2001-2003 ; ZA HONDAA Few Words About Safety Service Information ‘The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attampting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the propar methods and procedures for performing service, maintenance, and repairs. Some proce- dures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement par, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the ‘safe operation of the vehicl I you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly rec ‘ommend that you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safe- ty and the reliability of the vehicle. Any error or oversight while ser- | Improper service or repairs can create an unsafe vieing a vehicle can result in faulty operation, damage to the vehicle, | condition that can cause your customer or others or injury to others. to be seriously hurt or killed. For Your Safety Follow the procedures and precautions in this manual and other service materials carefully. Because this manual is intended for the professional service techni- cian, we do not provide warnings about many basic shop safety prac: ss (e.9,, Hot parts — wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to per- form the procedures described in this manual. Failure to properly follow instructions and pre- cautions can cause you to be seriously hurt or ‘Some of the most important general service safety precautions are | Killed. given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you can decide whether or not you should perform a given task. Follow the procedures and precautions in this manual carefully. Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: + Read all of the instructions before you begin, and make sure you have the tools, the replacement or repair parts, and the skills required to perform the tasks safely and completely. + Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other stored-energy components. If there is any doubt, put on eye protec tion, + Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. + Protect yourself and others whenever you have the vehicle up in the air. Any time you lift the vehicle, either with a hoist or 4 jack, make sure that itis always securely supported. Use jack stands. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: + Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. ‘+ Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. * Injury fom moving parc. he ineruction tells you to run the engine, be eure your hands, ingers and clothing ae out of 1 way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. + Use only a nonflammable solvent, not gasoline, to clean pars. + Never drain or store gasoline in an open container. + Koop all cigarettes, eparks and flames away from the battery and all fuel-related parts.HOWTO USE THIS MANUAL This service manus! describes the servo procedures for the Follow the Maintansnee Senecule (Secon 3) recommendations to ‘nsure thatthe vehicle sn peak operating concition an tbe emission levels are within the standards set by the Calfornin Air Resources Board ppeneses forthe intial wear that occurs during he breakin evo. Sections 1 and 3 apply tothe whole vehicle. Section 2 ilusrates pro clues for removalinaalation of component that maya req 0 perform service described inthe folowing sections. ‘ction #treugh 29 deserioe pans of mo vehicle, grouped secorsing Find the sttion you want on this page, then turn tothe table of con Most sections stort with an assemBly or system ilistration, service Information and treubiagnoating for he section The subsequent pages WW you doo't know the source of the trouble, go to Treubleshootng sion 26, CONTENTS [ceveratnrorwanon [wantenance dE FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER/PISTON ENGINE CENTRIFUGAL CLUTCH ‘Your aatty ane the safety of others is very important. To help you mote informed deisiona we have provided safety message tical or posible to warn you about all the hazards assaclated wit ering this vehicle. You must ure your awn geod judgement Yau wl fd Important safety information in variety of forms «Stary Labols on tho vehicle 1 Safety Mieaseges pracesed by asetety alot symbol ® ane.one af these signal words, DANGER, WARNING, or CAUTION. “hese signal words maar: RPE You WILL be KILLED or SERIOUSLY EE ic you on flow inseetons. CET ier ir you don't follow insrvevons FSETTY 302A = HT Ho est aw + Instructions howto service this vehicle omractly and eae ALTERNATOR/STARTER CLUTCH | | SUB-TRANSMISSION neanwneec/susrension «(CE ioassew ‘coomcosrey GN “evone nenovameracmon Il [euncenmsron ‘comarven curr «iA [auemaronstaen coro a 12 | CHASSIS REAR DRIVING MECHANISM ‘Ae you rand tis manual, yu wil ina information thats precoded by ' [NOTICE] symbol. The purpose of this message i 1 help prevent ‘damage to your vehicle, cther prope, or the environment BATTERY/CHARGING SYSTEM IGNITION SYSTEM | ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS’ PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL. [ABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO, LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT. INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS, OR ATVS. HONDA MOTOR CO, LTD SERVICE PUBLICATIONS OFFICE ELECTRICAL ELECTRIC STARTER LIGHTS/METERS/SWITCHES HONDAMATIC [23 | LL = WIRING DIAGRAMS j24 | TECHNICAL FEATURES El TROUBLESHOOTING Date of Issue: May, 2000 @ HONDA MOTOR CO., LTD.SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is req taining to these symbols, it would be explained specifically in the text without the use of the symbols. | Replace the partis) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified, | Use molybdenum cil solution (mixture of the engine oil and molybdenum grease in a ratio of 1: 1) Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or te equivalent). Example: Molykote® BR-2 plus manufactured by Dow Corning, U.S.A. ‘Multi-purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum equivalent) Bu Example: Molykote® G-n paste, manufactured by Dow Corning, USA Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, UK Rocol Peste menufactured by Sumico Lubricant, Japan fide paste (containing more than 40% molybdenum disulfide, NUGI #2 or Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 3 of DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified Use Fork or Suspension Fluid1. GENERAL INFORMATION | SERVICE RULES 1-1 LUBRICATION & SEAL POINTS +16 | MODEL IDENTIFICATION 1-2 CABLE & HARNESS ROUTING 1-19 En | SPECIFICATIONS 13 EMISSION CONTROL SYSTEMS 1-32 TORQUE VALUES 1-11 EMISSION CONTROL INFORMATION Toos 414 LABEL (U.S.A. only) 1:33 SERVICE RULES 4. Use genuine HONDA or HONDA. recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA's design specifications may cause damage to the motoreycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle, Metric bolts, nuts and screws are not interchangeable with English fasteners. 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 bolt first. Then tighten to the specified torque diag- nally in incremental steps unless a particular sequence is specified. 6, Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all eloctrical wires as shown on pages 1-19 through 1-31, Cable & Harness Routing 1-1GENERAL INFORMATION MODEL IDENTIFICATION MODEL IDENTIFICATION LABEL = ‘The model identification label is located on the left side frame down tube, ENGINE SERIAL’ NUMBER ‘The vehicle identification number (VIN) is stamped on the The engine serial number is stamped on the right side of front side of the frame. the crankcase. CARBURETOR IDENTIFICATION NUMBER COLOR LABEL ‘The carburetor identification number is stamped on the left The color label is attached on the right side of the frame side of the carburetor body. under the seat. When ordering color-coded pans, always specify the designated color code, 1-2GENERAL INFORMATION EE SPECIFICATIONS 7 GENERAL mem | ‘SPECIFICATIONS DIMENSIONS | Overall length 2,072 mm (816 in) Overall width 4.184 mm (466 in) Overall height 11194 mm (479 in) Wheelbase 11287 mm (50.7 in) ~ Front tread 914 mm {36.0 in) Rear tread 925 mm (36.4 in} Seat height £862 mm (33 in} Footpeg height 337 mm (133 in} Ground clearance 198 mm (78 in) Dry weight 273 kg (602 Ibs) Curb weight 285 kg (628 Ibs) - Maximum weight capacity 220 kg (485 lbs) FRAME Frame type Double cradle Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Front rim size Rear rim size Front tire brand Rear tire brand ~ Front brake Rear brake Caster angle Trail length Camber angle Fuel tank capacity Fuel tank reserve capacity Double wish-bone 170 mm (6.7 in) Double tube ‘Swingarm 170 mm (6.7 in) Double tube A125 x 8-12 AT25 x 10-12 12x 8.0AT 12x75 AT DIRT HOOKS 15 (Bridgestone) DIRT HOOKS 14 (Bridgestone) Hydraulic drum brake (Dual leading) Mechanical drum brake (Leading-traling) 3 12mm (05 in) o 1é liters (3.7 US gel, 3.1 Imp gal) 2.8 liters (1.00 US gal, 0.84 Imp gal) Cylinder arrangement Boro and stroke Displacement Compression ratio Valve train Intake valve opens closes Exhaust valve opens closes Lubrication system Oil pump type Cooling system Ai filtration ENGINE Single cylinder, longitudinally installed 92 x 75 mm (3.6 x 3.0 in) 498.5 cm? (30.41 cu-in) 8 oKV 8° BTDC (at 1 mm lift) ‘35° ABDC (at 1 mm lift) 40° BBDC (at 1 mm lif) B® ATDC (at 1 mm lift) Forced pressure (dry sump) Trochoid Liquid cooled Oiled urethane foam 63.2 kg (139.3 Ibs)GENERAL INFORMATION —— YS , GENERAL (Cont'd) rem SPECIFICATIONS CARBURETOR | Cerburetor type Constant Vacuum (VE type) | Throttle bore 36 mm (14 in) DRIVETRAIN | Clutch system Centrifugal, wat Transmission HONDAMATIC (automatic; non-stage spead) with sub-transmission (constant mesh) Primary reduction 2.188 (70867) S Secondary reduction 2.000 (40720) Final reduction Front 3.231 (42/3) Rear 3.154 (61/13) Automatic transmission ratio Low—0.0. | 0.83.18, Sub-transmission gear ratio Drive 1.583 (38/24) Low 2.500 (45/18) Reverse 3.222 (28/18 x 28/14) | Gearshift pattern R—N-D-L (Sub-transmission) 0: 3-mode; Automatic 2-pattern (01/02) and Manual (ESP: 5-speeds) | L: 2-mode; Automatic and Manual (ESP: 5-speeds) | A: t-mode (fixed low ratio) | ELECTRICAL | Ignition systom DC-CDI (Direct current-Capacitor discharge ignition) | Starting system Electric starter moter and emergancy recoil starter Charging system Triple phase output alternator | Regulatorirecttier SCR shorted, triple phase full wave rectification Lighting system Battery | Y 1-4GENERAL INFORMATION a ~ LUBRICATION ; Sen ITEM STANDARD | ‘SERVICE LIMIT Engine ol capacity | After draining 7 ers OS at, 4.1 Imp a — After draining/filter change 49 liters (5.2 US qt, 4.3 Imp qt) — _| ‘After disassembly EB iors (6.8 US qt 48 Imp at — | Recommended engine ol Honda GN4 #-stroke ol or equivalent | inotor oi | Abt civice clasiication SF or SS a sity: SAE 10W40, Oil pressure At 1400 19m ‘Above 150 kPa (15 koflem®, 22 pal (@orcr7e) ‘At 6,000 pm ‘Above 800 kPa (6.2 kolem?, 16 pall — Oil pump Tip clearance - (0.15 (0.006) 10.20 (0.008) Body clearance [o.t2=0.22 (0.005—0.000) 025 (0.010) Side clearance 10.02—0.09 (0.001—0.004) 0.11 (0.004) _ FUEL SYSTEM SPECIFICATIONS Carburetor ident t VEBAB Main jot 7168 Slow jet [ 746 Jet needle lip position 2nd groove fom Top Pilot screw opening - ‘See page 5-15 Flost level 78.5 mm (0.73 in) | Idle speed 1,400 = 100 rpm Throttle lever free play 38 mm (1/85/16 in) - COOLING SYSTEM rem SPECIFICATIONS | Coolant capacity Radiator and engine 17 liters (1.8 US at, 1.5 Imp qt) Resorve tank 0.40 liter (0.42 US at, 0.35 imp qt) | Radiator cap relief pressure 108—137 kPa (1.1—1.4 kaffem?, 16—20 psi) Thermostat Bagin to open 80-840 (176—183°F) Fully open [ ‘95°C (203°F) Valve lift [ ‘8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HP Coolant or an equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors: Standard coolant concentration 50% mixture with distilled water 