressure at 6,000 rpm, OIL PRESSURE: 441 kPa (4.5 kgicm?, 64 psi) at 6,000 rpm (80° TH ATTACHMENT, 2) 176°F) Stop she engine. Apply 3:BOND® sealant or equivalent to 1 threads and instal TORQUE: 12 Nem (1.2 kg-m, 9 feb) ressure switch Connect the oll pressure switch wire and start the engine. Check that the oil pressure warning indicator goes out after ‘one 0° two seconds. f the oll pressure warning indicator stays ‘on, stop the engine immediately and determine the cause. 2-4LUBRICATION OIL PUMP/RELIEF VALVE REMOVAL Separate the crankcase (Section 11) Remove the bolt and pressure relief vaive cover. Remove the pressure relief valve from the oll pump. DISASSEMBLY Remove the snap ring and disassemble the relief valve TOOL: ‘Snap ring pliers 07914—3230001 INSPECTION Check the spring, O-ring and valve for fatigue, wear er dam- age Check the body for clagging or damage. Clean all the parts and assemble them in the reverse order of disassembly. Replace the ralief valve, if necessary, as an assembly OIL PUMP REMOVAL/DISASSEMBLY Remove the oil pump by removing two mounting bolts Fomove the dowel pine and O-rings. (1) PRESSURE RELIEF VALVE COVER () OFING (2) BODY (3) VALVE (4) SPRING (5) SNAP RING @ (1) BOLTSLUBRICATION Remove the oll strainer and oil pipe from the oll pump. Chock the O-rings and oil seal for fatigue or damage. Cleen the oil strainer and oil pipe with non-flammable or high flash point solvent Remove the three cover bolts. Disassemble the parts and clean them with non-flammable or hhigh flash point solvent. INSPECTION Install the outer and inner rotors to the pump body. Measure the outer rotor-to-pump body clearance, SERVICE LIMIT: 0.35 mm (0.014 in} (1) OIL STRAINER (2) O1L PIPE (1) OL SEAL BR 2 outer Rotor (2) O1L STRAINER, (3) O-RINGS (3) O-RING (1) COVER BOLTSLUBRICATION Remove the oil pump shaft from the oil pump and measure the pump end clearance. SERVICE LIMIT: 0.10 mm (0.004 in) Temporatily install the shaft in the pump body. (1) SHAFT Meesure the inner rotor tip clearance SERVICE LIMIT: 0.20 mm (0.008 in) A Replace the oil pump, if necessary as an assembly. (2) INNER ROTOR, ASSEMBLY (1) PUMP BODY (4) PRESSURE RELIEF VALVE BODY [2) OUTER ROTOR {6)SNAP RING (3) INNER ROTOR (5) VALVE (7) RELIEF VALVE / eq covER (14) DRIVE PIN (13) PUMP SHAFT (10) 0-RING 111) OIL STRAINER,LUBRICATION Install the outer rotor in the pump body with the punch mark facing the cover, then install the inner rotor. Install the drive pin and spacer on the shaft. Install the shaft in the body, aligning the drive pin with the Inner rotor groove Install the dowel pin and @ new gasket on the pump body, then install the cover. Tighten the cover bolts securely. Install the O-rings, oil seal, il strainer and cil pipe on the oi pump, CAUTION + Install the O-rings on the vil pipe with the tapered side facing fut as shown, or the engine will be damaged. O-RINGS (1) OUTER ROTOR (2) PUNCH MARK (3) SPACER a) PUMP SHAFT 6) INNER ROTOR DRIVE PIN (1) O1L PUMP BODY (4) GASKET (3) DOWEL PIN (2) OIL PUMP COVER (1) COVER BOLTS O-RINGSLUBRICATION |NSTALLATION install the dowel pins and new O-rings. iostall the oll pump as an assembly. Assemble the pressure relief valve and install it in the oil pump. Install the pressure relief valve cover with the bolt Assemble the crankcase (Section 11), 1) CAINGs/bOWEL Bing (1) PRESSURE RELIEF VALVE eee nee (1) PRESSURE RELIEF VALVE COVER |LUBRICATION CONTROL CABLE LUBRICATION Periodically disconnect the throttle and choke cable at their upper ends. Thoroughly lubricate the cables and their pivot points with @ commercially available cable lubricant or @ light, weight cil LUBRICATION POINTS Use general purpose grease when not otherwise specified here. Appiy oll or grease to the other sliding surfaces and cables not shown here. (1) CLUTCH AND BRAKE 2) THROTTLE LEVER PIVOTS: PIPE (3) SWINGARM, PIVOT BALL AND NEEDLE BEARINGS =n | Groot reg pwors anp | 5eeF eee Eon Sat (11) STEERING HEAD BEARINGS — or equivalent ea (10) FORK oe (9) SPEEDOMETER | re pena BRVEGEAR gees Shae (B) BRAKE =a (GEAR OIL SAE #80—90) CALIPER PIVOTS }) SIDE STs 1AIN STAND artes 16) SIDE STAND 6 m 2-103. MAINTENANCE SERVICE INFORMATION MAINTENANCE SCHEDULE FUEL LINE THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER (CRANKCASE BREATHER ‘SPARK PLUG VALVE CLEARANCE CARBURETOR SYNCHRONIZATION CARBURETOR IDLE SPEED RADIATOR COOLANT COOLING SYSTEM CYLINDER COMPRESSION SECONDARY AIR SUPPLY SYSTEM (California model only) SERVICE INFORMATION 34 33 34 34 35 36 36 37 39 39 3410 3-10 EVAPORATIVE EMISSION ] CONTROL SYSTEM {California model only) 311 DRIVE CHAIN, 312 BRAKE FLUID 3.13 BRAKE PAD WEAR 314 BRAKE SYSTEM 314 BRAKE LIGHT SWITCH 314 HEADLIGHT AIM 3.15 CLUTCH SYSTEM 3.15 SIDE STAND 3-16 ‘SUSPENSION 3-16 NUTS, BOLTS, FASTENERS 3.17 WHEELS/TIRES 317 STEERING HEAD BEARINGS 318 Support the motorcycle on the center stand on a level surface before starting any work If the engine must be running to do same work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loxs of consciousness and lead to death. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the Work area oF where gasoline is stored. GENERAL + Engine oil See page 23 + Engine cil filter chenge See page 2-4 SPECIFICATIONS lanition timing Initial 10° BTOC at idle Full advance 31° BTDC at 7,000 + 200 rpm Spark plug ex ape] Standard DPRBEA.9 X24EPR.US For cold climate (below 5°C/41°F) | DPR7EA9 X226PR-US For extended high speed riding DPRSEA 9 X27EPR.US Spark plug gap 0.8—0.9 mm (0.031 —0.035 in) Valve clearance IN 0.18 = 0,02 mm (0.006 = 0.0008 in) (COLD) EX 0.20 + 0.02 mm (0.008 + 0.0008 in) Ile epeod Cylinder compression Throttle grip tree play 1,200 + 100 rpm 1,324 = 196 kPa (13.5 + 2.0 kg/cm?, 192 = 28 psi) 2-6 mm (1/16— 1/4 in Fevaod, June 108) 11981 Amorcan Honda Motor Co Inc. - lights Reserves ‘sv 8611106) B89) NTBBOMAINTENANCE Clutch lever free play Drive chain slack 10~20 mm (3/8—3/4 in) 2030 mm (3/4—1-3/16 in) Refer to page 3-12 Tite size (Tubeless type) Gold tire pressures kPa (kg/om?, psi) Tire brand = Front Rear 110/80-17 57H 150/70-17 69H Up to 90 kg (200 Ibs) 225 (2.25, 33) 225 (2.25, 33) otis airing Seat 225 (2.25, 33) 250 (2.50, 36) | capacity Bridgestone 65476 548 Dunlop KS505G K505 60g Maximum {809 Maximum Wheel balance waight TORQUE VALUES Eccentric bearing carrier pinch bolt Valve adjusting screw lock nut “Timing hole cap Crankshaft hole cap Spark plug TOOLS Special Valve adjusting wrench Vecuum geuge 07908~KE90000 75 Nem (7.5 kg-m, 54 ft-lb) 23 Nem (2.3 kg-m, 17 ft-lb) 10 Nem (1.0 kg-m, 7.2 ft-lb) 15 Nem (1.5 kgm, 11 14 Nem (1.4 kg-m, 10 ib) threads bb) Apply molybdenum disulfide grease to the 074040030000 or M937B—021 —XXXXX Vacuum gauge setMAINTENANCE MAINTENANCE SCHEDULE The following items requi some mechanical knowledge. Certai ‘ore technical information and tools. Owners should consult their authorized Honda dealer. Perform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. items (particularly those marked * and **) may require | INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. CLEAN R: REPLACE L: LUBRICATE a FREQUENCY NOTE ODOMETER READING (NOTE 1) ae gy mendee[s [o [ [1 [20 Trea = | FUEL LINE o f+ fy [il sa * | THROTTLE OPERATION 1 lt 1 34 * [CARBURETOR CHOKE 1 t t[ 3s | ‘AIR CLEANER (NOTE 2) F rR, 358 | CRANKCASE BREATHER | (NOTE 2) ejelclelc|c| ss 27 | sPank plu Fl[a;a|alalal| 30 = * | VALVE CLEARANCE 1 1 1 1 38 ENGINE OIL L R R R a | 23 ENGINE OWL FILTER R a R R24 | SrchnontzaTion 1 ' ' | se = | CARBURETORADLE SPEED 1 Co [RADIATOR COOLANT (NOTE 8) ! 1 39 = | COOLING SYSTEM 1 1 | 310 * | SECONDARY ASUPFLY Tiare 5) 1 (| an Baas noma ifn DRIVE CHAIN ae : ik 0 312 |_| BRAKE FLUID - 3.13 2) | ween wae a4 3 _| BRAKE SYSTEM 314 = =| aaake uHT swircH 314 3 > | HeabuicHr aim 315 2 |_| CLUTCH sysTeM 315 3 |_| SIDE STAND 316 = |= | susPension 216 2 | | NUTS, BOLTS, FASTENERS 347 2 |=) WHEELS/TiRES 317 ++] STEERING HEAD BEARINGS 318 cuaiified. ** In the interest of safety, we recommend these items be serviced only by an authorized Honda d At higher odometer readings, repeat at the frequency interval established her . Service more frequently when riding in unusually wet or dusty areas. NOTES: 1. 3 4. 8. Service more frequently when riding in rain or at full throttle California model only. ‘Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is machanically Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechani- cal skill, 3-3MAINTENANCE FUEL LINE Romove the seat (page 13:28). ‘Check the fue! lines for deterioration, damage or leakage. Raplace the fuel lines if necessary. THROTTLE OPERATION ‘Check for smooth throttle grip full opening and automatic full closing in all steering positions. Check the throttle cables and replace them if they are deterio- rated, kinked or damaged, Lubricate the throttle cables, if throttle operation is not smooth Measure the free play at the throttle grip flange, FREE PLAY: 2—6 mm (1/16—1/4 in) Throttle grip free play can be adjusted at either end of the throttle cable. Minor acjustments are made with the upper ad- Juster Major adjustments are made with the lower adjuster. ‘Adjust the free play by loosening the lock nut and turning the adjusting nut. Tighten the lock nuts. Recheck throttle operation. Replace eny dar necessary. ed parts, If (1) FUEL TANK — (2) FUEL FILTER (1) UPPER ADJUSTER (2) LOCK NUT = 3-4MAINTENANCE CARBURETOR CHOKE This model's choke system uses a fuel enrichening circuit con: tyollec by @ choke valve. The choke valve opens the enrichening circuit vie a cable when the choke lever on the handlebar is pulled back. Check for smooth upper choke lever operation. Lubricate the choke cable if the operation is not smooth, Remove the left and tight choke cable boots from the choke valve nuts. Loosen each choke valve nut and remove the choke valve from the carburetor. Push the choke lever on the handlebar all the way up to fully closed and measure the distance between the ends of the choke valve and nut. t should be 10~11 mm (0,390.43 in). Adjust the distance to wi fications by loosening the lock nut and tuming the cable's elbow at the left handlebar switch housing, Tighten the lock nut securely and recheck the distance. Thread the choke vaive in by hand and then tighten the choke valve nut 1/4 tuin with a 14 mm wrench. AIR CLEANER Remove the fuel tank (page 4-3), Remove the air cleaner case cover screws and cover. (7) CHOKE LEVER ‘ (1) CHOKE VALVE, (1) CABLE ELBOW 3-5MAINTENANCE Remove the air cleaner elamont. Replace the element in accordance with the maintenance schedule Also, replace the element any time it is excessively dirty or damaged. CRANKCASE BREATHER The crankcase breather drain; air cleaner case drain tube is behind the side stand. Remove the drain plug from the tube to empty any deposits. Reinstall the plug securely, NOTE + Service more frequently when the motorcycle has been ridden in rain, at full throttle, or after itis washed or over turned. Service if the deposit level can be seen in the trans: parent section of the drain tube. SPARK PLUG Disconnect the spark plug caps and remove the spark plugs: RECOMMENDED SPARK PLUG: NGK ND Standard DPREEAS | X@acPRUO | For cold climate fe dries DPRTEA-9 | X22EPR.Ua For extended high speed | epoca | xavernue tiding Measure the new spark plug gap with a wire-type feeler gauge SPARK PLUG GAP: 0.8—0.9 mm (0.031—0.035 in) Adjust the gap if necessary, by bending the side electrode carefully. With the plug washer sttached, thread each spark plug in by hand to prevent crossthreading. Continua tightening by hand until the spark plug bottoms. Then, tighten the spark plugs another 1/2 turn with a spark lug wrench to compress the plug washer. TORQUE: 14 Nem (1.4 kg-m, 10 fb) Connect the spark plug caps. Install the removed parts in the reverse order of removal (1) AIR CLEANER ELEMENT (3) CLIP ce a, (1) bePOsITS: 08-09mm = A (0.031 -0.035 in) 4 (1) SIDE [} ttectrove (2) CENTER ELECTRODE a (i srane rive SET 3-6VALVE CLEARANCE NOTE Inspect and adjust vaive clearance while the engine is cold (below 35°C/95°F} Remove the following parts: — seot (page 13-26) = fuel tank (page 4-3) air cleaner case (page 4-4) ‘thermostat housing mounting bolt and radiator mounting bolts to releasing tension of water hoses crankshaft and timing hole caps cylinder head cover Remove the cylinder haad covers. FRONT CYLINDER Rotate the flywheel counterclockwise to align the “FT"” mark with the index notch on the left crankcase cover. Make sure ne piston is at TDC (Top Dead Center) on the compression coke and the cam lobes are all facing down as shown, spect the clearance of all three valves by inserting a feeler gauge between the adjusting screw and the valve. VALVE CLEARANCES: (COLD) Intake: 0.15 + 0.02 mm (0.006 + 0.0008 in) Exhaust: 0.20 + 0.02 mm (0.008 = 0.0008 in) Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. Apply oll to the nut and screw thr ds. Hold the adjusting screw and tighten the lock nut. Toot! Valve adjusting wrench 07908-KE30000 TORQUE: 23 Nem (2.3 kgem, 17 ft-lb) MAINTENANCE (2 TIMING HOLE CAP (1) CAM Lopes (7) VALVE ADJUSTING | WRENCH (2) FEELER GAUGEMAINTENANCE REAR CYLINDER Rotete the flywheel counterclockwise to align the "RT" mark ‘with the index notch on the left crankcase cover. Make sure the piston is at TDC on the compression stroke and the cam lobes are all facing down, Inspact and adjust the valve clearance using the seme method a for the front eylinder. Install the front and rear cylinder head covers. Apply molybdenum disulfide grease to the threads of the timing and crankcase hole caps, then install and tighten them. 10 Nem (1.0 kg-m, 