S6-387 XR250R4IMPORTANT SAFETY NOTICE | Incates a str posit of severe personal injury oF los of life instructions are no followed. CAUTION: Indicres 0 posbility of personal inary or equipment damage if isructions ae not followed. NOTE: Gives helpful information. Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. Itis important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service pernonnel ot could damage a vehicle or render it unsafe. Please Understand that those warnings could not cover all conceivable ways in which service, whether or not recommended by Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda inves tigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must saristy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools. selected.HOW TO USE THIS MANUAL Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 16 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 proceudres. If you don’t know what the source of the trou- ble is, refer to section 18, Troubleshooting. All information, illustrations, directions and spect fications included in this publication are based on the latest product information available at the {ime of approval for printing. HONDA MOTOR CO., LTD. reserves the right to make changes at stmewr unten ema | HONDA MOTOR CO., LTD., Service Publication Office Date of Issue: September, 1986 © HONDA MOTOR CO.,. LTD, CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE | FUEL SYSTEM ENGINE REMOVAL/INSTALLATION Ea CYLINDER HEAD/VALVES |_GYLINDER/PISTON ENGINE CLUTCH/KICK STARTER ALTERNATOR CRANKCASE/CRANKSHAFT/BALANCER TRANSMISSION L i] HYDRAULIC BRAKE | REAR FENDER/EXHAUST PIPE = | ELECTR TEM. z :CTRICAL SYS" 25) WIRING DIAGRAM |_ TROUBLESHOOTING INDEX [719 |1, GENERAL INFORMATION GENERAL SAFETY 1 SERVICE RULES 11 MODEL IDENTIFICATION 12 SPECIFICATIONS 13 TORQUE VALUES 18 TOOLS 17 CABLE & HARNESS ROUTING 19 NOISE EMISSION CONTROL SYSTEM (U.S.A. ONLY) 1-12 GENERAL SAFETY ro If the engine must be running to do some work, make sure the ‘area is well-ventilated. Never run the engine ina closed area. The exhaust contains poisonous carbon monoxide gas that Gasoline is extremely flammable and is explosive under certain ‘conditions. Do not smoke or allow flames or sparks in your working area ‘may cause loss of consciousness and lead to death. SERVICE RULES © Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents, Parts that do not meet HONDA’s design specifications may damage the motorcycle. © Use the special tools designed for this product. © Install new gaskets, O-rings, cotter pins, lock plates, etc. when reassembling © When torquing bolts or nuts, begin with the larger-diameter or inner bolts first, and tighten to the specified torque diagonal- ly, unless a particular sequence is specified. © Ciean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before re- ‘assembly, ‘After reassembly. check all parte for proper installation and operation, Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use of incorrect tools and fasteners may damage the motorcycle. © Route all electrical wires as shown on pages 1-9 through 1-11, Cable and Harness Routing, and away from sharp edges ‘and areas where they might be punched between moving parts y 1-1GENERAL INFORMATION MODEL IDENTIFICATION TV NuMBER ‘86 shown: After '86 similar ‘The vehicle identification number (VIN) is on the left si of the steering head. (3) CARBURETOR IDENTIFICATION NUMBER ‘The frame serial number is stamped on the right side of the ‘The carburetor identification number is on the right side of Sage steering head, the carburetor body. (5) COLOR LABEL ‘The engine serial number is stamped on the lower left side The color code label is attached on the left frame tube of the crankcase. Under the seat. When ordering a color coded part, Se specity its designated color code. 1-2GENERAL INFORMATION SPECIFICATIONS DIMENSIONS | Overal length Overall wicth | Overall height Ground clearance Whee! base | Seat height | Foot peg height Dry weight [srawe tye SOS | Front suspension, travel ‘SPECIFICATION 2,100 mm (82.7 in) 910 mm (36.8 in) 1,226 mm (48.3 in) 326 mm (12.8 in) 1,424 mm (56.1 in) 925 mm (36.4 in) 420 mm (16.5 in) 108.6 kg (239.4 Ib) ‘Semi double cradle Telescopic 280 mm (11.0 in) Rear suspension, travel Pre-link 280 mm (11.0 in} Front tire size, pressure 80/100—21 81M, 100 kPa (1.0 kg/em?, 15 psil Rear tire size, pressure 110/100—18 64M, 100 KPa (1.0 kgiom?, 15 psi) Front brake, swept area Disc, dual piston caliper, 342.8 cm? (53.13 sq. in) Rear brake, swept area Internal expending shoes, 86.3 cm? (13.38 sq. in) Fuel capacity 9.0 lit (2.38 U.S. gal, 1.98 Imp gall | Fuel reserve capacity 2.0 lit (0.83 U.S. gal, 0.44 Imp gall Caster 64212" | Trait 100 mm (3.9 in) Front fork oil capacity 538 ce (18.1 US oz, 18.8 Imp 02) ENGINE Type | Gasoline, air-cooled 4-stroke SOHC Cylinder arrangement | Single cytinder inclined 15° Bore and stroke | 73.0 x 59.5 mm (2.87 x 2.34 in) Displacement | 249 c0 (18.2 ou in) Compression ratio 10.2:1 Valve train 4-valva, single chain driven SOHC ‘Maximum horsepower | 24.9 PS/8,000 rpm ‘Maximum torque 2.33 kg-m!7,000 rpm il capacity | 1.6 li (1.70 US. gt, 1.41 Imp atl Lubrication system Forced pressure and dry sump Air filtration system Oiled polyurethane foam Cylinder compression 1300— 1800 kPa (13.0-16.0 kg/om?, 184.9-213.3 psi) Intake valve Opens 10° (BTCD) at 1 mm lift Closes 40° (ABDC) at 1 mm lift Exhaust valve Opens 40° (BBDC) at 1 mm lift Closes 10° (ATDC} at 1 mm lift Valve clearance Intake 0.05 mim (0.002 in} Exhaust 0.08 mm (0.003 in} CARBURETOR | Type: Piston valve 1.D. number | pDosa, Main jet #128 Slow jet | #40 Pilot screw | 2.1/4 tums out Float level | 12.5 mm (0.50 in} Idle speed 1,300 = 100 rpm, DRIVE TRAIN | Clutch | Wer multi-plate Transmission B-speed constant mesh Primary reduction 3.100: 1 Gear ratio 1 2.769: 1 Gear ratio | neat 1 Gear ratio I 1.480: 1 Gear ratio IV a7a 1 Gear ratio V 0'360: 1 Gear ration VI 0.815: 1 Final reduction 3.692: 1 Gear shift pattern Left foot operated return system 1-N—2~3-4-5-6 1-3GENERAL INFORMATION ITEM ‘SPECIFICATION, ELECTRICAL Ignition Ignition timing Initial Full advance Alternator Spark plug ct 8° BTOC at 1,300 + 100 rpm (F mark) 28° = 2° BTDC at 4,300 rom AC generator 100W/5,000 rpm [ Standara DPREZ—(NGK) | X27GPR-U (ND) For cold climate DPREZ —(NGK) (below 5°C/41°F) X24GPR-U (ND) Spark plug gap Headlight Taillight (0.60.7 mm (0.024—0.028 in) 12v/35W awGENERAL INFORMATION TORQUE VALUES ENGINE ‘on ory ‘Thread dia, TORQUE mm om Cylinder head bolt (10 mm) 4 10 37-43 (6 mm 2 8 10-14 Cam sprocket bolt 2 7 18-22 Cylinder head cover bolt (6 mm) 2 8 8-12 am 1 8 28-30 Rocker arm shaft | 2 “ 25-30 | Sub-rocker arm shaft IN jz] 2 25-20 | Sub-rocker arm shaft EX 2 - 20-25 | Valve adjusting screw lock nut ja] o¢ 17-23 | Cylinder bolt | 4 10 37-43 | Ot pass pipe bok } 3 6.7 1-14 | Clutch lock nut |i | % 50-60 | Drive gear lock nut Ja | ae 50-60 Fight erankcase cover bolt w | 6 10-14 Gearshift cam bolt }r]oos 10-14 Shit cram stopper om bolt Jal 22-26 Flywheel bott Ja 12 100-110 Crankcase bolt | 2 8 1-14 | 10-14 Ot drain pug \4 12 20-20 | 20— Oil fiter cover | a 6 3-12 | 08-12 Loft crankcase cover bolt Lo 6 roma | hocta FRAME ent ary Thread dia. TORQUE mm Nem keer ie Steering stem nut 7 24 95-140 | 05-140] 69-101 Steering beering adjustment nut 1 26 a2 | o1-02 | o7-14 Handlebar holder 4 8 24-30 | 24-30 | 17-22 Front fork upper pinch bolt 4 8 25-20 | 25-30 | 18-22 Front fork lower pinch bolt 4 8 30-35 | 30-35 | 21-26 Front axle holder 4 6 10-14 | 10-14 | _7=10 Front axe nut, 4 2 so-20 | 50-80 | 36-58 Rear exe aut 1 16 s0-10 | 80-110) 58-80 Final driven eprocket bolt 6 8 27-33 | 27-33 | 20-24 Swing arm pivot bat 1 14 ao-100 | 80-100) 58-72 Rear shock absorber mounting bok (upper 1 10 40-50 | 40-80 | 29-36 tower 1 10 30-40 | 30-40 | 22-29 Swing arm-to-shock arm bolt 1 12 60-20 | 60-20 | 43-58 Shock inkto-flome bolt 1 10 40-50 | 40-50 | 29-36 Shock linkto-shock arm bolt 3 10 40-50 | 40-50 | 29-26 Brake caliper bolt 2 8 24-30 17-22 Brake dise 4 8 14-16 10-12 Brake hose bolt (master cylinder) 1 10 30-40 | 30-40 | 22-29 (caliper 1 10 go—20 | 30-80 | 22-29 Spoke nipple = | ecas | 25-80 | 025-050) 18-36 Caliper bleeder valve 1 8 4-7 | 04-07 | 