15GENERAL INFORMATION ——_.W $s aoo4J2 ssSSSSS— | Piston ringtorring ~ CYLINDER HEAD/VALVE EOE omits) Tem STANDARD ___ service unr Cylinder compression at 450 rpm ‘608—802 kPa (6.2—9.2 kgtiem?, — 88131 psi) | Vaive clearance IN| 0.15 (0.008) - | ex [023(0009) SSS~CSSS | Vaive, Valve stem OD. IN| §.475—6.490 (02186-02161) 5.5 (0215) valve guide LEX | S455—6.470 (02148-02154) «#43 (0.214) Valve guide 1.0. [INEX | 5.500512 (0.2165 0.2170) 553 (0.218) a ‘Stem-to-guide clearance | IN 0,010—0.037 (0.0004—0.0015) 0.12 (0.005) EX | 0.030—0.057 (0.0012—0.0022) | 0.14 10.006) Valve guide projection IN [758-162 (0.62—0.64) — ‘| seoveclincerhead | Tex —Taa=iaa 0.74076) = Valve seat width LINX 7 1.0—1.1 (0.039—0.083) | 14 (0.06) | | Valve spring Free length Inner | 38.82 (1.528) _ 378 (1.49) (Outer (5117 (2.018) ons Rocker arm Arm 1.0. IN/EX | 12.000—12.018 (0.4724—0.4731) [72.05 (0.474) (Sha OD, INEX | 119547188 (471004716) 1192 (0.489) Arm-to-shaft clearance | INEX | 0.016-0.054 (0 0008—0.0021) 0.08 (0.003) Camshat and | Cam lobo height IN | 38:9602—34.1202 (1.33701—1.34381) 33.790 (1.5905) saetclione © _| 34-1959—34.3569(1.34629—1.35259) 33,948 (1.5365) ‘Cam follower OD, IN(EX | 22,467—22.482 (0,8845—0.8851) 22.46 (0.884) Follower bore INIEX | 22.510—22.526 (0.8862—0.8868) 22.54 (0.887) [Foliowerio-bore clearance | INEX | 0026-0.089 (0.001—0.0023) 2.07 0.003) Cvlinder head warpage — 0.100.004) — CYLINDER/PISTON a wn inl item STANDARD SERVICE Lint Cylinder 1D. 92.000—92.010 (3.6220—3.6224) 92.10 (3.626) _| Out of round — - 0.10 (0.004) Taper — 0.10 10.004) | Warpage — 0.10 (0.004) Piston, Piston 0.D. at 15 (0.6) from bottom | 91.965—91.985 (3.6207—3.6214) 91.90 (3.618) piston pin, Piston pin hole LD. 20.002—20,008 (0.7875—0.787) 20.04 (0.789) _| Piston ring Piston pin 0.0. 19.994—20.000 (0.7872—0.7874) 19.96 (0.786) Pistontovpston pin earares 0.002001 (0001-00006) 0.08 (0.008) [Paton ing end gap Top | 06—as0 0080.01 asracal Second 0.30—0.45 (0.012008) 0510.02) ‘Oil side rail) | 0.20—0.70 (0.080.028) a groove clearance | TopiSecond —_| 0,020,060 (0.0012—0.0024) 0.08 (0.004) | Cylinder-to-piston clearance 0.015—0.045 (0.0006—0.0018) 0,10 (0.004) Connecting rod small end 1D. 20.020—20.041 (0.7882—0.7890) 20.07 (0.780) Connecting rod-to-piston pin clearance 0.020—0.047 (0.0008—0.0019) 0.1 (0.008) 1-6GENERAL INFORMATION EE CENTRIFUGAL CLUTCH Unit: mm din) ] mm STANDARD service um | Cluteh Drum LD. 150.0—150.2 (5.906—5.913) | 150.4 (6.92) | Weight lining thickness [3010.29 200 (0.08) Clutch spring height 3:72 (0.148) 3610.14) | Clutch weight spring free length 23.2 (0.91) 2411095) Giateh drum boss LD. 79.000—29.020 (141711478) 29,05 (1.144) ‘Crankshaft 0.D. at clutch drum 5 28.959—28.980 (1.1401—1.1409) 28.93 (1.139) _ ALTERNATOR/STARTER CLUTCH Unit'mm (in) ITEM ‘STANDARD | ‘SERVICE LIMIT | Starter riven gear boss OD. 51:705—51.718 (2.0356—20361) BA705 2.0556) _ SUB-TRANSMISSION oe ent TEM ‘STANDARD: ‘SERVICE LIMIT Shift fork iD. F000 71071 (0.4391—0.4338) 7104 (0435) Claw thickness 493-6000 (0,194 0.197) 45 (0.18) Shaft 0D. 70.966 —10.984 (04317-04928) | 1096 (0.31) Transmission | Gear LD. 28,020—28.041 (1.1031—1.1040) | 28.07 (7-105) Reverse idle 14.000—14.018 (0.5512—0.5519) | Wa04 (0.553) Gear bushing 0.0. | OR. 771979—28.000 (1.1015— 1.1024) 7198 (1.100) 1 L 77984—28.005 (1101711028) [ange (1.100) “Geartobushing D.R | 0.020--0.062 (0.0008—0.0028) [0.10 0.004) | clearance: [e 0.015—0.057 (0,0006—0.0022) “0.10 10.008) Gear bushing LD, | DJR. | 25.000—25.013 (0.9843—0.9848) 25.04 (0.986) Countershaft 0.0. | at D., R. 24,959—24.980 (0.9825—0.9835) 24.93 (0.981) | Reverse idle shaft 0.D. 13.966—13.984 (0.5498—0.5506} 13.93 (0.548) Bushing-to-shaft - T poems DR. | 0.020-0.054 (0.0008~0.0021) 0.10 (0.008) Reverse idle gearto-shafi clearance | 0.016—0.052 (0,0006—0.0020) 10.10 (0.004) - CRANKSHAFT/AUTOMATIC TRANSMISSION UNIT Unit: mm (in) ___-senvice unt trem STANDARD | Crankshaft Runout — [0.05 (0.002) Big end side clearance 0.05—0.65 (0.002—0.026) 0.8 (0.03) Big end radial clearance (0.006—0.018 (0.0002—0.0007) 10.05 (0.002) 1-7GENERAL INFORMATION —.4 ooo y- FRONT WHEEL/SUSPENSION/STEERING rem STANDARD SERVICE Unt Minimum tire tread depth: 7 a 4.0 mm (0.16 in) Cold tire pressure | Standard _ 25 kPa (0.25 kaficm?, 3.6 psi) “Minimum 22 kPa 022 Kafer 32 ps) = Maximure 28 kPo 028 kgfer, 40 ps — | With cargo 7 25 kPa (0.25 kgf/cm?, 3.6 psi) —_— Tie-rod distance between the ball joints 382 1mm (15.0 + 0.04 in) — Toe _ ‘Toe-out: 24 = 15 mm (1 = 9/16 in) — REAR WHEEL/SUSPENSION rem STANDARD SERVICE LMT | Minimum tire tread depth [4.0 mm (0.16 inp Cold tre pressure | Standard 25 kPa (0.25 eae? 38 os Minimum 22 kPa (0.22 kgficm?, 3.2 psi) — | Maximum, 28 kPa (0.28 kgfiom?, 4.0 psi) — With cargo 25 kPa (0.25 kgfiem?, 3.6 paid — ~ BRAKE SYSTEM so rem STANDARD SERVICE LIMIT | Front brake Recommended brake fluid DOT 3 or DOT 4 brake fiuid = Drum 1.0. 160.0 (6.30) - 161 (6.34) Shoe lining thickness 01016 2.0 (0.08) | | Brake panel warpage — 0.4 (0.02) Waterproof seal lip length 2 (0a) 20 (08) Master cylinder 1D. 14000-14043 (0.55120 5529) 14.055 (0.5533), Master piston O.D. 13,.957—13.984 (0.4983 0.4984) 13.945 (0.5490) | Rear brake Whee! cylinder ID. 18,050—19. 102 (0-7500—0.7520) 79.12 (0.783) | Wheel cylinder piston 0.0. 