7.2 feb) Crankshaft hole cap: 15 Nem (1.5 kg-m, 11 feb) CARBURETOR SYNCHRONIZATION NOTE + Parform this maintenance with the engine at normal operat ing temperature, the transmission in neutral, and the motor- cycle on its center stand. Remove the rear fuel tank mounting bolt first, then remove the {front side (page 4-3). Carefully raise the tank and support it in the frame using a suitable base. FRONT CYLINDER: Remove the plug from the front cylinder intake port and install the vacuum gauge adaptor. REAR CYLINDER: Remove the plug from the rear cylinder intake port and install the joint plug (P/N: 16124—MBO—000).. Connect the vacuum gauge tube and vacuum gauge: Too: Vacuum gauge 074040030000 or Vacuum gauge set M937B—021 —XXXXX Warm up the engine and adjust the idle speed with the throttle stop screw. + the engine must be running (0 do some work, make sure the ‘area is well-ventilated. Never run the engine in an enclosed area. + The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death, IDLE SPEED: 1,200 = 100 rpm 3-8 (1) CAM Lopes: ( INDEX NOTCH (2) "RT" MARKMAINTENANCE Check that the difference in vacuum readings is 49 mm (1.6 in) Hg oF less. NOTE The rear cylinder carburetor is the base carburetor, Ii necassary, synchronize to the specification by turning the synchronization adjusting screw. Recheok the idle speed and synchronization. Disconnect the gauge and adaptors and install the removed parts. CARBURETOR IDLE SPEED NOTE + Inspect and adjust idle speed after all other engine adjust- ments are within specifications. + The engine must be werm for accurate adjustment. Ten minutes of stop-and-go riding is sufficient. Warm up the engine, shift to NEUTRAL, and place the motor cycle on its center stand. + If the engine must be running to do.some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to deat Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,200 = 100 rpm RADIATOR COOLANT 1eck the coolant level of the reserve tank with the engine ‘running at normal operating temperature © If the engine must be running 10 do some work, make sure the area is well-ventilared. Never run the engine in an enclosed +The exhaust comains poisonous carbon monoxide gas that may loss of consciousness and lead 10 dea The level should be between the level ines. “UPPER” and “LOWER” If necessary, remove the reserve tank cap. Fill up to the upper level line with 50/50 mixture of distilled water and antifreeze, Re tall the reserve tank cap.MAINTENANCE COOLING SYSTEM Remove the radiator shroud and check the radiator air pas: sages for clogging or damage. Straighten bent fins or collapsed core tubes with @ small flat blade screwdriver as shown and remove insects, mud or any obstructions with compressed air or low pressure water. Replace the radiator ifthe airflow is restricted over more than 30% of the radiator’s surtace. For radiator replacement, refer to page 5-5. Make sure the hoses are in good condition. Replace any hose that shows any sign of deterioration Check that all hose clamps are tight, CYLINDER COMPRESSION Warr up the engine to normal operating temperature. + Uf the engine must be running to do some work, make sure the ‘rea is well-ventilated. Never run the engine in an enclosed + The exhaust contains potsonous carbon monoxide gus that may cause loss of consciousness and lead (o death SStop the engine, disconnect both spark plug caps and remove one spark plug. NOTE + Te measure the cylinder compression ot each individual ey inder and remove only one plug at a time. ‘Turn the engine stop switch OFF. Insert the compression gauge, Open the throttle all the way ‘anc crank the engine with the starter motor. Crank the engine until the gauge reading stops rising. The maximum reading is usually reached within 4—7 seconds, COMPRESSION PRESSURE: 1,924 = 196 kPa (13.5 + 2.0 kg/em®, 192 = 28 psi) | compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or the piston HH comprassion is low, pour 3-5 cc (0.1—0.2 US. 02) of clean engine oil into the cylinder through the spark plug hole and re. check the compression. Hf the compression increases from the previous va ‘the cylinder, piston and piston rings. If the compression is the same as the previous value, check ‘the valves for leakage. 3-10 checkMAINTENANCE SECONDARY AIR SUPPLY SYSTEM (California model only) ‘ck the sir and vacuum hoses and tubes for bending or swisting and straighten if necessary, .ck the system hoses and tubes for damage, deterioration, ‘caging or loose connections. ck the air suction valve for damage (page 4-17) the vacuum hose routing diagram label for hose con- nections as shown below. EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) ck the hoses between the fuel tank, canister, purge control valve (PCV), air vent control valve (AVCV), and carburetor for oration, damage or loose connections. (3) FUEL TANK (2) PURGE CONTROL VALVE (1) CARBURETORS MANIFOLDS: (4) DRAIN (5) CHARCOAL CANISTER CONTROL VALVE VACUUM HOSE ROUTING DIAGRAM ENGINE Fat (CALORNA VEHICLE Also check the tubes for bending or twisting and straighten if necessary. Check the canister for cracks deterioration, or other damage. Refer to the vacuum hose routing diagram label for connec sions as shown right.MAINTENANCE DRIVE CHAIN CHAIN SLACK INSPECTION os + Never inspect or adjust the drive chain while the engine is run- ‘Turn the ignition ewitch OFF, support the motorcycle on its center stand and shift the transmission into neutral Place the chain slack gauge against the reference arrow on lower edge of the swingarm as shown. Pull the lower run of the drive chain down with your finger and check slack using the gauge. NOTE + Th hain slack gauge and eccentric bearing carrier wrench supplied with this motoreyele. + The chain slack gauge is using the “UP” mark facing the swingarm without fail + Make sure the upper edge of the chain is between lines A id B on the gauge. A—B: Good. Above A: Too tight. Below C: Too loose. CHAIN ADJUSTMENT Loosen the eccenttic bearing carrier pinch bolt. Turn the eccentric bearing carrier clockwise or count clockwise by the bearing carrier wrench to obtan the drive chain slack as necessary. Tighten the eccentric bearing cartier pinch bolt. TORQUE: 75 Nem (7.5 kg-m, 64 ft-lb) Recheck chain slack. Lubricate the drive chain with SAE #80 or 90 gear oil Check the chain wear lebel on the swingarm. If thered zone on the label aligns with the driven sprocket teeth after chain has. been adjusted, the chain must be replaced. REPLACEMENT CHAIN: RK525 SM3 or DID525 V7 (112 LE) LINK: 112 Links 3-12 (2) DRIVE CHAIN (8) MEASURING PONT \ (f) ORIVE CHAIN SLACK GAUGE (EQUIPMENT TOOL) (2) DRIVE CHAIN, (1) DRIVE CHAIN SLACK GAUGE (EQUIPMENT TOOL) WG GARRIER PINCH BOLT [1) ECCENTRIC BEARING CARRIER WRENCH (EQUIPMENT TOOL} ZLUBRICATION AND CLEANING When tha drive chain becomes extremely dlity, It should be saned prior to lubrication. Giean the drive chain with a non-flammable or high flesh point and wipe dry. ‘The rive chain on this motorcycle is equipped with small O- 19gs between the link plates. The O-rings can be damaged by steam cleaners, high pressure washers and certain solvents, joricate only with SAE #80 or 90 gear oil ‘ommercial chain lubricants may contain solvents which suld damage the rubber O-rings. DRIVE AND DRIVEN SPROCKET i-spect the sprocket teeth for excessive wear or damage. Re- piace if necessary. TE + Never install @ new drive chain on worn sprockets or a worn chain on new sprockets. Both chain end sprockets must be In good condition, or the new replacement chain o sprock- ote will wear repidly. BRAKE FLUID FRONT 12ck the front brake fluid level with the handlebar turned so nat the reservoir is level Check the front brake fluid through the sight glass. If the level '$ visible, check pad wear first; replace the pads if necessary. Then remove the cover, set plate and diaphragm. Fill the rese oie to the upper level with DOT 4 fluid from a sealed contain- ‘eCheck the system for leaks. CAUTION * Do not remove the reservoir cover until the handlebar has been turned 0 that the reservoir is level. * Do not mix different types of fluid, as they are not compatible with each other. + Do not allow foreign material to enter the system when filing the reservoir, + Avovd spilling the fluid on painted, plastic or rubber parts Place a rag over these parts whenever the system is serviced, Refer to section 14 for brake bleeding procedures. REAR (Check the reer brake fluid level after supporting the motor- cycle upright on level ground. it Is near the lower line, f first; replace the pads if necessary. Then remove the cover, set plate and diaphragm. Fill the reservoir to level with DOT 4 fluid from a sealed container. (Check the system for leaks. MAINTENANCE — £ ¥ (2) WUBRICATE SAE #80 or #90, GEAR OIL (0) Wenn G (2) NORMAL (1) COVER (2) UPPER, LEVEL 3-13MAINTENANCE BRAKE PAD WEAR FRONT Check the front brake pads for wear, through from the lower fend of the caliper. REAR Check the rear brake pads for wear, through ftom the rear of the caliper CAUTION + Always replace the brake pads as a set 10 assure even dise pres (1) Pal if Ss ni See saction 14 for brake pad replacement. BRAKE SYSTEM Inspect the brake hoses and fittings for deterioration, eracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as requires. REAR BRAKE PEDAL Check the rear brake pedal height To adjust the brake pedal height, loosen the jock nut and turn the raster cylinder push rod. Tighten the lock nu’ NOTE + Adjust the brake light switch after adjusting the brake pedal height. BRAKE LIGHT SWITCH NOTE + Perform the rear brake light switch adjustment after adjust- ing the brake height. +The front brake light switch does not require adjustment. ‘Adjust the brake light switch so that the brake light will come ‘on when brake engagement begins. ‘Adjust by turning the adjuster while holding the switch body. Tighten the adjuster lock nut and recheck the brake light switch operation. NOTE + Do not turn the switch body 3-14MAINTENANCE HEADLIGHT AIM lust vertically by loosing the headlight mounting bolts djust horizontally by turning the horizontal adjusting screw. NOTE + Adjust the headlight beam as specified by local laws and regulations. {n improperly adjusted headlight may blind oncoming drivers, or lt may fail 10 light the road for a safe distance. CLUTCH SYSTEM Measure the cluteh laver free play at the lever end, FREE PLAY: 10-20 mm (3/8—3/4 in) nor adjustments are made with the upper adjuster Pull the levar cover back, loosen the lock nut and turn the ad. rer to obtain the specified free play ighten the lock nut and install the cover Check eluteh operation. Major adjustments are made with the lower adjuster Loosen the lock nut and turn the adjusting nut to obtain the pecifed free play. ahten the lock nut and check the clutch operation. NG Pe oil! (vertical ADJUST BOLTS (1) HORIZONTAL ADJUSTING _ScREW “a Sa —— - (1) 19-20 mm (3/8 —3/4 in) i (1) Lower’ ADJUSTER 991 Amorcan Honaa Motor Co, ne, igh Reserves ‘usverT tog) 88°91 NTBHOMAINTENANCE SIDE STAND Place the motorcycle on its center stand. Check the rubber pad on the side stand for daterioration and wear Replace the rubber pad if wear extends to the wear line. Chack the side stand operation: When lowerd, the stand should move easily 10 the fst stop, then lock forward to support the motorcycle when the pad touches the ground and the weight of the motorcycle is cup ported When the motorcycle Is raised, the stand should automatically move to the first stop, then retract easily when kicked If the side stand does not operate smoothly, disassemble and, ccheck the side stand assembly as following procedure: Romove the return spring at the retracted position. Remove the pivot bolt and side stand. Check the following parts: — inside of the pivot and pivot collar for wear or damage. — pivot dust seal for damage. Lubricate the pivot area with clean grease and reassemble the side stand. TORQUE: Side stand pivot bolt: 38 Nem (3.8 kg-m, 27 feb) CAUTION ‘+ Insill the dust seal lip spring is facing out. + Make sure that the dust seat lp spring is seated securely. Check the side stand operation as indicated above. SUSPENSION FRONT Check the suspension action by compressing it several times, Check the entire fork leg assembly for signs of lasks or dam: age. Replace any components which ere unrepairable. ‘Tighten all nuts and bolts to the specified torque value. =a + Do not ride a vehicle with faulty suspension. Loose, worn, or damaged suspension parts may affect stability and rider con- tol. "s WEAR MARK welt (ay ferqucreo o~ () WASHER (2) DUST SEALS _(3) PIVOT COLLAR 3-16REAR ck the action of the rear suspension components by com- pressing the suspension several times. Check the entire suspension assembly, being sure itie securely mounted and not damaged or distored. Place the motorcycle on its center stand. Check for worn swingarm bearings by grabbing the swingarm, attempting to move the swingarm side to side, Replace ‘ne bearings if any looseness is noted (page 13-19) Tighten all quts and bolts. NUTS, BOLTS, FASTENERS ‘Tighten the bolts, nuts and fasteners at the intervals shown in he Maintenance Schedule (page 3-3). ck that all chassis nuts and bolts are tightened to their cor ‘ect torque values ipage 1-5 and 6), ck all cotter pins and safety clips. WHEELS/TIRES TIRE PRESSURE NOTE + Tie pressure should be checked when the tires are COLD. MAINTENANCE Front Rear Tire size (Tubeless) 110/80-17 57H 150/70-17 69H) Cold tire [Up to pressures| maximum Pee lene” | 226 (2.28, 33) | 280 12.50, 26) (kg/om?, [capacity Ps) [Up to 90 kel (200 tbs) | 225 (2.25, 33) 225 (2.25, 33) load Tire [Bridgestone] G547G G548 brand __|Dunlop 5056 K505 3-17MAINTENANCE Check the tires for cuts, imbedded nails, or other sharp ob- jects Check the front and rear wheels for trueness (Section 12 ané 13) Measure the tread depth at the center of the tires. Replace the tires if the tread depth reaches the following limit: ‘MINIMUM TREAD DEPTH: Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in) STEERING HEAD BEARINGS [—_ NoTE 1) STEERING) HEAD BEARINGS A + Check that the control cables do not interfere with handle. bar rotation Raise the front whee! off the ground Check that the fork pivots freely from side to side. Ifthe fork pivots unevenly, binds, or has vertical movement, insnect the steering head bearings (Section 12) 3-18FUEL SYSTEM ‘88 Shown: 12 Nem (1.2 kg-m, 9 feb) 4-04, FUEL SYSTEM SERVICE INFORMATION. a1 CARBURETOR INSTALLATION 4-13 TROUBLESHOOTING 42 PILOT SCREW ADJUSTMENT 414 FUEL TANK 43 HIGH ALTITUDE ADJUSTMENT (AIR CLEANER CASE 44 (U.S.A. ONLY) 414 CAURETOR REMOVAL ET aan ae CARBURETOR DISASSEMBLY 45 AIR VENT CONTROL VALVE CARBURETOR ASSEMBLY 49 INSPECTION (California model only) 4-16 CARBURETOR SECONDARY AIR SUPPLY SEPARATION/ASSEMBLY 4-12 SYSTEM (California model only) 417 SERVICE INFORMATION + Gasoline is extremely flammable and is explosive under certain conditions work ina well ventilated area with the engine stopped. Do noi smoke or allow flames or sparks in the work area or where gasoline is stored. + Ifthe engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may’ cause lass of consciousness and lead to death. GENERAL, ‘© Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments. ‘© When disassembling fuel system parts, note the locations of the O-rings; replace them with new ones on reassembly. The cerburetor float chambers have drain screws that can be loosaned to drain residual gasoline. For fuel pump inspection refer to section 18. ‘© All hoses used in the evaporative emission control system are numbered for identification. When connecting one of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4-15 (California madel only], for its routing. CAUTION + Do noi bend or twist control cables. Damaged control sables will not operate smoothly and may stick or bind. NOTE If the vehicle is to be stored for more than one month, drain the float chambers. Fuel left inthe float chambers may causa clogged jets resulting in hard starting or poor driveability SPECIFICATIONS. 88 After ‘88 49 St. model__| California mode! 48.St_model__| California mode! L : Constant Velocity dual carburetor 36.5 mm (1-4 in) Identification No. VOGKA VOGLA VOGKA VOGLA Float level 9.2 mm (0.36 in} 9.2 mm (0.36 in) Main jot - Front: #138, Rear: #132 Front: #138, Rear: #132 Slow j #42 42 Ilo speed 41,200 = 100 rpm Throtte grip free play - 26mm (8-14) Pilot e2rew initial opening 2118 24/2 Front: 1-1/2, Rear: 1 1318 41FUEL SYSTEM TORQUE VALUES Fuel tank mounting bolt = Front 12 Nem (1.2 kgem, 9 fb) Rear 22 Nem (2.2 kg-m, 16 ft-lb) TOOLS ‘Special Vacuumn/Pressure pump Pressure pump A937X—041 —XXXXX or ST—AH—255—MC7 (U.S.A. only) Vacuum pump ST—AH—260-—MC7 (U.S.A. only) Common Flost level gauge TROUBLESHOOTING Engine cranks but won't start + No fuel to carburetor + Engine flooded with fuel + No spark at plug (ignition system faulty) + Clogged air cleaner + Intake air leak + Improper choke operation + Improper throttle operation Hard starting of stalling after starting Improper choke operation Ignition malfunction Faulty carburetor Fuel contaminated Intake air leak Incorrect idle speed Incorrect valve clearance (Section 3) Incorrect carburetor synchronization (Section 3) + Improper choke valve operation. Rough idle Faulty ignition system Incorrect idle speed Incorrect valve clearance (Section 3) Incorrect carburetor synchronization Faulty carburetor Fuel contaminated Foulty air cut off valve (California model only:) Faulty purge control valve Faulty alr vent control valve Worn/damaged emission system hoses Atterburning during deceleration + Faulty ignition system + Faulty air cut off valve + Lean mixture |California model only:) Wornidamaged emission system hoses 074010010000 Misfiring during acceleration + Faulty ignition system Backtiring + Faulty ignition system + Faulty carburetor Poor performance (driveability) and poor fuel economy + Clogged fuel system + Faulty ignition system + Dirty air cleaner (Calitornia mode! only:} : Faulty air vent control valve : Worn/damaged emission system hoses Lean mixture + Clogged fuel jets + Stuck vacuum piston Faulty float valve Low float level Clogged fuel tank breather Clogged fuel strainer Restricted fuel line Intake air leak Restricted or faulty fuel pump Rich mixture + Clogged air jets + Faulty float valve + Float level too high + Dirty air cleaner 4-2FUEL SYSTEM FUEL TANK REMOVAL + Gasoline is extremely flammable and is explosive under certain ‘conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks ia the wark area or where gasoline is stored. Romove tho seat (pago 13-25) and turn the fual valve OFF. Disconnect the fuel tube from the fuel tank 188 Only California model only: All models: Remove the rear fuel tank mounting bolt first, thon the front bolt and remove the tank from the frame. CAUTION {17 vou remove the front mounting bolt fist, it may damage the front mounting collar. Cheek that fuel flows out of the fuel vaive freely. { flow is restricted, clean the fuel startiner. After BB) Remove the rear fuel tank mounting bolt first, then the front Screw the rear mounting bolt in the front mounting collar Remove the rear mounting bolt and the collar as a set. Calitornia model only: Disconnect the No. 1 fuel breather tube (to canister) from the fue! tank, (2) FRONT MOUNTING COLLAR All models: Femove the fuel tank from the frame, INSTALLATION 88, After ‘88: Install the fuel tank in the frame. Ingtall the front mounting collar and the bolt first, then the rear mounting bolt TORQUE: Front: 12 Nem (1.2 kg-m, 9 ftb) Roar: 22 Nem (2.2 kg-m, 16 ft-lb) Connect the removed tubes securely. et Se rae ot isa ( @ > (GZ Reconnect the air tubes from the carburetors. Ge ony oo mM 2 (4) 6) i WasHIN Squeeze our GEAROL SQUEEZE OUT Sowvent souvent’ (SAE #8590) Excess Ol ‘THOROUGHLYFUEL SYSTEM CARBURETOR REMOVAL = + Gasoline is extremely flammable and is explosive under certain conditions. Work ina well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the work area or where gasoline is stored. Loosen the drain screws and drain the fuel into a container. Remove the air cleaner case. Disconnect the throttle cables from the carburetor. NOTE + Turn the choke lever fully in to avoid losing the choke valves. Remove the choke valves ftom the carburetor and loosen the carburetor insulator bands. California model only: Disconnect the purge control valve No. 5 tubes and air vent contrel valve No. 6 and 11 tubes from the carburetor. Pull the carburetors upward and away from the engine. CARBURETOR DISASSEMBLY NOTE + The carburetors can be disassembled without being sepa rated. Remove the fuel tube from the carburetor. VACUUM CHAMBER Remove the four screws and vacuum chamber cover.FUEL SYSTEM Remove the spring, piston/diaphragm. (1) DIAPHRAGM/PISTON (2) SPRING Inspect the vacuum piston for wear, nicks, scratches or other damage. ‘Make sure the piston moves up and down fr ber. Push the jot needle holder in and turn it in 90 degreas counter: clockwise. (1) JET NEEDLE HOLDER ‘Then remove the needle holder, spring, jet needle and from the (2) JET (3) HOLDER. piston. NEEDLE Inspect the noodle for excessive wear at the tip, bending or other damge. Inspect the diaphragm for damage, fatigue or pin holes. Inspect the vacuum piston for wear or damage. (1) DIAPHRAGM) PISTON. A. (a) SPF FLOAT CHAMBER, FLOAT AND JETS WPT) FLOAT CHAMBER Remove the four screws and float chamber.FUEL SYSTEM femove te lot pin, float and float velves. fipFLOAT Pin Check the float valve and valve seat for scratches, clogging or damage. inspect the operation of the float valve. Remove the main jet, needle jet, slow jet and valve seat/fiter. (1) NEEDLE JET Check each part for wear or damage. sed air (2) MAIN an each jet with non-flammable or high flash point solvent. \ospect the float valve seat and filter for groaves, nicks or de- posits. = (5) FILTER —= us (4) VALVE SEAT (3) SLOW JET Cleen the filter with low-pressure compressed air. PILOT SCREW REMOVAL (1) PILOT SCREW PLUG re factory pre-set and should not be re moved unless the carburetors are overhauled. + The pliot screw plugs are factory installed to pravent pilot screw misadjustment. Do not remove the plugs unless the pilot screws are being removed. + Cover all openings with tape to keop metal perticles out when the plugs are drilled.FUEL SYSTEM Center punch the pilot screw plug to center the dri point. (1) CARBURETOR (2) ORILL BIT Drill through the plug with a 4 mm (5/32 in) dril it. Attach a drill stop to the bit 3 mm (1/8 in} from the end to prevent drill ing into the pilot screw. CAUTION + Be careful not to drill into the pilot screw. + Both pilot screws must be replaced even if only one requires it, for proper pilot screw adjustment (page 4-14). Force a self-tapping 4 mm screw, P/N 93903-35410) into (1) SELF TAPPING SCREW the ofilled plug and continue turning the screwdriver until the plug rotates with the screw. Pull on the screw head with pliers to remove the plug. sn the pilot screw area and remove Use compressed metal shavings. Turn each pilot screw in and carefully count the number of turns unti it seats lightly. Make a note of this to use as a refer- tence when reinstalling tho pilot screws. (1) O-RING caunon (2) SPRING 2 Damage to the pilot screw seat will oceur if the pilot serew is ‘ghtened against the seat Femove the pilot screws and inspect them. Replace them if @ they are worn or damat ~ a (4) WASHER o & (3) PLOT scREW—= AIR CUT OFF VALVE } (1) AIR CUT OFF VALVE COVER Remove the two screws, the set plate and the alr cut off valve NOTE + The air cut off valve cover is under spring pressure. Do not loose the spring and screws.FUEL SYSTEM Visualy check the following: Th) oRIgIce ~ diaphragm for deterioration, pin hole or other damage. — spring for deterioration or other damage. — diaphragm needle for excessive wear at the tip or other damage. — orifice of air vent for clogging, — O-ring for damage. (2) O-RING (3) DIAPHRAGM Replace the air cut off valve as an assembly, if nec: (4) SPRING CARBURETOR CLEANING Remove the float valve, all jets, and the pilot screws. Siow opan all carburetor body openings with compressed air. '1) CARBURETOR BODY CARBURETOR ASSEMBLY (5) HOLDER, (0) SPRING . (3) Jer NEEDLE Stowe & = (7) SPRING. (2) APHRAGM, (1) PISTON. E (8) O-RING (9) AIR CUT-OFF VALVE COVER (18) NEEDLE JET (15) VALVE SEAT SS_(10) plot . “ SCREW Hane. ~ SOP, sow = hE SS 2 iy 11) SLow ser are \' (1) FLOAT (12) MAIN Jer CHAMBERFUEL SYSTEM INSTALLATION I the air tube joint was removed, install a new Osring onto the air tube joint. Install the air cut off valve cover with the joint set plate and tighten the screws securely. Be sure the 1am and spring are properly seated. Install the pilot screws and return them to their original posi- 4 PA) O-RING (2) WASHER tion as noted during removal. : F Perform pilot screw adjustment if new pilot screws are in- stalled (page 4-14). —————————— (4) PiLoT ScREW Do not instal new plugs on new pilot sorew holes until after adjustment has been made. + If you replace the pilot screw in one carburetor, you must replace the pilot screw in the other carburetor for proper pilot screw adjustment. (3) SPRING FLOAT CHAMBER, FLOAT AND JETS QB Fi stow sz} Install the pilot screw and turn it in until it seats lightly “Tuen the pilot serew out the number of turns recorded during removal, ‘CAUTION Damage to the plot screw seat will occur ifthe pilot screw is lightened against the seat Install the valve seat, slow jet, needle jet and main jet. Pe rEDue JET Install the float with float valve in the carburetor body, then in- (iin stall the float arm pin through the body and the float. fos 4-10FUEL SYSTEM FLOAT LEVEL, (1) FLOAT LEVEL GAUGE Measure the float level with the float tang just contacting the float valve, FLOAT LEVEL: 9.2 mm (0.3 Adjust the float level by carefully bending the tang, Install the new O-ring in the float chamber groove. (1) O-RING install the float chamber and tighten the screws securely. NOTE Install the fuel tube clamps. VACUUM CHAMBER (2) DIAPHRAG! ‘BYPISTON install the washer, jot needle, spring and jet needle holder in the vacuum piston. Push the jet needle holder in and turn it in 90 degr Hold the vacuum piston up to almost full open to avoid pinch- pa 1g the diaphragm with the chamber cover ss cloc- (1) JET NEEDLE HOLDER | (4) FINGERFUEL SYSTEM Install the vacuum piston, aligning the tab of the diaphragm (1) CHAMBER COVER ‘with the groove of the carburetor. Install the chamber cover with the spring, aligning the cover with the hole in the carburetor, and secure with at least two screws befora releasing the vacuum piston. Install the fuel tubes 2s shown. CARBURETOR SEPARATION/ASSEMBLY 7 ria SEPARATION ie Loosen the synchronization adjusting screw. meri) THRUST, SPRING | So NOTE + When separating the carburetors, be carefulnottolose the ‘thrust spring and synchronization adjusting spring. & (2) SYNCHRONIZATION SPRING ADJUSTING SCREW Seperate the carburetors by removing the two attaching Remove the synchronization spring. 