3-5 Master cylinder bleeder valve 1 8 4-7 | 04-07 | 3-5 Catiper ped pin 2 10 15-20 | 1s-20 | 1-14 per rod ond nut 1 12 242g. | 24-29 | 17-21 Reservoir damping valve 3 24 25-35 | 25-35 | 18-25 Rim lock 2 8 1-15 | 10-18 | 711 1-5GENERAL INFORMATION FRAME ToRaUE hem ory ‘mm ium kgm iw Gearshift change pedal 1 6 ise | a4-18 | 10-18 Broke celper pn bit (upper 1 8 20-28 | 20-28 | 4-18 tower 1 8 is-20 | ts-20 | 11-14 Front brake lver adjuster lock nut 1 5 B-7 | 08-07 | 36-30 Rear brake arm bolt }oa 6 g-12 0.8-1.2 6-9 From fork cap bol 2 | 2 ve3s | 28-35 | 18-25 Front fork bertom bot 2) ie Goss | Go-84 | 43-61 Front for dain bot 2 4 to-20 | 010-020 | o7-18 Fear shock ebvober hose joint bolt i 10 yeas | “zs-38 | 19-28 Swing erm choin aduster heer nut 2 10 30-40 | 30-80 | 22-29 Swingarm brake eptng hook bol i 3 as-00 | 04-060 | 33-43 Rear shock abwovoer sting eduster lock nut | 1 a 0-80 | 40-80 | 29-26 Fgh foot peg (10 men i 10 so-e0 | so-c0 | 26—a9 {12 mn) 1 2 b0-100 | 80-100 | 88-72 Kick starter peel ' & | 2-20 | 20-30 | t4—z2 Fuel valve mounting sere : ¢ | “ez | ote | ‘es Bide send pivet bolinut 1 10 seas | 35-46 | 25-20 Exhaust pie protector 2 8 tora | tonta | 7-10 Exhaust pipe joint aut 2 8 12 | oe12 | 6-8 Engine hanger bolt (8 mm) 6 8 24-30 | 2.4-3.0 17-22 tommy 5 10 ge-as | 38-8 | 25-80 Oi pipe bot 2 2 te-20 | 16-20 | 12-14 Mfr mounting bot ont) i 8 30-38 | 30-38 | 22-28 (reer) L1 10 35-45 3.5-4.5 25-33 ‘Torque specifications listed above are for specific tightening points. I a specification is not listed follow the standards below: STANDARD TORQUE VALUES TYPE | TORQUE Nem tkg-m, fib} TYPE TORQUE Nem (kg-m, fib) Smmbolt, nut | 4.5-6.0(0.45-06, 3.3-4.3) | Smmscrew 3.5—5 (0.35-0.5, 253.6) | mm bolt, nut | 8-12 (0.8-1.2, 6-9) 6 mm screw 7-11 (0.71.1, 5-8) | @mm bolt, aut | 18-25 (18-25, 13-18) | 6 mmbokt with 8mmhead | 7-11 (0.7—1.1, 5-8) 10mm bolt, nut | 30-40 (3.0—4.0, 22~29) | 6 mm flange bolt, nut, 10-14 (1.0—1.4, 7-10) 12mm bolt, nut | 50-60 (5.06.0, 36-43) | _& mm flange bolt, nut 24~30 (2.4~3.0, 17-22) 10 mm flange bolt, nut 35~45 (3.5—4.5, 25~32) 1-6GENERAL INFORMATION TOOLS DESCRIPTION TOOL NUMBER ‘ALTERNATIVE TOOLINUMBER | REF. TO PAGE Compression gauge attachment | 07908—KK60000 or equivalent commercially | 310 Clutch center holder 07923—KE10000 available in U.S.A. | 85,14 Piston base 07958—3000000 [2 equivalent commercially | 1316 COMMON Float level gauge. | 07401—0010000. 412 1-7GENERAL INFORMATION COMMON DESCRIPTION TOOL NUMBER | ALTERNATIVE TOOLINUMBER | REF. TO PAGE Artechment, 42x47 mm | -07746-0010300 | 108, 1219, | 136 Attachment, §2 x 5 mm 077480010400 107 Attachment, 62 x 68 mm 077460010500 10.6 Pot. 15 me 077460040300 107,128 Pilot, 17 mm | 077460040400 108, 12.6 Pot, 20 men 077460040800 108, 136, 28 Por, 22 men 077460041000 107 Pilot, 28 men 077480041100 106 Diver 077490010000 | 106,12, | 19,196, 7, 23, 30 Bearing remover head, 15 mm | 07745-0050800 1, sexivatnt commercial 28 Bearing remover shat (07746-0080100 | |_2F Sauivslent commercially 126,135 | Bearing remover head, 17 mm | 0776—-0050500 : 135 | Bearing remover nead, 20 mm | 077460050600 135 Valve guide diver 8.5 mm 077420010100 6-10 Valve spring compressor 07757-0010000 | _07987~3280001 6,14 VALVE SEAT CUTTER DESCRIPTION [Toot NuMeea | ALTERNATIVE TOOUNUMBER | _ REF. TO PAGE ‘Sest cutter, 33 mm (45° IN) | 07780—0010800 6-12, 13 Seat cuter, 24.8 mm (@5° EX) | 07780-0010100 642/13 Fiat cuter, 33 mm (32° IN) | 077800012000 | | Not avaible in USK, 842,13 Flat euter, 26 mm (32° €x) | 077800012000 | | Eauivalnt commercially 842.13 Interior cutter, 30 mm (60° IN/EX) | 07780—0014000 . 6-12, 13 Cotter holder 5.5 mm 077810010101 61 1-8CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: © A loose wire, harness or cable can be a safety hazard. After ‘clamping, check each wire to be sure it is secure, © Do not squeeze © wire against @ weld or the end of its clamp. © Secure wires and wire harnesses to the frame with thelt re- spective bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires, wire harneses. © Route harnesses so they are not pulled taut or have exces: sive slack, © Protect wires and harnesses with electrical tape or tubing where they contact a sharp edge or corner. Clean all surfac: fs thoroughly before applying tape. © Do not use wires or harnesses with damaged insulation. Repair the wires by wrapping them with protective tape, of replace them, © Route wire harnesses to avoid sharp edges or corners. © Avoid the projected ends of bolts and screws. © Keep wire harnesses away from the exhaust pipes and other hot parts. Be sure grommets are seated in their grooves properly. @ A‘ter clamping, check each harness to be certain that it ie not interfering with eny moving or sliding parts. ‘© After routing, check that the wire hamesses are not twisted or kinked. ‘© Wire harnesses routed along the handlebars should not be Pulled taut, have excessive slack, or interfere with adjacent or surrounding parts in any steering position, © Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick oF bind, GENERAL INFORMATION pape (©: CORRECT X.: INCORRECT 1-9GENERAL INFORMATION (1) CLUTCH CABLE (4) THROTTLE CABLES (2) MANUAL DECOMPRESSOR CABLE (5) ENGINE STOP, (3) FRONT BRAKE HOSE (9) CRANKCASE BREATHER TUBE (8) MANUAL, DECOMPRESSOR CABLEGENERAL INFORMATION (2) CLUTCH CABLE (1) THROTTLE (3) MANUAL DECOMPRESSOR CABLES CABLE (7) ENGINE STOP SWITCH (4) MAIN WIRE WIRE HARNESS (8) SPEEDOMETER, (5) FRONT BRAKE HOSE CABLE (7) FRONT BRAKE HOSE (9) MAIN WIRE (11) TAILLIGHT WIRE HARNESS (10) CARBURETORGENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM (U.S.A. ONLY) © The U.S. Environmental Protection Agency requires manufacturers to certify that motorcycles built after January 1, 1983, will comply with applicable noise emission standards for one year or 1,865 miles (3,000 km) after the time of sale to the ul timate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor’s Warranty for the Honda Motorcycle Noise Emission Control System is necessary in order to keep the noise ‘emission control system in effect. ‘¢ 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, of replace ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale ‘oF delivery to the ultimate purchaser or whi it isin use; or (2) the use of the vehicle 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 the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal of, oF 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 those speci- fied by the manufacturer 1-12MEMOLUBRICATION 2-02. LUBRICATION SERVICE INFORMATION 2-1 ENGINE OIL STRAINER CLEANING 23 TROUBLESHOOTING 2-1 O1LPUMP. 23 ENGINE OIL LEVEL CHECK 2-2 OILPASS PIPE 28 ENGINE OIL CHANGE 2-2 OIL COOLING sysTeM 28 LE ENGINE OIL FILTER REPLACEMENT 2-3 LUBRICATION POINTS: 211 SERVICE INFORMATION GENERAL © This section describes inspection and replacement of the engine ol and ol filter, oil strainer cleaning, and oil pump, cil pass pipe and oil cooling system serviee. SPECIFICATIONS Oil capacity 1.6 lit (1.70 U.S. qt., 1.41 Imp qt) at engine assembly 1.3 lit (1.37 US. qt, 1.14 Imp qt) at oll change 1.4 lit (1.48 U.S. gt, 1.23 imp qt) at oil and oil filter change Recommended oil Use Honda 4-Strake Oil or equivalent. API Service Classification: SE or SF VISCOSITY: SAE 20W—50/10W—40 NOTE Uso SAE 10W.