18.997—19.030 (0.7473—0.7492) 18.81 (0.741) Drum 1.D. - 180.0 (7.09) - 181 (7.1) | Lining thicknase 53 (0203) To index mark - FRONT DRIVING MECHANISM Unit: mm (in) ‘rem STANDARD ___seavice unr Fron ifrental | Oil eapaciy| Afor draining | DAT aw? 182 US os, 65 Imp ox) — ‘After cisassombly | 275 om? (9.3 US et, 97 Imp o2) — Recommended oil Hypoid gear oil SAE #80 — Gear backlash 0.05—0.25 (0.002—0.010) 0.4 (0.02) Backlash difference - — ~_ 020.01) ‘| Sip torque TW Ni (1aS—178 Ka, 12Nim (12 kat, toa bit Aen Foe eamtochowsing distance | 68-67 (025-08) 63 025) Differential housing cap depth __ 9.55—9.65 (0.376—0.380) 9.55 (0.376) Cone spring free height 2.8(0.1) 7 2.6 (0.10)GENERAL INFORMATION —— _ REAR DRIVING MECHANISM See E—=ee TEM ‘STANDARD SERVICE LIMIT ‘ale ranout 30 (0.12) Rear final drive: Oil capacity After draining 90 cm3 (3.0 US oz, 3.2 Imp 02) — After disassembly | 100 em® (2.4 US 02,35 Imp o2) a Recommended oi! Hypoid gear oil SAE #80. | Gear backlash 0.05—0.25 (0.002—0.010) 0.4 (0.02) Backlash difference — 0210.01) | Ring gearto-stop pin clearance | 0.30.6 (0.01—0.02) — _ BATTERY/CHARGING SYSTEM rem SPECIFICATIONS Banery Capacity av 12Ab Current leakage 1. mA max. ‘| [Voltage Fully cher 13.0-13.2V {20°C/68°F) [Needs charging Below 12.3V Charging current Normal T4Ax5—10h “Quick — 6OAx1Oh Alternator Capacity - 330.W/5,000 rpm. [Charging coil resistance (20°C/68°F) 01— 1.00, - IGNITION SYSTEM TEM SPECIFICATIONS | Spark plug Stendard TUR7AS (NGK), VX228C (DENSO) - [For cold eimate ibolow C/A" UR6AQ (NGK), VX20BC (DENSO) Spark plug 98m 0.8—0.9 mm 0.03—0.04 in) Ignition coil primary peak voltage 100V minimum _ Ignition pulse generator peak voltage 0.7V minimum - ignition timing (F™ mark) 15° BTDC atidle | ~ ELECTRIC STARTER Yow mm Gn) rem STANDARD SERVICE LIMIT Starter motor brush length 12.5 (0.49) 9.0 (0.35) 1-9GENERAL INFORMATION 02 p MIGHTS/METER/SWITCHES rem SPECIFICATIONS | Bulbs Headlight (high/low beam) — 12V - 30/30 W x2 | Assist headlight — Ta -45W Taillight 7 2V-5Wx2 - Neutral indicator - LED _ Reverse indicator Leb Coolantioil temperature indicator LED | Meter light I 2 LED x 12 Fuse Main fuse 0A Transmission contral motor 30A Sub-fuse 5 Ax2, WAX? 1-10GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE TORQUE [ rasTenen ie Nom {kfm bt) FASTENERTPE _ Neen (kam, Itt) mm bolt and nut 3105.36) | Smmscrew 410.429) 6 mm bolt and nut 10(10,7) | 6 mm screw 9103, 6) 8 mm bolt and nut 222.2, 18) | 8 mmflange bolt (mm heed, small flange) | 10 (10,7) 40 mm bolt and nut 3435, 25) | 8 mmflange bolt mm head, large lange) 12 (1.2, 9) 12mm bolt and nut 54(6.5, 40) | mm lange bolt (10 mm head) and nut 12(1.2, 9) 8 mm flange bolt and nut 26 (23,20) 40 mm flange bott and nut 39 (4.0, 28) + Torque specifications listed below are for important fasteners. + Others should be tightened to standard torque values listed NOTES: 1. Apply locking agent to the threads, above. 2. Apply engine oil to the threads and seating surface. 3. Apply grease to the threads and seating surface. 44 ALOC boltisorew: replace with a new one, 5. Lock nut: replace with a new one. 6. Castle nut: tighten to the specified torque and further tighten until its grooves aligns with the cotter pin hole. 7. Special bolt: replace with a new one. &, Stake 8. Apply sealant to the threads. ENGINE — THREAD DIA. TORQUE rem avy (emm) [Nim (kgf, Ibfft) | REMARKS MAINTENANCE: Spark plug 1 2 18118, 13) Valve adjusting lock nut 4 6 747.12) ‘Timing hole cap 1 4 301107) Engine oil drain bolt (crankcase and cil tank) 2 12 25 (2.5, 18) Engine ol iter center bolt 1 20 18 (18, 13) LUBRICATION SYSTEM | Oil gallery sealing bolt (front crankcase cover) 2 10 34 (35, 25) FUEL SYSTEM Cerburetor insulator band screw 2 5 4 (04,29) CYLINDER HEAD/VALVE: | Cylinder head cover cap nut 4 0 5315.4,3) | NOTE2 ‘CENTRIFUGAL CLUTCH: Centrifugal cluteh lock nut 1 20 118120,87) | NOTE2,8 Oil feed pipe setting cap 1 | 20 18 (18, 13) Oil gallery sealing bolt (inside of front crankcase cover) 10 1010.7) ALTERNATOR/STARTER CLUTCH: Starter clutch outer bolt 6 6 3008.1, 22) NOTE? Recoil starter driven pulley bolt 1 2 108 (11.0, 80) | NOTE 2 Alternator stator bolt 3 6 4019, 7) | _ {nition pulse generator bolt 2 5 (06,43) | NOTE ‘SUB-TRANSMISSION: Gearshift drum center bott 8 26(27,20) | | NOTE? Goarshitt drum stopper arm pivot bolt 6 12(12,8) | NOTE? (CRANKSHAFT/AUTOMATIC TRANSMISSION: Primary driven gear bolt ‘ 6 17(17,12) | NOTE2 Oil pump driven sprocket bolt 1 6 12(12,8) | NOTE1 LIGHTS/METER/SWITCHES: Coolant thermosensor 1 Pre to(10,8) | NOTE Gil thermosensor 1 2 18118, 13) 1-11GENERAL INFORMATION ee F ENGINE (Cont'd) THREAD DIA. | TORQUE mem ory (rum) —_| Nem tkgtm, otf) REMARKS HONDAMATIC. Angle sensor bolt 2 5 610643) NOTEX Throttle sensor tore screw 2 5 4104.29) | NOTE > FRAME THREAD DIA. | TORQUE trem ov (mm) Nem (kgtm, bt) | REMARKS FRAME/BODY PANELS/EXHAUST SYSTEM: Front carierleary pipe bolt ® 8 37 (38,27) Gearshit lever knob serew 2 5 2(02,14) | NOTES Rear carrier bolt 6 8 37 (38,27) | Muffler band bot 2 8 23 (23, 17) | Front exhaust pipe cover band screw 2 5 310.3, 2.2) | Rear exhaust pipe cover end band screw 2 5 | 610.6, 4.3) | center band screw boa 3 3103, 22) Murer cover serow 2 5 3103, 22) Footpes bracket aut 4 8 3233, 24) MAINTENANCE: Front differential ol filler cap 1 20 12(12,9) drain bolt 1 8 12112'9) fear final gear case oil chack bolt 1 8 12(12,9) filler cap 1 30 1212/9) | drain bolt 1 8 12(12,9) Tie-rod lock nut 4 2 54 (55, 40) FUEL SYSTEM: Sterting enrichment (SE) valve nut 1 4 2102, 14) Throttle drum cover serew 1 4 2102, 14) ENGINE REMOVAL/INSTALLATION: Lefe lower engine hanger bracket bolt 2 3233, 24) Lower engine hanger nut left and right) 2 0 54065, 40), Upper engine hangar bolt (frame side) 1 0 54 (55, 40) {engine side) 2 8 32 (33, 28 SUB-TRANSMISSION: Gearshift Iver box cover bolt 6 | 5105.36) Gearshit lever linkage arm pivot bolt 1 8 26 (27,20) Gearshit lever linkage tio-rod lock nut 4 6 10:10, 7) FRONT WHEEL/SUSPENSION/STEERING: Handlabar lower holder nut 2 10 39(40,29 | NOTES | Front whee! mut 8 70 6465, 47) | Front whee! hub aut 2 6 7818.0, 58) | NOTES | Shock 2bsorber mounting nut 4 0 4445.33) | NOTES | Upper arm pivot nut 2 0 34(35,25) | NOTES Lower arm pivot nut 4 0 48(45,33) | NOTES Upper and lower arm ball joint nut 4 2 233.0, 22) NOTES Broke nose clamp bot 4 6 12112, 9) Tie-rod ball joint nut 4 2 5455, 40) NOTES Steering shaft end nut 1 1 108 (116, 80) NOTES Steering shaft holder bolt 2 a 32 (33, 24) REAR WHEEL/ SUSPENSION: | Rear whee! nut 8 0 84 (65, 47) | Shock absorber mounting bolt (lower) 2 10 44 (4.5, 33) Swingarm