412ASSEMBLY Loosen the synchronization adjusting screw until there is no ‘pring tension, stall the thrust spring between the throttle links: Secure the carburetors together with the two screws. install the synchronization spring and synchronization adjust. Inspact throttle operation as described bolow: Open the theottle slightly by rotating the throttle valve, then release the throtie. Make sure that there is no drag when ‘opening and closing the throttle Turn the throttle stop serew to align the rear cylinder carbure or throttle valve with the edge of the by-peas hole Jign the front evlinder carburetor throttle valve with the by: sss hole edge by turning the synchronization adjusting oke sure the throttle returns smoothly to the fully closed po (1) THRUST SPRING. FUEL SYSTEM (2) THROTTLE STOP SCREW (1) SYNCHRO! ScREW IZATION ADJUSTINGFUEL SYSTEM CARBURETOR INSTALLATION {stall the carburetors onto the cylinder heads and tighten the insulator bands securely. (1) CARBURETOR Install the following parts 1 tank T oN (2) CHOKE CABLES — throttle cables 5 ~ choke cables Adjust as follows: = pilot screw — carburetor synchronization (page 3-8) — throttle grip free play (page 3-4) = carburetor idle speed (page 3-9) — carburetor choke (page 3-5) (3) INSULATOR, BANDS PILOT SCREW ADJUSTMENT (4) THROTTLE CABLES IDLE DROP PROCEDURE (U.S.A. ONLY) necessary unless the pilot scraws are replaced. + Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change. 1. Turn each pilot screw clockwise until it seats lightly and back it out to the specification given. This isan initial setting prior to the final plot screw adjust- dt wma orenwc: a. nod | “Cao dl a [Fi tens ot | 2 me ot] Aner [ Font 12 gout | 1-3 tm xt camou + Damage to the pilot screw seat will scour if the pilot screw is tightened against the seat. 2. Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient 3. Attach a tachometer according to the manufacturer's in structions 4. Adjust the idle speed with the throttle stop screw. 4-14 (1) PILOT SCREWFUEL SYSTEM 5. Turn each pilot screw 1/2 turn out from the intial setting 6. If the engine speed increases by 50 rpm or more, turn ‘ech pilot screw out by an additional 1/2 turn until engine speed drops by 50 rpm or less, 7. Adjust the idle speed with the throttle stop screw. 8. Turn the rear cylinder carburetor pilot screw in until the engine speed drops 50 rpm. 9. Turn the rear cylinder carburetor pilot screw 1 turn out from the position obtained in step 8. ©. Adjust the idle spoed with the throttle stop screw. 1. Perform steps B, 9 and 10 for the front cylinder carburetor plot screw. 12. Drive new pilot screw plugs into the pilot screw bores with a 7 mm valve quide driver (PIN 07942 ~ 8230000) When fully seated the plug surfaces will be recessed 1mm. HIGH ALTITUDE ADJUSTMENT (U.S.A. only) WUhen the vehicle is to be operated continuously atove 2,000 "(6,500 feet] the carburetors must be readjusted as follows ‘0 improve driveability and decrease exhaust emissions. .mave each pilot sctew plug (page 4-7). jarm up the engine to operating temperature. Stop and go ing for 10 minutes is sufficient. Turn each pilot screw clockwise 1/2 turn, Adjust the idle speed to specification with the throttle stop IDLE SPEED: 1,200 + 100 rpm NOTE This adjustment must be made at high altitude to ensure proper high altitude operation. Drive new pilot screw plugs into the pilot screw bores (page “7, Antach a Vehicle Emission Control Information Update label on he let sub-frame upper pipe as shown. See SL# 132 for infor ‘mation on obtaining the label NOTE Do not attech the label to any part that can be easily re moved from the vehicle, Wom SSS ‘Operation at an altitude lower than 1,500 m (5,000 feet) with the carburetors adjusted for high altitudes may cause the engine {0 idle roughly and sal When the vehicle is te be operated continuously below 1,500 ‘ (5,000 foot), turn each pilot screw counterclockwise 1/2 turn to its original position after removing each pilot screw plug and adjust the idle speed to specification ipage 4-1) Drive new pilot screw plugs into the pilot screw bores (pace 4-7). Be sure to do these adjustments at low altitude with the engine at normal operating temperature. ©F-(1) VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL & ‘ ‘VOUCGE EMSSION CONTROL FORMATION UPDATE HONDA MOTOR CO, LTD TMS VEMCLE WAS BEEN ADNSTED TO IMPROVE EMISSION CONTRO. PERFORMANCE WHEN OPERATED AT MGH ALITUNE: ALTITUDE PERFORMANCE. ADUSTMENT INSTRUCTIONS ‘AREAVAILABLE AT YOUR AUTHORIZED MOMDA DEALER (1) UPDATE LABEL 4-15FUEL SYSTEM PURGE CONTROL VALVE INSPECTION (California model only) NOTE +The purge control valve should be inspected if hot restart is difficult Check all fuel tank, Purge Control Valve (PCV), and charcoal canister hoses to be sure they are not kinked and are securely ‘connected. Replace any hose that shows signs of damage or deterioration, NOTE ‘The PCV is located under the fuel tank. Diseenneot the PCV hoses from their connections and remove the PCV from its mount. Refer to the routing label on th ‘cleaner case cover for hose connections. Connect a vacuum pump to the 8 mm (0.31 in.) LD. hose No. 5 that goes to the 3-way joint, Apply the specified vacuum to the PCV. SPECIFIED VACUUM: 250 mm (9.8 in) Hg The specified vacuum should be maintained. Replece the PCY if vacuum is not maintained, TooL: Vacuum/Pressure pump A937X—041~XXXXX or Vacuum pump ‘ST—AH—260-MC7 (U.S.A, only) Remove the vacuum pump and connect it to the vacuum hose No. 11 that goes to the loft carburetor body. ‘Apply the specified vacuum to the PCV. ‘SPECIFIED VACUUM: 250 mm (9.8 in) Ho ‘The specified vacuum should be maintainec Replece the PCV if vacuum is not maintained, Toot: Vacuum/Pressure pump Vacuum pump A937X—041—XXXKX oF ST—AH-260-Mc7 (U.S.A. only) Connect a pressure pump to the 8 mm (0.31 in.) LD. hose No. 4 that goes to the charcoal canister. While appivirg the speci- fied vacuum to the PCV hose that goes to the 3-way joint [pump air through the canister hose. Air shoud flow through the PCV and out of the hose that goes to the 3-way joint Replace the PCV if air does not flow out. ‘CAUTION + Te prevent damage to the purge control valve, do not use high pressure air sources. Use a hand operated air purip only. A937X—041—XXXXX ot ST—AH—260-Mc7 ST—AH—255-Mc7 (U.S.A. only) Remove the pumps, install the PCV on its mount, route and r connect the hoses according to the routing label (page 4-18), Vacuum pump Pressure pump (1) PURGE CONTROL VALVE (3) TO WAY / (8)TO CHARCOAL CANISTER (4) TO CARBURETOR 800y (2) VACUUM PUMP (2) VACUUM PUMP J 4-16FUEL SYSTEM AIR VENT CONTROL VALVE INSPECTION (California model only) Disconnect the Air Vent Controt Valve (AVCV) hoses from reir connections and remove the AVCV from its mount, Refer = the routing label on the air cleaner case cover for hose con tions, ect @ vacuum pump to the No. 10 hase that goes to the ont carburetor body. oly the specified vacuum to the AVCV. SPECIFIED VACUUI TOOL: \VacuumiPressure pump vacuum pump 150 mm (9.8 in) Hg A937X—041—XXXXX or ‘ST—AH—260—MC7 (U.S.A. only) ~e spocitied vacuum should be maintained. lace the AVCV if vacuum is not maintained. CAUTION To prevent damage (0 the air veni control valve, do not use ‘igh pressure ar sources. Use a hand operated air pump only, ject the vacuum pump to the air vent port of the AVCV. ‘ply vacuum to the AVCV. The vacuum should hold steady, ‘place the AVCV if vacuum leaks. Tool: vacuum/Pressure pump vacuum pump, A937X—041—XXXXX or ST—AH—260—MC7 (U.S.A. only) -nnect the vacuum pump to the No. 10 hose that goes to the. ght carburetor body. nect the pressure pump to the air vent port of the AVCV. wile applying the vacuum to the AVCV No. 10 hose that oes to the right carburetor body, pump air through the air nt port. * should flow through the AVCV and out of the hose that 6 t0 the carburetor air joint pipe TooL: Vacuum/Pressure pump vacuum pump Pressure pump A937X—041—XXXXX or ST—AH-260-MC7 ST—AH—255-MC7 (U.S.A. only) Puug the hose that goes to the carburetor ar joint pipe. while applying vacuum to the AVCV No. 10 hose that goes to the Seway joint, apply air pressure. It should hold steady, Replace the AVCV if pressure is not retained Remove the pumps, install the AVCV on its mount, route and ‘econnect the hoses according to the routing label. TooL! Vacuum/Pressure pump A937X—041—XXXXX or Vacuum pump ‘ST—AH—260—MC7 Pressure pump ST—AH—255—MC7 (W.S.A, only) (2) TO OPEN AIR (1) 70 AIR 4 (9) AIR VENT CONTROL JOINT PIPE VALVE mo (4) TO CHARCOAL”~ Canister —_— (5) TO. ra exchioen INTAKE Pom (6) VACUUM PUMP (1) Vacuum PUMP SOR ey, 8G | (2) PRESSURE PUMP 7 (1) Vacuum PUMP (2) PRESSURE PUMP (1) BLOCKED TUBEFUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM (California model only) SYSTEM INSPECTION Start the engine and warm it up to normal operating tempera Disconnect tho secondary sr intake Hose tom the eon Nore + Do nat disconnect the fuel tubes from the tank ‘Check that the secondary air intake ports are clean and free of carbon deposits. Check the secondary air intake hose for clogging, deterioration ‘or damage and replace if necessary. Check the reed vaives in the air suction valve (ASV) if the Intake hose or supply hose Is damaged by exhaust gas. Disconnect the vacuum tube {No. 10) from the ASV and install, 2 plug in the vacuum tube to keep air from entering. Connect the vacuum pump to the ASV. A937X—041—XXXXX or ST—AH—260—MC7 (U.S.A. only) Vacuum purnp ‘Start the engine and open the throttle slightly to be certain that air 's sucked in through the intake hose. If air is not drawn in, check the air supply hoses and vacuum tube for clogging With the engine running, gradually apply vacuum to the ASV. Check that the air intake hose stops drawing alr, and that the vacuum does not bleed off. ‘SPECIFIED VACUUM: 300-370 mm (11.8~14.6 in) Hg If air is stil drawn in, or if the specified vacuum is not main- ‘aired, install a new ASV. Hf afterburn occurs on deceleration, even when the secondary air supply system is normal, check the air cut-off valve for cor rect vacuum operation. (3) AIR CLEANER — [AIR INTAKE HOSE —~—~=«SS) IR CLEANER | fs (5) No. 10 TUBE / (a) CARBURETOR (1) AIR INTAKE HOSE (2) ain suppLY 7 (4) VACUUM PUMP HOSE ‘VACUUM HOSE ROUTING DIAGRAM 4-18FUEL SYSTEM REED VALVE INSPECTION Disconnect the air supply hoses from the reed valve covers of the ASV, Disconnect the vacuum tube and air intake hose from the ASV. Remove the ASV mounting bolts and ASV. Remove the two screws, the reed valve cover and the raed valve from the ASV. Check the reed valve for damage or fatigue, and replace if nec- essary. install a new reed valve if the seat rubber is cracked or dam: ‘aged, or if there is clearance between the reed vaive and seat, ‘CAUTION + Do not disassemble the reed valve assembly or bend the reed stopper. + Ifthe stopper, reed or seat is faulty, replace the valve es an as- embly. Assemble and install the ASV in the reverse order of disassem- bly/removal. NOTE + After installing, make sure the air and vacuum tubes are correctly connected (page 1-10 to 15.) (asv) (3) REED (4) REED STOPPER (1) AIR SUCTION VALVE (2) REED VALVE 4-19COOLING SYSTEM (1) FILLER NECK (5) THERMOSTAT (4) RapiAfoR (2) SIPHON TUBE (3) WATER PUMP5. COOLING SYSTEM SERVICE INFORMATION 5-1 THERMOSTAT 53 TROUBLESHOOTING 5-1 RADIATOR/COOLING FAN 5-5 ‘SYSTEM TESTING 5-2 WATER PUMP 5-7 COOLANT REPLACEMENT 5-3 SERVICE INFORMATION GENERAL 5) + Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine must be cool before servicing the cooling system. If the engine must he running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. + Use only distilled water and ethylane glycol in the cooling system. A 5050 mixture is recommended for maximum corro- sion protection. Do not use alcohol-based antifreeze. Add coolant at the reserve tank. Do not remove the radiator cap except to refi, or drain the system, of to test the coolant ‘* Avoid spilling coolant on painted surfaces. ‘© After servicing the system, check for leaks with a cooling eystem test ‘© For temperature sensor and thermostatic switch inspection, rafar to section 18. SPECIFICATIONS TEM SPECIFICATIONS ief proseure 88127 kPa (0.9-1.9 kgiomé, 1318 psi) Freezing point (Hydrometer test) '55% Distilled water + 45% ethylene glycol: ~32°C | (-25°F) 50% Distilled water + 50% ethylene glycol: ~37°C _(-34°F) 45% Distilled water + 55% ethylene glycol: ~44.5°C (48°F) Coolant capacity: Coolant change: | 1.60 lit (1.51 US qt, 1.28 Imp at) Total system: 2.20 lit (2.92 US qt, 1.94 Imp gt) _ | Thermostat Bagins to open: 80° to B4°C (175° to 183°F) Valve lift: Minimum of 8 mm at 95°C (0.3 in at 203°F) — Boiling point (with 6060 mixture): Unpressurized: 107.7°C (226°F) Cap on, pressurized: 125.6°C (258°F) TROUBLESHOOTING Engine temperature too high Engine temperature too low = Faulty temperature gauge or sensor + Thermostat stuck open Thermostat stuck closed + Faulty radiator cap Coolant leaks + Ingutficient coolant or coolant level too low + Faulty pump mechanical seal + Passages blocked in radiator, hoses or water jacket + Detariorated O-rings + Cooling fan motor doss not turn — Burned or loose sub-fuse — Faulty fan motor — Faulty thermostatic switch — Poor connector contact or open circuit in harness + Faulty water pump 5-1COOLING SYSTEM SYSTEM TESTING (i) ANTI FREEZE TESTER COOLANT MIXTURE Remove the reserve tank cap. Test the coolant mixture with an antifreeze tester For maximum corrosion protection, a 50—50% solution of ethylene glycol and distilled water is recommended, Remove the fuel tank (page 4-3) Remove the radiator cap. = + Besure the engine is coo! before removing the cap or you may be severely scalded. RADIATOR CAP (1) COOLING SYSTEM TESTER COMMERCIALLY AVAILABLE Wet the radiator cap sealing surface, install the cap on the | tester, and apply pressure Replace the radiator cap if it does not hold pressure, or if it's relief pressure is too high or too low. It must hold specified pressure for at least six seconds. RADIATOR CAP RELIEF PRESSURE: 88—127 kPa (0.9—1.3 kg/cm*, 13-18 psi) SYSTEM PRESSURE TEST Remove the fusl tank and radiator cap, ‘Attach the tester to the radiator and apply enough pressure to test the radiator, engine and hoses, check for leaks, CAUTION + Excessive pressure can damage the radiator. Do not exceed 125 KPa (1.25 kg/en, 18 psi ~ (1) COOLING sysTEM Repair or replace components if the system will not hold speci TESTER fied pressure for at least six seconds. 