-40 oll when the outside temperature is below 0°C (32°F), Other viscosities shown in the chart may be used when the average temperature in your riding area is within the Indicated range. OIL viscosities 240680100 *F 2 8 are Tem STANDARD SERVICE LiniT Oil pump body clearance "0.10—0.21 mm 10.004—0.008 in) (0.25 mm (0.010 in} (il pump tip clearance (0.15 mm (0.006 in} (0.20 mm (0.008 in} il pump end clearance 0.02—0.08 mm (0.001 —0.004 in) (0.12 mm (0.005 in} il pump delivery 7.7 lit (8.14 U.S. at, 6.78 Imp. at) 18,000 rpm TORQUE VALUES Oil drain plug Gil fier cover Gil pass pipe bolt Oil pipe bote TROUBLESHOOTING Oil level too low: + Normal cil consumption + External oil leaks Worn piston rings Oil contaminatior + Oil not changed often enough + Faulty head gasket 20-30 Nem (2.0~3.0 kg-m, 14-22 feb} B12 Nem (0.8-1.2kg-m, 6— 9 tb) 10—14 Nem (1.0—1.4 kg-m, 7=10 fb) 16-20 Nem (1.62.0 kgom, 12—14 feb) Low oil pressure: + Faulty oil pump + Oil pump drive gear brokenLUBRICATION ENGINE OIL LEVEL CHECK (1) UPBER LEVEL Support the motorcycle upright on level ground. Start the engine and let it idle for 8 few minutes. Stop the engine. Check the oll level with the oil filler cap/ dipstick by inserting it in until the threads touch the filler neck, Do not screw the cap in when making this check the oil levels below the lower mark on the dipstick, fill to the upper lavel mark with the recommended cil = (3) LOWER LEVEL ENGINE OIL CHANGE NoTE + Change engine oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining Remove the oil filler-cap/dipstick and drain plug. Operate the kickstarter several times while pushing in the ‘engine stap switch to drain any oll which may be left in the en- gine, After the oil has drained, check that the drain plug sealing washer is in good condition, and install the plug. (1) DRAIN PLUS. TORQUE: 20-30 Nem (2,0-3.0 kg-m, 14—22 feb) NOTE + Clean the engine oil strainer, if required, before filling the crankease. Fill the crankcase with the correct quantity of the recommend- ed il Ol capacity: 1.3 lit (1.37 U.S. qt, 1.14 Imp qt) at oll change 1.4 lit (1-48 U.S. qt, 1.23 Imp qt) at oil and oil fit change RECOMMENDED OIL: Honda 4-stroke Oil or equivalent API service classification : SE or SF VISCOSITY : SAE 20W—50/10W—40 Install the oil filer capicipstick. Start the engine and let it idle for 2~3 minutes, Stop the engine and wait a few minutes then check tht the oil level is at the upper level mark with the motorcycle upright. Check that there are no oll leaks.LUBRICATION ENGINE OIL FILTER REPLACEMENT Remove the oil filter cover from the right crankcase then remove the oil filter and spring, Discard the oil fiter element. (2) BOLTS Check that the O-rings are in good condition. (1) o-RINGS: Install the spring, a new oil filter element and oll fier cover. (2) RUBBER Tighten the cover bolts to the specified torque. SEAL ‘TORQUE: 8—12 Nem (0.8—1.2 kg-m, 6—9 ftb) (3) ELEMENT Fill 0 the upper level with the recommended cil NOTE * Install the oll fier into the crankcase cover so that the side with the rubber seals facing out, toward the oil filter cover. (4) SPRING ENGINE OIL STRAINER CLEANING NOTE + Perform this maintenance before fi 19 the engine with oi Remove the right crankcase cover (page 8-3) Remove the oil strainer and clean it. Install the oil strainer Install the right crankcase cover (page 8-14), Fill the crankcase with recommended ol OIL PUMP REMOVAL Remove the right crankcase cover and clutch (section Remove the dowel pin with the O-ring. Remove the oll pump cover by removing two mounting bolts, (4) O-RING.LUBRICATION Remove the oil pump driven gear and oil pump mounting bolts "iy DRIVEN GEAR @) BOLTS then remove the oil pump body. Remove the gasket and dowel pins. Remove the oil pump body screws and pump shaft. (1) SCREWS Disassemble the oil pump. Clean disassembled parts with non-flammabale or high flash point solvent. (3) PUMP SHAFT \4) oureR (5) PUMP BODY ROTOR A (3) SPACER (2) INNER ROTOR 8 (pum SHAFT (6) bowel PIN (7) INNER ROTOR A (8) OUTER ROTOR 8 COVER 2-4LUBRICATION INSPECTION Body Clearance Install the inner rotor A and outer rotor A on the oil pump body, Measure the body clearance. SERVICE LIMIT: 0.25 mm (0.010 in) Install the inner rotor B and outer rotor B on the oll pump cover. Mesure ‘SERVICE LIMIT: 0.25 mm (0.010 in) Tip Clearance ‘Temporarily instal the pump shaft to the pump body and m sure the tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) ‘Temporarily install the pump shaft to the pump cover and mea- sure the tip clearance. Ath wt ci SERVICE LIMIT: 0.20 mm (0.008 in) eral to et miLUBRICATION End Clearance ‘Measure the end clearance of rotor A. SERVICE LIMIT: 0.12 mm (0.005 in} ‘Measure the end clearance of rotor B. 12 mm (0.008 in) ASSEMBLY (1) PUMP Cover (2) PUMP SHAFT (3) OUTER (ROTOR B Install inner rotor B and outer rotor B on the pump cover. 5.0 -ritm 398 (a) FLAT SURFACE Install the pump shaft through inner rotor B aligning flat surfac- (5) INNER ROTOR 8 idatall deo dowal'pin oft Sis punt eater: (1) PUMP BODY (2) HOLE (3), DOWEL PIN. Install the spacer on the pump cover aligning its hole with the dowel pin on the cover. / (4) SPACER Install inner rotor A onto the pump shaft aligning the flat sur- faces. Install the outer rotor A. Install the pump body, aligning its hole with the dowel pin (5) OUTER (6) INNER ROTOR A ROTOR A. 2-6LUBRICATION Tighten the pump body screws securely. (1) screws INSTALLATION Install the dowel pins and # new gasket. Install the oil pump and tighten the bolts securely. Install the pump driven gear on the pump shaft aligning the flat surfaces. Install the pump cover and tighten the bolts securely Install the dowel pin with the O-ring on the oll pump, Install the clutch, and right crankcase cover (section 8). (3) O-RINGLUBRICATION OIL PASS PIPE REMOVAL Remove the exhaust pipe (page 15-2). Remove the pipe bolts and copper washers. Remove the oil pass pipe. CAUTION Do not bend the oil pass pipe. INSPECTION (1) OIL PASS PIPE Check the oil pass pipe and pipe bolts for damage, bends or clogging and replace if necessary. If itis clogged, clean with non-flammable or high flash point solvent. INSTALLATION COPPER, Install the oil pass pipe _WASHERS Tighten the pipe bolts with new copper washers. TORQUE: 10—14 Nem (1.0—1.4 kgm, 7—10 feb) Install the exhaust pipe [page 15-3). OIL COOLING SYSTEM INSPECTION CCheck the oil cooler for damage, leaks or any mud caked on the fins. 2-8LUBRICATION Check the oil pipes for damage or leaks, (1) OW PIPES REMOVAL a JT) PIPE BOLTS: — the fuel tank (page 4-3). 7 — the headlight (page 16-6). — the oil cooler mounting bolts washers and cil cooler. a (3) OIL COOLER WASHER: Remove the oil pipe/wire clamp. Remove the bolts and set plate then remove the cil pipes end O-rings carefully. (2) Ol PIPES (3) SET PLATE INSPECTION (1) OUTLET PIPE Check the pipes and bolts for blockage. If clogged, clean them with non-flammable or high flash point solvent, Check the pipe bolt sealing washers for damage, Replace them if necessary (2) PIPE BOLTS (3) INLET PIPE 2-9LUBRICATION INSTALLATION ff Install the oll cooler on the steering head using the bolts, rubbers and washers. i (2) BOLT, WASHER ‘AND RUBBER (EACH SIDE) ! Install the ol pipes and pipe bolts with sealing washers. (7]PIPE BOLTS AND SEALING WASHERS Tighten the pipe bolts to specification: ‘TORQUE: 16~20 Nem (1.6—2.0 kg-m, 12-14 fb) Set the rubbers on the frame projections. (5) OUTLET 7 PIPE . A\4)/PROJECTIONS: Apply engine oll to the O-rings. (i) ORINGS Install the new O-rings on the pipe and install the right crank- Connect the oil pipes to the right erankease cover. Install the set plate and tighten the bolts securely. (4) OIL PIPES. Secure the oil pipes and pulse generator wire with the clamp. (1) OUTLET. PIPE Tighten the screw securely, Install the headlight and fuel tank (3) PUSLE GENERATOR, (5) SCREW 2-10LUBRICATION POINTS Use general purpose grease when not specified here. Apply oll or grease to the other sliding surfaces and cables not shown here. CONTROL CABLE LUBRICATION Periodically disconnect the throttle and clutch cables at their ‘upper ends. Clean the cable end mount in the throttle and clutch lever, then oll the cable ends and reinstall. It is not nec: essary to oil the cables: if a cable begins to bind, it must be re placed, Wy ] (2) THROTTLE GRIP Sn (1) CONTROL LEVER PIVOTS (15) FRONT FORK (13) STEERING STEM BEARINGS/GOTTOM | , SEAL ' | (14) SPEEDOMETER GEARY DUST SEAL Pivor "86 shown: After ‘86 similar 1 , (12) BRAKE PEDAL LUBRICATION Apply paste grease with 40% or more molybdenum disul- fide to the * mark components. NoTE Some sources of MoS: paste grease with 40% or more molybdenum are: + Molykore” G-n Paste manufactured by Dow Corning, USA. Honda Moly 45 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. + Rocol Paste manufactured by Sumico Lubricant. Japan ‘Any other manufacturer's paste grease equivalent to the above may also be used. (3) ENGINE 8 gem “REAR SHOCK ABSORBER UPPER MOUNT SPHERICAL BEARING/* DUST SEALS | ere © ex, “Snock AaM | (61 SWING ARM PIvoT SPHERICAL BEARING/ “DUST SEAL (7) DRIVE CHAIN SAE #80 OR #90 GEAR OIL a (11) SIDE STAND. Pivor