pivot bot (lot) 1 30 12 (114, 82) (right) 1 30 10:10,7) ‘Swingarm right pivot lock nut 1 30 a2, 82) 1-12GENERAL INFORMATION oo [- FRAME (Cont'd) THREAD DIA. | —ToRGUE | Trem Ty (mm) Nem (kgfm, Ibfft) | REMARKS BRAKE SVSTEM: rake ose ol bot a » 435,25 Wheel lng bled valve 2 ° bi08, 43) Front master vindr revere ap sorew a ‘ Diag, ta Front brake lover vot bl 1 6 io.02) mut : 8 bio, 43) Front brake switch screw 1 ‘ t0s,0.1 Fret master tinder holder bot 2 | 6 wtt2.3) Vines oindr bok +] 8 ice, 8a) nat ‘| 8 win Whee! evinder el pipe joint nut t | % rary Front orako panel bot 8 ° 25130,2) NOTE? Rear brake arm pinch bolt i 8 20(2.0,14) | Rear wheel hub nut 2 20 137 (14.0, 101) | NOTE 6 Rear orate pane rain bolt i ° ei) FRONT DRIVING MECHANISM: erential ving gear bot 6 8 49(60,38) | NOTE? Diferental pion baring loc nut 1 ee esiio6,72) | NOTES.8 Dierental cave cove bok 2 ° woveo.35) | NOTES é 2 Bie Diana mounting bot ‘ ° eus.s 2 3 mia, 18) out : ° Gtssy | Noes i) 8 2122, 1) REAR DRIVING MECHANISM | Final goar eve oinion bearing lok nt 1 “ se (100,72) | NOTES,8 Final or ease cover bot 2 fs 9150,38) | NOTES 6 2 Bias 0) Fina gar case mounting ut ‘ ® Seiee40) NOTES tot and ight exie housing mut 2 ® f1a5,33] NOTES Stra plato bolt 3 ° 2133.20 Rr brato panel nt ‘ i Hil45.30)__ Notes 1-13GENERAL INFORMATION SSS TOOLS NOTES: 1. Newly designed tool ~ 2 Equivalent commercially available in USA 3. Not avaliable in USA 4#.Altrnatve tool DESCRIPTION TOOL NUMBER REMARKS REF SECTION Corburetor oat level gauge «740%-0010000 5 | Universal bearing puller (07631.0010000 NOTE 2 8 Gear holder a77240070100 | NOTE SINOTE 2 8 Fiyaoe! holder 07725-00400 | NOTE 2 n Bearing remover weight 07747-0010201 | NOTE 4: 07898-3710208 or 10, 12,13, 15,17 18 07936:3710200 (U.S.A, only) Valve guide driver, 5.5 mm 07742-0010100 a — Arachment, 37 x &0 mm 77es.0010200 12,13, 18 Attachment, 2.47 mim 07748.0010300 10,12, 13, 14 fttaonment,52.%59 mn o7748-0010400 12,13, 14, 17.18 ‘attachment, €2 x 68 min o7748-0010500 18 Attachment, 24x28 mm 07748-0010700 n Attachment, 22 x24 min o774-0010800 14.15, 17,18 Attachment, 1 mm 1D. (07748-0020200 7 ‘tachment, 20 mn 1D. 07746-0020400 ” Diver, 40 mm 1D. 07746-0030100 8 Attachment, 30 mm 1. 07746-0030200 8 Filet, 10 mm 07746-0040100 n Pilot, 15 mm 07746-0040300 8 Pilot, 17 mm 07746-0040400 10, 12,18 Pilot 20 mm 077460040500 rr Pilot, 25 mm 07748 0040600 13,13 Y Pit, 20 mm 07746-0040700 34 Pilot, 35 mm 07748 0040800 8 Pit, 40 mm 0746-0040800 3 | Pilot, 22 mm 07748.0041000 0,1 Pilot 28 mm 07746-0041100, 18 Pilot, 44 mm o77ss.0081200 48 Piles, 16 mm 07748:0041300 14,15 Driver o7749-0010000 ewe Valve spring compressor 07757-0010000 8 Valve seat cutter 35 mm (IN 45°) | gyfeD-o0r0400 | NOTE 2 8 | Valve seat cuter 33 mm Ex -45%) | 977800010800 | NOTE 2 8 | Fiet cuter, 23 mm (EX 32") 07780-0012800 | NOTE 2 8 Fiat cutter, 38 mm (IN 32°) orreaoorsso0 | NOTE 2 8 Interior euitar, 30 mm (EX 60 o77e0-00%4000 | NoTE 2 8 Interior utter, 2¢ mn (IN 60") orreaoar700 | NOTE? 8 Y Cutter holder, 5.5 mm 07781-0010101 NOTE 2 8 Lock nut verench «7re08-4690008 6 Pilot screw wrench a7e08-4730002 5 Snap ring piers o7314SA60001 | NOTE 4; 07914-3230001 16 Lock nut wrench, 30 x 64 mm o7sv6-me00002 118 Puller shaft 07931-ME40000 NOTE 4:073¢1-ME4O108 and 1% 07931-HB3020A (U.S.A. only) _ Flywne! pllor 07933-3950000 0 Bearing remover handle 07996 3710100 10,12,13 Bearing remover 1? mm 07936-3710300 10,12, 13 Bearing remover, 20 mm 07936-3710800 12,13 | amachment, 26 x30 mm 07946-1870100 i | Driver 7949-3710001 i Y Oil seat aver 07966,KES0200 NOTE 4: 07947-KASOI00 USA. only) | 17.18 Oi seal driver 07965-41C70100 16 saa SSS 1-14GENERAL INFORMATION EEO DESCRIPTION TOOL NUMBER | REMARKS [REF SECTION Assembly collar 07965:VMo0100 Te Assombly shat o7aes:vmo0200 | NOTE SINOTE 4:07S91-ME4O10B and | 13,17 07931-HBBOZOA(U.S.A, only) Threaded adaptor o7ges:vmoosco | NOTE 9MOTE 407921-KF00200-— 13, Valve guide reamer, mm raet-2000001 | NOTE 4:67884-2000000 (USA. only) | € Pressure gauge hose | Grrevreaon0 | NOTE amore 2 ‘ Attachment, 7 x 90 mm o7GAb Sbani01 8 Inspection adaptor orem wLe0100 2 Hub bearing driver orHAD-Scoo100 0 Pinion puller base OTHMC-NIMGCTIO. | NOTE 4: OTHMCAMMEOHA (USA. only) 17,18 Aaiustable bearing remover set 07JAC-PH80000 NOTE 4: 07736-A0T0008 or 6 *07736-A01000A (U.S.A. only)| Remover attachment o7sac-PHE0100 | lis Remover shaft assembly orvacrre0z00 8 Oil seal driver atachment O7uAD PHEDTGO 8 Oil seal driver 07JAD-PH80101 ja Differential inspection tool O7KMK-HCS0101 NOTE 4: 07KMK-HC5010A (U.S.A. only) | 17 Pressure gauge attachment OrKPsVDE0100 | NOTE 27 4 NOTE 4: G7KPU-VDSOI0A (U.S.A ony Driver attachment o7.ap-Pws0500 8 Bal joint omover orMac-s.o0200 ta Pitot 32 mm SrMAb-PRe0200 1318 Recoil pulay holder GrSMB-HN70100 i Pinion holder Grsnte-HM70200 t8 Becring remover head, 4 mm GrWMCKFGOWO | NOTE 4: 07836-KC10200 ana 1718 Bearing remover shat, 18 mm 07936-KC 10100 G7YMC-OOT0108 (USA. only) | 17,18 Bal joint removerinstaller crwaiHNoor00- “ Oil prossure gauge c7vas-co10100 | NOTE 3INOTE 2 t Oil preceure gouge 7vas-0010300 4 Diterontial Bering Clip Compressor | O7YMEHNAO10 7 ‘Threaded adaptor o7yMF-HNAoTOA ” Clute notaer set orzMBHN20000 | NOTE 10 Clutch holder plate orzMe-HNzoT00 i Clutch holder pin 07ZMB-HN20200 10 Gulside serew puller 40x 15mm | O7ZMC-HN20100 | NOTE 1 | 10 Use with commercially available 3/8"x16 slide hammer. 