5-2COOLING SYSTEM COOLANT REPLACEMENT a The engine must be cool before replacing the coolant or severe Seaiding may result. If the engine must be running t0 do some work, make sure the area is well-ventilated. Never run the engine in an enclosed The eehous contains pobsnous carbon monoxide gt that may ~ wer a cause loss of consciousness and lead 10 death. Remove the radiator cap (page 5-2), (1) DRAIN BOLT Drain the coolant from the system by removing the drain bolt 1 the water pump cover. install the drain bolt (1) FILLER i the system with 50-50 mixture of distilled water and eth. ne alycol. ed air from the cooling system. + Support the motoreyela on its center stand and shift the ‘uansmission into neutral Start the engine and snap the throttle grip, 3—4 times at 4,000-5,000 rpm. Then add coolant up to the radiator filer neck. Reinstall the radiator cap, Check the level of coolant in the reserve tank and fill to the correct lovel if the level is low. THERMOSTAT REMOVAL (1) HOUSING MOUNTING BOLT Remove the follo, — fuel tank (page 4-3) air cleaner case {page 4-3) (8) COVER BoLTs Disconnect the upper radiator hose at the filler neck and the LP Ra water hoses at the thermostat housing fF 5 Ronee ac » (9)THERMOSTAT <>. ererethe torrents housing cass: and tilenrect-tomrthe NP Remove the housing cover attaching bolts and separate the > case from the cover, - Remove the thermostat from the housing case. (5) WATER HOSES oa 7 3COOLING SYSTEM INSPECTION 1) THERMOSTAT Inspect the thermostat visually for damage. Me Suspend the thermostat in heated water t0 check its opera- tion NoTE : (2) THERMOMETER If the thermostat or thermometer touches the pan, you'll got a false roading, Replace thermostat if valve stays open at room temperature, or if it responds at temperatures other than those specified. Data: Start toopen | 80° toBA°CI176—183°F)__| Vatve lift 8 mm (0.3 in) minimum when | heated to 95°C (203°F} fer five INSTALLATION Install the following: the thermostat into the housing case. — the new O-ring into the case groove. the cover onto the case, with the bolts Assemble the case and filler neck with the new O-ring Tighten the bolts Install the thermostat housing case and filler neck onto the By es eee NOT frame. (8) COVER BOLTS Connect the removed hoses and tube securely. (3) FILLER NECK Install the removed parts in the reverse order of removal, Fill the system with coolant and air bleed it. (7) HOUSING Cover: (6) HOUSING CASE (5) WATER Hoses 5-4COOLING SYSTEM RADIATOR/COOLING FAN REMOVAL Drain the cooiant (page 5-3). (1) LOWER HOSE] sconnect the cooling fan motor connector m Disconnect the lower radiator hose at the radiator. femove the radiator side covers by removing mounting Remove the radiator lower mounting bolts. -onnect the upper radiator hose st the radiator. ‘ove the radiator upper pivot bolt and radiater from the‘COOLING SYSTEM DISASSEMBLY Disconnect the cooling fan motor wire connector from the thermostatic switch and remave the wite from the clamp, Remove the ground wire terminal bolt. Remove the cooling fan motor mounting bolts and cooling fan motor. RADIATOR INSPECTION NoTE + See section 18 for thermostatic switch inspection. Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc., are clogging the radiator, wash them off with low pressure water Carefully straighten any bent fins. (1) RADIATOR (3) PIVOT BOLT | (2) MOUNTING BOLTS ‘aware CONNECTOR (3) GROUND TERMINALIBOLT [1) COOLING FAN MOTOR | (3) MOUNTING BOLTS (1) COOLING FAN MOTOR. ys (2) GROUND TERMINAL/BOLT 3 (a) THERMOSTATIC ‘SWITCH (2) FIN mh IT) RADIATOR (2) SIDE Covers (4) LOWER MOUNT BOLTSCOOLING SYSTEM 2s _OOOLING SYSTEM ASSEMBLY/INSTALLATION (4) WIRE [2) MOUNTING BOLTS CONNECTOR nA Install the cooling fan motor, Connect the ground terminal and thermostatic switch wire connecter. Install the mounting bolts. [ (3) MOUNTING BOLT: a (3) MOUNTING BOLTS (1) cooLING FAN MOTOR If the thermostatic switch was removed, install a new O-ring and tighton to the specified torque. THERMOSTATIC SWITCH: Bed 2) ch TORQUE: 18 Nem (1.8 kg-m, 13 feb) PS Seen “5, TERMINAL/BOLT install the radiator in the reverse order of removal (a) THERMOSTATIC SWITCH WATER PUMP MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs of mechanical coal coolant leakage. Repiace the water pump as an assembly if the mechanical seat « leaking, REMOVAL Drain the engine oil (page 2-3), Remove the water pump cover mounting bolts and cover. Remove the O-ring and dowel pins from the water pump as sembly and disconnect the water hose. Remove the water pump from the crankcase. lees (3) DOWEL PINSCOOLING SYSTEM INSPECTION (1) O-RING 12) WATER PUMP ASSEMBLY Check the water pump for mechanical seal leakage and bear ing deterioration. Replace the water pump as an assembly if necessary. (3) WATER PUMP. (4) O-RING | INSTALLATION Connset the water hose with the clamp. Apply @ coat of clean engine oil to a new O-ring and install tin the water pump shaft housing groove. {Align the water pump shaft groove with the oil pump shaft and insert the water pump into the crankcase. Apply a coat of engine oil to. new O-ring and install it around ° (1) DOWEL PINS) tho impeller housing, Install the two dowel pins. 13) O-RING Install the water pump cover and tighten the cover mounting bolts Fill the system with coolant (page 5-3) Fill the engine with the recommended engine oll (page 2-3} Check the cooling system for leakage (1) WATER PUMP COVER 5-86. ENGINE REMOVAL/INSTALLATION ‘SERVICE INFORMATION 6-2 ENGINE INSTALLATION 65 ENGINE REMOVAL 6-3 65 Nem (6.5 ko-m, 47 feb) 15 Nom (1.5 kg-en, 11 feb) (6.5 kgm, 47 feb) 40 Nem (4.0 kgm, 28 ft-lb) 10 Nem (1.0 kgm, 7.2 fio)ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL © Support the motorcycle using a hoist, a floor jack or other adjustable support. © ‘The following parts can be serviced with the engine installed in the frame: + Clutch + Alternator + Gearshift linkage + Starter motor + Camshafts + Carburetors + Cylinder heed + Water pump © To sorvico tho crankshaftitransmission, oll pump, and cylinder the engine must be removed from the frame. ‘© When using the lock nut wrench, use a 20 inche long deflacting beam type torque wrench. The lock nut wrench increases ‘te torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut, SPECIFICATIONS Engne dry weight 61 kg (134 Ib) Oil eapacity 2.8 lit (2.94 US at, 2.46 Imp qt) at disassembly Coolant capacity 2.0 lit (1.89 US at, 2.27 Imp qu) total TORQUE VALUES Muffler mounting bolt 27 Nem (2,7 kg-m, 20 ft-lb) Exhaust pipe joint nut 27 Nem (2.7 kg-m, 20 ft-lb) Gearshift arm bott 12 Nem (1.2 kg-m, 9 ft-lb) Drive sprocket bolt 10 Nem (1.0 kg-m, 7.2 ft-b) Swingarm pivot nut 65 Nem (6.5 kg-m, 47 ft-b) Swingarm pivot lock nut 65 Nem (6.5 kg-m, 47 ft-1b) ‘Swingarm pivot adjusting bolt 15 Nem (1.5 kg-m, 11 ft-lb} Front engine bracket bolt 28 Nem (2.8 kg-m, 20 ft-lb} Front engine mouning bott 40 Nem (4.0 kg-m, 29 ft-b) Rear upper engine mouning bott 40 Nem (4.0 kg-m, 29 ft-b) = mounting bolt lock nut 55 Nem (5.5 kg-m, 40 ft-lb) = mounting bolt adjusting bolt 11. Nem (1.1 kg-m, 8 ft-lb) Fue tank mounting bolt: Front 12. Nem (1.2 kg-m, 9 ft1b) Rear 22 Nem (2.2 kg-m, 13 ft-lb) TOOL Special Loce nut wrench (07908 ME90000ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL er fs Drain the engine oil (page 2-3). = ce the motorcycle on its center stand. Disconnect the battery negative cable fom dhe batery term } : Remove the following: > i « ad fuel tank (page 4-3). * oan FE carburetor (page 4-5), = * < Remove the thermostat housing with water hoses attached. isconnect the clutch cable from the clutch lifter arm by re “ving the holder bolt. |arclorde cnt AC HOLDER J Remove the swingarm pivot nut,ENGINE REMOVAL/INSTALLATION Places floor jack or other adjustable support under the engine CAUTION + The jack height must be continually adjusted 10 relieve stress ‘for ease of bolt removal + Dono! jack up the engine atthe oil fer. Remove the angina upper bracket bolts and bracket Remove the front angine lower mounting bolt. Loosen the rear engine upper mounting bolt lock nut and remove the rear engine upper mounting and adjusting bolts. Romeve the swingarm pivot adjusting bolt lock nut TOOL: Lock Nut wrench 07908-MES0000 ‘Turn the pivot bolt with the adjusting bolt counterclockwise to (1) PIVOT BOLT/ADJUSTING BOLT release the engine mounting frame. fox Lo = Pull the swingarm pivot bolt out to clear the engine mounting hole, but do not remove it Remove the engine from the frame. 6-4 a8) Aran Mora Moc, ne Rags RessENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION wre Install the engine into the frame correctly. “Hh Pvor sory Engine installation is essentially the reverse order of removal Use # floor jack or other adjustable support to carafully manuaver the engine into place. CAUTION + Carefully align the mounting points with the jack prevent damage to mounting bolt threads and wire harness and cables. Insert the swingarm pivot bolt while aligning the serrations of the pivot bolt and adjusting bolt. Turn the pivot bolt with the adjusting bolt clockwise fully to t the swingarm laft pivat collar. ighten the bolt to the specified torque. TORQUE: 15 Nem (1.5 kg-m, 11 ft-lb) ‘stall the lock nut onto the adjusting bolt. (2) LOCK NUT WRENCH Tighten the lock nut to the specified torque while holding the \ fr jot bolt and adjusting boit together. aw yn p TOROUE: ‘Actual: 65 Nem (6.5 kg-m, 47 fb) Ingicated: 59 Nem (5.9 kg-m, 43 ft) Too: Lock nut wrench 07908~-MES0000 (1) Lock NUTENGINE REMOVAL/INSTALLATION Install the swingarm pivot nut and tighten it to the specified torque TORQUE: 65 N-m (6.5 kgm, 47 feb) Install the rear engine upper mounting adjusting bolt. Turn the mounting adjust bolt clockwise fully to seat the engine mount Tighten to the specified torque. TORQUE: 11. Nem (1.1 kg-m, 8 Fb) Install the lock nut onto the adjusting bolt TORQUE: 55 N-m (5.5 kg-m, 40 feb) Install the rear engine upper mounting bolt and tighten it to the specified torque. TORQUE: 40 N-m (4.0 kg-m, 29 ft4b) Tighten all the fasteners to the torques given on page 6-1 and 2, NOTE + Route the wires and cables properly (Section 1), + Fillthe crankcase to the proper level with the recommended cil (page 2-1) + Fill the cooling system (page 6-3). * Perform the following inspection and adjustments: ‘Throttle operation ipage 3-4), Clutch (page 3-15) iy fvor hr 1 ‘ 5 neh i © 1 oh. S 4) ZL \ e 6-6CLUTCH/GEARSHIFT LINKAGE 7-07. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION TROUBLESHOOTING RIGHT CRANKCASE COVER REMOVAL CLUTCH REMOVAL GEARSHIFT LINKAGE 7-1 PRIMARY DRIVEGEAR 7-2 CLUTCH INSTALLATION 7-3 RIGHT CRANKCASE COVER 7.4 INSTALLATION 78 7-10 7A 714 SERVICE INFORMATION GENERAL ‘© This section covers the removal and installation of the clutch, oil pump five chain, gearshift linkage and primary drive gear. All these operations can be done with the engine installed in the frame. © If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 11). © Coat the new clutch discs with clean engine oil before reassembly. SPECIFICATIONS nt rea Tea STANDARD SERVICE UIT Caiech[S ro ath PYYET] ee) Sota edo 7A76/28.2 kame (90.18/08 ben} = | ~ Dise thickness Disc A 2.92—3.08 (0.115—0.121) T 2.60 (0.102) Disc 8 21622, 78 (0,10320.108) 2.90 (6081) Fas 0:0 (0.012) utr suits ~ 21.991 22.016 0.0668-0.8668 —22.09.0.870) 00: 31.959—91.976 (1.2682—1.2808) | 31.92 (1.2671 ee 32.000—32.026 (.2898~1.2008) | 82.10 1.204 Olas dia sweden 32:000=82.026 (125981 2608) | 32.10 1260) alate -0.0 acta gD 21.967=21,900 (0.0648.-0.0656) | 21.92 0.863) TORQUE VALUES Shift drum stopper plate bolt Primary drive geer bolt Oil pump driven sprocket bolt Cluteh lock nut 5il pass pipe bolt (8 mm! (7 mm) Clutch center holder Gear holder Common Lock nut wranch, 17 x 27 mm. (07923-KE10000 or 07HGB—-001000A (U.S.A. oniy) 077240010100 Not available in U.S.A, 26 Nem (2.6 kgem, 19 ft-lb) Apply locking agent to the threads 90 Nem (8.0 kg-m, 65 ft-lb) 15 Nem (1.5 kg-m, 11 ft-lb) Apply locking agent to the threads 180 Nem (13.0 kg'm, 94 ft-lb) Staked nut 23 Nem (2.3 kg-m, 17 ft-lb) 10 Nem (1.0 kg-m, 7.2 ft) (077160020300 Equivalent commercially available in U.S.A. 7-1CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch lever free play Clutch slips when accelerating + No trae play + Dises worn + Springs weak Clutch will not disengage + Too much free play + Plates warped Motorcycle creeps with clutch disengaged + Too much free play Pletes warped Excessive lever pressure Clutch cable kinked, damaged or dirty Lifter mechanism damaged Clutch operation feels rough + Clutch outer slots rough + Dirty clutch cableCLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL pire urten TERT Drain the engine oil (page 2-3) Remove the exhaust pipe, Fomove the clutch cable holder and disconnect the clutch cable from the clutch lifter erm. Loosen the oil pipe holder and remove the oll pipe bolt and seal- ing washers from the right crankcase cover, Remove the right crankcase cover bolts and cover, nore _ +R crankease cover can be serviced with rear exhaust pipe remaval any Remove the dowel pins and gasket. Remove the oil orifice. CLUTCH LIFTER Romove the clutch lifter piece, and remove the snap ring and return spring from the right crankcase cover. Remove the clutch lifter shaft Check the clutch lifter piece and shaft for damage or excessive seratching Check the return spring for fatigue or damage. * SF (2) eee SHAFT aCLUTCH/GEARSHIFT LINKAGE Check the needle bearings for wear or damage or a loose fit in the cover, ‘Check the dust seal for fatigue or damage. (2) NEEDLE Apply grease to the dust seal and needle bearing. say DUSLISEAE BEARINGS Install the clutch lifter shaft, snap ring and return spring. Hook the spring end in the cover tab securely, and turn the shaft. Install the clutch lifter piece, aligning the piece end with the ‘groove in the clutch lifter shat (3) SPRING (4) SNAP RING CLUTCH REMOVAL Giro Remove the following: clutch bolts lurch lifter plate springs NOTE + Remove the bolts in a crisserase pattern in 2 steps. Unstake the clutch lock nut with a dill or grinder. NOTE + Be careful not to damage the shaft threads. 