Sm (70) "SHOCK ARM PIVOT NEEDLE BEARINGS/ ‘SHOCK LINK PIVOT NEEDLE BEARING/ “DUST SEALS/*COLLARS. (9) DUST SEALS $A SSS 2-11MEMO.3._ MAINTENANCE SERVICE INFORMATION 3-1 DRIVE CHAIN SLIDER 312 MAINTENANCE SCHEDULES 33 BRAKESYSTEM 313 COMPETITION MAINTENANCE BRAKE FLUID 314 sine a 34 BRAKE SHOE/PAD WEAR 314 since $5 HEADLIGHT AIM 3.15 FUEL STRAINER SCREEN 35 Gwichsverem ane THROTTLE OPERATION 35 SipESTAND 3416 AIR CLEANER 36 — suspeNsioN aie spancrius 37 SPARK ARRESTER 3.47 VALVE CLEARANCE 37 NUTS, BOLTS, FASTENERS 347 DECOMPRESSOR SYSTEM 38 wHeeismmiRes 3418 Sate nenOe OLE Se 3-9 STEERING HEAD BEARINGS 318 CYLINDER COMPRESSION 3.10 DRIVE CHAIN 3.10 SERVICE INFORMATION GENERAL + Engine ollovel check. page 2-2 + Engine cilchange poe 22 Engine ol fiter replacement page 2-3 + Engine ol strainer cleaning - 909023 SPECIFICATIONS. Ignition timing Full advance: Spark plug Spark plug oap Valve clearance IN ex Idle speed Cylinder compression Starter decompressor lover free play Manual decompressor lever free play 18° BTDC at 1,300 + 200 rpm (F mark) 28° = 2° BTDC at 4,300 rpm Standard (NGK) DPREZ (ND) _X27GPR-U For cold elimate (NGK) DPRaZ (below 5°C/a1°F)_| (ND) X24GPRU 0.80.7 mm (0.024—0.028 in} (0.05 mim {0.002 in) (0.08 mm (0.003 in) 1,200 = 100 rpm 130—150 kPa (13.0 = 18.0 kglom?, 184,9~213.3 psi) 1=2 mm (1/16— 1/8 in} 5—8 mm (3/16—5/16 in)MAINTENANCE Throttle grip free play Front fork air pressure standard Max Rear brake pedal free play Cluteh lever free play Drive chain slack Drive chain length (107 pins) Drive chain slipper Tire pressure Front Reor Tire size Front Rear Tire cleat depth TORQUE VALUES Rear axle nut Spoke nipple Fim lock Valve adjusting screw lock nut Chain adjuster holder nut Side stand pivot Fuel valve mounting screw TOOLS Common Wrench, 10 x 12 mm Timing cap wrench Spanner C, 5.8 x 6.1 mm 2-6 mm (1/8—1/4 in) (0 kPa (0 kg/em?, Opsid 100 kPa (1.0 kgiem?, 14 psi) 20—30 mm (3/4—1-1/4 in} 10—20 mm (3/8—3/4 in) 36—45 mm (1-3/8— 1-2/4 in) standard 1,699 mm (66.9 in) service limit 1,716 mm (67.6 in) 15 mm (0.6 in) Max 100 kPa (1.0 kgicm®, 15 psi) 100 kPa (1-0 kglem®, 15 psi) 80/100-21 51M 110/100—18 64M 3.mm (1/8 in} Min 80-110 Nem (8.0— 11.0 kg-m, 58-80 ft-1b) 2.55.0 Nem (0.25-0.50 kg-m, 1.8~3.6 ft-lb) 1015 Nem (1.0—1.5kg-m, 7—11 fo) 1723 Nem (1.72.3 kgem, 12-17 feb) 20-40 Nem (3.04.0 kg-m, 21-29 {tb} 3546 Nem (3.54.5 kg-m, 25~33 ft-lb] 812 Nem (0.8—1.2 kgm, 6-9 feb] 077080030200 or equivalent commercially available in U.S.A 077090010001 07701 0020300 or equivalent commercially available in U.S.AMAINTENANCE 1) AAA MAINTENANCE MAINTENANCE SCHEDULE REGULAR MAINTENANCE SCHEDULE Perform the PRE-RIDE INSPECTION in the Owner's Manual at every maintenance period |: INSPECT AND CLEAN, ADJUST, LUBRICATE, OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE FREQUENCY | BREAKIN REGULAR SERVICE | se MAINTENANCE INTERVAL, 7 inst week of Even REFER TO 7 a “peaton= | operaingsey- | PAGE about 200 mi about 1,000 mi Tem | (350 km) 11,800 km) +] FUEL LINE ' 35 * | FUEL STRAINER SCREEN - € 35 + | THROTTLE OPERATION [ o 35 AIR CLEANER NOTE 1 c 36 SPARK PLUG a t 37 «VALVE CLEARANCE o 1 37 “[CENGINEOL R R 22 [| ENGINE 1 FILTER _ R R 23 «| DECOMPRESSOR SYSTEM (2... i 38 «| CARBURETOR IDLE SPEED H Ui 39 1. L Every 10 operating DRIVE CHAIN | notes he day — about 300 mi | 3-10 (500 km) DRIVE CHAIN SLIDER t 1 342 BRAKE SYSTEM t 1 343 BRAKE FLUID 2 YEARS *R 1 | aaa "| BRAKE SHOE/PAD WEAR Ez U 314 * | HEADLIGHT AIM L 318 CLUTCH SYSTEM [ a 1 i 315 SIDE STAND a q 316 + | susPeNsioN A 316 + | SPARK ARRESTER NOTE 2 c 347 + | NUTS, BOLTS, FASTENERS q ' 347 WHEELS/TIRES i t 3.48 <*] STEERING HEAD BEARINGS ae 0 348 + SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS THE PROPER TOOLS AND IS MECHANICALLY QUALIFIED. ** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS 8E SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTE: 1. Service more frequently when ridden in wet or dusty conditions: 2.US.A, only 3-3MAINTENANCE COMPETITION MAINTENANCE SCHEDULE Check all items before each race. Refer to the REGULAR MAINTENANCE SCHEDULE (page 3-3) for regular (non-competition use service intervals ITEMS INSPECT FOR, ACTION AS REQUIRED | REFER TO PAGE ‘ALL PRE-RIDE INSPECTION | NOTE 2 TEMS ’ ENGINE O1L Contamination ‘Change 22 FUEL LINE Deterioration, damage or leakage | Replace a5 | VALVE CLEARANCE Correct clearance Adjust 37 (CARBURETOR IDLE SPEED | Conect idle speed ‘Adjust 39 (CARBURETOR-CHOKE Proper operation = = DECOMPRESSION MECHANISM | Proper free play ‘Adjust 38 ‘CLUTCH DISCS Proper operation see (NOTE 1) Replace 3415 AIR CLEANER ELEMENT Contamination or tears Clean or replace 36 Tiahtness, proper heat range, and | Tighten, replace or rane e high tension terminal security secure aad ‘STEERING HEAD Free rotation of handiebars and | adjust or tighten 318 steering stom nut tightness ‘Smooth operation, no oll leaks, FRONT SUSPENSION {9004 boot condition, air Replace or adjust 3.16 pressure and oil volume ‘Smooth operation, oil leaks and REAR SUSPENSION Smeath opr Replace or edust 347 ‘SWING AAW BEARINGS [TSmaoth operation fevlce B18 REAR SUSPENSION LINKAGE | weg, tks a7 SEAFINGS BRAKE SHOESIPADS “Wear beyond sevice Tpace Sia Lent aive CHAIN 1768 mm (68.8 in/109 pins | Replace 310 SPROCKETS Wear and secure ietaloion | Roplaco or than sit SEAT Security [Tighten 151 HEADLIGHT Proper beam aim 7 7 Adjust 3-15 SPEEDOMETER/TAIP METER | Proper operation Replace — cic cece tg. ot teeth cewnion, hime wet 24 correct routing — pesto ot Teplens 1.9 they. 1-11 ENGINE MOUNTING BOLTS Tightness Tighten 5a NOTE 1. Competition use necessitates more frequent service. 2. Refer to the Owner's Manual PRE-RIDE INSPECTION, 3-4FUEL LINE Check the fuel line and replace any cracked, damaged or leak- ing parts. FUEL STRAINER SCREEN ‘Turn the fuel valve OFF, disconnect the fuel line at the carbure- ‘Turn the fuel valve to ON and RES and drain the fuel into @ clean container. Rx = ‘Keep gasoline away from flames or sparks. ive up spilled gasoline at once, Remove the fusl tank (page 4-3. Remove the two screws attaching the fuel valve to the fuel tank then remove the fuel fit Clean the fus! strainer sore ‘Make sure the O-ring is in good condition and install the fuel valve Tighten the screws to the specified torque. TORQUE: 8—12 Nem (0.8—1.2 kg-m, 6-9 feb) Install the fuel tank and connect the fuel line. After filling the fuel tank, check for leaks. THROTTLE OPERATION Check that the throttle grip opens smoothly to full throttle and fully closes automatically, in all steering positions. Make sure there is no deterioration, damage, or kinking in the throttle cables, and that the throttle grip free play is 2—6 mm. (1181/4 in) at the throttle grip flange. Throttle grip free play can be adjusted at either end of the throttle cable, Replace any damaged parts before beginning this adjustment. Minor adjustments are made with the upper adjuster. Adjust the free play by sliding the rubber cover off, loosening the lock nut and turning the adjuster. Tighten the lock nut and put the rover cover back. Recheck for proper throttle operation MAINTENANCE (1) FUEL LINE (1) FUEL VALVE (2) FUEL STAINER SCREEN \ (3) SCREWS. (4) O-RING (1) THROTTLE GRIP FREE PLAY: 2-6 mm (118174 in) (1) RUBBER CoveR (2) ADJUSTER (3) Lock NUT 3-5MAINTENANCE Major adjustments are made with the lower adjuster on the carburetor. ‘Adjust free play by loosening the lock nut and turning the ad- juster. Tighten the lock nut. Recheck throttle operation. Replace any damaged parts, Install the fuel tank and seat. AIR CLEANER Unhook the three fasteners and remove the left side cover, NOTE + Ifthe inlet dust cap is attached, remove the seat and inlet dust cap. Release the sir cleaner element clamp and remove the element with the holder. Separate the element from the holder Wash the element’ in non-flammable or high flash point sol vent, and let it dry. Soak the element in gear oll (SAE #8090) and squeeze out the excess. Install the removed parts in the reverse order of disassembly. (3) ELEMENT CLAMP (1) WASH IN. SOLVENT (3) GEAR OIL (SAE #80-80) )- Sosa (SY E Pon (-$ (2) SQUEEZE OUT (4) SQUEEZE SOLVENT our THOROUGHLY EXCESS OILMAINTENANCE SPARK PLUG Dione he po hig ap en reve oh tL voe-070m oo