1-15GENERAL INFORMATION ee LUBRICATION & SEAL POINTS p ENGINE Locarion MATERIAL REMARKS. ‘Camshaft cam lobes Molybdenum disulfide | Rocker atm shaft sliding surface solution (a mixture of Valve stem (valve guide sliding surface) 2 engine oil and 1/2 Piston pin outer surface molybdenum disulfide Starter driven gear bearing grease) Starter reduction gear shaft and journals Starter reduction gear teeth Sub-transmission gear sliding surfaces and gear bushings Starter motor shaft splina Control motor shaft splines Rocker arm followers and adjusting screw tips Engine oil Cam chain Cam follower whole surfaces Cylinder head cap nut threeds and seating surfaces Connecting rod small end inner surface Piston outer surface and piston pin hole Piston rings Cylinder bore Centrifugal clutch drum crankshaft contacting surface Centrifugal clutch drive plate sprag clutch contacting surface Centrifugal clutch centor lock nut threads and seating surface Automatic transmission control motor reduction gear teeth, | driven gear teeth and shaft Recoil starer driven pulley bolt threads and seating surface Starter sprag clutch whole surface Sub-transmission gear teeth Sub-transmission mainshaft and countershaft journals Shift fork shaft Shift drum grooves Primary driven gear bolt threads and seating surfaces Each bearing rotating area Each O-ring whole surface Each oil seal lip Recoil starter driven pulley oil seal lips Multi-purpose grease Oil gallery separate plate bolt threads (inside of oll tank) | Locking agent Ignition pulse generator bolt threads Starter clutch bolt threads Oil gallery sealing bolt threads (inside of front erankcase cover) Gearshift spindle stopper plate bolt threads Gearshift drum stopper arm pivot bolt threads Gearshift drum center bolt threads Oil pump driven spracket bolt threads Cam chain tensioner slider pivot bolt threads Primary drivon gear bolt threads Angle sensor bolt threads Coolant thermosensor threads Do net apply to the sensor head. Oil tank mating surfaces Liquid seaiant Alternatariignition pulse ganerator wire grommet seating groove Front erankcase cover mating surface Rear crankcase cover mating surface Crankease mating surface 1-16GENERAL INFORMATION ee > FRAME LOCATION MATERIAL REMARKS: | Throttle cable end ‘Multi-purpose grease Throttle cable adjuster threads (lever side) (NLGI #2) Throtle lever pivot and dst sea ip Rear (parking) broke lever pivot Parking lock arm pivot (screw) | Steering shaft bushing inner surface Apply 2-3 9 Steering shat dust seal ips Steering shatt end nut threads Knuckle outer cust sea lips Knuckio inner dust sea lips (inner and sid lips) Fill up 253.9 per each seal Upper arm pivot collar outer surface Upper arm pivot dust seal cap lis Front shock absorber lowor bearing and dust seal lips Rear shock absorber lower bearing and dust seal lips Rear brake cam dust soa lips Rear brake cam spindle groove Apply 051 9 Roar brake anchor pin grooves 4 Roar brake cam sliding surface Roar brake drum cover dust seal lips (Inner and side lips) Rear brake pedal pivot Rear brake pedal pivot dust sea ips Rear brake panel dust seal and O-ring Far brake cable (pedal and lever) ends Front differential case oil seal lips (drive shafts and pinion joint) anc O-ring (pinion gear and filer cap) Loftrear axle housing dust seal ips and O-ring tinal gear case) Right axle housing O-ring final gear case) Rear final geor case cil seal lips (ring goar and pinion joint) ‘and O-ring (pinion geer. fille cap and swingarm) Gearshift lover linkage arm pivot bolt groove Gearshift lever linkage ball joints Front brake drum water proof seal lips Multi-purpose grease | Fill up 14—16 g per each seal (NLGI #3) ‘Swingarm pivot bearing Shell 6459 grease ‘Swingarm pivot dust seal lips Steering shaft spline Molybdenum disulfide Rear wheel hub dust seal lips greose Front propeller shaft seal outer surfaces (2 places) Front propeller shaft splines (pinion joint and output Fill up 58 g per each spline shaft joint) Front differential pinion gear spline (pinion joint) Output shaft splines (output shatt joint) Front drive shaft spline (wheel side) Front drive shaft inboard joint inside Fill up 5575 9 por each joint outboard joint inside Fill up 50—70 g per each joint Rear axle splines (left, right and center) Universal joint splines (output shaft and final drive shaft) Rear final drive shaft seal outer surface Rear final drive shaft splines (pinion joint) Fill up 58.9 Gearshift lever knob push button sliding surface Goarshift lever lock pin rod sliding area Gearshift box pivot and sliding area Rear brake cam felt seal [Engine oil 1-17GENERAL INFORMATION —.J2 [ FRAME (Cont'd) Location MATERIAL, REMARKS Front brake leverto-master piston contacting area Silicone grease Front brake lever pivot and sub-arm pivot collar Wheel cylinder adjuster screw threads and adjuster nut spindle outer surface Wheel cylinder body boot groove and piston boot groove Brake panel shoe metal contacting areas Wheel cylinder adjuster groove and piston groove (shoe contacting grooves) | Throte cable outer inside Cable lubricant Choke cable outer inside Rear brake cable (pedal and lever) outer inside Master cylinder piston and cups DOT 4 brake fluia Wheel cylinder piston and cup Handlebar grip rubber inside Honda Bond A or Air cleaner case-to-connecting tube (carburetor and ait»: Honda Hand Grip intake duct) mating surface Cement (U.S.A. only) or equivalent | Whee! eylinderto-brake panel mating surface Liquid sealant Front differential case covar mating surface | Rear final gear case cover mating surface Cooling fan motor shaft nut threads Locking agent 1-18GENERAL INFORMATION CABLE & HARNESS ROUTING CHOKE KNOB. REAR (PARKING) BRAKE CABLE LEFT HANDLEBAR SWITCH WIRE MODE SELECT SWITCH IGNITION SWITCH REAR (PARKING) BRAKE CABLE FUELTANK BREATHER use select switch wire ~ Left handlebar switch wire Meter wire Brake switch wire Accessory socket wire = Assist headlight wire = ~ Ignition switch wireGENERAL INFORMATION Inside of the assist headlight case: COMBINATION METER Reverso side of the front fender: U) , WS \ HEADLIGHT WIRE REAR (PARKING) BRAKE CABLE eu: ~ Mode select switch wire - Left handlebar switch wire - Meter wire rake switch wire \ccessory socket wire \\ oa) Na ssist headlight wire [ignition switch wire 1-20GENERAL INFORMATION Breather tubes: peaR Bi \ oa \ CREAR (PARKING 8 3) PNY Rooke (NS g \ GO ee 1-21GENERAL INFORMATION P ray motor 2P connector *. — LEFT HANDLEBAR SWITCH 10P CONNECTOR Y 1 LEFT