7-4CLUTCH/GEARSHIFT LINKAGE es AUTONET Cie "TS i a Hold the clutch center with the spacial tool and loosen the clutch lock nut. Remove the tools and the lock nut. TooLs: Clutch center holder 07923—KE10000 or (07HGB—001000A (U.S.A, only) Lock nut wrench, 17 x27 mm — 07716—0020300 Equiva. lent commorcialy available inUS.A, NOTE IT you will remove the oll pump driven sprocket, loosen the driven sprocket mounting bolt at this time. Remove the following: washer clutch center, judder spring and spring seat — discs and plates pressure plate Remove the thrust washer and clutch outer. oa 7 7 g(2) CLUTCH OUTER Remove the oll pump driven sprocket mounting bolt, driven sprocket and oll pump drive chain.CLUTCH/GEARSHIFT LINKAGE Remove the drive sprocket and clutch outer guide from the mairshaft INSPECTION Check the lifter plate bearing for damage. Turn the bearing inner race with your finger. ‘The bearing should turn smoothly and quietly. ‘Also check that the bearing outer race fits tightly in the clutch iter plate, Replace the bearing if necessary. Measure the spring free length. SERVICE LIMIT: 42.8 mm (1.69 in) Replace the clutch discs if they show signs of scoring or dis coloration, Measure the thickness of dises A and B. SERVICE LIMITS: Disc A: 2.60 mm (0.102 in) Dise B: 2.30 mm (0.091 in) 'S and plates as a set if any one is beyond (1) CLUTCH OUTER GUIDE (1) BEARING (2) CLUTCH LIFTER PLATE 11) CLUTCH DISCCheck the plate warpage on # surface plate using a thickness gauge, SERVICE LIMIT: 0.30 mm (0.012 in) et if any one is beyond Check the clutch center for nicks or indentations made by the clutch plates. Check the spring seat and judder spring for distortion, wear or cemace. Replace them if necessary. CCheck the slots in the clutch outer for nicks or indentations made by the clutch discs. Measure the 1.D. of the clutch outer. SERVICE LIMIT: ‘Clutch outer .D. 32.10 mm (1.264 in} CLUTCH/GEARSHIFT LINKAGE (PLATE (1) cuutcH CENTER (1) JUDDER SPRING (2) SPRING | SEAT < (1) CLUTCH OUTER. (2) DamageCLUTCH/GEARSHIFT LINKAGE Check the oll pump drive sprocket for damage, Mezsure 1.0 of the drive sprocket and the 0.0. and I.D. of the outer quide. SERVICE LIMITS: Oil pump drive sprocket I.D. 32.10 mm (1.264 in) ‘ Clutch outer guide 0.0. 31.92 mm (1.257 in) 1D. 22.09 mm (0.870 in) (2) CLUTCH OUTER GUIDE m.(1) GIL PUMP DRIVE SPROCKET Measure the mainshaft 0.D. at the clutch outer guide. 1 SS sar ‘SERVICE LIMIT: 21.92 mm (0.863 in) GEARSHIFT LINKAGE REMOVAL Remove the following — drive sprocket cover (page 8-2) = gearshift pedal arm from the gearshift spindle — tight erankease cover (page 7-3) — clutch assembly (page 7-4) — ol pump drive chain (page 7-5) Loosen the two oil pipe stay mounting bolts and remove the oil pipe mounting bolt. Pull the oil pipe out of the stay and oil pump.Somave the following: argh spindle Seal peor alt sowper noodle vv trum etaper plate bolt and topper peteldum NSPECTION ck the gearshift spindle for bending or damage. check the return spring for fatigue or damage, NSTALLATION ostall the collar, spring, stopper arm, washer and stopper arm colt and tighten the bolt. stall the dowel pins into the holes of the gearshift drum. up the drum stopper atm and install the drum stopper ate. ly locking agent to the threads of the stopper plate bolt 2nd tighten the bolt, TORQUE: 26 Nem (2.6 kg-m, 19 fb) stall the gearshift spindle, aligning the return spring ends with the pin in the case. CLUTCH/GEARSHIFT LINKAGE (1) SERBSREFSPINBLE Tian storven aa’ p (4) STOPPER PLATE, (1) SPINDLE (SLPLATE BOLL | (2) RETURN SPRING Somer NamCLUTCH/GEARSHIFT LINKAGE Install the oll pipe with @ new O-ring onto the oll pipe stay and oil pump. Tighten the bolts securely, Install the removed parts in the reverse order of removal, Install the gearshift arm to the gearshift spindle, Align the punch mark on the arm with the punch mark on the spindle. Tighten the gearshift arm pinch bolt TORQUE: 12 N-m (1.2 kg-m, 9 fb) Install the drive sprocket cover. PRIMARY DRIVE GEAR REMOVAL Remove the following = Fight crankcase cover (page 7-3) clutch assembly (page 7-4) Remove the pulse generator mounting bolts and pulse generators. . (1) PULSE GENERATOR __MOUNTING BOLTS. ‘Temporarily install the clutch outer, then install the gear holder ‘as shown, ‘Too: Goa holder 077240010100 Not available in U.S.A. \ Fomove the following primary drive gear bolt and pulse generator rotor clutch outer and gear holder — primary drive gear e clover Otten ontu.se cretnTon ROTOR 7-10CLUTCH/GEARSHIFT LINKAGE INSTALLATION install the primary drive gear with the “OUT” mark facing out. NOTE The primary drive gear end pulse generator rotor will only 490 on in one position because of the extra wie aligning spline, install the pulse generator rotor. Temporarily install the clutch outer and install the gear holder as shown. TooL: Gear holder 07724-0010100 Not available in U.S.A. astall the washer and bolt and tighten the bolt. TORQUE: 90 Nem (9.0 kg-m, 65 ft-lb) Remove the gear holder and clutch outer. inetall the following: erators NOTE + If the pulse generator wire grommets were removed from the case groove, reinstall them securely. CLUTCH INSTALLATION Apply MoS: paste grease to the outside of the olutch outer guide and install the oil pump drive sprocket over the outer gui.(CLUTCH/GEARSHIFT LINKAGE Install the oil pump drive chain on the drive sprocket. Install the oll pump driven sprocket with the “IN’" mark facing inside, Guide the drive chain over the sprocket. Apply locking agent to the threads of the driven sprocket, ‘mounting bolt and tighten it with the washer to the specified torque. TORQUE: 15 Nem (1.5 kg-m, 11 ft-lb) Align the grooves in the clutch outer with the bosses on the oil ump drive sprocket while turning the sprocket with the chain and pushing the clutch outer onto the shaft. Install the thrust washer onto the mainshaft. 712CLUTCH/GEARSHIFT LINKAGE ostall the pressure plate, clutch dises B, plates and disc A in ne clutch outer NOTE Stack the dises and plates alternately. Coat the new clutch discs with clean engine oil natalie spring sect and jutder spring onthe cutchcantoras ‘stall them in the clutch outer: NOTE Note the positions of the seat and disc A. stall the washer on the mainshaft, old the clutch center with the clutch center holder, and tight on the lock nut to the specified torque. TORQUE: 130 Nem (13.0 kg-m, 94 fb) roots: Clutch center holder Lock nut wrench, 17x27 mm Stake the lock nut with a center punch. A (4) JUDDER SPRING/SPRING SEATS : c if * PRESSURE PLATE (2) SPRING (5) JUDDER ‘SPRING a (3) bisc 8 14) DISC A 07923-KE10000 or 07HGB—001000a (U.S.A. only) 077160020300 Equiva. lent commercially available inU.S.A. (2) Lock NUT WRENCH “ (tocknur TN * 7-13CLUTCH/GEARSHIFT LINKAGE Install the clutch springs, lifter plate and bolts Tighten the bolts in a crisscross pattern in 2 or 3 steps. NOTE + Make sure the pressure plate firmly pushes the discs and plates. Install the bearing into tha litter plate. RIGHT CRANKCASE COVER INSTALLATION Check the oll orifice for clogging Install a new O-ring on the oil orifice Install the oil orifice with its smaller hole facing in, Install the dowel pins and new gasket. Tighton the right crankcase cover mounting bolts in a Ccisscross pattorn in 2 or 3 steps and install the clutch cable holder and oil pipe holder at the same time. Connect the clutch cable to the clutch lifter arm. ‘Tighten the oil pipe bolt with the new sealing washers, ‘TORQUE: 23 Nem (2.3 kg-m, 17 ft-lb) Install the exhaust pipe. ‘TORQUE: Exhaust pipe joint nut: 27 Nem (2.7 kg-m, 20 ft-b) ‘Mutflor band bolt: 27 Nem (2.7 kg-m, 20 ft-b) Fill she crankcase with engine oll page 2-3). Adjust the clutch lever free play (page 3-15) 7-14ALTERNATOR/STARTER CLUTCH "88 Shown: 8-08. ALTERNATOR/STARTER CLUTCH ‘SERVICE INFORMATION 8-1 FLYWHEEL INSTALLATION 85 LEFT CRANKCASE COVERREMOVAL 8-2._ LEFT CRANKCASE COVER FLYWHEEL REMOVAL eg MSTALLATION es STARTER CLUTCH 8-4 SERVICE INFORMATION GENERAL «© This section covers the removal and installation of the alternator, starter clutch and starter gears. © Refer to section 15 for troubleshooting and inspection of the alternator. SPECIFICATIONS mm (in) ITEM STANDARD | SERVICE LIMIT Hi Starter driven geer 0.0. 87.74957.768 (2.2736—2.2743) 57.60 (2.268) TORQUE VALUES Fiywhee! bott 130 Nem (13.0 kg-m, 94 ft) Left-hand thread Starter clutch torx bolts 30 Nem (3.0 kg-m, 22 ft-lb) Apply locking agent to the TOOLS Common Rotor puller 077330020001 or 078333280001 Fiywhee! holder 07725 -00400005, Sr al S7708_voro 100 F Equivalent ly available in U.S.A 8-1ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Disconnect the alternator wire SP connector (WHITE) Remove the gearshift arm pinch bolt and shiftarm from the spindle. Remove the drive sprocket cover. Place @ container under the left crankcase cover to catch the engine oil Remove the eleven loft crankcase cover bolts and the cover. Remove the dowel pins and gasket. STATOR REPLACEMENT Remove the wire clamp bolts and the clamps. Remove the stator mounting bolts and stator. Position the new stator and the grommets in the cover. Apply @ locking agent to the threads of the stator mounting bolts. Tighten the stator mounting bolts and the clamp bolts =(1) BOLTS! (4) CLAMPS (1) Bouts:ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL 1 OTE REDUCTION CEAR Sad Remove the starter idle/reduction gear by removing the shatt. Hold the flywheel with the flywheel holder and remove the fly: wheel bolt and washer. Toon: Flywheel holder 07725-00400 Equivalent commercially available in U.S.A. Note nd threads. «The flywheel bolt has left: Remove the flywheel with the rotor*puller. Too: Roter puller 07733-0020001 or 079333290001 Remove the needle bearing from the crankshaft, then remove the woodruff key. NOTE + Do not lose the woodrutf key.ALTERNATOR/STARTER CLUTCH STARTER CLUTCH DISASSEMBLY Reinstall the starter driven gear into the flywheel Inspect the starter clutch by turning the starter driven gear. ‘The gear should turn counterclockwise freely and should not, turn clockwise: if it tums incorrectly, replace the starter clutch, Hold the flywheel with the flywheel holder end remove the torx bolts using a torx bit Remove the starter clutch outer and oneway olutch, roots: Flywheel holder ——_-07725-0040000. Torx it 077030010100 FEaualent svatabie in Usa INSPECTION Measure the O.D. of the starter driven gear. SERVICE LIMIT: 57.60 mm (2.268 in} Inspect the oneway clutch for wear or damage and replace if necessary. (1) STARTER DRIVEN GEAR (2) FLYWHEEL (1) FLYWHEEL HOLDER (2) TORK BIT (1) STARTER DRIVEN GEAR, (1) ONEWAY CLUTCHALTERNATOR/STARTER CLUTCH ASSEMBLY (1) CLUTCH OUTER (2) FLANGE install the oneway clutch into the clutch outer with the flange: side facing inside. Hold the flywheel with the flywheel holder. Apply locking 2) TORX giT agert to the torx bolt threads and tighten the bolts ‘TORQUE: 30 N-m (3.0 kg-m, 22 ft-b) TooLs: ( Flywheel holder 077250040000. Torx bit 077030010100" Eauvalent ‘commercially 2 a ve svaiable Z inUSA = (1) FLYWHEEL HOLDER, FLYWHEEL INSTALLATION Claan the crankshaft and install the woodruff key. install the needle bearing onto the crankshaft Instell the driven gear and flywheel, aligning the woadruft key on the crankshaft with the flywheel keyway. Hold the flywheel with the flywhee! holder, install the washer and flywheel bolt and tighten the bolt TORQUE: 130 Nom (13.0 kg-m, 94 ft-lb) Too: Flywheel holder 07725-0040000 Equivalent commercially available in U.S.A. NOTE o +The flywheel bolt has laft hand threads. (FLYWHEEL HOLDER 8-5ALTERNATOR/STARTER CLUTCH Install the starter idle sduction gear with the longer shaft. ‘Th IDLE/REDUCTION OM (2) STARTER DRIVE GEAR, Install the starter drive gear with the “OUT” mark facing out and the shorter shaft, if the gear is removed. Install the dowel pins and new gasket LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover and tighten the cover bolts with the neutral and oil pressure switch wire harness clamps as shown, Route the alternator wire and connect the alternator 3P con- necter Insta the drive sprocket cover. Instal the gearshift arm onto the spindle by aligning the punch mark on the arm with the punch mark on the spirdle. ‘Tighten the gearshift arm pineh bolt. TORQUE: 12 Nem (1.2 kg-m, 9 fb) Insta the drive sprocket cover. Check the engine oll level and add the oil if necessary. (2) GEARSHIFT ARM) 8-6CYLINDER HEAD/VALVES "88 Shown: 23 Nem (2.3 kg-m, 17 ftb} 10 Nem (1,0 kg-m, 7.2 ftb) 10 Nem (1.0 kg-m, 7.2 ft-lb) 48 Nem (4.8 kg-m, 35 felb) 23 Nem (2.3 kgm, 17 feb) 23 Nem (2.3 kgm, 17 feb)9. CYLINDER HEAD/VALVES SERVICE INFORMATION TROUBLESHOOTING CYLINDER HEAD COVER REMOVAL CAMSHAFT REMOVAL CYLINDER HEADS VALVE GUIDE REPLACEMENT a1 93 93 97 911 VALVE SEAT INSPECTION/REFACING CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFT INSTALLATION CYLINDER HEAD COVER INSTALLATION 9-12 9-14 9.15 9.17 9-20 SERVICE INFORMATION GENERAL ‘¢ The cylinder heads can be removed without removing the engine. ‘© Camshaft lubricating oil is fed through an oil pass pipe, Be sure the holes in the oll pass bolts are not clogged. ‘© During assembly apply MoS2 paste grease to the camshaft holders, camshaft journels of the cylinder head, rocker arm shafte, rocker arm slipper faces and valve stems to provide initial lubrication, SPECIFICATIONS: Unt: men i vrew STANDARD SERVICE LMT aan Ti324 = 106 (13.5 + 2.0 kglem?, 192+ 28 psi) Comshatt | Camiabereight [IN| se.teg(ngoas) =| ~—aan.c0a) | EX 38.213 (1.5044) 38.19 (1.504) Journal | 21.959—21.980 (0.8645—0.8654) 21.95 (0.864) Runout —_ 0.030 (0.0012) [0.05 10.002) | Oil clearance [__0.040-0.083 (0.0015~0.0037) 0.11 (0.004) “Rockerarm | Rocker arm LD. | IN/EX [12.03 10.474) Recker erm abatt | ye 11.96 (0.471) “Valve end | Valve stem 0.0. LIN 5.475- 0.2161) . 47 (0.215) valve guide Ex 6.555. 0.2587) _ 6.55 (0.258) vate que 15. [1 $5008 512 (0.2168 0.2170) 5.630218) | ex 6.600 6.615 (0.2588 0.2604) 6.66 (0.262) Somieause [IN 0.010-0.037 (0.0004-0.0018) | 0.07 10.008) learance ex 0.080 0.060 (0.0014-0.0024) 0.11 10.004) Tene onal wa 0.9-1.10.036-0.043) | 150.08) | VaWve aude pro- [IN a4—18.6 0.78-0.77 tener ex 17:9—18.1 (0.70-0.71) Waive oping | Fre length | OUTER @2.14 1.659) 40.58 (1.598) 42.88 1.688) 41.25 (1.628) | INNER 2.11 (1.600) 96.47 11.436) | | 30.81 (1765) sri (477) iastioniwarens — 0.10 (0.004)CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head cover bolt Camshaft holder 8 mm bolt 8 mm nut 6 mm bolt 10 mm nut @ mm bolt 8 mm nut 6 mm bolt Comshaft sprocket bolt Cylinder head Cam chain tensioner bolt Oil pass pipe 7 mm bolt 8 mm bolt TOOLS Special Valve guide reamer (IN) Valve quide reamer (EX) Valve guide drivar attachment (IN) Value guide driver attachment (EX) Common Valve guide driver, 5.5 mm (IN) Valve guide driver, 6.6 mm (EX) Valve spring compressor Valve seat cutter (Not available Cutter holder IN 5.5 mm EX 6.6 mm IN 28 mm (32°) EX 36 mm (32°) Inte‘ior cutter IN 30 mm (60°) EX 37.5 mm (60°) IN 27.5 mm (45°) EX 35 mm (45°) TROUBLESHOOTING USA) Flat cutter Seat cutter 10 Nem (1.0 kg-m, 7.2 feb) 23 Nem (2.3 kg-m, 17 ft-lb) 23 Nem (2.3 kg:m, 17 ft-lb) 10 Nem (1,0 kg-m, 7.2 feb) 48 Nem (4.8 kgm, 35 ft-lb) 23 Nem (2.3 kgm, 17 ftb) 23 Nem (2.3 kg-m, 17 feb) 410 Nem (1.0 kg-m, 7.2 feb) 23 Nem (2.3 kgm, 17 ftlb) 10 Nem (1.0 kg-m, 7.2 fb) 10 Nem (1.0 kg-m, 7.2 ft-lb) 23 Nem (2.3 kg-m, 17 ft-lb) 07984 —200000" or 078%4~-2000008-7U.5.A. only (07984—2E20001 or 07984—ZE20008. (07943—-MF50100 07943—MF50200 077420010100 (077420010200 or 079426570100 U.S.A. only (077570010000 or 078573280001 077810010101 077810010201 07780—-0012100 077800012300 (077800014000 (07780—0014100 077800010200 077800010400 Engine top-end problems are usually performance-related and can usually be diagonosed by a compression test, Engne noises can usually be traced to the top-end with a sounding rod or stethoscope, Uneven or low compression + Valves — Incorrect valve adjustment — Burned or bent valves — Incorrect valve timing ~ Broken valve spring + Cylinder head — Leaking or damaged head gasket Warped or cracked cylinder head Cylinder and piston (Refer to Section 10) High compression Exc: + 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 teath Poor idling + Excessive carbon build-up on piston crown or combus- tion chamber 9-2CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL am po = - Remove the following parts: seat fuel tank ipage 4-3) air cleaner case (page 4-4) thermostat bolts radiator mounting bolts, and swing the radiator forward NOTE i at this time. FRONT: Disconnect the spark plug caps. Remove the cylinder head cover bolts and cover. der head cover is difficult to remove Remove the radiator mounting bolts and release the radiator from the frame grommets, Suspend the radiator with 3 piece of rope or something suitable. (refer to 9-8 pagel. REAR: Disconnect the spark plug caps. Remove the cylinder head cover bolts and cover. CAMSHAFT REMOVAL Remove the cylinder head covers and carburetors (page 4-4) Remove the timing hole cap and crankshaft hole cap from the left crankcase cover. Align the FT mark (rear: RT mark) on the flywheel with the index mark on the left crankcase cover timing hole by turning the crankshaft counterclockwise (3) INDEX MARKS. 4 (2) CRANKSHAFT HOLE CAP 9-3CYLINDER HEAD/VALVES Make sure the piston is at TOC (TOP DEAD CENTER) on the compression stroke with cam lobes are all facing down, I the cam lobe is facing up at TDC, turn the crankshatt 360° couterclockwise, and re-align the mark and notch Pull wedge A straight up while holding wedge B down, Secure wedge A with a 2 mm pin as shown, Remove the camshaft holder on the cam sprocket side by re- moving the two mounting bolts, Remove the cam sprocket bolt, rotate the crankshaft counter. clockwise one turn |360°) and remove the other cam sprocket bol. NoTe * Be careful not to let the cam sprocket bolts fall into the crankcase. Remove the three camshaft holder mounting bolts and the nist, the oil plate and the holder. 9-4CYLINDER HEAD/VALVES Remove the dowel pins. (1) DOWEL PINS. ang the cam chain on the camshaft behind the camshaft lange and remove the cam sprocket while lifting the camshaft aut. Attach @ piece of wire to the cam chain to prevent it from oeing dropped into the crankcase NSPECTION Cylinder head ‘spect the camshaft holder and cylinder head journal surfaces ‘or scoring or evidence of insufficient lubrication. Camshaft runout Support both ends of the camshaft with V-blocks and check he camshaft runout with a dial indicator. SERVICE LIMIT: 0.05 mm (0.002 in) Using a micrometer, measure the height of each cam lobe. SERVICE LIMIT: IN: 38.17 mm (1.503 in) EX; 38.19 mm (1.504 in) Check the camshaft journals for wear or damage. Measure the 0.D. of each journal. SERVICE LIMIT: 21.95 mm (0.864 in) (31 CAM recur | |\ 9:5CYLINDER HEAD/VALVES ‘Camshatt bearing oll clearance Wipe any oil from the journals. Lay a strip of plastigauge lengthwise on top of each camshaft journal NOTE + Avoid placing plastigauge over the oil hole. Ingtall the camshaft holders and tighten the mounting botts in a crisscross pattern in 2 or 3 steps. NoTE + Do not rotate the camshaft when using plastigauge. TORQUE 6 mm flange bolt: 12 Nem (1.2 kgm, 9 feb) 8 mm flange bolt: 23 Nem (2.3 kg-m, 17 ft-b) 8 mm flange nut: 23 Nem (2.3 kg-m, 17 feb) 12) 6 mm FLANGE | BOLTS, Remove the camshaft holder and measure the width of each plastigauge. The widest thickness determines the oil clear ‘SERVICE LIMIT: 0.11 mm (0.004 in) ‘When the service limit ie exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshatt holder if the clearance still exceeds the service limit, Comshatt holder/Rocker arm shaft/Rocker arm Flemove the rocker arm shafts by tapping the holder with & soft hammer.CYLINDER HEAD/VALVES Remove the rocker erms and wave washers from the shafts. nnspect the rocker arm shafts and rocker arms for wear or amage. Jack the rocker arms for clogged cil holes. SERVICE LIMIT: INEX: 11.96 mm (0.471 in} Measure the I.D. of each rocker arm. SERVICE LIMIT: 12,03 mm (0.474 in) CYLINDER HEAD REMOVAL NOTE + The smoved with the engin Drain the coolant (page 5-3) and remove the following: ~ camshaft (page 9-3) — exhaust pipes California model only: Remove the ASV pipes from the cylinder head. Disconnect the clutch cable from the clutch lifter arm by re- moving the clutch cable holder bolt Remove the oil pipe from the engine. NOTE + Donot bend the oil pipe during removal Remove the water pipes. (1) ROCKER ARMS Renan (2) WAVE WASHERS: (1) ROCKER ARM. — (2) ROCKER ARM SHAFT CALIFORNIA MODEL SHOWN 37 "8 SHOWN: (1) WATER PIPES]CYLINDER HEAD/VALVES Remove the cam chain tensioner mounting bolts and washers (1) CAM CHAIN TENSIONER BOLTSIWASHERS: from the cylinder head and cylinder. Loosen the 6 mm bolt, 8 mm bolts, 8 mm nut and 10 mm nuts) washers in a criss-cross pattern in 2 or 3 steps. Remove the bolts and nuts FRONT: Remove the radiator mounting bolts. Release the radiator from the frame grommets and suspend it with a piece of rope or something suitable Remove the upper exhaust port stud to allow frame clearance for cylinder head removal. ‘Lock two 8 mm nuts together on the stud to aid in removal Remove the front cylinder head. REAR: Remove the rear cylinder head. Remove the gasket, dowel pins and cam chain guide from the cylinder. (2), CAM CHAIN GUIDECYLINDER HEAD/VALVES DISASSEMBLY/INSPECTION (1) STRAIGHT EDGE Cylinder head CAUTION Avoid damaging the gasket surfaces. Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with the straight edge and feeler gauge. SERVICE LIMIT: 0.10 mm (0.004 in} Remove the valve spring cotters, retainers, springs, and valves using 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 ‘mare than necessary to remove the cotter. * (1) VALVE SPRING] ee COMPRESSOR, Merk all parts during disassembly so they can be placed ‘back in their original locations. (3) VALVE SPRINGS Remove the valve stem seals and valve spring seats. Remove carbon deposits from the combustion chember. valve corres - bec Ov (2) STEM SEAL ang (3) OUTER SPRING Measure the fr length of the Inner and outer valve springs. SERVICE LIMITS: INNER (IN): 36.47 mm (1.436 in) {EX}: 37.81 mm (1.477 in) OUTER (IN): 40.58 mm (1.598 in) (2) INNER SPRING (EX): 41.25 mm (1.624 in) Replace the springs as a set if they are shorter than the service limitsCYLINDER HEAD/VALVES Valve stem:-to-guide clearance (1) VALVE STEM, Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movernent in the guide and measure and record each valve stem 0.0. SERVICE LIMITS: IN: 5.47 mm (0.215 in) EX: 6.55 mm (0.258 in) Measure and record each valve guide 1.0. (1) CYLINDER HEAD NOTE + Ream the guides to remove any carbon deposits before checking clearances. SERVICE LIMITS: IN; 5.53 mm (0.218 in) EX: 6.66 mm (0.262 in) ‘Subtract each valve stem 0.D. from the cor [.D. to obtain the stem to guide cl sponding guide SERVICE LIMITS: IN: 0.07 mm (0.003 in) EX: 0.11 mm (0.004 in} If the stem-to-guide clearance exceeds the service limits, de: termine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guides as necessary and ream to fit. Toots: Valve guide reamor IW: 07984—2000001 or 07984 2000008-- U.S.A. only EX: 07984—ZE20001 or 07984—ZE20008- NOTE + It is important that the reamer always be rotated in the same direction when it is ingerted or removed, If the stem-to-quide clearance exceeds the service limits with new guides, also, replace the valves. NOTE + Roface the valve seats whenever the valve guides are re- place 9-10CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT (2) VALVE GUIDEREMOVER (1) CYLINDER HEAD Chill the vaive guides in the fr about an hour. Heat the cylinder head to 212°F (100°C) with a hat plate or oven. Maximum allowable temperature is 300°F (150°C) + To avold burns, wear heavy gloves when handling the heated evlinder head. 1zer section of a refiigerator for amen CAUTION + Do not use a torch 10 heat the evlinder head: ii may cause warping (2) VALVE GUIDE DRIVER ‘Support the cylinder head and drive out the old guices from the combustion chamber side of the cylinder head. Toots: Valve guide driver (in: 077420010100 (EX): 077420010200 or 07942- 6570100 |U.S.A, only) NOTE + Avoid damaging the cylinder head, Make note of the vaive quide projection specifications (follow: ing), then drive in new guides from camshaft side of the yl: der head, Tal | (1) VALVE GUIDE Toots: (2) GUIDE PROJECTION / Valve guide driver HEIGHT 5.5 mm (IN|: 07742—0010100 6.6 mm (EX): 07742—0010200 Attachment 5.5 mm (IN): 07943—MF50100 6.6 mm (EX): 07943—MF50200 VALVE GUIDE PROJECTION HEIGHT: IN: 19.4—19.6 mm (0.76—0.77 in) EX: 17.9- 18.1 mm (0.70—0.71 in} (1) VALVE GUIDE eam the new valve guides after 2 REAMER NOTE + Use cutting oll on the reamer during this operation. + It is important that the reamer always be rotated in the same direction when it is inserted or removed. Clean the head thoroughly after reaming the valve guides. Toots: Valve guide reamor IN: 079842000001 or 079842000008 (U.S.A. only) EX: 07984—ZE20001 oF 07984—ZE2000B IU.S.A. only) 9-11CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING (1) VALVE LAPPING TOOL, Clean the intake and exhaust valves thoroughly to remove carbon deposits. ‘Apply a light coating of Prussian Blue to each valve seat. Lap ich valve and seat using a rubber hose or other hand-lapping tool. Remove and inspect each valve. CAUTION +The valves cannot be ground. Ifa valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve, Inspect the width of each vaive seat STANDARD: _ 0.9-1.1 mm (0.035-0.043 in) SERVICE LIMIT: 1.5 mm (0.06 in} If the seat is too wide, too narrow or has low spots, the seat must be ground. VALVE SEAT CUTTERS 60° . rafacing equipment are recommended to corect aworn valve | Sora5~oo7aG00 IN: 0778070012100 (28 6) seat (30 6) EX: 077800012300 (35 2) Ex: 07780—0014100 NOTE (37.56) + Follow the refacer manufacturer's operating instructions: erating we IN: 07780—0010200 (27.5 ¢! EX: 077800010400 (35) (1) ROUGHNESS/IRREGULARITIES | Use 2 45 degree cutter to remove any roughness or irregular | ties from the seat. ! wore | J + Reface the seat with a 45 degree cutter when a valve guide is replaced. 1 VALVE SEAT REFACING 45° (2) VALVE SEAT 9-12CYLINDER HEAD/VALVES Use a 32 degree cutter to remove the top 1/4 of the existing valve seat material. Use @ 60 degree cutter to remove the bottom 1/4 of the old seat. Remove the cutter and inspect the area you have rafaced. Install a 45 degree finish cutter and cut the seat to the proper ‘width. Make sure that all pitting and irregularities are removed. Rafinish if necessary. Apply a thin costing of Prussian Blue to the valve seat. Press the valve through the valve guide and onto the seat to make 3 clear pattern. NOTE +The location of the vaive seat in relation to the valve face is If the contact sree is too high on the valve, the seat must be lowered using @ 32 degree flat cutter. (1) OLD Seat WioTH 1) OLD SEAT WIDTH > 0.9-1.1 mm (0.035—0.043 in) (1) CONTACT TOO HIGH ; ~ - (2) OLD SEAT WIDTH 2) 9-13CYLINDER HEAD/VALVES If the contact area is too low on the valve, the seat must be raised using 2 80 degree inner cutter. (1) CONTACT TOO LOW (2) OLD SEAT iDTH. Rofinish the seat to specifications, using @ 45 degree finish (1) VALVE LAPPING TOOL, cutter. ‘After cutting the seat, apply lapping compound to the valve face, and lap the vaive using light pressure. ‘After lapping, wash all residual compound off the cylinder head and valve. NOTE + Do not ellow lapping compound to enter the guides. CYLINDER HEAD ASSEMBLY a, Install the valve spring seats and new stem seals (2) STEM SEAL Lubricate each valve stem with MoS2 paste grease and insert the valve into the valve guide. Turn the valve slowly while in- (9) OUTER & serting to avoid damaging the seals. SPRING & ‘Move the valves up and down to check for smooth opert Install the valve springs with the tightly wound coils facing the sombustion chamber, (1) VALVE combustion chamber. valve Install the spring retainers. 9-14CYLINDER HEAD/VALVES ‘Compress the springs and install the valve cotters, CAUTION + To prevent loss of tension, do not compress the valve springs ‘more than necessary to instal the valve coters Tool: Valve spring compressor 07757-00100 or 07957—3290001 (1) VALVE SPRING COMPRESSOR| ‘Tap the valve stems gently with a soft ham the cotters, rt firmly seat (7) SOFT HAMMER TE + Support the cylinder head above the work bench surface to prevent possible valve dams Apply locking agent to the threads of the sealing bolts and tighten them, if removed. CYLINDER HEAD INSTALLATION Install the cam chain guide into the eylinder. Make sure that the cam chain guide bosses are in the grooves of eylinder. Clean the cylinder head surface of any gasket material Install the dowel pins and a new head gasker.CYLINDER HEAD/VALVES Install the carburetor insulator on the cylinder head, aligning iyBoss™ the boss on the cylinder head with the slot in the insulator. a Tighton the screw securely Install the cylinder head. Feinstall the upper exhaust port stud securely, Install the 10 mm nut/washer, 8 mm nut/washer, 8 mm bolt! ‘washer and 6 mm bolt and tighten them in a crisscross pattern in 2 oF 3 steps. ‘TORQUE: 10 mm nut: 48 Nem (4.8 ko-m. 35 tb] 8 mm bolt: 23 Nem (2.3 kg-m. 17 ftb) 8 mm nut: 23 Nem (2.3 kg-m, 17 feb) {6 mm bolt: 10 Nem (1.0 kg-m, 7.2 fb) Install the following — cam chain tensioner with washers and bolts. — water pipes ‘TORQUE: Cam chain tensioner bolt: 10 Nem (1.0 kgm, 7.2 fb) (1) CHAIN TENSIONER WASHERS/BOLTS Check the oll pass pipe bolts and oil pass pipe for clogging or bending Install the oil pass pipe, new sealing washers, oll pass pipe bolts and the pipe holder bolt. Tighten the bolts Toraut Oil pass pipe bolt: 7 mm: 10 Nem (1.0 kg-m, 7.2 ft-lb) 8 mm: 23 N-m (2.3 kg-m, 17 ft-lb) "8 SHOWN: Install the following —camshatt (page 9-17) = camshatt holders (page 9-18) (2) HOLDER 9-16California model only install the ASV pipes onto the cylinder All mods ‘stall the oylinder heed cover (page 8-20) Reinstall the radiator, and exhaust pipes. CAMSHAFT INSTALLATION Apply MoS2 paste grease to the rocker arm shatts. install the rocker arms, rocker arm shafts and wave washers in the camshaft hol NOTE install the wave washers in the proper position as shown. Position the grooves in the rocker arm shafts vertically, align- ng the bolt holes of the holder with the holes of the shafts. Apply MoS2 grease to the rocker arm slipper faces. FRONT CAMSHAFT ONLY Turn the crankshaft counterclockwise and align the “RT” mark on the flywheel with the index mark on the timing hole. Make sure the REAR cam lobes are all facing UP. If they are hot, turn the crankshaft counterclockwise one revolution so that the REAR cam lobes are all facing UP. (NOTE: This is the valve overlap positon.) Continue turning the crankshaft counterclockwise (128°) until ‘the “FT” mark on the flywheel aligns with the index mark on ‘the timing hole (approximately 3/8 turn. CYLINDER HEAD/VALVES ‘CALIFORNIA MODEL SHOWN) Mos: (5) ARMS (IN) (3) SHAFT (EX) (© SHAFT (IN) (1) GROOVES (1) INDEX MARK IN (2) "FT" MARK (3) "RT" MARK. 9-17CYLINDER HEAD/VALVES NoTE + Ifthe front and rear cylinder camshafts were removed, do Rot confuse them. Check the identification mark on the end of the shat, Install the dowel pins into the cylinder head. Install the camshaft in the cylinder head through the cam chain and install the cam sprocket on the camshaft. With the cam lobes all facing down, align the timing marks (index lines) on the cam sprocket with the top of the cylinder head, Place the cam chain on the sprocket Inatall the cam sprocket on the camshaft flange and recheck that the timing marks (index lines) align with the top of the cy! inder head. Align the cam sprocket bolt holes in the cam sprocket and ‘camehaft, install and tighten the cam sprocket belt TORQUE: 23 Nem (2.3 kgm, 17 ftlb) Install the holder, oll plate, 8 mm bolts, 8 mm nut and 6 mm bolts ‘TORQUE: ‘8 mm bolt: 23 Nem (2.3 kg-m, 17 ftb) 1B mm nut: 23 Nem (2.3 kgm, 17 ftb) 6 mm bolt: 10 Nem (1.0 ka-m, 7.2 ft-lb) Tum the arankshattcounterclockwite $60° ond fatal the aT Finm NUTET®, , POUL PLATE other sprocket bolt. - Irate eto caurion 5 tei Wissen 9 Te ea ed WTB, al Pk aloe one bo joe 1) HoLoens a Aftorinstalling the front cylinder camshaft, turn the crankshett ‘counterclackwise 232° (approximately 5/8 turn) and align the RT mark with the index on the timing hole, then install the rear cylinder camshaft using the same procedure as for the front inder. 9-18Lubricate the cam lobes with fresh engine oil If the cylinder head was removed with the engine in the frame, install the following: radiator — exhaust pipe REAR CAMSHAFT ONLY Turn the crankshaft counterclockwise and align the “FT” mark on the flywheel with the index mark on the timing hole Make sure the FRONT cam lobes are al facing DOWN. if they are not, turn the crankshaft counterclockwise one revolution 0 that the FRONT cam lobes are all facing DOWN. Continue turning the crankshaft counterclockwise (232°) until the “RT” mark on the flywheel aligns with the index mark on the timing hole (approximately 6/8 turn). Place the camshaft into correct position with the cam lobes a ‘acing down, Install the cam sprocket and camshaft holders using the same procedure as for the front cylinder (page 9-17). FRONT AND REAR CAMSHAFTS Turn the crankshaft counterclockwise and align the ‘FT’ mark on the flywheel with the index mark on the timing hole, Install the front camshaft with all the cam lobes facing DOWN. Align the index marks on the cam sprocket with the top of the cylinder head. Continue turning the crankshaft counterclockwise (232°) until the “RT” mark on the flywheel aligns with the index mark on the timing hole (approximately 6/8 turn. Install the rear camshoft with all the cam lobes facing DOWN. Align the index lines on the cam sprocket with the top of the cylinder head, CYLINDER HEAD/VALVES: (1) CAM Lopes (1) INDEX MARK (2) "FT" MARK (1) CAM Lopes 9-19CYLINDER HEAD/VALVES Remove the 2mm pin holding cam chain tensioner wedge A. NOTE + Be careful not to let the 2 mm pin fall into the crankcase + Donot forget to remove the 2 mm pin before installing the cylinder head cover. CYLINDER HEAD COVER INSTALLATION Clean the gasket and apply contact cement to the gasket groove, ox oy yeas” cover Install the cylinder head cover, rubber washer, washer cover | ‘and cylinder head cover bolts. Tighten the cover bolts. TORQUE: 10 Nom (1.0 kg-m, 7.2 ftb) (2) WASHER > cover OQ) Connect the water hose to the water pipe and install the spark plug caps, Instal the following parts: — carburetors page 4-19) — air cleaner case (page 4-4) fuol tank (page 4-3) Fill the cooling system (page 5-3) 9-20CYLINDER/PISTON 10-010. CYLINDER/PISTON SERVICE INFORMATION 10-1 PISTON RING INSTALLATION 10-5 TROUBLESHOOTING 10-1 PISTON INSTALLATION 10-5 CYLINDER 10-2. CYLINDER INSTALLATION 10-6 PISTON 10-3 SERVICE INFORMATION GENERAL «© This section covers service of the eylinder and piston. ‘© The engine must be removed to service ta cylinderipiston, © To service the crankcase stud bolts, refer to page 11-13. SPECIFICATIONS Unit: me find ITEM STANDARD SERVICE LIMIT cylinger [WD 79.000-79.015 (3.1102—3.1108) | 79.05 (3.112) —= 0.10 10.004) _ = [0.06 10.002) Out-of-round - —_ 0.06 (0.002) Piston, Piston ring-to-ring TOP 055 (0.001 ~0.002) 0.11 (0,004) ee ‘SECOND 0018) | 0.10 (0,008) tnd piston | Ring end gap TOP, (0.20-0.36 (0.008-0.014) 0.65 (0.026) | pin SECOND (0.35 0.50 (0.014 0.020) (0.65 (0.026) “ot 0.20—-0.80 (0.008 0.031) _ 0.96 (0.037) Piston 0.D. 78,970—78.990 (3.1086—3.1098) | 78.92 (3.107) Piston pin bore 20,002—20.008 (0.7874-0.7877) | 20.018 (0.7881) [Connecting fod sma end LD. | 20.016—20.094 (0.7850-0.7887) | 20,04 (0.789) [Piston pin 0.0. 19.994 20.000 (0.7871 0.7874) 19.984 (0.7867) Piston-to-piston pin clearance 0.002 —0.014 (0.0001 0.0006) 0.034 (0.0013) Cylinderto-piston clearance 10.010-0.035 (0.0004—0.0074) | _ 0.13 (0.008) 0.016--0.040 (0.0008-0,0018) | 0.080 (0.0024) TROUBLESHOOTING Low or uneven compression Piston noise + Worn cylinder or piston rings. + Worn cylinder and piston. + Leaking head gasket. + Excessive carbon deposits + Incorrect valve timing. Excessive smoke + Worn eylinder and piston rings. + Improperly installed piston rings. + Damaged piston or evlinder. Overheating + Excessive carbon deposits on piston or combustion chamber 10-1CYLINDER/PISTON CYLINDER REMOVAL, Remove the following — engine from the frame (page 5-2) ~ eylinder head cover (page 9-3) cylinder head (page 9-7) gaskets, dowel pins, and cam chain guides. Disconnect the water hose from the coolant connector. Remove the clip and slide the cylinder joint collar toward either the front or rear cylinder. Remove the cylinder to be serviced. Remove the cylinder gasket and dowel pins from the crank- case. INSPECTION Clean the top of each cylinder thoroughly. Inspect the eylindar walls for scratches and wear ‘Measure and record the cylinder I.D. at three levels in both an X and Y axis. Take the meximum reading to determine the cy- (1) CYLINDER. inder wear, ‘SERVICE LIMIT: 79,05 mm (3.112 in) Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.13 mm (0.005 in) Calculate the cylinder for taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.06 mm (0.002 in) Calculate the cylinder for out-of-round at three levels in an X ‘and Y axis. Take the maximum reading to determine the out of round. > (2) EX ‘SERVICE LIMIT: 0.06 mm (0.002 in) * “The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded. ‘The following over 0.25 mm (0.010 pistons are available: } and 0.50 mm (0.020 in) ‘The cylinder must be rebored so that the clearance to an over size piston is 0.010-0.035 mm (0.0004—0.0014 in). = — 10-2CYLINDER/PISTON Inspect the cylinders for transverse warpage across the top. (2) STRAIGHT EDGE NOTE ‘Measure warpage using a straight edge and feeler gauge as shown, SERVICE LIMIT: 0.10 mm (0.004 in) (1) FEELER GAUGE PISTON REMOVAL Place a shop towel into the crankcase and remove the piston pin clips. NOTE Do not let the clips fal into the crankcase. Push the piston pin out and remove the piston. FON PIN CLIP INSPECTION (1) PISTON (2) PISTON RING. Clean the piston domes, ring lands and skirts. Measure the piston ring-to-groove clearance. “e ee _— SERVICE LIMITS: a Top: 0.11 mm (0.004 Second: 0.10 mm (0.004 If clearance is excessive, replace the piston ring. Remove the piston rings and mark them to indicate the correct (1) PISTON (2) PISTON RING cylinder and piston position for reassembly. / NOTE + Do not damage the piston rings when removing them 10-3CYLINDER/PISTON Measure the piston 0.0. NOTE + Take measurements 10 mm (0.4 in) from the bottom, and 90° to the piston pin hole, SERVICE LIMIT: 78.92 mm (3.107 in) Calculate the piston-to-cylinder clearance by subtracting the piston 0.D. from the cylinder 1.D. {page 10-2) SERVICE LIMIT: 0.13 mm (0.005 in) ‘Measure the top and second piston ring end gaps: using @ pis ton, push the ring into the cylinder squarely and make the mea: surement, SERVICE LIMITS: Top: 0.65 mm (0.026 in) ‘Second: 0.65 mm (0.026 in) Oil: 0.95 mm (0.037 in) Meesure each piston pin bore SERVICE LIMIT: 20.018 mm (0.7681 in} Measure each piston pin 0.0. SERVICE LIMIT: 19.984 mm (0.7867 in) Calculate the piston pin-to-piston clearance. ‘SERVICE LIMIT: 0.034 mm (0.0013 in) Measure the .D. of the connecting rod small end SERVICE LIMIT: 20.04 mm (0,789 in} Calculate the piston pin-to-connecting rad clearence. SERVICE LIMIT: 0,060 mm (0.0024 in) Refer to section 11 for connecting rod replacement. 1) PISTON (1) PISTON RING eS TEER Cause «stow imstou ew 10-4