bas in (0.024—0.028 in) Visually inspect the sperk plug. Discard it if the Insulator is cracked or chipped. ‘Measure the spark plug gap with @ wire-type feeler gauge. Adjust the gap by bending the side electrode carefully SPARK PLUG GAP: 0.6—' .7 min (0.024~-0.028 in) RECOMMENDED SPARK PLUG: Standard (NGK) DPRoZ (ND) X27GPR-U For cold climate INGK) DPREZ (below 5°C/41°F) (ND) x2aGPR-U ‘Make sure the sealing washer is in good condition. Install the spark plug, tighten it by hand, then use a spark plug ‘wrench for the final tightening. Connect the spark plug cap. VALVE CLEARANCE NOTE (1) INDEX NOTCH (2) TIMING HOLE CAP. + Inspect and adjust valve clearance while the engine is cold ibelow 36 °C/95 ° Fi, + Make sure the decompressor valve lifters have some free play during this maintenance. (3) TIMING CAP WRENCH 077030010001 Remove the seat. ‘Turn the fuel valve OFF, disconnect the fuel line, and remove the tank. Remove the crankshaft and timing hole caps. Remove the valve hole caps. Rotate the flywheel counterclockwise to align the “ with the index notch on the left erankease cover. Make sure the piston is at TDC (Top Dead Center) on the com: pression stroke. mark Check the clearance of all four valves by inserting a feeler ‘Gauge between the adjusting screw and the sub-rocker arm. NoTE + When checking the clearance slide the feeler gauge from the inside out in the direction of the arrow. VALVE CLEARANCE: IN: 0.08 mm (0.002 in) EX: 0.08 mm (0.003 in)MAINTENANCE ‘Adjust by loosening the lock nut and turning the adjusting ‘screw untll there isa slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut. TORQUE: 17—23 Nem (1.7— 2.3 kgm, 12-17 feb) Adjust the starter and manual decompressor free play. (3) WRENCH, 10 x 12 mm. (077080030200 OR EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A. Check the O-rings for damage and tighten the valve hole caps securely Install the fuel tank and seat. DECOMPRESSOR SYSTEM KICK STARTER NOTE + Always adjust the decompressor linkage (manual and kick- starter) after adjusting the valve clearance (page 3-7) Remove the crankshaft and timing hole caps. Rotate the flywheel counterclockwise to align the “T"" mar with the index notch. Make sure that the piston is at TDC (Top Dead Center) on the compression stroke. ‘Measure the kickstarter decompressor cable free play at the tip of the decompressor valve lifter lever. FREE PLAY: 1—2 mm (1/16—1/8 in} ise was ‘Adjust the decompressor cable by loosening the lock nut and ‘turning the adjusting nur. 2) FREE PLAY CAUTION =2 mm (1/16—1/8 in) + Excessive fre play causes hard starting. Insufficient free play may cause erratic engine idling and valve damage. Tighten the lock nut. Operate the kickstarter and check the operation of the decom- pressor mechanism. Recheck free play. 3-8MAINTENANCE MANUAL ‘Measure the free play at the tip of the manual decompressor lever. FREE PLAY: 5—8 mm (3/16—5/16 in) Adjust by turning the manual decompressor adjusting nut at the engine. After adjusting, tighten the lock nut. Recheck the free play at the lever. CARBURETOR-IDLE SPEED NOTE + Inspect and adjust the idle speed after all other engine ad justments are within specifications. + The engine must be warm for an accurate idle inspection ‘and adjustment, Ten minutes of stop and go riding is sufti- cient Warm up the engine, shift to NEUTRAL, and hold the motor. cycle upright. Connect a tachometer. Turn the throttle stop screw to obtain the specified idle speed. IDLE SPEED: 300 = 100 rpm (1) FREE PLAY 5-8 mm (3/16~S/16 in} (1) Lock Nur (2) ADJUSTING NUT 3-9MAINTENANCE CYLINDER COMPRESSION Warm up the engine. ‘Stop the engine and remove the spark plug, Disconnect the kick etarter decompressor at the cylinder head. Connect a compression gauge. Open the throttle grip all the way. Operate the kick starter several times and check the gauge reading. NoTE + Check that there is no leakage at the gauge connection. (1) COMPRESSION GAUGE OR EQUIVALENT COMMERCIALLY AVAILABLE IN U.S.A. ‘COMPRESSION: 1300—1500kPa (13.0-15.0 kglem?, 184.9-213.3 psil Low compression can be caused by: + Improper valve adjustment + Valve leakage + Leaking cylinder head gasket + Worn piston ring or cylinder + Improper decompressor adjustment High compression can be caused by: + Carbon deposits in combustion chamber, or on the piston Disconnect the compression gauge, then reinstall the kick: starter decompressor linkage. Adjust the kick starter decompressor free play, as required, Reinstall the spark plug, DRIVE CHAIN Turn the engine off. Raise the rear whee! off the ground by placing a work stand or box under the engine. Shift the trans- R ~ mission into neutral Measure the slack inthe higher drive chain run midway bex ory RG tween the sprockets. 1) SLACK 1 35—45 mm (1-3/8 1-3/4 in) STANDARD SLACK: 36—45 mm (1-3/8—1-3/4 in) { 7 Adjust as follows: NC SNe Loosen the rear axle nut and chain adjuster holder nuts, then tum both adjusters equally until the chain slack is correct, CAUTION (2) ADJUSTER Be sure the same adjuster index marks align with the stopper ins on both sides of the swingarm. Tighten the axle nut. TORQUE: 80-110 Nem (8.0~11.0 kg-m, 58—80 ft-b) ‘Tighten the chain adjuster holder nuts on both sides. TORQUE: 30—40 Nem (3.0—4.0 kg-m, 21-29 feb) Rechock chain slack and free wheel rotation, 3-10MAINTENANCE ‘When the drive chain becomes extremely dirty, it should be re- moved and cleaned prior to lubrication. Remove the drive sprocket cover Remove the chain retainer olip carefully. Remove the master link and remove the drive chain. (1) MASTER LINK ales CAUTION + Be careful not to lose the O-rings when the clip and master link are removed. Clean the drive chain with non-flammable or high flash point solvent or kerosene that will not damage the O-rings; wipe dy. CAUTION + Do not use a steam cleaner or high pressure washers as these wil damage the O-rings. cal wre Om hy (a) SAE #80 ~ SAE #90 (3) LUBRICATE bam Inspect the drive chain and O-rings for possible wear or dam: ‘age. Replace the chain if it is worn excessively or damaged. | ‘Messure the drive chain length with the chain held so that links are straight. (1) SERVICE LIMIT: 1.716 mm (67.6 in) PINS LENGTH: STANDARD: 1,699 mm (66.9 in} goesesey “ SERVICE LIMIT: 1,716 mm (67.6 in “ (87,8 (2) Measure a span of 107 pins Lubricate the drive chain with SAE #80—#90 gear oil. Inspect the sprocket teeth for excessive wear or demage, Replace i necessary x x (1) DAMAGE (2) WEAR NoTE + Never install a new drive chain on worn sprockets or a worn cchain on new sprockets. Both chain and sprockets must be jn good condition, or the new replacement parts will wear rapidly. XA ° (3) NORMAL 3-11MAINTENANCE Install a new drive chain, Install the master link with O-rings and a chain retaining clip. Install the drive sprocket cover. ‘Adjust the drive chain (page 3-10), CAUTION ‘Do not assemble the drive chain without the four master link Orrings. + Be sure that there s no space between the master link and the chain retainer clip. DRIVE CHAIN SLIDER CHAIN SLIDER Check the chain sider for wear CAUTION +I the chain slider becomes worn down through to the swing farm, the chain will wear against the swing arm. CHAIN SLIPPER, Inspect the chain slipper and replace itf the depth of the chain ‘groove leaves less material than specified. ‘SERVICE LIMIT: 15 mm (0.6 in} CHAIN GUIDE SLIDER Inspect the chain guide slider for wear and replace it if you can ‘see the chain through the wear limit opening (1) MASTER LINK (2) (NO SPACE) ie (3) CHAIN RETAINER CLIP (4) O-RINGS 3-12MAINTENANCE BRAKE SYSTEM ae FRONT BRAKE LEVER FREE PLAY (2) ADJUSTER The front brake lever is provided with a free play adjuster. Specified free play, measured at the tip of the lever, is 0.6: 7.8 mm (1/14~5)8 in). To increase free play, loosen the lock ‘nut and turn the adjuster counterclockwise. To decrease free play, turn the adjuster clockwise. If the brake lever free play exceeds 7.8 mm (5/8 in} with the clearance between the adjuster and the front brake master cyl- MA" (3S LOCK NUT inder piston below 1.4 mm (0.08 in), there is probably air in the brake system and it must be bled (page 143). a + Never use any adjuster other than those designed for this ‘motorcyele, Install a new adjuster from the lever side with the lock nut under the head of the adjuster. (i) Lock NOT (2) STOPPER BOLT BRAKE PEDAL HEIGHT. To adjust: Loosen the lock nut and adjust the pedal height by turning the ‘stopper bolt. Tighten the lock nut. ‘Adjust the brake pedal free play. & BRAKE PEDAL FREE PLAY NoTE + Adjust the brake pedal free play after adjusting the brake } pedal height Measure the brake pedal free play. FREE PLAY: 20-30 mm (3/4—1-1/4 in) (1) FREE PLAY: 20-30 mm (3/4—1-1/4 in) H adjustment is necessary, turn the brake adjusting nut, AMBIT absusTinG NUTMAINTENANCE BRAKE FLUID Check the front brake fluid reservoir level, If the level is near the lower level mark, remove the cover and diaphragm. Fill the reservoir with OOT-4 Brake Fluid to the casting ledge. If the level was low, check the entire system for leaks. CAUTION J Do not remove the cover until the handlebar has been turned so thatthe reservoir is level ‘Avoid operating the brake lever with the cap removed. Brake ‘Suid will squirt out if the lever is pulled. + Do not mis different fluid types, as they are not compatible. + Avoid spilling 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 procedure. BRAKE SHOE/PAD WEAR BRAKE PAD WEAR Check the brake pads for wear. Replace the brake pads if the wear line on the pads reaches the ‘edge of the brake disc (page 14-5) ‘CAUTION + Always replace the brake pads as a set to assure even dise pres BRAKE SHOE WEAR Replace the brake shoes if the arrow on the brake arm aligns with the reference mark ““A’" on the brake panel when the brake is applied 3-14 Mi) LOWER LEVEL MARK (1) CASTING LEDGE Ti) WEAR LINES (2L BRAKE DISC (1) ARROW |, | (2) 7A" MARKHEADLIGHT AIM Adjust the vertical beam by turning the adjusting screw on the headlight cover. CLUTCH SYSTEM ‘Measure the clutch lever fr play at the lever end, FREE PLAY: 10-20 mm (3/8—3/4 in) Adjust as follows: ‘Minor adjustments are made with the upper adjuster. Pull the cover back. Loosen the lock nut and turn the adjuter. Tighten the lock nut and install the cover Major adjustments are made with the lower adjuster. I major adjustment is required, turn the upper adjuster all the way in and back out 1 turn, Loosen the lower lock nut and turn the adjusting nut. Tighten the lock nuts. Check the clutch operation. MAINTENANCE . [(1) ADJUSTING SCREW (1) FREE PLAY 1020 mm (3/8—3/4 in} (1) Lock NUT (2) ADJUSTER Sut (1) ABGUSTING NUTT (2\"TOCR WOTMAINTENANCE SIDE STAND [Check the side stand spring for damage andor loss of tension. ‘Check that the side stand assembly is not bent and that it moves freely Tighten the pivot bot if necessary TORQUE: 35—45 Nem (3.5—4.5 kg-m, 25—33 ft-lb) (2) SIDE STAND SUSPENSION FRONT ‘Check the action of the front forks by compressing them sev- eral times. Check the entire fork assembly for signs of leaks or damage Replace any components which are unrepairable. Torque all nuts and bolts. [esse + Do not ride a vehicle with faulty suspension. Loose, worn, or damaged suspension parts may affect stability and rider con- trol ‘Check the front fork aie pressure when the forks are cold, Lift the front wheel off the ground by placing @ work stand or bbox under the engine. Remove each air valve cap and measure the alr pressure. [STANDARD AIR PRESSURE: 0 kPa (0 kgiom?. 0 psi, MAXIMUM AIR PRESSURE : 10 kPa (1.0 kgicm?, 14.2 psi) For pressure adjustment, see Owner's manual REAR Place the motorcycle on a work stand or box to raise the rear whee! off the ground. Move the rear wheel sideways with force to see if the swing, arm bearings or wheel bearings are worn. Replace if excessively worn,MAINTENANCE Bounce the rear of the motorcycle up and down to check for aA3Th, proper operation, Check the entire rear suspension being sur curely mounted and not damaged or cistorted Torque all nuts and bolts to their specified vaives (pages 1-5 and 3-2) verything is se Pump grease into the swing arm pivot bearings through the grease fitting on the swing arm, and linkage bushings through ‘the grease fittings on the linkage pivots. SPARK ARRESTER Remove the muftler ld Start the engine and increase the rpm to blow carbon out of the exhaust pipe while momentarily creating an exhaust system back pressure by blocking the end of the muffler with a shop towel Repest until carbon stops coming out. + Do not perform this operation while the exhaust system Is hot. Perform this operation in a well-ventilared area, free from fire hazards, Use adequate eve proveetion. After cleaning the spark arrester, intall the muffler lid and ‘gasket and tighten the bolts. Be sure that the muffle lid and gasket are in good condition. CAUTION + Be sure that the spark arrester screws are securely in place. NUTS, BOLTS, FASTENERS (Check that all chassie nuts and bolts are tightened to their cor rect torque values (section 1) at the intervals shown in the Maintenance Sehedule (page 3-3) Check all cotter pins, safety clips, hose clamps and cable stays.MAINTENANCE WHEELS/TIRES TIRE PRESSURE NOTE +The pressure should be checked when thi Tite pressure: Front: 100 kPa (1.0 kglom®, 15 psi) Roar: 100 kPa (1.0 kg/cm, 15 psil Tire size: Front: 80/100—21 51M Rear; 110/100—18 64M. Cheek the tires for cuts, embedded nails or other sharp ob: jects. Check the tire cleat depth, SERVICE LIMIT: 3 mm (1/8 in) Tighten the wheel spokes snd rim lock. ‘TORQUE VALUES: ‘SPOKE NIPPLE: 2.5—5.0 Nem A AEPANNER. (0.25-0.50 kg-m, 1.8—3.6 ft-lb) 5,8 x 6.1 mm 07701 ~0020300 OR EQUIVALENT RIM LOCK: 1015 Nem (1.0--1.5kg-m, 7—11 lb) COMMERCIALLY AVAILABLE IN U.S.A. STEERING HEAD BEARINGS Raise the front wheel off the ground and check that the handlebar rotates freely. Check that the control cables do not interfere with handlebar rotation. If the handlebar moves une: venly, binds, or has vertical movement, adjust the steering head bearing adjusting nut (page 12-20).MEMOFUEL SYSTEM Be 4-04. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING FUEL TANK AIR CLEANER CASE CRANKCASE BREATHER CARBURETOR REMOVAL 4-1 CARBURETOR DISASSEMBLY 46 4-2 CARBURETOR ASSEMBLY 49 4-3 CARBURETOR INSTALLATION 412 4-4 PILOT SCREW ADJUSTMENT 413 4-5 TEMPERATURE AND ALTITUDE 4.¢6 ADJUSTMENT 413 SERVICE INFORMATION GENERAL + Keep gasoline away from flames or sparks. Wipe up spilled gasoline at once. ‘CAUTION +_Do not bend or twist conirol cables. Damaged conirol cables will not operaie smoothly and may stick or bind. ‘© When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. © The carburetor float bowls have érain screws that can be loosened to drain residual gasoline, SPECIFICATIONS Fuel tank capacity Reserve capacity, Carburetor Type Identification number Jet needle setting Float level Pilot screw opening Main jet Slow jet Idle speed Air cut-off valve operating press. Throttle grip free play TORQUE VALUE Fuel vale mounting screw TOOL Common Float level gauge 9.0 lt (2.38 U.S. gal, 1.98 Imp gall) 2.0 lit (0.83 U.S. gal, 0.44 Imp gall Piston valve PD 05 A 3rd groove 42.5 mm (0.49 in) 2-114 tuens out #125 #40 1,300 = 100 rpm 390 mm Hg (15.4 in Hg) 2—6 mm (1/8—1/4 in) 8—12 Nem (0.8—1.2 Kg-m, 6~9 fib) (074010010000 41FUEL SYSTEM TROUBLESHOOTING Engine cranks but won't start + No fuel in tank No fuel to eylinder ‘Too much fuel getting to oylinder + No spark at plug (ignition malfunction} + Air cleaner clogged Engine idles roughly, stalls, or runs poorly Idle speed incorrect, + Ignition malfunction Low compression (Section 6) Rich mixture Lean mixture Air cleaner colgged Air leaking into manifold Fuel contaminated Lean mixture + Carburetor fuel jets clogged Fuel cap vent blocked Fuel strainer clogged Fuel line kinked or restricted Float valve faulty Float level too low Sh mixture + Choke stuck closed Float valve faulty Float level t00 high Carburetor air jots clogged Sticking float Dirty air clearFUEL SYSTEM FUEL TANK FUEL TANK REMOVAL, (1) SEAT Remove the seat. ‘Turn the fuel valve OFF and disconnect the fuel line. Remove the mounting strap, bolts and fuel tank. + Keep gasoline away from flames or sparks. + Wipe up spite gasoline at once. Check that fuel flows out of the fus! valve freely. If flow is restricted, clean the fuel strainer (page 2-5) FUEL TANK INSTALLATION (1) FUEL TANK Install the fuel tank with the two mounting bolts and strap. Connect the fue! line. Install the seat, NOTE + After assembling, make sure there are no fuel leaks +o not overtighten the fuel valve screws. (31 BOLT (EACH SIDE) RA\ (1) BREATHER TUBE (2) STRAP | (3) FUEL VALVE 6 ‘3-12. Nem (0.81.2 Kom, 6-9 feb) 43FUEL SYSTEM AIR CLEANER CASE REMOVAL Remove the seat and side covers Remove the mudguard mounting bolts and mudguard. Unfasten the wire band on the air cleaner case, Loosen the air cleaner connecting tube clamp. Remove the air cleaner mounting bolts. Remove the air cleaner ase from the left side, INSTALLATION Install the air cleaner case in the reverse order of removal. (2) MUDGUARD} LY, (1) BOLTS Es (2) WIRE BAND (3) CONNECTING TUBE’ CLAMP, (1) AIR CLEANER 4-4FUEL SYSTEM Route the crankcase breather tube as shown. ) CRANKCASE BREATHER TUBEFUEL SYSTEM CARBURETOR REMOVAL TU reseavoin Remove the fuel tank (page 4.2). Remove the reservoir mounting bands, and the reservoir from its mount bracket. Loosen the drain screws and drain the fuel into @ suitable ow (1) clamps container, Mmm ‘Keep gasoline away Jrom flames or sparks, wipe up spilled ‘gasoline at onee. Loosen the carburetor clamps. Pull the carburetors away from the right side of the engine. Disconnect the throttle cables and remove the carburetor. CARBURETOR DISASSEMBLY (1 SCREWS (27 FLOAT FLOAT, FLOAT VALVE, AND JETS Remove the over flow tube, drain tube and air vent tube, Remove the three float chamber screws and the float ‘chamber.FUEL SYSTEM. Remove the float pin, float and float valve. Inspect the float valve and its seat for grooves, nicks, oF contamination. Inspect the operation of the float valve. CChack the float for deformation or presence of fuel. Remove the main jet, needle jot holder, needle jet and slow jet. ‘Turn the pilot screw in and carefully count the number of turns before it seats lightly. Make a note of this to use as a reference when reinstalling the pilot screw. CAUTION + Damage 10 the pilot screw seat will occur if the pilot screw is tightened against the seat. Remove the pilot screw and inspect it. Replace itt itis worn or damaged, Check each part for wear or damage. Blow open al jets with compressed alr. THROTTLE VALVE Remove the two screws attaching the csrburetor top cover ‘and the body, (1) FLOAT. (1) FLOAT VALVE fe (ay PLOT SCREW (2) 16P cover (2) FLOAT VALVE yi oe / (3) FLOAT BIN (2) stow (3) MAIN JeT JEL sta ag (1) screws: (4) NEEDLE JET HOLDER (5) NEEDLE JetFUEL SYSTEM Remove the link arm set screw, the throttle drum assembly, (1) screw (2) Plastic. the plastic washer and throttle valve assembly from the WASHER throttle bore, (3) THROTTLE DRUM (4) THROTTLE VALVE Remove the two screws attaching the link arm to the throttle (1) screws: valve and separate the link arm from the throttle valve. (2PLINK ARM Remove the jet needle. (1) THROTTLE VALVE Check the throttle valve and jot needle for wear, nicks or other damage. (2) JeT NEEDLE AIR CUT-OFF VALVE (1) cover. (2) screw (3) SETTING Remove the choke lever setting plate, and lover. PLATE Remove the two screws attaching the air cut-off valve cover, ‘and the cover. (5) CHOKE LEVERFUEL SYSTEM (DIAPHRAGM (2) O-RING a r (8) SPRING CARBURETOR ASSEMBLY 49FUEL SYSTEM Blow open all passages with compressed air before installing jts and valves. AIR CUT-OFF VALVE Assemble the sir cut-off valve in the reverse order of dis- ‘assembly, NOTE + Install the O-ring with its flat side towar body. ‘the carburetor Tighten the screws securely. Install the choke lever and setting plat THROTTLE VALVE Assemble the throttle valve in the reverse order of disassem- bly. STANDARD: Install the throttle valve assembly into the throttle bore, Install the throttle drum through the carburetor body, plastic ‘washer and link arm. Tighten the set screw securely. NOTE + Align the hole in the link arm with the threaded hole in the link arm shaft and install the set screw. (1) DIAPHRAGM : (2) O-RING ‘. (3) cover ce f a (4) sPaING (1) THROTTLE (2) cL Valve = a As (3) JETNEEDLE (1) SCREW (2) PLastic. WASHER DRUM (4) THROTTLE VALVEFUEL SYSTEM Install a new cover gasket and cover. Tighten the screws securely, Inspect throttle operation as described below: + Open the throttle slightly by pressing on the throttle linkage. Then release the throttle, + Make sure that there is no drag when opening and closing the thrott FLOAT, FLOAT VALVE AND JETS. Install the pilot screw and tun it in until it seats lightly ‘Turn the pilot screw out the number of turns when it was removed. CAUTION + Damage to the pilot serew seat will occur ifthe pilot screw is tightened against the seat Install the slow jet, needle jet, needle jet holder and mé Install the float with float valve to the carburetor body and install the float erm pin through the body and float. (1) cover: (2) GaskeT (1) NEEDLE JET (2) NEEDLE JET HOLDER ue ee ey NS © les (a) stow cnwhsnen (6) mdr screw "Ser (1) FLOAT (2) FLOAT VALVE! || (3) FLOAT PIN 4-11FUEL SYSTEM FLOAT LEVEL ‘Measure the flost level with the float tang just contacting the float valve. ‘SPECIFICATION: 12.5 mm (0.49 in) Adjust the float level by carefully bending the float tang. (1) FLOAT LeveL GAUGE Install the float chamber and tighten the screws securely (2) FLoat CHAMBER Connect the tubes as shown. CARBURETOR INSTALLATION Installation is essentially the reverse of removal ‘+ Route the throttle cables properly (page 1-9 to 1-11) Perform the following inspections and adjustments. + Throttle operation (page 3-5). + Idle speed (page 3-3} 4-12FUEL SYSTEM PILOT SCREW ADJUSTMENT ‘Turn the pilot screw clockwise until it seats lightly and then bback it out to the specification INITIAL OPENING: 2-1/4 tums out CAUTION + Damage to the pilot serew seat will occur if the pilot screw is lightened against the seat ‘Warm the engine up to operating temperature, Stop the engine aid connect 2 tachometer. Start the engine and adjust the idle speed ta 1,300 + 100 rpm with the throttle stop screw. (3) THROTTLE STOF | SII SCREW ‘Check thatthe engine speed increases smoothly by turning the throttle grip. ‘Turn the pilot screw until the highest idle speed is obtained. Reset the idle spead to 1,300 = 100 rpm with the throttle stop. TEMPERATURE AND ALTITUDE ADJUSTMENT Use the chart on the right to determine if carburetor adjust ments are necessary because af changes in temperature and altitude. Draw a line straight up from your temperature to your altitude. ‘Where those lines intersect, draw a horizontal line straight to ‘the lett. Where that line meets the left edge of the chart is your correction factor, To adjust the main jet size, multiply the standard main jet size by your correction factor. If the correction factor is 0.98, or below, raise the jet needle clip by one position and turn in the pilot screw 1/2 turn. If the correction factor is above 0.98, adjustments to the jet needle and pilot screw are not necessary. (3) Atitude Contection Factor c Soy ban a dn dat For example: ‘At a temperature of 30°C (86°F) and an altitude of 3,000 m (9840 ft), carburetor recommendations are as follows: Ores + Main jet 125 x 0.92 = 115 + Jet needle ‘rd groove from top minus 1 = 2nd groove from top. + Pilot screw opening 2-1/4-1/2 = 1-3/4 turn out ‘Standard Carburetor Setting ‘Main jot F125 Jet needle setting 3rd groove Pilot screw opening 2-1/4 tums out 4-13ENGINE REMOVAL/INSTALLATION 24-30 Nem (2.43.0 kg-m, 17-22 feb) 38-45 Nem (3.545 kom, 25—33 feb) =14 Feb) 24-30 Nem (2,4~3.0 kg-m, 17-22 feb) (3.54.5 kg-m, 25-33ft-lb) 80-100 N-m' (8,010.0 kgm, 58—72 tb) 50-60 Nem (5.06.0 kg-m, 36-43 feb) 8-12 Nem (0.8-1.2 ke-m, 6-9 feb) 35—45 Nn 24-"30 Nem (2.54.5 kgm, (2.4—3.0 kom, 25-33 eld) | 17-22 feb) a 14=18 Nem (1.4—1.8 kg-m, 10~13 ft-lb}5. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 5-1 ENGINE INSTALLATION 54 ENGINE REMOVAL 5-2 SERVICE INFORMATION GENERAL During removal and installation, support the motorcycle with @ work stand or box. © A jack or adjustable support is required to maneuver the engine, © Parts requiring engine removal for servicing Crankshaft Section 10 Crankease Section 10 Balancer Section 10 Transmission Section 11 SPECIFICATIONS Engine dry weight 34.5 kg (76.06 Ibs) Engine oll capacity 1.6 lit, (1.70 US at, 1.41 Imp at) after engine disassembly, TORQUE VALUES Engine hanger bolts: 8 mm bott 24—30 Nem (2.4—3.0 kg-m, 17—22 feb} 10 mm bolt 35-45 Nem (3.84.5 kg-m, 2533 feb) Right foot peg mounting bolt (10 mm) 5060 Nem (5.0—6.0 kg-m, 36—43 fb) (12. mm) 80-100 Nem (8.0—10.0 kg-m, 58~72 ft-b) Exhaust pipe joint nut 8—12 Nem (0.8~1.2 kg-mm, 6-9 feb) FRear axle nut 80-110 Nem (8.0— 11.0 kg-m, 88-80 ft-lb) Oil pipe bote 16—20 Nem (1.62.0 kgem, 12~14 feb} Gearshift change pedal 14-18 Nem (1.4—1.8 kg-m, 10-13 feb 5-1ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL (1) PULSE GENERATOR Drain the oil from the engine (page 2-2). Remove the seat and fuel tank Disconnect the pulse generator coupler and remove the pulse generator wire from the clamps. Remove the spark plug cap from the spark plug. 3) CLAMPS, Remove the alternator connectors. (i)WIRE BAND Remove the wire band and wire from the clamps. S12) CLAMPS ls Remove the reservoir mounting bands and the reservoir from (1) RESERVOIR its mount bracket. Remove the crankcase breather tube. Remove the carburetor. (2) BANDS (3) CRANKCASE BREATHER TUBE Remove the drive sprocket cover and drive chain protector. Loosen the axle nut and turn the drive chain adjusters to loosen the chain. Remove the drive sprocket and the drive chain,Loosen the exhaust pipe clamp bolts and remove the follow- ing: — exhaust pipe joint nuts and the exhaust pipe — clutch cable from the lifter arm = manual decompressor cable from the cylinder head — kick starter decompressor band Romove the following: = oil pipe bolts and sealing washers from the oll cooler = bolts and set plate ~ oil pipes from the right crankcase cover Remove the following: — brake rod from the brake arm — return spring from the swing atm — brake pedal pinch bolt and brake pedal pivot brake pedal nt foot peg Remove the front engine hanger bolts and plates. Remove the engine guard and engine hanger bolts. ENGINE REMOVALI/INSTALLATION (1) CLAMP BOLTS (3) CLUTCH CABLE ‘aisoinr nuts Se 15} OIL PIPE BP son cooter (17 BRAKE PEDAL PIVOT 2) BRAKE PEDAL (2) FRONT ENGINE HANGER, BOLTS (1) FRONT ENGINE HANGER PLATES (4) HANGER: BOLTSENGINE REMOVAL/INSTALLATION Remove the rear engine hanger bolts and plates. (1) REAR ENGINE HANGER PLATES Remove the rubber caps and upper engine hanger bolts and (1) RUBBER CAP plates. Remove the engine from the right side of the frame. - (3) HANGER. BOLTS (2) UPPER ENGINE HANGER PLATES (2) 10 mm BOLTS /( (1) 8 mm BOLTS ? ENGINE INSTALLATION 17) 8 mam BOUTS Install the engine in the reverse order of removal, noting the {ellos Replace any damaged or leaking exhaust pipe gaskets. Tighten ail bolts to proper torque specifications. ‘TORQUE VALUES: ‘& mm bolts: 24—30 Nem (2.4—3.0 kg—m, 17~22 fib) 10 mm bolts: 3545 Nem (3.5~4.5 kg—m, 25—33 ft-lb) Foot peg mounting bolts: 10mm: 50-60 Nem (5.0—6.0 kg—m, 36—43 ft-lb) 12mm: 80—100 Nem (8.0~10.0 kg-m, 58~72 ft-lb) il pipe bots: 16—20 Nem (1.6-2.0 kg—m, 12 Ae eee" PEG MOUNTING BOLTS feb) Route all wire haw 18808 and cables properly (page 1-9 t0 11). Perform the following inspections and adjustments. Engine oil (page 2-2) Throttle grip free play (page 3-51 Decompressor cable adjustment (page 3-8) Drive chain (page 3-10) Roar brake pedal free play (page 3-13) Clutch lever free play (page 3-15) Check all electrical equipment. 5-4MEMOCYLINDER HEAD/VALVES 20-25 Nem (2.02.5 kg-m, 15-18 feb) 10-14 Nem (1.0-1.4 kg-m, 710 feb) 6-0 28-30 Nem (2.6—3.0 kgm, 19-22 ft-lb} 25—30 Nem (2.5—3.0 kg-m. 18-22 felb) 37-43 Nem (3.74.3 kg-m, 27-31 fib) eB6. CYLINDER HEAD/VALVES SERVICE INFORMATION 6-1 VALVE SEAT INSPECTION AND TROUBLESHOOTING 6-2 REFACING 6-11 CYLINDER HEAD COVER REMOVAL 6.3 CYLINDERHEAD ASSEMBLY 6-13 CYLINDER HEAD COVER DISASSEMBLY 6-3 CYLINDER HEAD INSTALLATION 6-14 CAMSHAFT REMOVAL 6-5 CAMSHAFT INSTALLATION 6-16 CYLINDER HEAD REMOVAL 6-7 CYLINDERHEAD COVER ASSEMBLY 6-17 | CYLINDER HEAD DISASSEMBLY ga CYLINDER HEAD COVER INSTALLATION 6-19 SERVICE INFORMATION GENERAL © This section covers maintenance of the cylinder head, valves, camshaft and rocker arms, ‘© Pour clean engine oil into the oil pockets in the cylinder head to lubricate the cam, SPECIFICATIONS Tre STANDARD SERVICE Una ae - 180—18.0 halon? 184.9-216.355) | Camano 2.8m 1.1628 9 [28.34 rm 1.188 in) Comshat x 29.880 mm (1.1547 in 29,14 mm (1.147 i uno = 0.04 mm 10.002 in Sobeockat win (EE: N 7.000 —7.018 mm (0.2756—0.2762 in) | _7.05 mm (0.278 in} ex 7.000 7.016 mm (0.2756-0.2762 in) | 7.08 mn (0.278 Subvecker em |p p IN| 6.972-6.087 nm (0.2748-0.2781 in) | 6.92 mm (0.772 n) eheft 3 6.972—6.987 mm (0.2745—0.2751 in}. 6.92 mm (0.272 in) Sub-rocker arm-to-shaft clearance 0,013-—-0.043 mm (0.0005—0.0017 in} 0.10 mm (0.004 in) Rocker arm 10. | 11.800—11.518 mm (0.4528-0.4536 in| 11.63 mm (0.454 in} [Rocker arm shaft 0.0. 11.466—11.484 mm (0.4514—0.4821 in) | 11.81 mm (0.449 i) Rocker armtoshet cleans 0.016 0.082 mr (0.0008 0.0020 in) | 0.10 rm (0.008 in) Frae length [inner 38.83 mm (1.529 in) ‘37.9 mm (1.49 in} re ae mS veer 36.30 rm (1-508 in) 37.1-mm 1.46 in| [pmoeanengn liner [1502 10922.8 mm 8.12 22m/089m | — | Outer | 45.4 = 8.0 49/28.0 mm (100.1 = 6.6 b/.02 in = - |den on we 5.475 —5.490 mm (0.2166—0.2161 in) 5.48 mm (0.216 in) | le 8.467=5.477 mm(0.2162-0.2156 in) | 6.45 mu (0.218 in [ouae io iN 5.500 5.512 mm 10.2165 0.2170 in) | 6.68 mm (0.216 in) ©X | .600—6.612 mm (0.2165 0.2170 in) | 8.63 mm (0.218 im ibaa Stem-to-guide [IN (0.010—-0.037 mm (0.0004—0.0015 inl | 0.07 mm (0.003 in) ee, EX (0.023 —0.045 mm (0.0009—0.0018 in} 0.08 mm (0.003 in) [Naive taco [| _ 1.21.4 mm (0,080.06 in 2.0 mm (0.08 n)_] wth ex 1.2-1.4 mm (.05-0.00 in) | 2.0 mm (0.08 | | Warpage = - 0.10 mm {0.004 in} Jevinder need [Voie seat aye 1.21.4 mm ©.08-0.06 in) 2.0 mm (0.08 in) ‘ 6-1CYLINDER HEAD/VALVES. TORQUE VALUES Cylinder head bolt — 10 mm Simm ‘Cam sprocket bolt Cylinder head cover 6 mm bolt 8 mm bolt Rocker arm shaft ‘Sub-rocker atm shaft IN ‘Sub-rocker arm shaft EX Valve adjusting screw lock nut Upper engine hanger 8 mm. 10 mm TOOLS Special Valve guide reamer Common Valve guide driver, 5.5 mm Valve spring compressor TROUBLESHOOTING Engine top-end problems are ususlly performance-related and can usually be diagnosed by @ compression test 37-43 Nem (3.7—4.3 kg-m, 27-31 ft-lb) 10-14 Nem (1.0—1.4 kg-m, 7—TOFtb) 1822 Nem (1.82.2 kg-m, 13—16 ft-lb} 8—12 Nem (0.8—1.2 kg-m, 6-9 ft-lb} 26 —30 Nem (2.6-3.0 kg-m, 1922 ft-lb) 25—30 Nem (2.53.0 kg-m, 18-22 ft-lb) 25-30 Nem (2.5—3.0 kg-m, 18-22 feb) 20-25 Nem (2.0-2.5 kg-m, 15—18 ft-lb} 17-23 Nem (1.7-2.3 kg-m, 12-17 fb) 24-30 Nem (2.43.0 kg-m, 17—22 ft-lb) 35 —45 Nem (3.54.5 kg-m, 25—33 ftb) (07984— 2000000 (or 07884—200000A) (077420010100, 07757 —-0010000 (or 079573280001) Engine noise can usualy be traced to the top-end with a sounding rod or stethoscope. Low compression + Valve = 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 + Cylind Ih compression tion chamber 6-2 and piston (Refer to Section 7) Decompressor out of adjustment Excessive noise + Incorrect valve adjustment ‘Sticking valve or broken valve sping + Loose of worn can chain Worn or damaged cam chain tensioner + Worn cam sprocket teeth Poor idling + Compression too low + Decompressor out or adjustment Kick starting difficult + Decompressor out of adjustment Excessive carbon build-up on piston crown or combus- Damaged or worn rocker arm or camshaftCYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL Remove the seat and fuel tank Remove the cable holders and disconnect the decompresssor cables from the valve lifter lever. Remove the upper hanger plate rubber and upper hanger wy (i) RUBBER plates. oe (2) UPPER HANGER! PLATE, Remove the spark plug cap. ‘Turn the crankshaft counterclockwise and align the “"T"” mark ‘on the flywheel with the index mark on the left erankease cover. Verify that the engine is at T.D.C. on the compression stroke by removing all valve covers and checking for move- ment at both adjusters. If no movement is felt, rotate the ‘crankshaft 380° and re-align the ‘"T’” mark Remove the cylinder head cover bolts and the cover. Remove the dowel pins end head cover gasket (2) CYLINDER HEAD COVER CYLINDER HEAD COVER DISASSEMBLY Remove the front-right val pin using @ screw drive hole cap and drive out the dowel shown, Remove the valve lifter lever and spring,