HANDLEBAR ‘i 2 SWITCH 10P CONNECTOR, FRONT BRAKE HOSE \ eZ : ie € ‘FRONT BRAKE BREATHER TUBE BRAKE SWITCH 2° CONNECTOR’ < \ ENGINE OIL PIPE \ / \\ \ \\ MAIN WIRE HARNESS“) / IGNITION COIL 1-22GENERAL INFORMATION CHOKE CABLE Z, REAR (PARKING) BRAKE CABLE BAND: = Main wire harness = Siphon tube = Rear breke breather tube = Final gear case breather tube = Rear (parking) brake cable ENGINE OIL HOSE OIL'THERMOSENSOR WIRE 1-23GENERAL INFORMATION BRAKE SWITCH 2P CONNECTOR, IGNITION SWITCH 4P. CONNECTOR \ | SPARK PLUG WIRE ASSIST HEADLIGHT 2P CONNECTOR FW 4 THROTTLE SENSOR &e] EF CONTROL MOTOR 2p — "| CONNECTOR s AUTOMATIC TRANSMISSION : ACONTROL MeTOR S CONTROL MOTOR WIRE ANGLE SENSOR WIRE 1-24GENERAL INFORMATION CHOKE CABLE ‘CARBURETOR HEATER 2P © CONNECTOR 1-25GENERAL INFORMATION —.j4q—aoa— CLIP: = Main wire harness = Siphon tube = Rear brake breather tube STARTER MOTOR = Final gear case breather tube CABLE FINAL GEAR CASE BAND: BREATHER TUBE = Main wire harness ~ Battery (-) cable ~ Starter motor cable MAIN WIRE HARNESS. CARBURETOR HEATER WIRE REAR BRAKE REAR BRAKE ‘BREATHER TUBE BREATHER, FINAL GEAR CASE BREATHER TUBE ALTERNATOR/ IGNITION Ar 7 REAR (PARKING) Swrenwine ead endie'd\\ \. a Re Q a vom Ly Cre = Gear position switeh wire BATTERY (-) CABLE = Speed sensor wire 1-26GENERAL INFORMATION ALTERNATOR/IGNITION PUI GENERATOR 5P CONNECTOR =< < ~ Alternatorfgnition pulse generator wire GROUND CABLE, \\!" Gear position swith wire sion ose Ensineto-frame) —_ Spegd sensor wire Final gear caso breather tube = Rear broke breather tube FINAL GEAR CASE BREATHER TUBE REAR BRAKE BREATHER TUBE CARBURETOR onauNTUBE ISPEED SENSOR ce generator wi | - Gear position switch wire = Speed sensor wire GEAR POSITION SWITCH WIRE 1-27GENERAL INFORMATIONGENERAL INFORMATION /_______ JAIULIGHT CONNECTORS TAILLIGHT CONNECTORS, ECM 5P CONNECTORS ECM 34P CONNECTORS LEFT TAILLIGHT WIRE ENGINE CONTROL MODULE RESERVE TANK (ecm) BREATHER TUBE RIGHT TAILLIGHT WIRE REGULATOR/RECTIFIER: Gm —_ FUSE BOX 2P CONNECTOR STARTER RELAY 2 CONNECTOR | MAIN WIRE HARNESS STARTER MOTOR BATTERY 4{-) CABLE BATTERY BOX AIR CLEANER —(-) CABLE HOUSINGGENERAL INFORMATION CLAMPS:GENERAL INFORMATIONGENERAL INFORMATION EMISSION CONTROL SYSTEMS ‘The California Air Resources Board (CARB) requires manufacturers to certify that their ATVs comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided. SOURCE OF EMISSIONS ‘The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions is very important ‘because, under certain conditions, they react to form photochemical smag when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocar- bons. EXHAUST EMISSION CONTROL SYSTEM ‘The exhaust emission control system is composed of @ lean carburetor setting, and no adjustments should be made excapt idle speed adjustment with the throttle stop screw. The exhaust emission control systam is separate from the crankcase omis. sion control system CRANKCASE EMISSION CONTROL SYSTEM. ‘Tho engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. CRANKCASE BREATHER PIPE FRESH AIR fem 8 L027 Gas NOISE EMISSION CONTROL SYSTEM ‘TAMPERING WITHTHE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. federal law prohibits, or Canadian provincial law pro- hibits the following acts or the causing thereof: (1) The removal or rendering inoperative by ny person, other than for poses of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the urpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use: (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 of the muffle, 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 specified by the manufacturer. 1-32GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL (U.S.A. only) EMISSION CONTROL INFORMATION LABEL The Vehicle Emission Control Information Label is attached on the loft of the battery box, 1-33MEMO,2. FRAME/BODY PANELS/EXHAUST SYSTEM | ‘SERVICE INFORMATION 2-1 INNER FENDER TROUBLESHOOTING 2-1. FRONT CARRIER/CARRY PIPE BODY PANEL LOCATIONS 2:2. FRONT FENDER | RECOIL STARTER COVER 2:3 REAR CARRIER SEAT 23 REAR FENDER ENGINE GUARD 23 TOOLBOX ‘SIDE COVER 2-4 OUTER FENDER FUEL TANK COVER 2-5 HEADLIGHT GRILL CENTER MUD GUARD 25 EXHAUST SYSTEM FRONT MUD GUARD 26 SERVICE INFORMATION GENERAL + This section covers removal and installation of the body panels and exhaust system. + Always replace the gaskets when removing the exhaust system. + Always inspect the exhaust system for leaks after installation. TORQUE VALUES Front cartiericarry pipe bolt 37 Nem (3.8 kgf, 27 [oF Gearshift lever knob screw 2.N-m (0.2 kgm, 14 Ibfft) ALOC screw Rear carrier bolt 37 Nem (3.8 kgfim, 27 Ibr) Mutfler band bolt 23 Nem (2.3 kam, 17 IbFtt) Front exhaust pipe cover band screw 3 Nem (0.3 kgm, 2.2 bff) Rear exhaust pipe cover end band scrow 6 Nm (0.6 kgf'm, 4.3 Ibrft) center band scrow 3 Nem (0.3 kgfm, 2.2 bff) Muffler cover screw 3.Nim (0.3 kgf, 2.2 bff) Footpeg bracket nut 32 Nem (3.3 kgfim, 24 Ibfft) TROUBLESHOOTING Excessive exhaust noise + Broken exhaust system Exhaust gas leaks Poor performance + Deformed exhaust system xhaust gas leaks Clogged muffier 26 27 27 28 28 29 29 29 2-10FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (14) (1) Recoil starter cover (page 2-3) (9) Front Carrier/Carry Pipe (page 2-7) (2) Seat (page 2-3) (10) Front Fender (page 2-7) (3) Engine guard (page 2-3) (11) Rear Carrior (page 2-8) (4) Side Cover (page 2-4) (12) Rear Fender (page 2-8) (6) Fuel Tank Cover (page 2-5) (13) Too! Box (page 2-9) (6) Center Mud Guard (page 2-5) (14) Outer Fender (page 2-9) (7) Front Mud Guard (page 2-6) (15) Headlight Grill (page 2-9) (@) Inner Fonder (page 2-6) BODY PANEL REMOVAL CHART This chart shows removal order of body panels by means of arrow. [tercenermea Guard] [ty Reci Stoner Gover | —»! a) Rear Fender —{ i Rawr Carer Pe [eer onn ein i sy ([DiFrontmoa Guar] iSite Cover _[_ oat (aot Box : i | (olfrontGaried -—»{_tanFront Fender +1) Fuatank Gover | Carry Pipe (3) Engine Guard | [Glinner Fender (18) Outer Fender (15) Headlight grill 2-2FRAME/BODY PANELS/EXHAUST SYSTEM RECOIL STARTER COVER Be careful not to islodge the gion Remove the recoil starter cover by releasing the three bosses from the grommets. Install the recoil starter cover in the reverse order of removal, RECOIL STARTER COVER SEAT REMOVAL Unlock the seat by turning the release lever upward. Pull the seat back and remove it. INSTALLATION Install the seat by inserting the prongs into the soat retainer on the frame. Push the seat forward and align the mounting bosses, with the mounting rubbers, then press down to lock it. ENGINE GUARD Remove the following: ~ four bolts and 28 mm washers = front engine guard = two bolts and 28 mm washers ~ rear engine guard Installation is in the reverse order of removal. GROMMETS Bosses. SEAT BOSSES PRONGS RUBBERS RETAINERS FRONT ENGINE GUARDFRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER RIGHT SIDE: Remove the following ~ seat (page 2-3) = recoil starter cover (page 2-3) = four trim clips ~ side cover (release two tabs of cover by sliding cover rearward) (between the tank cover and fender) RIGHT SIDE COVER Installation is in the reverse order of removal. LEFT SIDE: Remove the following: ~ seat (page 2-3) = setting screw = four trim clips = side cover (release two tabs of cover by sliding cover rearward) Installation is in the reverse order of removal LEFT SIDE CovER’ ‘Tim clip removal and retaining procedure: ~ Release by pulling the center pin up using a snap ring pliers or flat blade screwdriver and remove the trim clip. When nsialirg the — Install the clip and lock it by pushing the center pin tim cio, caretuly securely, ign the cl hole to avoid damaging t the ofp, Vd J —cenrer PIN = Release Lock 2-4FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK COVER Remove the following: ~ seat (page 2-3) = four trim clips = fuel tank breather tube and fuel fill cop = fuel tank cover (release four tabs by sliding cover rearward) Install the fuel fll cap. Trim clips Installation is in the reverse order or removal CENTER MUD GUARD up. Py RIGHT SIDE: Remove the following: . recoil starter cover (page 2-3) two trim clips and mud guard lid two bolts and footpeg two socket bolts five trim clips ‘center mud guard TRIM CLIPS LEFT SIDE: Remove the following: = two bolts and footpeg = two socket bolts = seven trim clips = center mud guard Installation is in the reverse order of removal. RIGHT CENTER MUD GUARD LEFT CENTER MUD GUARD Lips 2-5FRAME/BODY PANELS/EXHAUST SYSTEM FRONT MUD GUARD RIGHT SIDE: Remove the following: ~ two trim clips and mud guard lid LEFT SIDE: Remove the following: ~ left center mud guard (page 2-5) = seven trim clips = front mud guard Installation is in the reverse order of removal. TRIM CLIPS ; ad LEFT FRONT MUD GUARD’ INNER FENDER Remove the following: ~ two stay bolts = two trim clips = two tapping bolts = setting bolt = Inner fender Installation is in the reverse order of removal. SETTING BOLT» RIGHT FRONT MUD GUARD TRIM CLIPS TRIM CLIPS TAPPING BOLTS \ 2-6FRAME/BODY PANELS/EXHAUST SYSTEM FRONT CARRIER/CARRY PIPE 2 FRONT CARRIER FRONT CARRIER: Remove the following: = two 6 mm bolts and two collars = four 8 mm bolts Be careful net © — front carrier ‘scratch the font @ mm BOLTS fendi, 6 mm BOLTS AND COLLARS CARRY PIPE: Remove the following = front cartier (page 2-7) = two 6 mm bolts (headlight case) = four 8 mm bolts 9 caretul not 9 = carry pipe damage the head ‘ght ar. Installation is in the reverse order of removal. ‘TORQUE: & mm bolts: 37 Nim (3.8 kgfm, 27 Ibf ft) FRONT FENDER ‘8 mm BOLTS Remove the following: GEARSHIFT LEVER KNOB = fuel tank cover (page 2-5) ~ side covers (page 2-4) front carrier and carty pipe (page 2-7), A ‘wo screws and gearshift lever knob headlight connector eight trim clips four tapping bolts front fender (while spreading rear portion) Gears ever ine Installation is in the reverse order of removal serows should be ‘epiaced wth sew TORQUE: Knob screw: 2 Nm (0.2 kgm, 1.4 IbFft) es. 4 connector f trim cupsFRAME/BODY PANELS/EXHAUST SYSTEM REAR CARRIER ‘8 mm BOLTS, AND WASHERS REAR CARRIER Remove the followin = taillight wiring harness band = two 8 mm bolts and two collers = six 8 mm bolts and two washers Installation is in the reverse order of removal, TORQUE: 8 mm bolts: 37 N-m (3.8 kgm, 27 Ibfft) REAR FENDER Remove the battery (page 19-8) FUSE 8 Remove the following from the battery box: CONNECTORS iad = fuse box STARTER FELAY = 2P connectors SWITCH = starter relay Remove the following body panels: = recoil starter cover (page 2-3) ~ left side cover (page 2-4) STARTER MOTOR: ~ rear carrior (see above) CABLE Remove the following from the rear fender: = radiator reserve tank cap ~ setting screw (right side) = four trim clips (upper side) = eight trim clips (mud guard side) Disconnect the taillight connectors (above toolbox REAR FENDER and behind ECM). Remove the starter motor and battery (-) cables out of the rear fender and remove the rear fender. Installation is in the reverse order of removal. Route the wires and cables properly (page 1-19) CONNECTORS REAR > oF TRIM CLIPS) \ UNIT VIEW WITH REAR Wey FENDER REMOVED.FRAME/BODY PANELS/EXHAUST SYSTEM TOOL BOX ECM CONNECTORS Remove the rear fender (page 2-8). Disconnect the engine control module (ECM) connec- tors and remove the ECM from the stay on the tool box. Remove the two screws and the tool box. Installation is in the reverse order of removal OUTER FENDER TOOL Box Remove the eight trim clips and the outer fender. TRIM CLIPS Installation is in the reverse order of removal. FRONT OUTER FENDER TRIM CUPS, ee REAR OUTER FENDER HEADLIGHT GRILL Remove the headlights (page 22-3). Remove the following four bolts and carry pipe guard two screws four trim clips headlight grill (releasing from four tabs of fender) Installation is in the reverse order of removal Route the headlight wires properly (page 1-19). HEADLIGHT GRILL: