Honda Tr200 Fatcat Service Manual Repair 1986-1987 TR 200 Fat Cat

8S-B7
:'l"R200
F A T CAT™
, - - - - - - - - - IMPORTANT SAFETY NOTICE - - - - - - - ,
Indicat~s a strong possibility of sel'ere personal injury Of foss oj life if instructions afe not fo l/o .....ed.
CAUTION : Indicates a possibility of personal injury or equipmetJI damage if instrllctions are not Jolfowed.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations afe not included. It is
important to note that this manual contains some warnings and cautions against some specif ic service methods which
could cause PERSONAL INJURY to service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover all conceivable ways in whic h service, whether or not recommended bV Honda
might be done or of the possibly hazardous consequences of each conceivable way. nor could Honda investigate aU
such ways.
Anyone using service procedures or tools, whether or not recommended by Honda must s8tisfy himse" thoroughly
that neither personal safety nor vehicle safety will be jeopardiled by the service method or t ools selected ,
HOW TO USE THIS MANUAL CONTENTS
Sections 1 through 3 apply to the whole
TA20Q, while Sections 4 through 17 describe GENERAL INFORMATION
parts of the TR20Q, grouped according to lo-
cation. LUBRICATION
~
Find the sect ion you want on this page, then [ i AINTENANCE ~=====ID
-=-
turn to the table of contents on page 1 of that
section.
I FUEL SYST
= E=M= = = = = = =
== -=' -
Most sections start with an assembly or
system illustration and all the required specifi-
I ENGINE REMOVAL/INSTALLATION
cations, torque values, general instructions,
CYLINDER HEAD/VALVES
tools and troubleshooting for the section. The
subsequent pages give det ailed procedures. ~ r========~===
" CYLINDER/PISTON
1f you don ' t know what the source o f a prob- iii [ CLUTCH/-K-IC-K- ST
- A- R-TE- R-/ - -~~
lem is, refer t o sect ion 18, TROUBLES HOOT-
ING. I ~ GEARSHIFT LINKAGE = = = = = = ==:
ALTERNATOR/ STARTER CLUTCH
KSHAFT/
~ ~ill!~=~=
~ ;-;;EAR WHEEL/BRAKE/SUSPENSION
U I FENDERS/ EXHAUST MUFFLER

===
.. I IGNITION SYSTE~M==
5' BATTERY/CHARGING SYSTEM
~ ~=== = = 0 == = = = == =
~ [ STARTER SYSTEM _ _
w ~=----===
LIGHTS/SWITCHES
TROUBLESHOOTING
, --
~D~
1. GENERAL INFORMATION
GENERAL SAFETY ,-, TORQUE VALUES '-5
SERVICE RULES ,-, TOOLS ' -7
MODEL IDENTIFICATION ' -2 CABLE & HARNESS ROUTING ' -9
SPECIFICATIONS '-3 NOISE EMISSION CONTROL SYSTEM
'-'3
GENERAL SAFETY
''4§.i;liii}@ 'IUMwa
Ifthl' engine musl hI' rtllln;n: to do somt I<'ork, make SUfI' tht: Gasofine is rxtrtltl,ly flammable (lnd i.s txpfos;"e Imdtr Ql:rt/l;n
area is K'ell-\'enrifaud. Ntl'tr rlln Ihe engine in a clostd area. cQmliriolls. 1)0 1101 smoke or alloll' flames or j'parks ;/1 ),Ollf
The e;r;hDlI.u cOllfuillS "oisol/ous carbon monoxide gas Ihar 11'0rk urea.
//lay ((lUSt! loss of con,\'cjollsntss ami lead /0 death.
le·JAW;
.. it .1 The hullery tleclrolylt' cllllluins sui/uric aeM. ",oteet )'I)I/f
The batll'r)' gef/erUies hydrogen gas which can be highly f'XpJo- 'yes, skin IIml dOlhing. /n cau oj tomar" flush thorOl/ghly
sil't. /)0 nOi Jmoke Of ul/ow flumes Of sparks lIear the battery. "'ilh H'(l/t'r ami mil Q doctor if ~/~('frofyte gets ill J'Dllr eyes.
upedull)' whilf! charging if.
SERVICE RULES
1. Use genuine HONOA or HONDA·recommended parts and lubricants or their eqUivalent. Parts that don' t meet HONDA's
design specifications may cause damage to the motorcycle
2 . Use the special tools designed for this product to avoid damage and incorrect assembly.
3. Use only meuic tools when servicing this motorcycle. Metric bolls. nuts, and screws are not interchangeable with English
fasteners.
4. Install new gaskets. O-rings, cotter pins, lock plates. etc. when reassembling.
5_ When tightening a series of bolts or nuts, begin with the larger-diameter or Inner bolt first. Then ughten to the speCified
torque diagonally In 2 or 3 steps, unless a panicular sequence IS speCified.
6. Clean parts In non-flammable or high flash point solvent upon disassembly .
7. Lubricate any sliding surfaces before reassembly .
8. Alter reassembly, check all parts for proper installat ion and operation.
1-1
-=-.
GENERAL INFORMATION
MODEL IDENTIFICATION
FR'<ME SERIAL NUMBER
The frame serial number is stamped on the right side of the The engine serial number is stamped on the lower left side
steering head . of the crankcase.
The carburetor identification number is on the right side of

the carburetor body.
1-2
GENERAL INFORMATION
SPECIFICATIONS
ITEM SPECIFrCA TfONS
DIMENSIONS Overall length 2,020 mm (79.5 in)

Overall width 820 mm i32.3 in)
Overall height 1,075 mm (42.3 in)
Wheel base 1,365 mm (53.7 in)
Sea t height 755 mm (29.7 in)
Foot peg height 310 mm (12.2 in)
Ground clearance 230 mm (9.1 inl
Dry weight 120 kg (264 Ib)
FRAME Type Semi-double c radle
Front suspension, travel Telescopic, 150 mm (5.9 in)
Rear suspension, travel Swing arm, 120 mm (4.7 in)
Tire size Front 24.5 x 8.00-1 1
Rear 23.5 x 8.00-1 1
From tire standard pressure 4.3 psi (30 kPa. 0.3 kgl cm 1 )
Rear tire standard pressure 4.3 psi (30 kPa , 0.3 kg /cm 2 )
Front brake, lining swept area Internal expanding shoes
24 em' (3.7 sq in) x 2
Rear brake, lining swept area Internal expanding shoes
24 cm 2 (3.7 sq in) x 2
Fuel tank capacity 7.0 liters (1.9 US gal , 1.5 Imp gal)
Fuel reserve capacity 2.0 liters (0.5 US gal, 0.4 Imp gal)
Caster angle 28°
Trail 95 mm (3.7 4 in)
Vehicle capacity load 82 kg (180 !bs)
ENG!NE Type Air cooled 4-stroke
Cylinder arrangement Single cylinder inclined 25°
Bore and stroke 65.0 x 60.0 mm (2.56 x 2.36 in)
Displacement 199.1 cm 3 (12.1 cuin)
Compression ratio 9 .0:1
Valve train Single overhead camsh aft , chain driven
Oil capacity 1.8 liters 11.9 US qt, 1.6 Imp qt) after disassembly
1.5 liters /1.6 US qt, 1.3 Imp qt) after draining
Lubrication system Forced pressure and wet sump
Air fil t ration Oiled double urethane
Cylinder compression 1,275:,: 98 kPa 113.0:,: 1.0 kgl cm 2 • 184 ± 14 psi)
Intake valve Opens 8° BTDC
Closes 35° ABDC
Exhaust valve Opens 40° BBDC
Closes 5 ° ATDC
Valve clearance (co(d) Intake 0.08 mm (0.003 in)
Exhaust 0 .08 mm (0.003 in)
Idle speed l ,400 :i; 100 rpm
CARBURETOR Type Single valve
Identification number PD69A
Ven t uri diameter 24 mm 10.94 inl
Air screw initial opening 1-1 /4 turns out
Jet needle 3rd groove
Float level 14 mm 10.55 inl
1-3
GENERAL INFORMATION
ITEM SPECIFICATIONS
DRIVE TRAIN Clutch Wet multi-plate, semi-automatic

Transmission 5-speed constant mesh
Primary reduction 3.087 (71 /23)
Gear ratio I" 3.667 144/1 2)
2nd 2.267134/ 151
3,d 1.632 (3 1/ 19 )
4th , .273 (2B/ 22)
5th 1.042 (25/24)
Final reduction 3.000 (39/13)
Gearshift pattern Left foot operated return system
N· 1 -2-3.4-5
ELECTRICAL Ignition COl
Ignition timing Initial 10 0 ;t 2° BTOC at idle
Full advance 28 D :t: 2° BTOC at 3,500:t 100 rpm
Alternator capacity 120WIS,OOO rpm
Battery 12V - QAH
Spark plug DABES - l (NGKI
X24ESA - U (N O)
Spark plug gap 0.6 - 0.7 mrrr(Q.024 - 0.028 in)
Fuse lOA
Headlight lZV 45W/ 45W
Taillight 12V 3.4W
Neutral Indicator 12V 3.4W
1-4
GENERAL INFORMATION
TORQUE VALUES
ENGINE
Thread Dia Torque

Item Q'ty Remarks
!mm) N·m kg -m ft -Ib
Engine oil drain bolt 1 12 35-40 3.5-4.0 25-29

Spark plug 1 12 12-19 1.2-1.9 9-14
Clutch adjusting screw lock nut 1 8 19 - 25 1.9-2.5 14-18
Cylinder head nut 4 8 28-30 2.8-3.0 20-22
Camshaft bearing holder 2 6 10-14 1.0-1.4 7-10
Valve adjuster lock bolt 2 6 10-14 1.0-1.4 7-10
Apply oil to the
Centrifugal clutch lock nut 1 18 86 - 94 S.6 - 9.4 62 - 68
threads.
Manual clutch lock nut 1 16 76 - 84 7.6 - 8 .4 55 - 61
Flywheel'bolt 1 8 45 - 55 4 .5 - 5 .5 33 - 40
Gear shifter bolt 1 6 10 - 14 1.0 - 1.4 7 - 10
Apply a locking
Starter clutch bolt 1 8 26 - 30 2.6 - 3.0 19 - 22
agent to the
Pulse generator bolt 2 5 8 - 12 0.8 - 1.2 6- 9
threads.
Crankcase bolt 1.0 -1 .4 7-10
Cam chain tensioner slipper nut " 1
6
6
10-14
10-14 1.0 - 1.4 7 - 10
Apply oil to the
threads.
Shift drum stopper bolt 1 6 10 - 14 1.0 - 1.4 7 - 10
Centrifugal clutch cover 3 6 10 - 12 1.0 - 1.2 7- 9
FRAME
Thread Dia Torque

Item Q ' ty Remarks
(mm) ft -Ib
N·m kg -m
Gearshift pedal adjuster lock nut 2 6 8-12 0.8-1.2 6-9

Engine hanger bolt 6 8 30-36 3.0-3.6 22-26
4 10 60 - 70 6.0 - 7.0 43 - 51
Engine rear mounting bolt 1 10 60 - 70 6.0 - 7.0 43 - 51
Steering stem nut 1 24 70 - 90 7.0-9.0 51 -65
Steering bearing adjustment nut
Initial 1 24 25-35 2.5 - 3.5 1S -25 Refer to page
Final - - 5.5-6.5 0.55-0.65 4-4.7 11 -24
Handlebar upper holder bolt 4 8 18 -30 1.8-3.0 13 - 22
Handlebar lower holder nut 2 10 40-48 4.0-4.8 29 - 35
Front fork upper bolt 2 12 50 - 60 5.0 - 6 .0 36 - 43
Front fork lower pinch bolt 4 8 30 - 40 3.0 - 4.0 22 - 29
Front axle nut 1 14 55 - 65 5.5 - 6.5 40-47
Rear axle nut 1 14 80 - 100 S.0 - 10.0 5S-72
Final driven sprocket nut 6 8 28 - 34 2.8 - 3.4 20-25 Apply oil to the
threads.
Gearshift pedal pivot bolt 1 8 24 - 30 2.4-3.0 17-22 Apply a locking
agent to the
threads .
1-5
GENERAL INFORMATION
Torque
Item O'ty
Thread Dia
(mm)
N-m kg-m ft -Ib
-- Remarks
Gearshift pedal arm bolt

Swing arm pivot nut
Brake arm bolt Front/Rear
1
1
2
,.
6
6
14 - 18
80 - 100
8 - 12
1.4 - 1.8
B.0 - l0.0
0.8 - 1.2
10 - 13
58 - 72
6- 9
Rear shock absorber mounting bolt 2 10 70 80 7.0-8.0 51 - 58
Brake drum mounting bolt
Front / Rear 8 8 25 - 35 2.5 - 3.5 18 - 25
Front fork drain bolt 1 6 6- 9 0.6-0.9 4.5 - 6,5
Righi and left footpeg boils
Kick starler bolt
•1 10
8
70 -
20 -
80
35
7.0 - 8.0
2.0-3.5
51 -
14 -
58
25
Exhaust muffler clamp boh 1 8 15 - 25 1.5-2.5 11 - 18
Exhaust muffler mounting bolt 2 8 20 30 2.0-3 .0 14 - 22
Exhaust pipe joint nut 2 6 8- 12 0.8-1.2 6- 9
Side stand pivot bolt 1 10 10 - 20 1.0 -2.0 7 - 14
Side stand lock nut 1 10 35 .5 3.5 - 4.5 25 - 33
Side stand bracket bolt 1 8 30 36 3.0-3.6 22 26
Wheel hub nut Front / Rear 8 10 60 - 70 6.0- 7.0 43 - 51
- - tions listed above are for the most Important tightening pOints. If a torque speCIfication
Torque speCIfica -- IS notltsted, follow
the standards given below .
STANDARD TORQUE VALUES
Item Torque N ·m {kg-m, ft-Ibl hem Torque N ·m {kg-m, ft -Ib)
5 mm bolt, nut 4.5 - 610.45-0.6,3 - 4) 5 mm screw 3.5 - 510.35-0.5,2 - 4)

6 mm bolt, nut 8 - 12 (0.8-1.2, 6 - 9) 6 mm screw, 6 mm flange
8 mm bolt, nut 18 - 25 \l.8 - 2.5. 13 - 18) bolt with 8 mm head 7- 11 (0.7-1.1,5 - 8)
10 mm bolt. nut 30 - 40 (3.0 - 4 .0,22 - 29) 6 mm flange bolt, nut 10 - 14 (1.0-1.4, 7 - 10 )
12 mm bolt, nut 50 - 60 (5.0-6.0, 36 - 43) 8 mm flange bolt , nut 24 - 30 (2.4-3.0,17 - 22)
10 mm flange bolt, nut 35 - 45 (3.5- 4 .5, 25 - 33)
1-6
GENERAL INFORMATION
TOOLS
SPECIAL
DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER REF. PAGE

Clutch holder 07GMB - HB30100 U.S .A . only 07923 - HB3000A 8·6,8
Clutch puller 07GMC - HB30100 U.S,A . only 07923 - HB3000A B-6
Clutch center holder 07923 - 9580000 8·9,12
Crankshaft assembly coliar 07965 VMOO100 10- 11
Shaft puller 07931 - ME40000 07931 - ME4000A 10- 11
Threaded adaptor 07GMF - HBS0100 U.S.A. only 07965 - HB3000A 10- 11
Universal bearing puller 07631 - 0010000 or Equivalent commercially 10· 10
available in U.S.A.
Bearing remover set, 1 5 mm 07936 - KC10000 ~ Not ""'ab'e In U_S .A. 10-7
Bearing remover, 15 mm 07936 - KC10500 10-7
Remover weight 07741 - 0010201 Remover weight 07936 - 3710200 10-7
Valve guide reamer , 5.5 mm 07984 - 2000000 6-7,9
or Equivalent commercially
Bearmg remover shaft 07GGO - 00101oo 11 -7
available in U.S .A .
Steering stem socket 07916 - 4300000 07916-3710100 11 -22, 24
Ball race remover 07953 - 3330000 11-22
Attachement 07946 - 3290000 Use steering head outer 11 -23
races
Steering stem driver 07946 - 4300101 07946-MBOOOOO 11 -23
Universal bead breaker GN - AH - 958 - BB1 with GN - HT - S4 11 -8
(U.S.A. only) (U.S.A. only)
COl tester spark adaptor 07GGK - 0010100 Not available in U .S. A. 14 -2
COl tester inspection adaptor 07508 - 0012300 Not available in U .S. A. 14 -4
COM MON
DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER REF. PAGE
Float level gauge 07401 - 0010000 4 -9

Flywheel holder 07725 -0040000 or strap wrench, cammer· 9-3,6
dally available in U.S.A.
Rotor puller 07733 - 0020001 Rotor puller 07933-2160000 9-3
Lock nut wrench, 07716 - 0020400 or Equivalent commercially 11 -22,24
30)( 32 mm available in U.S .A .
Attachment , 32 )( 35 mm 07746 - 0010100 10·7, 10-8
Pilot , 15 mm 07746 - 0040300 10-7,
11 -7.
12- 5
Attachment , 42 )( 47 mm 07746 - 0010300 10-7, 10,
11 · 7,
12· 5,
12· 14
Pilot , 20mm 07746 - 0040500 10-7
1-7
GENERAL INFORMATION
DESCRIPTION TOOL NUMBER AL TEANATE TOOL TOOL NUMBER REF . PAGE

Attachment, 52 )( 55 mm 07746-0010400 10-8
Pilot, 22 mm 07746-0041000 10-8
Driver 07749 - 0010000
Bearing remover head, 15mm 07746 - 0050400 f- or Equivalent commercially 11 ·7, 12· 5
available in U.S.A.
Driver handle B 07746 - 0020100 07749 - 0010000 6-5
(U.S.A. only)
Attachement, 15 mm 07746 - 0020200 M9360-277-9177S 6-5
(U.S.A. only)
Fork seal driver 07747 - 0010100 11 - 19
FOlk seal driver attachment 07747 - 0010400 11 - 19
Valve guide remover, 5.5 mm 07742 - 0010100 f- Valve guide remover 07942 - 3290100 6 -8
Val'lle spring compressor 07757 - 001 0000 I- Valve spring compressor 07957 - 3290001 6 -6,12
Attachment, 62 x 68 mm 07746 - 0010500 10- 11
Pilot, 28 mm 07746 - 0041 lOa , 0-' 1
~Not available in U.S.A.

Tire braker set 07772 - 0050000 11 · 9
Compressor breaker arm 07772 - 0050100 11 -9
Breaker arm 07772 - 0050200 11-9
VALVE SEAT CUTTER
Valve seat cutters are commercially available in the USA Therefore , the following cutters are not required in the USA
DESCRIPTION TOOL NUMBER REF. PAGE
Valve seat cutter, 27.5 mm (EX 45°) 07780-0010200 6-9

Valve seat cutter, 33 mm (IN 45 °) 07780-0010800 6-9
Valve seat cutter, 28 mm (EX 32°) 07780 - 0012100 6-9
Valve seat cutter, 33 mm (IN 32°1 07780-0012900 6-9
Valve seat cutter, 30 mm (IN / EX fiOO) 07780-0014000 6-9
Valve seat cutter holder, 5.5 mm 07781-0010101 6-9
1-8
GENERAL INFORMATION
CABLE & HARNESS ROUTING

Note the following when routing cables and wire harnesses:
• A loose wire . harness or cable can be a safety ha~ard . A ft er

clamping, check each wire to be sure it is secure.
• Do not squeeze a wi re against a weld or end of it s clamp

when a weld·on clamp is used .
o X
fa
• Secure wires and wire harnesses to the frame with their re -
spective wire bands at the designated locations . Tighten
the bands so that only the insulat ed sur f aces contact the
wires or wire harnesses.
• Route harnesses so they are not pulled taut or have exces-

sive slack.
• Protect wires and harnesses with electrica l tape or tubes if

they conta ct a sharp edge o r corner.
Clean the attaching surface t horoughly be fore applying
tape .
• Do not use a wire or harness with a b roken insulator . Repair

by wrapping them with protec ti ve tape or replace th em .
• Route wire harnesses to avoid sharp edges or corners. Also

avoid the projected ends 01 bolts and screws.
• Keep wire harnesses away from the exhaus1 pipe and other
parts that get hot.
• Be sure grommets are seated in their grooves properly.
• After clamping, check each harness to be certain that it is

not inerfering with any movin g of sliding parts .
• Wire harnesses routed along t he han dlebars should not be

x x x
pulled taut, have excessive slack. be pinch ed by , or int er -
fere with adjacent or surrounding parts in all steering posi-
tions.
• After routing, check that the wire harnesses ar e not twisted

or kinked .
• Do not bend or twist control cables.

Damaged cont rol cables will not operate smoothly and may
stick o r b ind
0: CORRECT
x: INCORRECT
1-9
GENERAL INFORMATION
n) THROTTLE CABLE
' - - - (21 lEFT HANDLEBAR SWITCH WIRE

13) FRONT BRAKE CABLE
After '86: (4) REAR BRAKE CABLE
(5) IGN ITION SWITCH
(6) INOICATOR LIG HT

m MAIN W IRE HARNESS
(8) CHOKE CABLE
n ) THROTTLE CABLE
(9) BATTERY GROUND W IRE
After '86 : -.."I.JI

(4 ) REAR BRAKE LEVER CABLE
110) GROUND W IRE
('
Aft er ' 86 :
(12) CUPS
n 11 REAR BRAKE PEDAL ROO
1-10
GENERAL INFORMATION
' 86 :
( 11 WIRE BANDS
:':>_--- (31 MAIN W IRE HARNESS
(2 ) CHOKE CABLE
(4 ) SPARK PLUG
(6 ) ALTERNATOR COUPLERS , CONNECTORS )5 ) R.TT " RY GROUND CABLE

AND TAILLIGHT WIRE CONNECTORS
I After
(8) BATT ERY

GROUND
)
)9 ) OTAO·'.R
CABLE
(10) AL"'RN.OT'OR/1:.7!
WIRE
2 1 REGULATOR/ RECTIFIER
f14 1 NEUTRAL WIRE
n 3 ) REGULATOR / RECTIFIER COUPLERS
1-11
GENERAL INFORMATION
(1) FUEL TUBE
WIRE HARNESS
STARTER MOTOR CABLE
~';S~~)~====:;. (4) WIRE

f!
ALTERNATOR
(6) CRANKCASE
BREATHER TUBE;:;r---">
1-12
GENERAL INFORMATION
NOISE EMISSION CONTROL SYSTEM (U.S.A. only)

The U.S. Enviromental Protection Agency requires manufacturers to certify that vehicles built after January 1. 1983 will
comply with applicable noise emission standards for one year or 1,865 miles (3.000 kml after the time of sale to the ultimate
purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distribu-
tor's Warranty for the Honda Vehicle Noise Emission Control System is necessary in order to keep the noise em ission control
system in effect.
TAMPERING WITH THE NOISE CONTROL SYSTEM 15 PROHIBITED: Federal law prohibits the following acts or the causing
thereof: (1) The removal Of rendering inoperative by any person, other than for purposes of mintenance, repair, or replace ·
ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in 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:
,. Removal of, or puncturing the muffler, baffle, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any parlsof 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.
1-13
LUBRICATION
LUBRICATION DIAGRAM
(11 ROCKER ARM SHAFT ---tAtai~~t.~
121 CR,'NKSH,"T
m lOlL
FILTER
(3) Oil PUMP
(4 ) MAIN$HAFT
(8) OIL TER SCREEN
(5) COUNTER$HAFT
(6) I STARTER
SHAFT
2-0
2. LUBRICATION
SERVICE INFORMATION 2-1 OIL FILTER ROTOR ANO SCREEN 2 -2
TROUBLESHOOTING 2-1 OIL PUMP 2-4
ENGINE OIL 2-2 LUBRI CATION POINTS 2-7
SERVICE INFORMATION
SPECIFICA TIONS
Eng ine oil capacity 1.8 iii (1.9 US qt, 1.6 Imp QII at disassembly
1.5 lit (1.6 US qt, 1.3 Imp qll at draining
Engine oil recommendat ion Use Honda 4-stroke oil or equivalent.
API Service Classification: SE or SF ENGINE OIL VISCOSITIES
Viscosity: SAE lOW ~ 40
"
Other viscosities shown in the chart may be
used when the average temperature in your
riding area is within the indicated range.
CAUTION
. Do flOI use oils with graphiie or molybdenum additil'es . TIley
wif( adl'ersely aj/eci celllrijugal dlllell opera/ion.
ro
I I
0
" ~
." 100 'r
• " " " .,

•
Oil pump ·ro -0 0
ITEM STANDARD SERVICE LIMIT

Rotor tip clearance 0.15 mm (0.006 in ) 0.20 mm (0.008 in)
ROlor-le-body clearance 0.15-0.21 mm W,006-0.008 in) 0.25 mm (0.010 in)
Pump end clearance 0.05-0.13 mm(O.002 - 0.005 in) 0.15 mm(0.006 in)
TORQUE VALUES
Engine oil drain bolt 35 - 40 N·m (3.5-4.0 kg~m, 25-29 It-Ib)

Centrifugal clutch cover 10 - 12 N ·m ( 1.0 -1.2 kg-m, 7-9 It·lb)
TROUBLESHOOTING
Oit level too low - h igh oil cons u mption Oil contamination
External oil leaks Oil not changed or filter screen not cleaned olten
Worn or damaged piston rings enough
Oil not changed often enough Head gasket faulty
Faulty head gasket Worn piston ring s
Entry o f water
Whitish exh aust gass
Oil-up
- Worn o r damaged piston rings
- Improperly installed piston rings
- Worn cylinder
Oil· down
- Worn or damaged stem seals
- Worn valve guide
2-1
LUBRICATION
11 1
ENGINE OIL
OIL LEV EL CHECK
Start the engine and allow it to idle for 2 or 3 minutes.

Stop the engine and place the motorcycle on a level surface.
Check the oil level with the oil fille r cap/dipstick .
Do not screw It in when making this check.
If the oit level is below or near the lower level line on the dip·
stick , add the recommende d oil (page 2· 1) up to the upper
level line.
(1)
OIL CHANGE
NOTE
Change engine oil with the engine warm and the motorcycle
on level ground t o assure complete draining.
Remove the oil filler cap/dipstick and drain bolt, and drain t he
engine oil.
Check that the sealing washer on the drain bolt is in good con-
dition and install the drain bolt .
TORQUE: 35 - 40N ·m (3 .5 - 4 .0 kg -m , 25 - 29 ft -Ibl
Fill the crankcase with' .5 liters (1.6 US qt, 1,3 Imp qtl 01 the
recom m ended oil (page 2- 1).
Install the oil filler cap/dipst ick.
Start the engine and let it idle fo r 2 or 3 minutes.
Stop the engine and check t hat the oil level is at the upper level
hne on the dipstick . Make sure there are no oil leaks .
OIL FILTER ROTOR AND SCREEN

Drain the engine oil.
Remove the right crankcase cover and gasket (page 8·31.
2-2
LUBRICATION
Remove the centrifugal clutch cover by removing three bolts.
Clean the centrifugal clutch cover and inside of the centrifugal

clutch using a clean lint· free cloth.
CAUTION
Do nOI alfow dust or dirt (Q enter the crankshafT oil passage.
DonOI useco~,,~,p:,~~
::od
~: u:
~C'____________________________
Reinstall the centrifugal clutch cover with a new gasket align-

ing the bolt holes in the cover and gasket.
TORQUE : 10 - 12 N·m 11.0 - 1.2 kg-m . 7 - 9 ft-Ib )
Remove the oil filter screen from the right crankcase.

Clean the oil fiiter screen by washing it in clean solvent and
blowing it dry with compressed air.
Reinstall the oil filter screen int o the right crankcase .
Install the dowel pins and a new gasket .
2-3
LUBRICATION
Install the right crankcase cover and disassembled parts !page

8 ~ 17).
Fill the crankcase with the recommended oil (page 2-21.
OIL PUMP
REMOVAL
Remove the nght crankcase cover (page 8-3 "

Remove the oil separator plate.
Remove the snap flng and oil pump driven sprocket from the oil
pump shah .
Remove the two mounting bolts and the oil pump from the
right crankcase .
2 -4
lUBRI CA nON
111 Oil PUMP COVER (2) SCREW

INSPECTION
Remove the oil pump cover attaching screw and cover.
Measure the oil pump body-Ie-rotor clearance.
SERV ICE LIMIT: 0 .25 mm 10.010 in)
Measure the pump rotor tiP clearance.
SERVICE LIMIT: 0 .20 mm (0 .008 in)
Remove the oil pump drive shaft and measure the pump end
clearance.
SERVICE LIMIT ; 0 .15 mm (0.006 in)
2-5
LUBRICATION
III SHAFT 12) PUMP BODY (3) PUMP COVEA

Check the all parts for scratches, wear or damage.
/
Assemble the oil pump .
Tighten the attaching screw securely.
ROTOR
INSTALLATION
Install the oil pump onto the right crankcase and tighten the
bolts.
Install the oil pump driven sprocket with the drive chain and (11 Oil PUMP:.£~~~::~~
secure it with the snap ring.
CAUTION
• /flSrafl/he snap ring with sharp edge facing out.
)
Install the separator plate.

Install the right crankcase cover {page 8- 18!.
2-6
LUBRICATION
LUBRICATION POINTS
Use general purpose grease when no other specification is
given, Apply oil or grease to any 2 sliding surfaces and cables
not shown here.
o I STEERING HEAD BEARINGS

(INNER AND OUTER RACES)
_e=
--
(2) BRAKE LEVER PIVOTS
CABLE END
--1-_,
(4 ) REAR BRAKE PEDAL PIVOT SHAFT
AND DUST SEAL
/
/ (5) REAR SHOCK ABSORBER

'Uw," BUSHING
--- I
(15) FORK OIL
I
I
(SILICONE GREASE)
--,
(1 4 ) FRONT BRAKE
BRAKE CAM
AN(:Hel" PIN
(SILICONE GREASE)
REAR BRAKE
BRAKE CAM
ANCHOR PIN
---/
---
(12) KICKST ARTER PIVOT
(8( SIDE STAND
PIVOT
171 WHEEL B"'""'GS
OUST SEAL
----
/111 GEARSHIFT LINKAGE
PIVOTS
(13) WHEEL BEARINGS
DUST SEAL
(10) FODTPEG JOINTS
(9) SWING ARM

PIVOT BUSHING (See page 3-14)
PIVOT DUST SEAL
2 -7
MEMO
3. MAINTENANCE
SERVICE INFORMATION 3-1 BRAKE SYSTEM 3 -11
MAINTENANCE SCHEDULE 3-2 BRAKE LOCK LEVER 3- 13
FUEL LINE 3 -4 HEADLIGHT AIM 3 -13
FUEL STRAINER SCREEN 3 -4 CLUTCH SYSTEM 3- 13
THROTTLE OPERATION
CARBURETOR-C HOKE
3-4
3 -5
GEARSHIFT PEDAL PIVOT
SIDE STAND
3-14
3- 14 III
AIR CLEANER 3 -5 SUSPENSION 3- 14
SPARK PLUG 3 -6 SPARK ARRESTER 3-15
VALVE CLEARANCE 3-7 NUT, BOLT, FASTENER 3-15
CARBURETOR-IDLE SPEED 3 -B WHEEL 3 -16
DRIVE CHAIN 3-8 STEERING HEAD BEARING 3-16
DRIVE CHAIN SliOER 3- 10 CYLINDER COMPRESSION 3 -16
BRAKE SHOE WEAR 3-10
SERVICE INFORMATION
SPECIFICATIONS
Throtlle grip free play 2 - 6 mm (1/8 - 114 in)

Recommended spark plug DABES-L (NGKI
X24ESR -U (ND)
Spark plug gap 0.6 - 0.7 mm 10.024 - 0.028 in)
Valve clearance Intake/Exhaust 0.08 mm (0.003 in)
Idle speed 1,400:!: lOa rpm
Cylinder compression 1,275:!: 98 kPa /13.0:!: 1.0 kg fcm 2 , 184 :t 14 psi)
Drive chain slack 25 - 35 mm (1-t-3/8 in)
Front br ake lever free play 25-30 mm (1- 1-1/4 in)
Rear brake lever free play 25-30 mm ( 1-1-1 /4 in)
Rear brake pedal free play 20-30 mm (3 /4-1-1 /4 inl
Recommended tire pressure (Col d ) Front 4.3:,: 0.4 psi (30:,: 3 kPa, 0.3:,: 0.03 kg/c m 2)
Rear 4 .3:t 0 .4 psi (30 ± 3 kPa, 0.3:,: 0.03 kg /cm 2)
TORQUE VALUES
Spark plug 12 - 19 N ·m (1.2 - 1.9 kg -m, 9- 14 ft-Ib)

Aear axle nut 80-100 N·m (8.0- 1 0.0 kg -m. 58 - 72 ft -Ib)
Clutch adjusting screw lock nut 19-25 N ·m 11 .9-2 .5 kg -m . 14 - 18 ft-lbJ
Side sland pivot bolt 10- 20 N·m (1.0-2 .0 kg-m. 7 - 14 ft -Ib)
Side stand pivo t lock nut 35- 4 5 N· m (3.5- 4 . 5 kg -m, 25 - 33 ft -Ibl
Gearshift pedal adjuster lock nut 8 - 12 N -m (0.8 - 1.2 kg-m. 6-9 ft -Ib)
Rotor cap 10 - 20 N ' m (, .0 - 2.0 kg -m. 7 - '4 ft-Ib)
3-1
MAINTENANCE
MAINTENANCE SCHEDULE
'86:
Perform the Pre-ride Inspection in the Owner's Manual at each scheduled maintenance period.
I : Inspect and dean, adjust , lubricate. or replace if necessary .
C: Clean
A : Replace
A : Adjust
L · Lubricate
FREQUENCY REGULAR
BREAK-IN
MAINTENANCE
MAINTENANCE
INTERVAL Refer to
EVERY First month of
Every 6 month page
operation-about
operation-about
200 mi (350 km)
ITEM 1000 mi (1600 km)
· FUEL LINE 1 3-'

· FUEL STRAINER SCREEN C 3-'
· THROTTLE OPERATION 1 3-'
· CARBURETOR-CHOKE 1 3-5
AlA CLEANER NOTE 1 C 3-5
SPARK PLUG 1 3-6
· VALVE CLEARANCE
ENGINE OIL
1
R
1
R
3-7
2-2
· ENGINE OIL Fil TEA SCREEN C 2-2
· ENGINE OIL CENTRIFUGAL FIL TEA C 2-2
· CARBURETOR-IDLE SPEED 1 1 3-8
Every 2 months of
DRIVE CHAIN NOTE' I, l operation L L About 3-8
300 mi (500 km)
DRIVE CHAIN SLIDER 1 1 3-10
BRAKE SHOE WEAR 1 3 -10
BRAKE SYSTEM 1 1 3 -11
BRAKE LOCK LEVER 1 3-13
- HEADLIGHT AIM 1 3-'3
CLUTCH SYSTEM 1 1 3-13
· GEARSHIFT PEDAL PIVOT I, l 3- '4
SIDE STAND 1 3-1 4
· SUSPENSION I, l 3-1 4
· SPARK ARRESTER NOTE 2 C 3-15
· NUT, BOLT , FASTENER 1 1 3-15
.. WHEEL 1 1 3-16
·. STEERING HEAD BEARING 1 1 3-16
Should be serviced by an authorized Honda dealer , unless the owner has proper tools and service data and is mechanically
qualified .
In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES: 1. Service more frequently when ridden in wet or dusty conditions.

2. U.S.A. only.
3-2
MAINTENANCE
After '86:
Perform the Pre-ride Inspection in the Owner' s Manual at each scheduled maintenance period .
I : Inspect and dean, adjust, lubricate, or replace if necessary .
C: Clean
A : Replace
A : Adjust
L : Lubricate
FREQUENCY BREAK-IN
REGULAR
MAINTENANCE
MAINTENANCE
INTERVAL Refer to
EVERY First week of
Every 30 operating page
operation-about
day -about
200 mi (350 kml
ITEM 1000 mi 11600 kml
· FUEL LINE 1 3-4
· FUEL STRAINER SCREEN C 3-4

· THROTTLE OPERATION 1 3-4
· CARBURETOR-CHOKE
AIR CLEANER NOTe 1
1 3-5
C 3 -5
SPARK PLUG 1 3 -6
· VALVE CLEARANCE 1 1 3-7

,-,
ENGINE OIL R R
· ENGINE OIL Fil TEA SCREEN C ,-,
· ENGINE OIL CENTRIFUGAL Fil TEA C ,-,
· CARBURETOR-IDLE SPEED 1 1 3-8
Every 10 operating
DRIVE CHAIN NOTEl I, L day about 3-8
300 mi (500 kml I, L
DRIVE CHAIN SLIDER 1 1 3 · 10
BRAKE SHOE WEAR 1 3- 1 0
BRAKE SYSTEM 1 1 3-11
· HEADLIGHT AIM
CLUTCH SYSTEM
1 3-13
1 1 3- 1 3
· GEARSHIFT PEDAL PIVOT

SIDE STAND
I, L 3-14
3-14
1
· SUSPENSION I, L 3 -14
· SPARK ARRESTER NOTE 2 C 3 · 15

· NUT, BOLT. FASTENER 1 1 3-15
.. WHEEUTIRES 1 3- 1 6
.. STEERING HEAD BEARING 1 1 3-16
• Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically
qualified . .
•• In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
NOTES : 1. Service more frequently when ridden in wet or dusty conditions.

2 . U.S .A. only.
3-3
MAINTENANCE
FUEL LINE FUEL LINE
Check the fuel line.

Replace any parts which show signs of deterioration, damage
or leaks .
FUEL STRAINER SCREEN V (1 FUEL CUP
Turn the fuel valve off.

Remove the fuel cup, O-ring and strainer screen, and drain the
gasoline into a suitable container.
Gasoline is flammable ami is exp/osil't IInder certain condi-

l;oIlS. D o I/O/ smoke or allow j1mnes or sparks lIear ,fie equip-
mellt whife drailling /llel.
Wash the cup and strainer screen in clean, non-flammable or

high flash-point solvent.
Reinstall the strainer screen, aligning the index marks on the
fuel valve body and strainer screen.
Install a new O-ring into the fuel valve body.
Reinstall the fuel cup, making sure the O-ring is in place.
Hand tighten the fuel cup securely.
CAUTION
Do 1101 overtighten the f ue! flip.
After installing, turn the fuel valve ON and check that there are
no fuel leaks .
THROTTLE OPERATION 2-6 mm (1 /8- 1/4 inl
Check for smooth throttle grip full opening and automatic full
closing in all steering positions.
Inspect the throttle cable for deterioration. damage, Of kinks.
Replace the cable as required.
Measure throttle grip free play at the throttle grip flange.
THR OTTLE GRIP FREE PLAY : 2- 6 mm !1 /8 - 1f4 in l
3-4
MAINTENANCE
AdjuSt as follows: (1) RUBBER BOOT (21 NUT

Slide the rubber boot off the cable adjuster.
Loosen the lock nut and adjust the throttle cable free play by
turning the cable adjuster.
Tighten the lock nut and install the rubber boot securely.
CARBURETOR·CHOKE ~2) FULLY
Check for smooth choke knob operation.

Lubricate the choke cable If necessary.
Pull the choke knob all the way up to the fully closed position I
-
and check that the choke valve IS fully closed by moving the
choke lever at the carburetor .
I
I
""
Adjust if necessary. by loosening the choke cable clamp on the
carburetor and ~oving the choke cable casing so the choke
valve IS fully closed.
Tighten the clamp.
Push the choke knob all the way in to the fully open position.
Make sure that the choke valve is fully open by checking for
fr ee pia V in the cable between the lever on the carburetor and
cable casing.
AIR CLEANER
Remove the seat.
Release the retaining clip holding the air cleaner case cover,
and remove the air cleaner case cover.
3-5
MAINTENANCE
loosen the air cleaner element band screw and remove the ele-
ment assembly from the case.
Remo ve the element from the element core (page 4·51.
Wash the element in non-flammable or high flash point sol-

vent, squeeze out the solvent thoroughly. and allow to dry .
Soak the element in gear oil (SAE lIIao or 90) and squeeze out 14) GEAR OIL
excess. (SAE #80 or 90)
Place the element onto the element core and replace the ele-
ment band and holder.
Inst all the element in the air cleaner case. (1) WASH IN (2) SQUEEZE OUT (5) SQUEEZE OUT
Install the air cleaner case cover and clip. SOLVENT SOLVENT EXCESS OIL
InstaU the seat. THOROUGHLY
SPARK PLUG
Disconnect the spark plug cap and remove the spark plug.
Visually inspect the spark plug electrodes for wear.

The center electrode should have square edges and the side
electrode should have a cons t ant thickness.
Discard Ihe spark plug if there is apparent wear or if t he insula-
tor is cracked or chipped.
Measure the gap with a wire -type feeler gauge and adjust if
necessary by cafefully bending the side electrode.
SPARK PLUG GAP: 0 .6 - 0 .7 mm (0.0 24 - 0 .0 28 in )
RECOMMENDED REPLACEMENT PLUG ; OA8ES-L (NGK)

X24ESR-U (NO) ( 1) SIDE ELECTRODE O.'i - ".7mm 10.024 -0.028 in)
Check the sealing washef and replace with a new one if dam- '\..GF==f~
aged.
With the sealing washer attached, thread the spark plug in b~
hand to prevent crossthreading.
Tighten the spark plug.
TORQUE : 12- 19 N·m (1.2- 1.9 kg-m , 9 - 14 ft ·lb)
InSlall the spafk plug cap.
121 eel""'; ELECTRODE
3-6
•
MAINTENANCE
VALVE CLEARANCE
Remove the timing hole cap and rotor cap from the left crank·
case cOlier.
NOTE
Adjust the valve clearan ce while the engine is cold (below
35°C/95°FI.
Turn the crankshaft slowly counterclockwise and align the

"T" mark on the flywheel with Ihe index mark on the lefl
crankcase cover .
Disconnect the spark plug cap from the spark plug. 11 f SPARK PLUG
Remove the valve adjuster cover by removing the bolts.
Remove the timing hole cap from the cylinder head cover.
Check that the timing indicator plate on the cam shaft end is III TIMING INDICATOR PLATE
visible (facing upl.
If the mark not visible, turn the crankshaft 360 0 and fe -align
the "T" mark on the flVwheel with the index mark on the left
crankcase cover .
NOTE
-
When the "T" mark is aligned with the index mark and the
t iming mark is visible (facing up!. the piston is at the top
dead center on the compression stroke.
3-7
MAINTENANCE
loosen the valve adjuster lock bolts fully.

Move the intake and exhaust valve adjusters counterclockwise
fully until resistance is felt .
Then move them clockwise correctly the equivalent of 1/2

graduation. Tighten the adjuster lock bolts.
NOTE
1/2 graduation on the adjusters equals 0.08 mm 10 .003 In'
which is the specified clearance.
Install the timing hole cap onto the cylinder head cover and
valve adjuster cover. (1) 1 2 GRADUATION 121 INDEX MARKS
Install the timing hole cap and rotor cap onto the left cra nkcase
cover .
Tighten the rotor cap.
TORQUE : 10-20 N·m 11,0 -2. 0 kg-m . 7- 14 ft·lbl
CARBURETOR·IDLE SPEED
NOTE
(3) ADJUSTER LOCK BOLTS
Inspect and adjust the idle speed after all other engine main-
tenance items have been performed and are within specifi-
cations .
The engine must be warm for accurate idle speed inspec-
tion and adjustment.
Shift the transmission into neutral.

Warm up the engine for about ten minutes and connect a ta -
chometer .
Turn the throttle stop screw as required to obtain the specified
idle speed with the motorcycle supported in an upright posi -
tion.
IDLE SPEED: 1,400 ~ 100 rpm
DRIVE CHAIN
'IRwaN
Nel'er irupect or aajust the ,Iril·e chaill while the engine is ",n-
lIing.
CHAIN SLACK INSPECTION
Stop the engine and shift the tran sm ission into neutral.
Place the engine on a box or work stand .
Measure the slack in the lower drive chain run midway be ·
tween the sprockets.
SLACK: 25 - 35 mm !1 - 1-318 in l
Adjust the drive chain slack (page 3 ·9) if necessary.
3-8
MAINTENANCE
CHAIN SLAC K ADJUSTMENT (1 f REAR AXLE NUT a:
\~
loosen the fear axle nut, then turn the adjusting nu ts on both
sides of the swingarm equally until the correct chain slack is
obtained.
CAUTION
Be sure Ihe same adjuster index marks align wifh the index
.~
marks on bOIl! sides of fhe swing arm.
Tighten the axle nut.
T ORQUE: 80 - 100 N·m (8 .0 - 10.0 kg-m, 58 -72 ft·lb l

i
r;1';31'·A::::D'J;;U"S~T~
ING NU
:;..T,--_
REMOVAL AND INSPE CTI ON
When the drive chain becomes extremely dirty, it should be re-

moved and cleaned before lubrication.
Remove the drive sprocket cover.
Remove the chain retaining clip carefully.
Remove the master link, D-rings and the drive chain.
CAUTION
Be careful nOllO lose Ihe a-rings when fhe clip and masler fink (
are relllo~'ed.
ill RETAIN ING
Visuallv inspect the drive chain for kinks or damage.

(1) Measure a span of 100 pins
Measure a section of the drive chain to determine whether the

drive chain is worn beyond its service limit. Remove the drive
chain and measure the distance between a span of 100 pins
from pin center to pin center.
In a new chain. this distance will measure 1,571. 6 mm 161.9
info If the distance exceeds 1,580 mm (62.2 in). the drive
chain is worn out and should be replaced.
(21 SERVICE LIMIT: 1,580 mm
REPLACEMENT DRI VE CHAIN : (62.2 in)
DID 520 VC -3 or RK 520 MO
Clean the drive chain with a small amount of non-flammable

(1) WIPE DRY
solvent and wipe dry.
CAUTION
(2) LUBRICATE
Do nOI use a Sleal1l deaner. high pressure .....ashers or aerosol ---,. SAE #80 or 90
elwin lubricants as Ihew' wi/( damage Ihe O-rings. . iii G EAR OIL
Inspect the drive chain and O-rings for possib le wear or dam ·
age. Replace the chain, if it is worn excessively or damaged.
Lubricate the drive chain with SAE #80 or gO gear oil.
,
3-9
MAINTENANCE
Inspect the sprocket teeth fo r excessive wear or damage. Ae -

place if necessary .
NOTE
)( )(
Never install a new drive chain on worn sprockets or a worn 13) WEAR
chain on new sprockets . Both chain and sprockets must be ttl DAMAGE
in good condition, or the new replacement chain or sprock-
ets will wear rapidly.
o
(2, NORMAL
IN STALLATION (4 ) RETAINING CLIP

(1 I M ASTER LINK
Install the drive chain. o
o
Install the master link with D-rings and chain retaining clip.
Note the installation direction of the chain retaining clip.

Its open end should face in the opposite direction of the wheel
rotation as shown.
Adjust the drive chain slack.
CAUTION
D 13) (NO SPACE)
Do nOf assemble the drive chain without the jour O-rings. Be
(21 OUT SIDE (5) O-RINGS
sure tha/lheN> is no space belwt't"n the master fink and chain re-
laining clip.
SLIDER
DRIVE CHAI N SLIDER
Remove the drive sprocket cover .
Inspect the chain slider for excessive wear .
SERVICE LIMIT: (from upper surface I: 3 mm 10 .1 Inl

3mm I
Install the drive sprocket cover.
BRAKE SHOE WEAR r ~1 '''INDiCATOR PLATE filii'

FRONT BRAKE
Replace the brake shoes if the indicator plate aligns with the
brake panel index mark when the ' ront brake lever is applied.
REAR BRAKE f
Replace the brake shoes if the indicator plate aligns with the
brake panel index mark when the rear brake lever or pedal is
applied.
(2) INDEX MARK
3-10
MAINTENANCE
BRAKE SYSTEM
FRONT BRAKE
25 - 30 mm
Check the cable and brake lever for loose connections, exces-
sive plav. Of other damage. Replace or repair if necessary_ ~::~::~~::::r1-~1' ~ ,- t /4 in)
Disconnect the brake cable at the upper end .

Inspect the brake cable for kinks or damage, and thoroughlv lu-
bricate the cable and pivot point w ith a commercially available
cable lubricant to prevent premature wear . Install the brake
cabl'!.
FRONT BRAKE LEVER FREE PLA Y (1f ADJUSTER LOCK NUT
At the tip of the brake lever, measure the distance the lever
moves before the brake starts to take hold.
FREE PLAY: 25-30 mm (1 - 1 -1/4 in)
Minor adjustments can be made with the upper adjuster.

Slide the dust cover off the adjuster, loosen the lock nut and
adjust the free play by turning the adjuster.
Tighten the lock nut with a pair of pliers after adjustment.
Major adjustments should be made with the lower adjusting

nut at the hont brake arm.
NOTE
Make sure the cut~out on the adjusting nut is seated on the
brake arm pin.
Recheck the brake lever free play.
REAR BRAKE
Check the cable, brake lever and brake pedal for loose connec-
tions, excessive plaV or other damage.
Replace or repair if necessarv.

Disconnect the brake cables at the brake lever or pedal end.
Inspect the brake cable for kinks or damage, and thoroughlv lu-
bricate the cables and their pivot point with a commerciallv
available cable lubricant to prevent premature wear.
Install the cables.
25 - 30 m:m:.-...L~=::;""';;;;;::IIIII
REAR BRAKE LEVER FREE PLAY
It - 1. 1/4"",'n"I...,--._
~ .......-
Measure the rear brake (parking brake) lever free plav at the
end of the brake lever.
FREE PLAY : 25-31)..mm 11 - 1 -114 in l
3-11
1
MAINTENANCE
Minor adjustments can be made with the upper adjuster. (1) ADJUSTER (2) DUST COVER
Slide the dust cover off the adjuster, loosen the lock nut and
adjuSt the brake lever free play by turning the adjuster.
Tighten the lock nut with a pair of pliers alter adjustment .
(3) LOCK NUT
Major adjustments should be made with the brake lever adjust . LEVER ADJUSTING NUT
ing nut at the rear brake arm.
NOTE
Make sure the cut -out on the adjusting nut is seated on the
brake arm pin.
Recheck the brake lever free play.

:?" ~
•
REAR BRAKE PEDAL HEI GHT
To adjust:
Loosen the lock nut and adjust the brake pedal height by turn -
ing the stopper bolt. Tighten the lock nut.
Adjust the brake pedal free play _
REAR 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 13/4 - 1-114 inl
3-12
MAINTENANCE
If adjustment is necessary, turn the brake pedal adjusting nut

al the rear brake arm.
NOTE
Make sure the cut-out of each adjusting nul is seated on the
brake arm pin.
Recheck the brake pedal free play.
~RM(E PEDAL AU.JU>
BRAKE LOCK LEVER (1) BRAKE LOCK LEVER

(2) REAR BRAKE
'86 : LEVER
A brake lock adjustment may be required if the brake lock does
not hold the rear wheel.
Check the rear brake lever free play and adjust the reaf brake
b v turning the adjusting nut.
Pull the rear brake lever back and lock it.
HEADLIGHT AIM
Adjust the vertical beam by turning the adjusting screw on the
headlight cover .
-
CLUTCH SYSTEM
With the engine off, loosen the clutch adjusting screw lock
nut.
Slowly turn the adjusting screw counterclockwise until resis

tan ce is felt . Then turn the adjusting screw clockwise 1/4 turn,
and tighten the lock nur.
TORQUE ; 19 -25 N·m 11 .9 - 2 .5 kg·m , 14 - 1 B ft-Ibl
After adjustment. start the engine and check for proper clutch
operation.
3-13
MAINTENANCE
GEARSHIFT PEDAL PIVOT

The height of the gearshift pedal can be adjusted.
To adjust, loosen the gearshift pedal adjuster lock nuts and
turn the adjuster as necessary.
Tighten the lock nut.
TOROUE : 8 - 12 N·m 10.8 - 1.2 kg-m . 6 - 9 ft -fbl
NOTE
Adjust the pedal so it will not Inlerfere with proper pedal op-
eration.
The adjuster should be threaded into the joints on both ends 131 GEARSHIFT PEDAL LOCK NUTS
by at least half its entire length .
Il) SIDE STAND (2) PIVOT BOLT AND

SIDE STAND LOCK NUT
Check the side stand spring for damage and loss of tension.
Spring tension is correct if the measurements fall within 2 - 3
kg {4 .4 - S.6 Ibl with the side stand lower end pulled with a
spring scale.
Check that t he side stand pivot is not bent and that it moves
freely.
Tighten the Pivot boll and lock nut if necessary.
TORQUE :
PIVOT BOLT: 10 - 20 N·m 11.0 - 2 .0 kg·m . 7 - 14 ft·lbl
LOCK NUT: 35 - 45 N·m 13.5-4.5 kg·m , 25 - 33 ft·lbl
Lubricate the pivot with grease.
SUSPENSION
'" %
/)0 not ride a IIIQlOrqcle with fault)' SUl"pens;on. I. oose. worn
or domagnt suspension porrs impair motorc}'cle sfObility and
cottrrol.
Check the action of the frontJrear shock absorber by com·

pressing them several times.
Check the entire shock absorber assembly for leaks or dam·

age . Replace damaged components which cannot be repaired.
3-14
MAINTENANCE
Raise the rear wheel using the box or workstand.

Move the rear wheel sideways with force to see if the swing
arm bushings are worn.
NOTE
If rear wheel has excessive free play, remove the wheel and
move the swing arm sideways with fo rce to determine
whether the swing arm pivot bushings or wheel bearings
are worn.
Replace them if they are excessively worn.

Refer to page 12-4 for rear wheel hub bearing replacement and
page 12-' 2 for swing arm pivot bushing replacement.
Check the entire rear suspension being sure everything is se- / 1} SWING ARM GREASE FITTING
curely mounted and not damaged or distorted .
Torque all nuts and bolts. '"
loosen the swing arm pivot nut and pump grease into the
swing arm pivot bearings through t h e grease fitting on the
swing arm.
~(2) PIVOT NUT ...
SPARK ARRESTER
Do not touch the exhaust components while the exhaust system

is hot.
Perform this operation in a well-L'entilated area. free from fire
hazard.
Use adequate eJ'e protection.
Remove the bolts. gasket and spark arrester lid.

Block the end of the muffler with a shop towel.
Sum the engine with the transmission in neutral , and purge ac-
cumulated carbon from the muffler bV momentarilv revving up
the engine several times.
Stop the engine and allow the exhaust system to cool.
Make sure that the bolts and gasket are in good condition. Re-
place tl)ej)olts and gasket if necessary.
~
Install ihe'gasket and spark arrester lid, and tighten the bolts '\
securely.
)
NUT, BOLT, FASTENER
~ (1) GASKET
Tighten bolts, nuts and fasteners at regular intervals shown in
the Maintenance Schedule (page 3 -2).
- - 12) SPARK ARRESTER LID
Check that all chassis nuts and bolts are tightened to their cor-
<kll 11.
,
rect torque values Ipage 1·51. Check that aU cotter pins and (3) BOl T5
safety clips are in place.
3-15
MAINTENANCE
WHEEL
Check the tires for cuts. embedded nails, or other damage.
Check and adjust the tire pressure.
Re commended pressure Front and Rear :

4 .3 ~ 0.4 psi (30 ± 3 kPa. 0.3 ± 0 .03 kg /cm 2j
NOTE
• Tire pressure should be checked when the tires are COLD.
d
STEERING HEAD BEARINGS
Raise the front wheel off the ground and check th at the
handlebar rotates freely. Check that the control cables do not
interfere with handlebar rotation.
Move the front fork forward and backward and check that it is
not loose.
If the handlebar moves unevenly, binds, or is loose, adjust the
steering head bearings by turning the steering head bearing ad-
justment nut (page' 1-21).
CYLINDER COMPRESSION
Warm up the engine.
Stop the engine and remove the spark plug.
Install a compression gauge.
Open the throttle all the way and crank the engine with the
start er' motor until the gauge reading stops rising.
NOTE
The maximum reading is usually reached within 4 -7 sec-
onds.
COMPRESSION PRESSURE:
1,275 :t 98 kPa 113 .0 ± 1 .0 kgl cm 2 , 184 ± 14 psil
Low compression can be caused by :

Blown cylinder head gasket
Improper valve adjustment
Valve leakage
Worn piston ring or cylinder
High compression can be caused by:

- Carbon deposits in combustion chamber or on piston head
3-16
MEMO
FUEL SYSTEM
After ' 86
4 -0
4. FUEL SYSTEM
SERVICE INFORMATION 4 -1 CARBURETOR DISASSEMBLY 4 -6
TROUBLESHOOTING 4-2 CARBURETOR ASSEMBLY 4-8
FUEl TANK 4-3 THROTTLE VALVE 4-9
AIR CLEANER CASE 4 -4 CARBURETOR INSTALLATION 4-10
THROTTLE VAL VE DISASSEMBLY 4 -6 AIR SCREW ADJUSTMENT 4-10
CARBURETOR REMOVAL 4-6 HIGH ALTITUDE ADJUSTMENT 4 -11
SERVICE INFORMATION
GENERAL
I¥#iiiii!d
Casoline is extremely flammable and is explosil'e IInder cerlain conditiolls. Work in a ...elll'f!milated area. Do not smoke or 011011'
/lames or sparks in the work QreQ.C._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ __ _ _ _~_ _ _
• When disassembling the fuel system parts, note the location of the O-rings. Replace them wi th new ones on reassembly.
• Before disassembling the carburetor drain the fuel in the float chamber by opening th e drain screw.
CAUTION
• Do not bend or twist camral cables. Damaged con/rol cables .....il1nOI operate smoolhly alld may Slick or bind.
SPECIFICATIONS
Fuel tank capacity 7.0IitI1.9U5gal.l.5 Impgall

Fuel reserve capacity 2.0 lit W.5 US gal. 0.4 Imp gal)
Carburetor
I'- ~ndentificatlon number PO 69A
Type Single valve
Venturi diameter 24 mm (0. 94 in)
Float level 14 mm (0.55 in)
Air screw opening
Idle speed
- 1- 1/4 turn s out
1 ,400 :to 100 rpm
#95
r-- ~:: ~:: #50
Throttle lever free play 2 - 6 mm (1 / 8 - 1/4 in)
Jet needle 3rd groove
TOOL
Common
Float level gauge 07401-0010000
4-1
FUEL SYSTEM
TROUBLESHOOTING
Engine c ranks but won't start lean mixture
No fuel in tank Clogged fuel jets
Restricted fuel line Faulty lIoat valve
- Clogged fuel line or fuel strainer screen low float level
- Pinched fuel tank vent tube Blocked fuel cap vent tube
Engine flooded with fuel Clogged fuel strainer screen
No spark at plug Ifaulty ignition system) Intake air leak
Low cylinder compression Clogged air vent tube
Intake air leak
Improper choke operation Rich mixture
Incorrect choke cable adjustment Clogged air jets
Improper throttle operation Faulty float valve
Float level too high
Hard starting or stalling after starting Carburetor choke stuck closed
Improper choke operation Cloggde air cleaner
Incorrect choke cable adjustment Incorrect choke cable adjustment
Ignition malfunction
Restricted fuel line
- Clogged fuel line or fuel strainer screen
- Pinched fuel tank vent tube
Lean or rich mixture
Contaminated fuel
Intake air leak
Incorrect idle speed
low cylinder compression
Rough idle
Improper choke operation
Incorrect choke cable adjustment
Ignition malfunction
Restricted fuel line
- Clogged fuel line or fuel strainer screen
- Pinched fuel tank vent tube
lean or rich mixture
Contaminated fuel
Intake air leak
Incorrect idle speed
low cylinder compression
Misfiring during acceleration

Faulty ignition system
Lean mixture
Intake air leak
Back firing during deceleration

lean mixture
Poor performance (driveability) and poor fuel economy

Clogged fuel system
Air cleaner clogged
Rich mixture
4-2
FUEL SYSTEM
FUEL TANK
Remove the seat, right and left side covers.
Turn the fuel valve OFF.
Disconnec t the fuel line from the fue l valve.
Remove the two fuel lank mounting bolts and pull the fuel tank
back and remove it from the frame.
II
K"p gasoline Ok'OJ' from flames or sparks.
Wipe up spilled gasoline at onu.
Use a drain pan and check thai fuel fl ows freely out of the fuel
valve by turning the fuel valve ON .
If fl ow is restricted, clean the fuel strainer and fuel filter screen

(page 3·41.
Check the vent tube of the filler cap for blockage.

Installation is the reverse order of removal.
Alter Installation, make sure there Bre no fuel leaks.
""
~ 121 FUEL FiLLER CAP
~
11) FUEL TANK
f (3) FUEL FIL TEA SCREEN
~
0'
: ~:"",u~
(61 FUELSTRAI~0 " (4 ) D-RING
SCREEN A
~--(51 FUEL CUP
4-3
FUEL SYSTEM
AIR CLEANER CASE

Remove the following:
seat and side covers.
- main fuse, starter relay and alternator couplers/ wires from
the air cleaner case.
- air cleaner case cover.
- battery (page 15-2).
- tool box cover.
Loosen the exhaust muffler clamp bolt and remove the two
mounting bolts and exhaust muffler.
Loosen the air cleaner case-ta-carburetor connecting band
screw .
Remove the reaf fender B by removing the four mounting

bolts.
Remove the regulator/ rectifier mounting bolt.

Remove the air cleaner case mount plate bolts and nut, then
remove the plate.
4-4
FUEL SYSTEM
Slide the air cleaner case backward and remove it hom the
frame.
Install the removed parts in the reverse order of removal.
(8 ) CLEANER CASE MOUNT

PLATE
(1) AIR CLEANER CASE COVER
12) AlA CLEANER ELEMENT

V~,
PI CARBURETOR CONNECTING TUBe (6) DRAIN TUBE 15 ) AlA CLEANER CASE

(9) BATTERY
STAY
4-5
FUEL SYSTEM
CARBURETOR REMOVAL
Remove the fuel tank (page 4-3).
Remove the carburetor top from the carburetor.
Drain the fuel from the carburetor by loosening the drain
screws.
Disconnect the air vent and drain tube from the carburetor.
loosen the choke cable clamp and disconnect the choke cable
from the lever.
Remove the ca rburetor attaching nuts and loosen the air clean - (4) ATTACHI NG ~ U !1:k,;. oiD,« CABLE CLAMP
er connecting tube band screw.
Remove the carburetor.
TUBE
CARBURETOR DISASSEMBLY
THROTTLE VALVE REMOVAL
Remove the throttle cable from the throttle valve while de-
pressing the throttle valve spring.
CAUTION
The CQrburetor top is un inltgrol pari oj the throtlle cable as-
sembly_ The CQrburetor top con not be separa/ed from the as-
sembly wilhoUl causing damage to the cable.
Rem ove the needle clip retainer. (1) THROTTLE VALVE

Remove the jet needle and needle clip.
j
I ,"[H","'"
m JET NEEDLE
Inspect t he throttle valve and jet needle surfaces fo r dirt
scratches or wear.
I
(4 ) RETAINER
4-6
FUEL SYSTEM
FLOAT AND JETS f1) FLOAT CHAMBER
Remove the three float chamber screws and the float cham-
ber.
\ I
•
•
,
Remove the float pin, baffle plate. 110at and float valve. (1 ) BAFFLE PLATE
...J
Inspect the float valve for grooves and nicks, and rep lace as r e- (1) FLOAT VALVE SEAT
quired.
Inspect the operation of the float valve.
Remove the main jet, needle jet holder and needle jet. (1) NEEDLE JET HU,CUt,H
Remove the slow jet. MAIN JET
Remove the throttle stop screw.
• ••
(3) SLOW JET,
\
\
(4) THROTTLE STOP SCREW
4-7
FUEL SYSTEM
Turn the air screw in and record the number of turns before it
seats lightlV. Use this as a reference for reinstallation.
CAUTION
Damage 10 the air screw seat will occur if the ai, screw is tight-
ened againsl the seat.
Remove the air screw.
Inspect the air screw and each jet and replace them if they are
worn or damaged.
Blow open all jets with compressed air.
(1) AIR SCREW
, SPRINGS
(3) THROTTLE
STOP
(6) NEEDLE
SCREW
JET
HOLDER
(7) MAIN \
JET
\ \
I
NEEDLE JET
(5) SLOW JET
Blow open all carburetor body openings with compressed air.
CARBURETOR ASSEMBLY
FLOAT AN D JETS
III AIR SCREW
(2) SPRINGS
'.
Install the air screw and return it to its original positon as noted
during removal.
Perform an air screw adjustment if a new air screw is installed
(6) NEEDLE
--<: (3) THROTTlE
STOP
SCREW
(page 4 -1 Of.
JET
I
HOLDER
Install the throttle stop screw.

Install the needle jet, needle jet holder and main jet.
Install the slow jet. {7) MAIN\
JET
\" ~
CAUTION
Handle all jels wilh care. They can easily be scored or
scratched. (5) SLOW JET (4) NEEDLE JET
4-8
FUEL SYSTEM
Install the float valve, float, float pin into the carburetor body. !1) fLOAT
Check the float valve operation.
FLOAT LEV EL INSPECTION 111 CHIOK'.!!:
With the float valve seated and the float arm just touching the
valve, measure the float level with the float level gauge as
shown.
SPECIFICATIONS : 14 mm 10.55 in)
TOOL:
Float le vel gauge 01401 - 0010000
NOTE
Incline the carburetor body to sel the float level gauge. (21 FLOAT LEVEL GAUGE
Do not allow the choke lever 10 hit the gauge.
( 1) BAFFLE PLATE
Replace the float if the level does not meet the specification.
Check that the choke valve operates properly by moving the
choke lever.
Install the baffle plate .

Install the float chamber and tighten the screws.
.'"' • •
/p::
(2) FLOAT CHAMBER SCREWS
THROTTlE VALVE 111 THROTTLE VALVE
Install the needle clip on the jet needle. I 12I;ET NEEDLE

STANDARD SETTING: 3rd groove
Install the jet needle into the throttle valve and secure it w ith
the needle clip retainer.
141 NEEDLE CLIP /
(3 1 RETAINER
4 -9
FUEL SYSTEM
Assemble the carburetor top, throttle valve spring and throttle

valve, and connect the throttle cable to the throttle valve.
I
CARBURETOR INSTALLATION
Install the carburetor between the intake manifold.
Reconnect the connecting tube to the carburetor and tighten

the nuts and tube band screw securely.
Connect the drain and air vent tubes to the carburetor body.
(4) ATTACHING """"'VO CABLE CLAMP
Connect the choke cable to the choke arm, adjust the choke
cable and check the choke valve operation by pulling the choke
knob (page 3- 5).
NOTE
Route the throttle and choke cables and overflow and air
vent tubes properly _
Make sure that. the drain screw on the float chamber is lIght-
ened.
Align the throttle valve groove with the throttle stop screw,
and install the thranle valve into the carburetor and the carbu-
retor top onto the carburetor.
Install the fuel tank (page 4-3) .
Check the throttle operation (page 3-4\.

Adjust the carburetor idle speed (page 3-B\.
AIR SCREW ADJUSTMENT

NOTE
The air screw is factory pre-se t. Adjustment is not neces-
sary unless Ihe carburetor is overhauled or a new air screw
is installed.
CAUTION
Damage {O Ihe air screw seal will fXy.:ur if Ihe air screw is fighl-
ened againsl fhe seal.
1. Turn the air screw clockwise until it seats lightly and then
back it out to the specification.
AIR SCREW OPENING: t - t /4 turn s OUI
This is an initial selling prior 10 the final air screw adjust-

ment.
4 -10
FUEL SYSTEM
2. Warm the engine up 10 operatIng t emperature.

3. Stop the engine and connect a tachometer.
4. Start the engine and adjust the idle speed with the throttle
stop screw.
IDLE SPEED: 1.400 ± 100 rpm
5. Turn the air screw in or out slowly to obtain the highest

engine speed.
6 . Readjust the idle speed to the specified value with the throt-
tle stop screw.
7. Make sure that the engine does not miss or run erratically.
Repeat steps 5 and 6 until engine speed increases smooth-
IV·
8. readjust the idle speed with the throttle stop screw.
III MAIN JET

HIGH ALTITUDE ADJUSTMENT
SPECIFICATIONS
Below
6,000 ft (1,800 ml
Above
5,000 ft 11,500 ml
L •
Main jet #95 #88
The carburetor must be adjusted for high altitude riding (above

6,000 It/l.BOO m).
STANDARD SETTING : 6, 000 111 1,800 m ) m ax .

HIGH ALTITUDE SETTING : 5,00 0 ft 11 ,500 m ) min .
The hIgh altitude carburetor adjustment is performed as fol·

lows:
Remove the seat and SIde covors.

Turn the fuel valve off and disconnect the fuel line from the
carburetor.
Remove the carburetor ~page 4 -6).
Remove the three attaching screws and float chamber.
Replace the standard main jet with the high altitude size 1#88 ).
Assemble and install the carburetor.
Start the engine and adjust the idle speed at high altitude to
ensure proper high altitude operation.
CAUTION
S/iSToined operation below 5,0Q0 II (I ,5(J() mj with the high a/Ii·
rude setlings may couse engine ow!'rheOfing and engine damage.
Install the #98 main jet when riding below 5,000 II (I,5(J() rIIj.
4-11
ENGINE REMOVAL/INSTALLATION
30 - 36 N·m (3 .0 - 3 .6 kg -m ,
22 - 26 !t·lb)
60 - 70 N·m
(6 .0 - 7 .0 k g-m ,
43 - 51 h·tbl 60 - 70 N·m
~~;::::~~~=_- (6.0 - 7,0 kg-m ,
~ 43 - 51 ft -tb )
30 - 36 N·m
13 .0 - 3.6 kg-m ,
2 2 - 26 ft ·lbl 14 - 18 N·m
/1 ,4 - 1.8 kg-m . 70 - ""0 N·m (7 .0 - 8 .0 kg-m ,
10 - ' 3 ft·lb) 51 - 58 ft-lbJ
(
30 - 36 N·m
(3.0 - 3 .6 kg-m ,
22 - 26It-tbl
i'
70- 80
17 .0 - 8 .0 kg-m, ,
5 1 - 58 ft -tb)
•
5-0
•
5. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMA nON 5-' ENGINE INSTALLATION 5-4
ENGINE REMOAL 5-2
SERVICE INFORMATION
GENERAL
• Parts requiring engine removal for servicing:

Transmission (page 10-4)
• Shift drum and shift fo rks (page 10-4)
• Crankshaft (page 10- ' O!
SPECI FI CATION S
Engine oil capacity ' .8 lit /1.9 US qt, 1.6 Imp qU after disassembly
1.5 tit (1.6 US qt , 1.3 Imp qtl after draining
Engine dry weight 36 kg (79 Ibs)
TORQUE V ALUES
Engine hanger boh and nut 8 mm 30 - 36 N·m (3 .0 - 3.6 kg -m. 22 - 26 ft-lbJ

10mm 60 - 70 N·m (6 .0 - 7 .0 kg -m. 43 - 5 1 ft-lb J
Engine mounting bolt and nut 10 mm 60- 70 N'm (6.0 - 7 .0 kg -m, 43 - 51 h-lbJ
Right and left loolpeg bolt 70 - 80 N·m 17 .0 - 8.0 kg-m. 51 - 58 ft-lb J
Gearshift pedal arm bolt 14 - 1 8 N·m Cl.4 - 1.8 kg-m. 10-13 ft-lb )
5-1
,,
,
ENGINE REMOVALIINSTALLATION
ENGINE REMOVAL (1) BATTERY NEGATiVE

CABLE
~ seat and side covers.
~ fuel tank (page 4 ·3).
- exhaust pipe and muffler (page 13-3),
- skid plate.
.,
.. Shift the transmission into neutral.
Drain the engine oil (page 2·2) .
Disconnect the battery negative cable from the battery.
Place a workstan r other support under the engine.
-
Disconnect the engine breather tube at the cylinder head (1) BR:E2Cfj1Ei"'liilE
cover.
Remove Ihe carburetor (page 4-6).
Disconnect the spark plug cap from Ihe spark plug.
Remove Ihe starter cable from the starter motor.

Remove the engine ground cable from the engine.
Disconnect the alternator couplers and wires.
Remove the gearshift pedal and left footpeg.

f Remove the drive sprocket cover.
5-2
ENGINE REMOVAL/I NSTALLATION
Loosen the rear axle nul and both drive chain adjusting nuts. ( 21 ADJUSTING " " "' -.,
Push the rear wheel forward.
Remove Ihe drive sprocket mounting bolts and drive sprocket.
Remove the right footpeg .

Unhook the brake pedal return spring from the swing arm,
Remove the brake pedal pivot shah by removing the brake
pedal.
Remove the front upper and lower hanger bollS, nuts and .. _ (1) UPPER HANGER PLATESi
4-- (2) REAR
plates.
Remove the rear hanger bolts and plate.
Remove the rear mounting bolt , nut and collar .
(3)
I
14 ) REAR MOUNTI
5-3
Remove the engine from the right side.
ENGINE INSTALLATION
NOTE
Be sure to use the engine mounting bolts in their correct po-
sitions.
Install the engine onto the frame.

, (1 ( COLLAR
Install the 10 mm rear mounting bolt , collar and nut.
Tighten the nut lightly.
Install the front lower hanger plates . 8 mm and 10 mm bolts 111 B mrn BOLTS
and nuts .
Tighten the nuts lightly.
5-4
Install the rear hanger plate, 8 mm and 10 mm bolts.

Tighten the bolts lightly .
Install the front upper hanger plates, 8 mm and 10 mm bolts

and nuts.
Tighten the nuts lightly .
Tighten the all fasteners to the specified torque.
TORQUE :
Engine hanger plates/mounting bolts and nuts:
•
8 mm bolt and nut :
30 - 36 N·m (3.0 - 3.6 kg-m . 22-26 ft -Ibl
10 mm bolt and nut :
60 - 70 N·m (6.0 - 7 .0 kg-m, 43 - 51 ft-fb l
Right and left foorpsg bolts:

70 - 80 N·m !7 .0 - 8.0 kg-m, 51 - 58 ft -Ib)
Engine installation is essentially the reverse of removal.
NOTE
Route the wires and cables properly (page 1-9) ,
Fill the crankcase to proper level with recommended oil
(page 2-21.
After installing the engine, perform the following inspections

and adjustments:
- Throttle grip free play Ipage 3 -4 ).
- Rear brake pedal free play (page 3 - 12).
- Drive chain slack (page 3-8).
- Eleclric operalion.
- Exhaust gas leaks.
5-5
CYLINDER HEAD/V ALVES
10 - 14 N-m 11.0 - 1 .4 Kg -m,

7 - 10 ft·lb)
10 - 14 N-m 11. 0 - 1.4 Kg-m,

7 - 101t-lb
10 - 14 N·m " ,0- 1 .4 Kg-m,

7 - 10 ft -Ib)
~~
.
" 14N·m
<I f~-Ib)
10 - 14Kg-m .
t 1.0 -
7-
lQ - 14N-m (1 .0 - 1.4 Kg -m,

7 - 10 ft·lb9
12 - 1SN·m
1 2 - 1.9 Kg-m,
9~ 14 ft -Ib)
6-0
6. CYLINDER HEAD/VALVES
SERVICE INFORMATION
TROUBLESHOOTING
CYLINOER HEAD COVER REMOVAL
CYLINDER HEAD COVER
DISASSEMBLY
CAMSHAFT REMOVAL
CYLINDER HEAD REMOVAL
CYLINDER HEAD DISASSEMBLY
VALVE GUIDE REPLACEMENT
SERVICE INFORMATION
GE NERAL
• This section covers maintenance of the cylinder head, valves, camshaft and rocker arms.
• Camshaft and rocker arm lubrication oil is fed through oil passages. Be sure the passages are not clogged.
• Valve spring colors are used to indentify the manufacturers.
The valve springs are marked with either white or yellow paint. When replaCing the valve spring, use the one with samE!,
paint mark .
SPECIFICATIONS

Cylinder compression pressure 1,275 + 98 kPa (13 .0 + 1.0 kg /cm 2 , 184 + 14 psi) --
Camshaft Cam lobe height IN 34.371 mm ( 1.3532 in) 34.191 mm (1.3461 in)
EX 34 .242 mm (1.3481 in) 34.062 mm (1.34 10 in)
Rocker arm Rocker arm 1.0. 12 .00Q - 12 .018 mm (0.4724 - 0.4731 in) 12.05 mm (0.474 in )
Shalt 0.0 11 .966- 11 .984 mm (0.4711 -0.4718 inl , 1.93 mm (0.470 in )
Valve Valve stem IN 5.475-5.490 mm (0.2156-0.2161 in) 5.45 mm (0.215 in )
0.0. EX 5. 4 55- 5.470 mm (0.2' 48 - 0.2154 in) 5.43 mm (0.214 in )
Valve guide 1.0. 5.500-5 .512 mm (0.2165-0 .2170 in) 5.52 mm (0.217 in)
Stem-l a -guide IN 0 .010 - 0 .037 mm (0.0004 - 0.0015 in) 0.12 mm (0 .005 in)
clearance EX 0 .030 - 0 .057 mm (0.0012 - 0.0022 in ) 0.1 4 mm (0.006 in)
Valve YeUow 31 .69 mm (1 .248 inl 29.5 mm (1.16 in)
Inner
spring 32.50 mm (1.280 in) . 30.5 mm (1.20 in )
White
free
length Yellow 38 .54 mm (1.517 in ) 415.5 mm (1.44 in)
Outer
Whi t e 36.90 mm (1.453 in) 35.0 mm 11.38 in)
Valve seat width ,., mm (0.0 4 3 in ) 1.4 mm (0 .055 in )
Cylinder head warpage - - 0.10 mm (0.004 in )
TORQU E VA LUES
Cylinder head B mm nut 28 - 30 N'm (2 .8 - 3 .0 kg-m. 20 - 22 ft -lb )

Spark plug 12 - 19 N·m (1.2-1.9 kg -m. 9-14 ft -Ib)
Camshaft bearing holder 10 - 14 N-m (1.0 - 1.4 kg -m. 7 - 10 ft -\b \
Valve adjuster lock bolt 10 - 14 N·m (1 .0 - 1.4 kg-m. 7-10 ft-Ib )
Rotor cap 10- 20 N·m (1.0- 2.0 kg-m. 7 - 14 ft -Ib)
6-1
TOOLS
Special
Valve guide reamer, 5.5 mm 07984 - 2000000
Common
Valve guide remover, 5.5 mm 07742-0010100 or 07942 - 3290100
Valve spring compressor 07757 - 0010000 or 07957 - 3290001
Driver handle B 07746 - 0020100 or 07749 - 0010000 (U.S.A. only)
Attachment, 15 mm 07746-0020200 or M9360- 277 -9 1775 (U.S.A. only)
Valve seat cutters; (Not available in U.S.A.)
Valve seat cutter. 27.5 mm (EX 45°) 07780-0010200
Valve seat cutter, 33 mm (IN 45°) 07780-0010800
Valve seat cutter, 28 mm (EX 32°) 07780 - 0012100
Valve seat cutter, 33 mm (IN 32°) 07780 - 00 12900
Valve seat cutter, 30 mm (IN/EX 60°) 07780 - 0014000
Valve seat cutter holder, 5.5 mm 07781 - 0010101
TROUBLESHOOTING
Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing
noises with a sounding rod or stethoscope.
Low compression
• Valves
- Incorrect valve adjustment
- Worn or damaged valve seats
- Burnt or bent valves
- Incorrect valve timing
- Broken valve spring
• Cylinder head
- Leaking or damaged head gasket
- Warped or cracked cylinder head
• Faulty cylinder or piston (Section 7)
Compression too high

Execcive carbon build-up on piston or combustion
chamber
Exessive noise
Incorrect valve adjustment
Sticking valve or broken valve spring
Damaged or worn camshaft
Loose or worn cam chain
Worn or damaged cam chain tensioner
Worn cam sprocket teeth
Worn rocker arm and or shaft
Excessive smoke
Damaged valve stem seal
• Faulty cylinder or piston rings (Section 7)
6-2
CY LINDER HEAD/VALVES
CYLINDER HEAD COVER REMOVAL

Remove the engine from the frame (Section 5).
Remove the valve adjuster cover.
Remove the rotor-csp and timing hole <;8p from the left crank-
case cover.
Remove the liming hole cap from the cylinder head cover. m INDICATOR PLATE
Align the " T'l mark on the flywheel with the index mark on the
Ileft crankcase cover.
Turn the crankshaft slowly until timing indicator plale faces up
to position the cam lobes down.
Remove the six bolts and breather cover.

Remove the a-rings from the cylinder head cover.
Remove the cylinder head cover mounting bolts and nut.
Remove the cylinder head cover and dowel pins.

Remove the rubber gasket from the cylinder head cover.
6-3
CYLINDER HEAD COVER DISASSEMBLY t1 ) ROCKER AR'~S, (2) ROCKER ARM SHAFTS
-.J~~~.A DJUSTEAS )
Remove the rubber gasket from the cvlinder head.
Remove the valve adjuster lock bolts.
Remove the rocker arm shafts Ivalve adjusters) and rocker
arms from the head cever.
LOCK BOLTS
Remove the circlip and decompressor cam from the shaft of

decompressor lever,
Remove the decompressor lever and return spring from the

cvlinder head cover.
<31 DECDM'>RES.sOR
14 , S P R I N G / LEVER
IN SPECTION 11, ROCKER ARM
Rocker arm
Inspect the rocker 8fms lor wear or damage to the camshaft
/
contact surfa ce or for a clogged oil hole.
Measure the I.D. of each rocker arm.
SERVICE LIMIT: 12.05 mm 10.474 in)
Rocker arm shah 11' ROCKER ARM SHAFT

Inspect the sliding surface of the rocker arm shaft for wear or
damage.
Measure each rocker arm shaft 0 .0 .
SERVICE LIMIT: 11 .93 mm (0.470 in'

I
6-4
CAMSHAFT REMOVAL (1) CAM CHAIN TENsmmR
Loosen the sealing bolt of the cam chain tensioner.

Remove the tw o cam chain tensioner attaching bolts and the
tensionar.
Remove the two camshaft bearing holder boilS and the bearing (2) BEARING
holder.
Remove the cam chain from the cam sprocket.
Suspend the cam chain with a piece of wire to keep it from fail-
ing into the crankcase.
Remove the camshaft.
NOTE
• Be careful not to drop foreign material into the crankcase.
INSPECTION
Check each cam lobe for wear or damage.

Measure the cam lobe height.
SERVICE LIMITS;
INTAKE : 34.19 1 mm )1. 3461 inl
EXHAUST : 34.062 mm (1.3410 in)
Check each camshaft bearing for play or damage.
Turn th e outer race of each bearing with your finger.

The bearings should turn smoothly and quietly
Replace the camshaft assembly with a new one if the right
camshaft bearing does not turn smoothly and Quietly.
NOTE
• The right camshaft bearing cannot be removed.
For left camshaft bearing replacement, remove the snap ring. (1) SNAP RING 121 IN[lIC,"()R PLATE
timing indicator plate, and bearing using a bearing puller.
Drive a new bearing onto the camshaft.
TOOLS;
Driver handle B 07746 - 0020100 or
07749 - 00 10000
(U.S.A. only)
Attachment, 1 5 mm 07746 - 0020200 or
M9360 - 277 - 9 1775
(U.S.A . only)
Install the timing indicator plate and snap ring.
6-5
CYLINDER HEA D/V ALVES
CYLINDER HEAD REMOVAL

Remove the two cylinder head cap nutS, four cylinder head
nuts and washers.
Remove the cylinder head.
Remove the cylinder head gasket and two dowel pins .
CYLINDER HEAD DISASSEMBLY

Remove the engine mount bracket and intake pipe from the
cylinder head.
Remove the spark plug .
Remove the valve spring cotters, relainers, springs, spring

seats and valves.
TOOL:
Valve spring compressor 07757 - 0010000 or
07957 - 3290001
CAUTION
To prevent loss 0/ tension, do nor compress the vull's springs
more thon necessary /0 'emo~'e (he cOllers. (1) VALVE SPRING COMPRESSOR
NOTE
• Mark all disassembled parts to ensure correct reassembly.
Remove the valve stem seals.
Remove carbon deposits from the combust ion chamber.
INSPECTION
Cylinder hoad
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight edge and
feeler gauge.
SERVICE LIMIT : 0.10 mm (0 .004 Inl
6-6
....
-
Valve spring
Measure the free length of the inner and outer valve springs .
SERVICE LIMITS:
INNER (IN . EX) : Yellow : 29 .5 mm 11.16 inl
White: 30.5 mm (1.20 in)
OUTER (IN , EX): Yellow : 36 .5 mm 11 .44 in)
White : 35.0 mm (1 .38 in)
NOTE
The valve springs are marked with either white or yellow
paint. When replacing the 1181ve spring, use the one with
same paint mark .
Velve stem-ta-guide clearance

Inspect each valve for bending, burning, scratches or
abnormal stem wear.
Check valve movement in the guide and measure and record
each valve stem 0 .0 .
SERVICE LIMITS:
IN : 5 .45 mm (0.215 in)
EX: 5 .43 mm 10.214 in)
NOTE (1) VALVE GUIDE R"'f-1"R
Ream the guide to remove any carbon build-up before

checking clearance.
Always rotate the reamer clockwise, never counter -
clockwise.
TOOL :
Valve guide reamer 07984 - 2000000
Measure and record each valve guide I.D ,
SERVICE LIMIT: 5.52 mm (0 ,217 in )
Subtract each valve stem 0 .0 , from the corresponding guide

1.0. to obtain the stem-to -guide clearance .
SERVICE LIMITS: IN : 0 . 12 mm (0 .005 in)

EX: 0 . 14 mm (0 .006 inl
6-7
If the stem-Ie-guide clearance exceeds the service limits, de-

termine if a new guide with standard dimensions would bring
the clearance within tolerance. If so, replace any guides as
necessary and ream to fit.
If the stem-Ie-guide clearance exceeds the service limits with
new guides also, replace the valves.
NOTE
Rafaee the valve seats whenever the valve guides are re -
placed.
VALVE GUIDE REPLACEMENT GUIDE REMOVER
Heat the cylinder head to 100- 150 oC i2 12 - 300 Q FI with a

hot plate or oven.
'WWiii!5
To ol'oid burns. wear heavy glol'tS whim handling Ihe heated
cylinder head.
CAUTION
Do nOt use Q IOrch to heat the cylinder head; il may calise
warping.
Support the cylinder head and drive out the old guides from the
combustion chamber side of the cylinder head. (1) VALVE GUIDE
TOOL :
Valve guide remover, 5.5 mm
CAUTION
07742- 0010100 or
079 4 2 - 3 2901 00 \
• A !loid damaging the cylinder head.
Place a new O~ring on the new valve guide .
/
(2) O-RING
I
Drive in the guide from the top of the head. t1I VALVE GUIDE REMOVER
TOOL:
V alve guide rem over, 5.5 mm 07742- 0010100 or
0 7 942 - 3 2901 00
Inspect the valve guide for damage .
6-8
Ream the new valve guide after installation. (1 ) VAL VE GU IDE REAMER
TOOL:
Valve guide reamer 07984 - 2000000
NOTE
Use c u tting oil on the reamer during this operation.
Always rotate the reamer clock wise, never counter-
clockwise.
Clean t he cylinder head thoroughly to remove any metal parti·

cles.
Aefaee the valve seat .
VALVE SEAT INSPECTION I REFACI NG

Clean the intake and exhaust valves thoroughly to remove
carbon deposits.
Apply a light coating of Prussian Blue to the valve seats. Lap
the valves and seats using a rubber hose or other hand-lapping
tool.
Remove the tool and inspect the width of each valve seat.
STAN DARD: 1. 1 mm (0.043 in)

SERVICE LIMIT: 1.4 mm (0 .055 in)
If the seat is too wide, too narrow or has low spots, the seat
must be ground.
CAU TION
The voh·es cOllnor be groUlld. Ij a vah·e jace is burned or badly
worn or if it COl1laClS the seat ulle~·ellly, replace the rall'e.
;=~~~~~~i~\(l ) SEAT WIDTH
VALVE SEAT CUTTERS
Honda Valve Seat Cutters, a grinder or e rquivalent vlave seat

rei acing equipment are recommended to correct a worn valve
seat.
NOTE
Follow the reface r manufacturer's operating instructions.
"'"
6-9
V ALV E SEAT REFACING

I
, 0 ) ROUGHNESS
Use a 45 degree cutter to remove any roughness or irregu-
larities from the seat.
~
NOTE ,
Ralaee the seat with a 4 5 degree cu tter when a valve guide .(
is replaced. 45 0
'/ \
Use a 32 degree cutter to remove t he top' 14 of the existing

valve seat material.
(1) OLD SEAT W IDTH
32 0
Use a 60 degree cutter to remove the bottom 1/4 of t he o ld

seat. Remove the cutter and inspect the area you have
fe f aeed. 11) OLD SEAT WIDTH
Install a 45 degree finish cutter and cut the seat to the proper
widt h . Make sure that all pitting a nd irregularities a re removed.
Refinish if necessary . 1.1 mm (0.04 in)
45 0
6-10
ApplV a thin coating of Prussian Blue to the valve seat. Press (1) CONTACT TOO HIGH
the valve through the valve guide and onto the seat to make a
clear pattern,
NOTE
(2) OLD SEAT WIDTH
The location of the valve seat in relation to the valve face is
very important for good sealing .
If the contact area is too high on the valve, the seat must be
lowered using a 32 degree flat cutter.
If the contact area is too Iowan the valve, the seat must be (,) CaNT ACT TOO LOW
raised using a 60 degree inner cutter.
(2) OLD SEAT WIDTH
Refinish the seat to specifications, using a 45 degree finish

cutter.
After cutting the seat, apply lapping compound to the valve
face, and lap the valva using light pressure.
After lapping, wash all residual compound off the cylinder

head and valve.
NOTE
• Do not allow lapping compound to enter the guides.
(1) OUTER SPR ING

CYLINDER HEAD ASSEMBLY (2) INNER SPRING
(3) SPRING SEAT
Install the valve spring seat and a new stem seal.
Lubricate the valve stems With molybdenum disulfide grease

and insert the valve into the valve guide.
To avoid damage to the stem seal, turn the valve slowly when
Inserting.
l
'.0
!
Install the valve springs with the tightly wound coils lacing the .......
(5) STEM SEAL
cylinder head. ~ (6) SPRING RETAINER
PI COTTERS
6 -11
•
CYLINDER HEAD/VAlVES
Install the valve spring retaine rs and install the valve cotters.
TOOL :
Val ve s pring compressor 07757 - 0010000 or
07957 - 3290001
CAUTION
To prev€nf loss oj tension, do not compress fhe valve spring
more than necessary.
Tap the valve stems gently with a plastic hammer to fi rmly

seat the cotters
CAUTION
SuPPOrt the cylinder head above the work bench surface to pre-
vent possible valve damage.
Install a new O-ring in the intake pipe groove and install the
intake pipe with two bolts.
Install the engine mount bracket and t ighten the bolts secure-
ly.
121 INT,," ' PIPE
CYLINDER HEAD INSTALLATION ,

Make sure th at the cam chain guide is positioned properly _
Install the dowel pins and a new cylinder head gasket.
6-12
Install the cylinder head.

Install the two 6 mm cap nuts, four washer and 8 mm nuts,
and t ighten them in the sequence shown in 2 or 3 steps.
TORQUE :
6 mm cap nut : 10 - 14 N-m 11 .0 - 1 .4 kg-m, 7 - 10 It-fb)
8 mm nut: 28 - 30 N·m (2.8-3. 0 kg-m , 2 0 - 22 ft ·lb)
CAMSHAFT INSTALLATION
Turn the crankshaft counterclockwise slowly and align "T"
'mark on the flywheel with the Index mark on the left crankcase
cover.
CAUTION
When turning the crankshaft, make sure the C(Jm cham dol's
1101 j am chain tension!'r or crankshaft.
Lubricate the camshaft bearings with clean engine oil.

Place the camshaft on the cylinder head, align the index lines
on the cam sprocket with the top of the cylinder head and in-
stall the cam chain over the cam sprocket .
Install the camshaft bearing and tighten the holder bolts.
TORQUE : 10 - 14 N·m !1.0 - 1.4 kg -m , 7 - 10 ft-Ibl
NOTE
• Be careful not to drop foreign material into the crankcase.
6-13
CYLINDER HEADIV ALVES
SlowlV turn the crankshaft counterclockwise 360 0 and align

the " T" mark on the flywheel with the index mark on the left
crankcase cover.
Make sure that the index lines on the cam sprocket align with
the top of the cylinder head.
NOTE
If the cam lobe on the camshaft is facing up, turn the crank·
shaft counterclockwise 360 0 again and align the "T" mark
with the index mark so that the cam lobe faces down .
Install the spark plug.
TORQUE : 1 2-19 N·m '1 .2-1.9 kg-m , 9 - 14 ft -Ibl
111 CAM CHAIN

Remove the cam chain tensioner sealing bolt and washer from TENSIONER
the tensioner.
Turn the tensioner shaft clockwise with a small screwdriver to
retract the tensioner and hold the tensioner in the fully retract -
ed position.
NOTE
The tensioner is projected by spring force when it is re-
leased.
Hold the tensioner shah with a piece of wire as shown to 23.0 mm

secure the tensioner. (0.91 in)
\ ·'to
4.0mm
(0.16 in)
Install the cam chain tensioner and tighten the attaching bolts
securely.
Remove the wire hom the cam chain tensioner.
Install the sealing washer and bolt. and tighten the sealing bolt
securely.
6-14
CY LINDER HEADIVALVES
CYLINDER HEAD COVER ASSEMBLY (2) CAM
Install the return spring onto the decompressor lever /shaft and
install the shaft into the cylinder head cover.
Install the decompressor cam onto the shaft and secure it with
the circlip.
/•
(3) DECOMPRESSOR LEVER
Install new O-rings onto each rocker arm shaft. (1) R]SJ~ (2) ROCKER ARM SHAFT
Coat the roc ker arm shafts With engine oil.
Install the rocker arms and shafts into the cylinder head cover .
Install the valve adjuster lock bolts loosely.
CYLINDER HEAD COVER INSTALLATION {2l RUBBER GASKET
Fill the camshaft with clean engine oil to provide initiallubrica-

lion for camshaft when the engine is started .
Install the dowel pins .
Install a new rubber gasket into the groove in t he cylinder head
cover.
Install the cylinder head cover.
Install new O-rings onto the oil orifice bosses of the cylinder
head cover .
Blow compressed air through the oil passage in the breather

cover .
Install a new rubber gasket Into the groove in the breather
cover.
Install the breather cover and tighten the bolts.
Adjust the valve clearance {page 3- 7 L
Install the valve adjuster cover .
6-15
CYLINDER/PISTON
7-0
7. CYLINDER/PISTON
SERVICE INFORMATION 7 -1 PISTON 7 -3
TROUBLESHOOTING 7 -1 PISTON /CY LINDER INSTALLATION 7 -5
CYLINDER 7 -2
SERVICE INFORMATION
GENERA L
• All cylinder/piston maintenance and inspection can be serviced with the engine in the frame.
Reier to Section 5 for engine removal and installation.
SPECI FI CATIONS
Cylinder I.D. 65.000 - 65.010 mm 12.5590 - 25594 in) 65.10 mm (2.563 in)
Taper -~
0.10 mm (0.004 in)
Out of round -~
0.10 mm (0.004 in)
Warpage across top -~
0.10 rnm (0.004 in)
Piston , Piston 0.0. 64.962 - 64 .982 mm 12.5576-2.5583 inl 64.90 mm 12.555 in)
piston pin, Piston pin bore 15.002 -15.008 mm (0.5906 - 0.5909 in) 15.04 mm 10.592 i~
piston rings
Piston pin 0.0. 14.994 - 15.000 mm (0.5903 -0.5906 in] 14 .96 mm (0. 589 in)
Piston-to-pin clearance 0.002 - 0.014 mm (0.0001-0.0006 in) 0.02 mm (0.001 in)
Piston ring-to-ring TOP 0.005 - 0.045 mm (0.0002-0.00 18 in) 0.09 mm (0.004 in)
groove clearance SECOND 0.015-0.045 mm (0.0006 - 0.0018 in) 0.09 mm (0.004 in)
Piston ring TOP/ SECOND 0.20 - 0.40 mm (0.008-0.016 in) 0.50 mmto.020 in)
end gap OIL 0.20 - 0.80 mm (0.008 - 0.031 in) -~
Cylinder-to ·piston clearance 0.018-0.048 mm (0.0007 - 0.0019 in) 0.10 mm (0.004 in)
Connecting rod small end 1.0. 15.010-15.028 mm (0.5909 - 0.5917 in) 15.06 mm (0.593 in)
Connecting rod -to-piston pin clearance 0.010 - 0.034 mm (0.0004-0.0013 in) 0.05 mm (0.002 in)
TROUBLESHOOTING
l ow or un stable compression Overheat in g
Worn cylinder or piston rings Excessive carbon bUild-up on piston or combustion
• Faulty cvlinder head or valves (Section 6) chamber wall
Fuel·air mixture too lean (Section 4 )
Excessive sm oke
Worn or damaged cylinder. piston. or piston rings Knocking or abn ormal n oise
Improper installation of piston rings Worn piston and cylinder
Damaged valve stem seal • Excessive carbon build-up
7-1
CYLINDER/PISTON
CYLINDER
REMOVAL
Remove the cylinder head !Section 6).
Remove the gasket, dowel pins, cam chain guide and cylinder.
Remove the cylinder gasket and dowel pins.
Clean off any gasket material from the cylinder surface.
NOTE
• Be careful not to damage the gasket surface.
INSPECTION
Inspect the cylinder walls for scratches and wear.

Measure and record the cylinder 1.0. at three levels in both an
X and Y axis. Take the maximum reading to determine the cyl -
inder wear.
SERVICE LIMIT: 65. 10 mm 12.563 in)
Calculate the piston-ta-cylinder clearance. Take the maximum

reading to determine the clearance.
Refer to page 7-4 for measurement of the piston 0.0 .
SERVICE LIMITS; 0 . 10 mm (0 .004 in)
Calculate the cylinder for taper at three levels in an X and Y

axis. Take the maximum reading to determine the taper .
• J
SERVICE LIMIT: 0 . 10 mm (0.004 in)
Calculate the cvlinder for out-ol-round at three levels in an X

and Y axis . Take the maximum rea ding to det ermine the out-
ol-round.
SERVICE LIMIT: 0 . 10 mm [0.004 in l
The cvlinder must be rebored and oversize piston fitted if the

service limits are exceeded.
11 liN <:0((;.- Y :))¢ /21 EX
(3) TOP X
The following oversize pistons are available: 1'-"-<----'/
0 .25 mm 10.010 in!. 0 .50 mm [0 .0 20 in) and 0.75 mm (0.030 V"
(4) M ID DLE [o--+--i\
in) . 1.00 mm 10.039 in)
f' -::.:=_::;::::-_-
The cvlinder must be rebored so that the clearance to an over-
(5) 80TTOM
--
Eo--+--i\
size piston is 0.018 - 0.048 mm (0.0007-0.0019 in!.
.... _--'---/
7-2
CYLINDER/PISTON
Inspect the top of the cylinder for warpage.
SERVICE LIMIT : 0 . '0 mm 10.004 in)
PISTON
Remo ve the piston pin clip with pliers.
NOTE
-
• Do not let the clips f all into t he crankcase.
Press the piston pin out of the piston and remove the piston.
Remove the piston rings.
NOTE
• Do not damage the piston rings during removal. 121 PIISTe)N
INSPECTION
Measure the piston ring -Io-groove clearance .
SERVICE LIMITS:
Top/ Second: 0 .09 mm 10.004 in )
Inspect the piston for wear or damage .
Insert each piston ring squarely into the cylinder and measure
the ring end gap.
NOTE
Push the rings into the cylinder with the top of the piston to
be sure they are squarely in the cylinder.
SERVICE LIMIT:
Top fSecond : 0.50 mm (0 .020 in)
7-3
CYLINDER/PISTON
Measure the diameter of the piston 10 mm from the bottom

and 90 0 to the piston pin hole.
SERVICE LIMIT; 64 .90 mm (2.555 in)
Compare t his measurement against the service limit and calcu -

late piston-la-cylinder clearance.
Refer to page 7-2 for measuring the cylinder.
Measure the piston pin hole 1.0.
SERVICE LIMIT: 15.04 mm {0 .592 inl
Measure the 0.0. of the piston pin .
SERVICE LIMIT: 14.96 mm (0 .589 in)
Calculate the piston-la-piston pin clearance .
SERVICE LIMIT : 0.02 mm (0.00 1 InJ
Measure the connecting rod small end 1.0.
SERVICE LIMIT : 15.06 mm (0.593 in)
Measure the connecting rod-la-piston pin clearance.
SERVICE LIMIT: 0 .05 mm (0.002 inl
7-4
CYLINDER/PISTON
PISTON/ CYLINDER INSTALLATION

PISTON RING INSTALLATION
Clean the piston ring grooves thoroughly and install the piston
rings.
NOTE
Avoid piston and piston ring damage during installation.
Install the top and second rings with the mark facing up.
Do not mix the top and second rings.
1 t) MARK
Space the piston ring end gaps 120 degrees apart.
Do not align the gaps in the oil rings (side rails).
After installation, the rings should be free to rotate in t he

grooves.
OJ TOP RING
(2) SECOND RING
151
SIDE RAIL
161 18) OIL RING

SPACER
(3) TOP RING
171
SIDE RA il
~ (4) SECOND RING
PISTON INSTALLATION
Clean off any gasket material from the crankcase surface .
NOTE
Be careful not to damage the gasket-surface.

• Be careful not to drop the gasket into the crankcase.
7-5
CYLINDER/PISTON
Position the piston "IN" mark on the intake valve side, and in- {ll PISTON I
stall the piston and piston pin .
Install new piston pin clips.
NOTE
Do not align the piston pin clip end gap with the piston cut·
out.
Do not let the clip fall into the crankcase.
CYLINDER INSTALLATION
Install the dowel pins and 8 new gasket .
Make sure the piston rings are installed correctly (page 7· 5).
Coat the cylinder bore and piston rings with engine oil and in-
stall the cylinder.
NOTE
Avoid piston ring damage during installation.
• Do not let the cam chain fall into the crankcase.
Install the cam chain guide.

Install the cylinder head (page 6- 1 2),
7-6
MEMO
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
O-~o~. IJ Ilj~OO®fm
76 - 84 N·m p.6 - S.4 kg -m, ~
""".. ~..·~@(1DDtO 86-94 N'm After '~~ . ___ _
jc:.91f~_I~;mil 'O- 1'2~kg

.m, ; ~~ •
a@, I
~~~-;;!~t_:~;m ~ ~~.
81
10 - 14 N ·m L. ______ .---...J
11.0 - 1.4 kg -m, 7 -1 a /t -Ibl ~ -I ft
I ~flIj · v
to-l'N-m ~~®") ~
: ~ IJ.~~~
' 86 :
fl.O - l.4 kg -m,
7 - 10 h -Ib) - . a>- 0 ~
fL . ~
~<:>
_J@Q.~:
~ - -C> 4 - 1SN·m
I~~~t~'~®~",~.-----,
11.4 - 1.8 kg -m,
10 - 13 h -Ibl
19 - 25 N'm
11 .9 - 2.5 kg-m,
14 - 18 h -Jb)
8-0
8. CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
SERVICE INFORMATION 8- 1 GEARSHIFT LINKAGE 8-14
TROU8LESHOOTING 8-2 KICK STARTER 8-16
RIGHT CRANKCASE COVER REMOVAL 8-3 RIGHT CRANKCASE COVER
INSTALLATION 8-19
CENTRIFUGAL CLUTC H 8-5
MANUAL CLUTCH 8-10
SERVICE INFORMATION
GENERAL
• This section co .... ers the centrifugal dutch, manual clutch and gearshift linkage service. These parts can be serv iced with
the engine installed in the frame .
SPECIFICATIONS
Centrifugal Drum 1.0. 116.0 - 116.2 mm 14 .567 - 4 .575 in) , 16.5 mm (4 .59 in)
clutch Weight lining thickness '86 1.5 mm (0. DB in)
1 .2 mm 10.05 in)
After '86 2.0 mm 10.08 inl
Drum bushing I. D. 24.000 - 24.02 1 mm (0.9449 - 0.9457 in) 24.05 mm (0.947 in)
Clutch spring
free hight
After ' 86 -- 2 .65 mm (0 . 104 in)
Manual Spring free length 35 .2 mm ( 1.39 in) 34.5 mm (1.36 in)

clutch Disc thi ckness 2.9 - 3.0 mm (0. 11 - 0.12 inl 2.6 mm (0. , 0 in)
Disc warpage 0.20 mm (0.008 in)
Plate warpage -- 0.20 mm (0.008 in)
Clutch outer guide 0.0. 27.959 - 27.979 mm (1.1007 - 1.1015 in) 27 .92 mm (1.099 in)
Kick starter Shaft end hole
14.000 - 14.018 mm (0.5 512 - 0.5519 in) 14.040 mm (0.5528 in)
(al right crankcase )
TORQUE VALUES
Centrlfu9al clutch lock nut 86 - 94 N·m 18.6-9.4 kg -m,

62-68ft-lb)
Manual clutch fock nut 76 - 84 N·m (7.6-8.4 kg-m,
55-61 ft -Ib)
Gear shifter bolt 10 - 14 N' m 11.0- 1.4 kg -m.
7-10 ft -Ibl
Shift drum stopper bolt 10 - 14 N·m 11.0- 1.4 kg -m.
7 -1 0 ft -Ibl
GearshIft pedal pivot bolt 24-30 N·m 12.4 - 3.0 kg -m,
17-22 ft-lbl - AppIV a locking agent to the
thread s.
Gearshift arm bolt 14- 18 N·m (1.4 - 1.8 kg -m, 10 - 1 3 ft -Ib)
Footpeg bolt 70-80 N·m 17.0-S.0 kg -m. 51 - 58 ft -lbJ
Centrifugal clutch cover 10 - 12 N·m 11.0 - 1.2 kg -m, 7-9 ft· lb)
TOOLS
Special
Clutch holder 07GMB - HS70100
Clutch puller 07GMC - HB30100
Clutch cen ter holder 07923 - 9580000 (not available in U .S.A.)
8-1
CLUTCH/KICK STA RTER/GEAR SHIFT LIN KAGE
TROUBLESHOOTI NG
Faulty clutch operation can usually be corrected by adjusting the clutch .
Clutch slips when accelerating

Incorrect clutch adjustment
Fauity clutch lifter mechanism
Worn discs and /or linings
Weak clutch springs
Engine oil mixed with molybdenum or graphite additive
Clut ch will not disengage

faulty clutch adjustment
Warped plates
Incorrect engine oil weigh t
Motorcycl e creep s with the engine idling

Faulty centrifugal clutch
• Incorrect engine oil weight
Clutch operation feels rough

Rough manual clutch outer slots
• Worn or damaged centrifugal clutch shoes or drum
Hard to shift
Clutch does not disengage
Bent gearshift spindle
Oamaged drum shifter
Damaged gearshift plat e
Transmission Jumps out of gear

Weak or broken shift drum stopper spring
Worn shift drum stopper
Worn or damaged shift arm pawl
Weak or broken shih arm spring
Gear shift pedal w ill not return

Weak or broken gearshift spindle return spring
• Bent gearshift spindle
Faulty kick st art er operation

Warn or damaged kick starter ratchet pawl
Faulty one-way clutch operation at centrifugal clutch
outer
Damaged kick sterter gear
Worn or damaged ratchet guide
Ratchet installed incorrectly
8-2
RIGHT CRANKCASE COVER REMOVAL

Drain the engine oil Wage 2-2)
Remove the skid plate.
••
I \,
,,
1
11) SKID PLATE
loosen the rear brake adjusting nut and unhook the brake
pedal return spring from the swing arm.
, Remove the kick starter pedal.
Remove the right crankcase cover bolts and cover.
Remove the gasket and dowel pins.
8-3
RIGHT CRANKCASE COVER DISASSEMBLY (1 HOLDER
Check the kick starter shaft end needle bearing on the right
crankcase cover for damage and replace if necessary.
Remove the kick starter drive gear holder mounting botts,

holder and kick starter drive gear.
Check the kick starter drive gear needle bearing fo r damage

and replace if necessary.
Check the dust seal for wear or damage and replace if neces- III SEAL
sary.
Remove the lock nut, washer, clutch adjusting screw and lifter
cam plate.
8-4
Check the lifter cam plale for wear or damage.

Remove the O-ring from the adjusting screw if necessary.
(3 ) WASHER
\ \)
, \
(5) LOCK NUT (4 ) O·RING
Install the washers onto the kick starter drive gear and drive
gear shaft into the cover.
Install the holder with the needle bearing and tighten the bolts
securely.
Screw the clutch adjusting screw into the lifter cam plate and
install the O·ring onto the screw.
Install the clutch adjusting screw and lifter cam plate aligning
the lifter pin with the hole in the right crankcase cover.
Install the washer and lock nut.
Tighten the lock nut after installing the right crankcase cover
and adjusting the clutch system.
CENTRIFUGAL CLUTCH
REMOVAL
Remove the centrifugal clutch cover.
WEIGHT LINING INSPECTION
Measure the weight lining thickness.
SERVICE LIMIT : '86 1 .2 mm (0.05 in)

After '86 2 .0 mm 10.08 in)
Replace the centrifugal weight assembly if the lining thickness

is worn beyond the service limit.
8-5
Clean the centrifugal clutch cover and inside of the centrifugal

clutch using a clean lint-free cloth .
Unst ake the centrifugal clutch lock nut.
Hold t he cen trifugal clutch weight assembly with a clutch

holder and remove t he lock nut with a long size 24 mm socket
wrench by turning the nut clockwise .
TOOL:
Clutch holder 07HMB - HB70100
NOTE
• The lock nut has left hand threads.
Remove the plain washer.
Remove the clutch weight assembly with a clutch puller.
TOOL:
Clutch puller D7GM C- HB30100
AFTER 'S6
IN SPECTION
Weight lining
Measure the weight lining thickness.
SERVICE LIMIT: 1.0 mm (0.04 in)

'0
8-6
CLUTCH/ KICK STARTER/GEARSHIFT LINKAGE
Weight Spring/Clutch Spring

(1) E-C LIPS (2) CLUTC H SPRING
Remove the E-clips, washer, clutch spring and washer.
(3) WASHE R (3) WAS HER
Check the weight spri ngs for wear or damage. and replace if
necessary_
Measure the height of the clutch spring.
SERV ICE LI M IT: 2 .65 m m (0 . 104 in )
Replace the spring if it is shorter th an the service limit.
(1) CLUTC H SPRING
Install the washer and clutch spring.
NOTE
• Install the spring with the dished face towards t he inside.
Install the outside washer with the locating pins facing out .
"0
8-7
Install the E-clips aligning their gaps with the locating pins on
the washer .
(1) E-CLIPS
Remove the clutch drum by aligning the drum gear with the
cutout on the manual clutch outer.
1
Clutch drum/one-way clutch

Remove the one-way clutch from the clutch drum.
Check the inside 01 the centrifugal clutch drum for scratches
or excessive wear. Replace if necessary.
Measure the I.D. of the clutch drum.
SERVICE LIMIT: 11 6.5 mm {4 .S9 in l
Measure the drum bushing 1.0.'5.
oo,~
SERV ICE LIMIT : 24 .05 mm (0 .947 in l W
Replace the clutch drum assembly if the drum bushing 1.0. is
greater than the service limit. '" """"
'-
c::::- ( I ;-ITl..
8 -8
Check the one way clutch roliers for eKcessive wear or dam- ON'E-I/;'A Y CLUTCH
age.
Instalilhe one-way clutch into the clutch drum with the tab on
the one-way clutch facing down .
Install the one way clutch weight onto the clutch drum.
Turn the clutch weight for smooth operation.
The clutch weight should turn clockwise and not turn counter-
clockwise .
( 21 TAB
INSTALLA TION
Install the centrifugal clutch weight assembly into the clutch

drum while turning the weight assembly clockwise.
Install the centrifugal clutch weight assembly and drum onto
the crankshaft, aligning the drum gear with the cutout on the
manual clutch outer.
Install the plain washer.
Install a new lock nut. hold the centrifugal clutch weight as-
sembly with a clutch holder and tighten the lock nut with a 24
mm deep socket wrench.
TORQUE: 86 - 94 N·m !8.6-9.4 kg-m, 62-68 ft -Ibl
TOOL:
Clutch holde, 07GMB - HB30 100
NOTE
• The lock nut has left hand threads.
8-9
Stake the lock nut into the crankshaft.

Install the centrifugal clutch cover.
TORQUE: 10 - 12 N'm (1.0-1.2 kg-m, 7 -9 ft-Ibl
MANUAL CLUTCH
REMO VA L
Remove the dutch lifter sub-lever.

Remove the ball retainer, thrust spring , lifter cam plate and
bearing .
Check the ball retainer and spring cam plate for wear or dam- I THRUST BEARING
age. i 1) CIFICLlP,
Check the thrust bearing and replace it with a new one jf it is
damaged or has excessive wear.
Remove the circlip and bearing.
Install the bearing and circlip securely.

- centrifugal clutch (page 8 -5)
- clutch bolts
- lifter plate
- clutch springs.
8-10
CLUTCH/ KICK STARTER/GEARSHIFT LINKAGE
UnSlake the manual clutch lock nut.

Install the clu tch center holder as shown, and remove t h e
clu t ch lock nut.
TOOL:
Clutch center holder 07923 - 9580000
Remove the plain washer.

Remove the clutch outer , discs, plates and pressure plate .
Remove the clutch outer and outer guide.
INSPECTION
Check the slots of the clutch outer for damage or wear caused
by the clutch discs. Replace if necessary.
Measure the 0.0. of the clutch out er guide.
SERVICE LIMIT: 27 .92 mm 11.099 inl
8-11
Measure t he spring free length .
SERVICE LIMIT: 34 .5 mm (1 .36 inl
Replace t he clut ch discs if they show signs of scoring Of dis-

coloration.
Measure the disc thickness.
SERVICE LIMIT : 2 .6 mm 10.10 inl
Check for plate and disc warpage on a surface plate using a

feeler gauge .
SERVICE LIMIT: 0 .20 mm (0 .008 inl
IN ST A LLATI ON
Install the clutch outer guide onlO the mainshaft.
8-12
Install the clutch outer.
Assemble the clutch pressure plate, discs, plates and clutch
,
(2) CLUTCH PRESSURE PLATE
center.
NOTE m CLUTCH CENTER

Stack the discs and plates alternately.
• Coat new clutch discs with engine oil.
t (3) CLUTCH PLATE (4 pcs)

(4) CLUTCH DISC (5 pes)
Install the plain washer and a new lock nut.
Install the clutch center holder as shown, and tighten the lock (2) CENTER
nut.
TORQUE : 76 - 84 N·m 17.6 - 8 .4 kg-m , 55 - 61 ft -Ib)
TOOL:
Clutch center holder 07923 - 9580000
Inot available in U.S. A .)
Remove the clutch center holder and stake the lock nut in t o
the mainshaft.
8-13
Install the following:

- III clutch springs
- (2) lifter plate
- (3) clutch bolts
- (4) bearing
- (5) lifter cam plate
- (6) ball retainer with thrust spring
Install the centrifugal clutch (page 8 -9).
Inslall the clutch lifter sub-lever.

Make sure that the position the clutch lifter sub-Ie'ller at the
groove in the 'ifter cam .
Align the steel ball in the ball retainer with the clutch lifter sub-
leve r.
Install the right crankcase cover (page 8- 181.
GEARSHIFT LINKAGE
Remove the left footpeg mounting bolts, gearshift arm bolt
and gearshift/ left footpeg .
Remolle the centrifugal clutch (page 8 -5) and manual clutch
(page 8· 10).
121 LEFT FOOTPEG MCIU'ITII"G
Unhook the shih arm spring from the gearshift plate.

Pull out gearshift spindle assembly from the crankcase.
GE.'R';HIIFT SPINDLE
8-14
Remove the shift guide plata and gearshift plate by removing

the gear shifter bolt .
Remove the drum stopper bolt, drum stopper, washer and

spring.
Remo ... e the drum shifter .
Remove the shift drum pin from the shift drum .
INSTALLATION (1 ) STOPPER SPRING
Assemble the drum stopper spring, washer, stopper and bolt , \

and install them onto the crankcase. jDRUM STOPPER
Tighten the drum stopper bolt.
TORQUE : 10 - 14N·m (1. 0 - 1.4kg·m, 1 - 10ft-lbl

(3) WASHER--- ( ) •
/
(4) DRUM STOPPER BOLT
Install the shift drum pin into the shift drum.

Lower the drum stopper using 8 screwdriver and install the
drum shifter with aligning the hole on the drum shifter and
shift drum pin .
8-15
CLUTCH /KICK STARTER/GEARSHIFT LINKAGE
Install the gearshift plate onto th e drum shifter.

Inslall the shift guide plate with aligning the tab on the plate
and the groove on the drum shifter.
Apply thread locking agent to the gear shifter bolt threads, in-
stall the shift guide plate onto the drum shifter and tighten the
gear shifter bolt .
TORQUE: 10 - 14 N-m 11 .0 - 1.4 kg-m , 7 - 10 ft -Ibl
Place the thru st washer between the crankcase and gearshift

plale and install the gearshift spindle t hrough the gearshift
plate and washer InlO the crankcase, aligning the return spring
ends with the stud.
Hook the shift arm spring to the gearshift plate as shown.
141 GEJ'RSHI -'-==__• ARM SPRING
Install the manual clutch (page 8- 12).

Install the centrifugal dutch jpage B· 9) .
Install the gearshift pedal onto the gearshift shaft aligning the
punch marks on the spindle and pedal.
Tighten the foot peg mounting bolts and gearshift arm bolt .
TORQUE :
Footpeg bolts: 70-80 N·m 17.0 - 8 .0 kg -m, 5 1 - 58
ft -Ibl
Gearshift arm bolt: 14 - 18 N·m 11,4 - 1.8 kg·m, 10 - 1 3
ft -lbJ
Check the gearshift operation.

121 GE .• R"HIIFr ARM BOLT
KICK STARTER
REMOVAL
Remove the centrifugal clutch (page 8 -5).

Remove the manual clutch (page 8-10),
Remove the kick starter shaft by turning the shaft clockwise to
free the ratchet from the ratchet guide plate_
NOTE
• Refer to page 8 -4 for kick starter drive gear removal.
8-16
DISASSEMBLY
III NEEDLE BEARING (2) SNAP RING (3( RA·TC>~FT SPRING
o' ---HDj II 00
C---
(9) 5T ARTER EAR
(!) 11
7 t
(6) SPRING SEAT
(10) KICK STARTER SHAFT (81 WASHER (7) RATCHET GUIDE
INSPECTI ON (1) KICK STARTER GEAR
Inspect the kick starter gear needle bearing for damage and /or
e)( cessive play. \
NEEDLE
BEARING
Measure the kick starter shaft end hole 1.0.
SERV ICE LIMIT: 14.040 mm 10.5528 in )
ASSEMBLY
Install the starter gear onto the shaft, washer and snap ring.
8-17
Align the punch marks and install the ratchet over the shalt . ~') O'.T;:;:;:";;;7,;;'
(2) PUNCH MII"':S

•
Install the ratchet spring and spring seat . (') RATCHET SPRING
(2) SPRING SEAT
Compress the ratchet spring and install the return spring with (2) COLLAR
/
insert its end into the hole in the shaft.
Install the collar, aligning its groolle with the end of the return
spring .
INSTALLATION
Align the return spring hook with the crankcase boss under the
ratchet guide plate.
Turn the kick starter shaft clockwise bV hand and insert the
boss of ratchet into the ratchet guide plate and crankcase.
8-18
RIGHT CRANKCASE COVER INSTALLATION

Install the dowel pins and a new gasket.
Install t he right c rankcase cover and tighten the bolts.
Install t he kick starter pedal.

Install the brake pedal return spring onto the swing arm.
Install the skid plate.

Adjust t he rear brake pedal free play IPage 3·12).
Fill the crankcase with the recommended engine oil (Page 2-21.
Inspect or adjust the following.
- clu tch system (Page 3 - 13).
- oil leaks
- gearShift operation
I
(1) SKID PLATE
8-19
ALTERNATOR/STARTER CLUTCH
' 86 After '86

;----------;
, ,,r------ -i
(2 .6 - 3 .0 kg -m,
8 - 12 N·m (0.8-1.2 kg-m,

6 - 9 ft -Ib)
45 - 55 N·m (4.5 - 5. 5 kg-m ,

33-40 ft ·lbl
~D
10 - 20 N'm ( kg-roo
7 - 14 ft -Ib)
9-0
9. ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION 9·' AL TERNATORI STARTER CLUTCH 9·3
TROUBLESHOOTING 9· ' LEFT CRANKCASE COVER
LEFT CRANKCASE COVER REMOVAL 9· 2
INSTALLATION 9·6
SERVICE INFORMATION
GENERAL
• This section covers remo val and installation of the alternator/s tarter clutch and starter gears.
• Refer to Section 15 for ahernator inspection.
TO RQUE VA LUES
Flywheel bolt 45 - 55 N·m ~4 . 5 - 5.5 kg -m, 33 - 40 ft -Ibl

Starter clutch bolt 26 - 30 N·m (2 .6 - 3.0 kg -m, 19 - 22 ft -Ibi
, Pulse generator bolt 8 - 12 N·m (0. 8 - 1.2 kg-m. 6 - 9 h -Ib)
Footpeg bolt 70-80 N' m /7.0 - 8 .0 kg -m . 5 1-58 It-Ibi
Gearshift arm bolt 14- 1 8 N·m (1.4 - 1.8 kg -m , 10 - 13 It·lb)
TQOLS
Common
Flywheel holder 07725 - 0040000 Of strap wrench, commercially available in U.S.A .
Rotor puller 07733 - 0020001 or 07933 - 2160000
TROUBLESHOOTING
Enginll does not t urn wh en operating start er m otor
Faulty one-way starter clutch
• Starter reduction gear broken
9-1
lEFT CRANKCASE COVER REMOVAL

- skid plate
- gearshift arm bolt and left footpeg mounting bolts.
- gearshift pedal and left footpeg
- drive sprocket cover by removing the nuts.
!
14) SKID PLATE
Remove the left side cover .

Disconnect the alternator coupler and wire connector.
Remove the starter gear cover .
Remove the starter reduction gear shaft and geal.

Check the teeth of the Starter reduction gaar for wear or dam·
age.
Remove
cover. the nine left crankcase cover mounting boils and r'I~111~~~~~~~~t1~~~~~\-~j-l
9-2
AL TERNATORI STARTER CLUTCH
Remove the gasket and two dowel pins.
ALTERNATOR/ STARTER CLUTCH 111 GR\~~~,."._ _

(2) PULSE G""RA
, STATOR REPLACEMENT
Disconnect the pulse generator wire, and remove the pulse

generator and wire clamp.
Remove the wire grommets and three bolts, and remove the
stator from the left crankcase cover.
Install the stator onto the left crankcase cover properly. (1) PULSE GENERATOR (2) TERMINAL
Apply locking agent to the stator bolts threads and tighten the
bolt.
Install the wire grommets into the groove in the cover secure-
ly.
Install the pulse generator and wire clamp with the socket
bolts.
Clamp the pulse generator wire onto the pulse generator and
connect it to the terminal.
FLYWHEEL REMOVAL
Hold the flywheel with the flywheel holder and remove the fly-
wheel bolt.
TOOL:
Flywheel holder 07725 - 0040000 or strap wrench commer-
cially available in U.S. A .
9-3
Remove the flywheel with the rotor puller.
TOOL:
Rotor puller 07733 - 0020001 or 07933 -2 160000
Remove the starter idle gear shaft and starter driven gear.
Remove the needle bearing and thrust washer from the crank ·
shaft.
Check the starter driven gear and needle bearing for wear Of
damage. (1) STARTER DRIVEN GEAR
(2) NEEDLE BEARING
9-4
Check the inner and outer idle gear for wear or damage. IDLE GEAR
111 INNER ID\ GEAR 121
NOTE
• The inner starter idle gear is welded to the shaft.
(3) IDLE GEAR SHAFT
STARTER CLUTC H INSPECTION
Check the rollers for excessive wear or other damage .

Temporarily install the starter driven gear and check its opera-
tion; the driven gear should turn counterclockwise and not
turn clockwise.
Replace the one-way clutch and outer, if necessary.
STARTER CLUTCH DISASSEMBLY/ASSEMBLY (If ONE-WAY CLUTCH m FLYWHEEL
Remove the bolts from the flywheel.

Remove the one·way clutch outer and one·way clutch.
Install a new one·way clutch and outer onto the flywheel.
Apply locking agent to the bolt threads and tighten the bolts.
TORGUE : 26 - 30 N·m (2.6 - 3.0 kg·m , 19 - 22 fl·lb)
Reckeck the one·way clutch operation using the driven gear.
(4) ONE·WA Y CLUTCH OUTER (3) BOLTS
FLYWHEEL INSTALLATION
Install the thrust washer and needle bearing.

If the woodruff key has been removed, install it into the crank·
shaft end groove.
9-5
Install the starter driven gear and starter idle gear shaft.
NOTE
Install the inner starter idle gear i 17TI and the outer starter
idle gear (21 T) correctly. Incorrect engagement could
damage the gears.
Engage the inner gear teeth and the starter driven gear
teeth correctly at installation.
Make sure that the inside of the flywheel and crankshaft are
not contaminated . Clean if necessary.
Install the f lywheel onto the crankshaft, aligning the key way
in the lIywheel with the key on the crankshaft .
Install the flywheel bolt and hold the flywheel with the fly.
wheel holder .
TOO L:
Flywheel holder 07725 -0040000 or strap wrench commer-
cially available in U.S .A.
Tighten the flywheel bolt.
TORQUE: 45 - 55 N'm (4 .5-5.5 kg ·m . 33- 40 ft·lbl
LEFT CRANKCASE COVER INSTALLATION

Install the outer starter idle gear (21 teeth).
Install the dowel pins and a new gasket .
\.
(2) DOWEL
9-6
Install the left crankcase cover and cover mounting bolts. (1)
Tighten the nine bolts in a crisscross pattern in 2 to 3 steps,
Install the starter reduction gear shaf t and reduction gear.

Make sure tha t the O-ring is in good condition.
Install the st arter gear covet and tigh t en the bolts.
Install the gearshift pedal onto the gearshift shaft,

aligning t he punch marks on the spindle and pedal.
Tighten the gearshift arm bolt.
TORQUE : 14 - 18 N·m 11 .4 - 1 .8 kg,m , 10 - 13 ft -Ibl
Connect the alternator coupler and wire connector.

Install the left side cover.
Install the left footpeg bracket to the frame and tighten the
foot peg bolts.
TORQUE: 70 - 80 N·m 17 .0 - 8. 0 kg-m . 5 1 - 58 ft -Ib)
Install the drive sprocket cover.

Install the skid plate.
(3) SKIO PLATE
9-7
CRANKCASE/CRANKSHAFT/TRANSMISSION
~~- -- 1 0 - 14 N·m (1.0 - 1.4 kg-m, 7 - 10 ft-Ib)
10- 1 N·m
11.0-1.4 kg-m.
7 - 10 ft -Ib)
10-0
10. CRAN KCASE/CRAN KSHAFT ITRANSM ISSION
SERVICE INFORMATION 10-1 TRANSMISSION 10-4
TROUBLESHOOTING 10-2 CRANKSHAFT 10-10
CRANKCASE SEPARATION 10-3 CRANKCASE ASSEMBLY 10-12
SERVICE INFORMATION
GENERAL
• For crankshaft and t ransmission repair. the crankcase must be separated .

• Remove the follow ing parts before separating th e crankcase.
Cylinder head (Section 6 ) Oil pump (Section2 )
Cylinder and piston (Section 7) Starter clutch and alternator (Section 9)
Clutch and gearshift linkage (Section 8) Starter motor (Secton 16)
SPECIFICATIONS
Crankshaft Connecting rod small end 1.0. 15.010- 15.028 mm 10.5909 - 0.5917 in) 15.06 mm fO.593 in)
Connecting rod big end axial
0.05-0.50 mm (0.002 - 0.019 in) 0.8 mm (0.03 in)
clearance
Connecting rod big end radial
0.004 - 0.012 mm (0.0002 - 0.0005 in) 0.05 mm (0.002 in)
clearance
Runout Right -- 0 .06 mm (0.002 in!
Left -- 0 .03 mm (0.001 inl
Shift fork , Fork !.o. 13.000 - 13.021 mm (0.51 18-0.5126 in) 13.04 mm (0 .513 in)
shaft Claw thickness 4 .93 - 5 .00 mm (0. 194 -0.197 in) 4.60mm (0 .181 in)
Shaft 0.0. 12.966 - 12.984 mm (0.5 105 - 0 .5112 in) 12.96 mm (0.510 in)
Trans- Gear 1.0. M4, M5 23.000 - 23.021 mm (0.9055 - 0.9063 in) 23 .04 mm (0 .907 in)
mission 21.000 - 21 .021 mm (0.8268-0.8276 in) 21.04 mm (0.828 in)
C1
C2, C3 25.000 - 25.021 mm (0.9843 - 0 .9851 in) 25 .04 mm (0.986 in)
Shaft 0 .0. at M4 19.959 - 19.980 mm (0.7858 - 0.7866 in! 19.94 mm (0 .785 in)
at C1 17.966-17.984 mm (0.7073-0.7080 in! 17.95 mm (0 .707 in)
at C2 , C3 and
21.959-21 .980 mm (0.8645 - 0.8654 in ) 21. 94 mm (0.864 in )
C collar
Gear bushing C1 1.0. 18.000 - 18.018 mm (0.7087-0.7094 in) 18.04 mm (0.710 in)
C10.O. 20.980 - 20.959 mm (0.8259 - 0.8252 in) 20.94 mm (0 .824 in)
C2 , C3 1.0. 22.000 - 22 .021 mm (0 .8665 - 0.8669 in) 22 .04 mm (0.868 in)
C2, C3 0.0. 24.959-24.980 mm (0.9826 - 0.9835 in) 24 .94 mm (0.982 in)
M4I.D. 20 .000 - 20.021 mm (0.7874-0.7882 in) 20.04 mm (0.789 in)
M4, M5 0.0. 22.980 - 22 .959 mm (0.9047-0.9039 in) 22.94 mm (0 .903 in)
C collar 1.0. 22.000 - 22.021 mm (0.8661-0.8669 in) 22.04 mm (0.868 in)
Gear-to - M4, M5 0 .020 - 0.062 mm (0 .0008-0.0024 in) 0.10 mm (0 .004 inl
bushing C1 0.020-0.062 mm (0.0008 - 0.0024 in ) 0.10 mm (0.004 In)
clearance
C2. C3 0.020-0.062 mm (0.0008 - 0.0024 in) 0 . 10 mm (0.004 in)
10-1
Trans- Bushing-to - Cl 0.016 - 0.052 mm (O.0008 - 0.0024 in) 0.10 mm (0.004 in)
mission shaft C2, C3 0.020 - 0 .062 mm (0.0008-0.0024 in) 0.10 mm (0.004 in)
clearance
M4 0.020 - 0.062 mm (0.0008-0.0024 in ) 0.10 mm (Q.004 in)
TORQUE VALUES
Crankcase bolt 10~ 14 N'm 0 .0 - 1.4 kg-m, 7 - 10 ft-Ib)

Cam chain tensioner slipper nut 10- 14 N'm 11 .0 - 1.4 kg-m, 7 - 10 ft -Ib)
TOOLS
Special
Bearing remover set, 15 mm 07936 - KC1 0000 (Not available in U.S.A.)
Bearing remover, , 5 mm 07936 - KC10 500
Bearing remover, weight 07741 - 0010201 or 07936 - 3710200
Universal bearing puller 0763 1- 0010000 or Equivalent commercially available in U.S.A.
Threaded adaptor 07GMF - HB 50100 INot available in U.S.A,)
07965 - HB3000A U.S.A. only
Shalt puller 07931 - ME4oooo or 07931 ~ME4oo0A
Crankshaft assembly coliar 07965 - VM00100
Common
Driver 07749 - 0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
Attachment, 32 )( 35 mm 07746-0010 100
Pilot , 15 mm 07746-0040300
Attachment , 52 )( 55 mm 07746 - 0010400
Pilot, 22 mm 07746 - 0041000
Attachment , 62 )( 68 mm 07746 - 0010500
Pilot , 28 mm 07746 - 0041100
TROUBLESHOOTING
Crankshaft noisy
Worn connecting rod big end bearing
Bent connecting rod
Worn crankshaft main journal bearing
Jumps out of gear

Shift fork bent or damaged
Shift fork shaft bent
Shift claw bent
Gear engagement dogs or slots worn
Shift drum cam grooves damaged
Hard t o shift
Shift fork bent or damaged
Shift fork shaft bent
10-2
CRANKCASE SEPARATION
NOTE
Put the transmission in neutral before separating the crank-
case,
Remove the oil pump drive chain and cam chain.

Remove the cam chain tensioner slipper.
Remove the neutral indicator plate from the shift drum.
NOTE
Make sure that the tab in the neutral indicator plate is in-
stalled facing down.
Remove the fight crankcase bolts.
(1) LEFT CR,.NI<CiISE

Remove the left crankcase bolts.
10-3
Place the crankcase assembly with the left crankcase down

and remove the right crankcase from the left crank case.
Remove the gasket and dowel pins.
TRANSMISSION
DISASSEMBLY
Remove the shift fork shaft, shift drum and shift forks.
Remove the mainshalt and countershaft as an assembly,
10-4
INSPECTION
Check the shift lork and shaft for wear or damage.

Measure the 1.0. of the shaft hole.
SERVICE LIMIT: 13.04 mm (O.513 in)
Inspect the shift fork guide pin for wear or damage. (1) GUIDE PIN
I
Measure the shift fork claw thickness.
SERVICE LIMIT : 4 .60 mm (0.18 1 inl
Measure the shift fork shaft 0.0 . at the shift fork sliding sur~
faces.
SERVICE LIMIT: 12.96 mm (0.510 in)
Inspect the shilt drum left journal for scoring, scratches, or (If SH IFT DRUM
lack of lubrication. {
Check the shift drum groove for damage.
10-5
Check the gear dogs. dog hotes and teeth for abnormal wear, tl)M5
or lack of lubrication.
Measure the 1.0. of each gear.
SERVICE LIMITS : M4, M5 23.04 mm (0.907 in)

C2, C3 25.04 mm (0 .986 in)
C1 21.04 mm (0.828 in)
/
Measure the 1.0. and 0.0. of each gear bushing and the
countershaft collar .
SERVICE LIMITS: C1 1.0 . 18.04 mm (0.7 10 in)

C1 0.0. 20.94 mm (0.824 in)
C2, C3 1.0 . 22 .04 mm (0.868 in)
C2, C3 0 .0 . 24.94 mm (0.982 in)
M4 1.0 . 20 .04 mm (0 .789 in)
M4, MS 0.0 . 22.94 mm (0.903 inl
Countershaft collar 1.0.
22 .04 mm (0.868 inl
Calculate the gear-ta-bushing clearance.
SERVICE LIMIT : 0. 10 mm (O .004 in )
Measure the 0.0 . 01 the mainshaft and countershaft. 111 MAINSIHAF'T
SERVICE LIMITS: 8t M4 19.94 mm (0.785 InJ

8t Cl 17 .95 mm (0.707 inl (21 COLLAR
8t C2, C3
Countershaft coller
21.94
2 1.94
mm 10.864 inl
mm (0.864 inl
I
Calculate the gear bushing-to-shaft clearance .
I
SERVICE LIMIT : 0 .10 mm (0.004 inl I I
C2
Calculate the gear·lo·shaft clearance. I
C3
SERVICE LIMIT : 0 . 10 mm {0.004 inl
(3) COUNTEASHAFT C1 I
Check the transmiSSion bearings for excessive play or damage
and replace necessary.
BEARING REPLACEMENT
Turn the inner ra ce of each bearing with your finger.

The bearings should turn smoothly and quietly.
Also check that the bearing outer race fits tightly in the c rank -
case.
Remove and discard the bearings if the races do not turn
smoothly, quietly, or if they fit loosely in the crankcase.
NOTE
• Replace the transmission bearings in pairs.
10-6
Right crankcase :
Remove the mainshaft bearing set plate.
Drive the mainshaft and countershaft beari ngs out o f the right
crankcase.
Drive new bearings in t he crankcase with t he following tools.
TOOLS :
Mainshaft bearing :
Driver 07749 - 0010000
Attachment, 42;1147 mm 07746 - 0010300
Pilot, 20 mm 07746 - 0040500
Install the mainshaf t bearing set plate.
TOOLS: ) DRIVER
Countershaft bearing:
Driver 07749 - 0010000
Attachment, 32 x 35 mm 07746 - 0010100
Pilot, 15 mm 07746 - 0040300
Left crankca se:

Remove the crankshaft (page 10- 10) .
Remove the mainshaft bearing with special tools.
TOOLS :
Bearing remover set, 1 5 mm 07936 - KC10000
0' {Not available in U.S .A.!
Bearing remover, 15 mm 07936 - KC10500
Bearing remo ver weight 07741 - 0010201 or
07936 - 371 0200
10-7
Install the oil iet plate with the conveJ( surface on the plate
facing up.
Install a new mainshaft bearing bV driving it into the crank
case.
TOOLS:
Driver 07749 - 0010000
Attachment, 32 It 35 mm 07746 - 0010100
Dri ve in a new countershaft bearing.
TOOL:
Driller 07749 - 0010000
Attachment, 52 x 55 mm 07746 - 0010400
Pilot, 22 rnm 07746 - 004 1000
ASSEMBLY
Assemble the mainshaft and countershalt.
Coat each gear and bushing with clean engine oil. and check
for smooth movement.
(3) CUPPED SIDE
(b~C;~oo~@ . .. 111 COUNTERSHAFT
C1
(44T)
C4 (2ST) C3 (31T) ~
910 ~7DcD'41 NO CHAMFER SIDE
W C5
(2ST) C2134T)
(2) MAINSHAFTY"~'~'--<.l ID- ~ (])@O~ @O(JI®

M\ M3 I \
122 I 119T) M5 M2
124TJ n 5T)
10-8
CRANKCASE/CRANKSHAFT/ TRAN SMISSION
Install the snap rings into the grooves and align their end gaps
with the lands of the spline .
Align the oil holes in the gear bushings with the oil holes in the
mainshaft and countershaft.
NOTE
Install the snap rings with their sharp edges facing the op-
posite direction of load .
Install the mainshaft and countershaft as an assembly into the

left crankcase.
(1) SHIFT FORK MARKS

NOTE
• The shift fork marks are: L for left. C for center, A for right.
Install the shift forks with their marks facing down Heft crank·
case).
O l SHIFT FORK ,""n ,

Install the shift drum and align each shift fork guide pin with
the guide groove in the drum.
Insert the shift fork shaft through the forks into the hole in the
left crankcase.
(3) SHIFT
DRUM
10-9
CRANKCASE/CRANKSHAFTITRANSMISSION
CRANKSHAFT
REMOVAL
Remove the transmission Ipage 10-4 ).

Remove the crankshaft from the left crankcase using a hydrau-
lic press.
If the left crankshaft bearing remiens on the cranksha ft ,

remove it with bearing puller.
TOOL:
Universal bearing puller 07631 - 0010000 or
Equivalent co mme rcially
available In U.S.A .
If the bearing remains in the left crankcase, remove it with the

driver and attachment.
TOOLS:
Driver 07749 - 0010000
Attachment , 42 It 47 mm 07746 - 0010300
Discard the left crankshaft bearing .
NOTE
Always replace the left bearing with a new one whenever
I~
the cra nkshaft is removed hom the leh crankcase. (1) UNIVERSAL BEARING PULLER
INSPECTION
Set the crankshaft on a stand or V -blocks and read the tunout

using dial indicators.
SERVICE LIMIT: Right 0 .06 mm (0 .002 in)

Left 0 .03 mm (0 .001 in)
(1) RIGHT (21 LEFT

6 mm (C.2in) 3 mm (0. lin)
(11 FEELER GAUGE

Measure the side clearance between the connecting rod big
end and the crankshaft flyweight with a feeter gauge.
SERVICE LIMIT : 0 .8 mm (0.03 in)
10-10
Measure the radial clearance at the connecting rod big end, at y

two points in th e directions indicated by the arrows.
SERVICE LIMIT : 0.05 mm (0.002 in )

X
/'" 1\ X
"- )
Turn the outer race of the right crankshaft bearing with your
finger. The outer race should turn smoothly and quietly.
Also check that the bearing inner race filS tightly in the crank·
shaft.
Replace the crankshaft bearing if the outer race does not turn
smoothly, Quietly, or if it fits loosely on the crankshaft.
INSTALLATION
Drive a new left crankshaft bearing into the left crankcase.
TOOLS :
Driver 07749 - 0010000
Attachment , 62 II 68 mm 07746 - 0010500
Pilot , 28 mm 07746 - 0041100
(2)
,
Draw the crankshaft into the left crankcase using the special (1) SH'IFT
tools.
TOOLS :
Threaded adaptor 07GMF - HB50100
(not availabla In U.S.A . I
07965 - HB3000A
(U.S.A onlv)
Shaft puller 07931 - ME40000 or
07931 - ME4000A
Crankshaft assemblv collar 07965 - VM00100
10-11
CRAN KCASE/CRANKSHAFT/TRAN SMISSION
CRANKCASE ASSEMBLY
Install the dowel pins and new gasket.
Install the right crankcase onto the left crankcase. 11) RIGHT CR,,"K:CASI
NOTE
• Make sure that the gasket stays in place.
Install the left crankcase bolts and tighten the bolts .
TORQUE: 10- 14 N·m 11.0 - 1.4 kg.m. 7 - 10 ft·lbl
Install the right crankcase bolts and tighten the bolts. CRANKCASE
TORQUE: 10 - 14 N'm 11.0 - 1.4 kg·m. 7 - 10 ft·lbl
10-12
Install the cam and oil pump drive chain .

Install the tensioner slipper, pivot collar and nut.
Tighten the nut.
TORQUE ; 10 - 14 N·m {1.0-1 .4 kg-m , 7 - 10 ft -fbl
Install the neutral indicator plate and tighten the bolt.
NOTE
Make sure that the t ab in the neutral position indicator plate
is installed facing down .
10-13
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
18 - 30 N·m (l.8 - 3 .0 kg·m .

13 -22 ft ·lb)
70-90 N·m 17.0-9.0 kg·m .

51 -65 ft ·lb)
'").~_ _ 50 - 60 N'm (5.0-6.0 kg·m .

~~~:l-1i1 36 - 43 ft ·lb)
>::/1-___ 40 - 48 N·m (4.0 - 4.8 kg·m.

29-35 ft ·lb)
_ _ _ _ 30-40 N·m \3.0-4.0 kg-m.

'- 22-29 ft ·lb)
I,
I
j
55 - 56 N·m (5.5 - 6.5 kg·m. 40 - 47 ft-Ib)
11-0
11. FRONT WHEEl/BRAKE/SUSPENSION/STEERING
SERVI CE INFORMA nON 11 · 1 TIRES 11 · B
TROUBLESHOOTING 11 · 2 FRONT BRAKE 11 · 13
HANDLEBAR 11 · 3 FRONTFDR K 11 · 15
FRDNTWH EEL 11 · 5 STEERING STEM 11 ·2 1
SERVICE INFORMATION
GENERAL
Brake dllSt m ay comain asbestos which can be harmful 10 your heafth,

A comaminated brab fining reduces slOpping power. Keep grease off the linings .
• This section covers maintenance of the handlebar grips, front wheel, brake panel and drum , front forks, steering stem and
tire removal / repa ir .
• A jack or other support is reQuired to support the front of the motorcycle except when working on the handlebar in thiS sec-
tion .
SPECI FI CATIONS
I-:Axle runout
Wheel ,im runout
ITEM
Radial
STANDARD
--
SERVICE LIMIT
0.2 mm (0.008 in)

2 .0 mrn (0.08 in)
m
Allial -- 2.0 mm (0.08 in)
Front brake drum 1.0. 110 mm (4.3 Inl 111 mm (4.4 in)
Front brake lining thickness 4.0 mm (0. 16 m) 2.0 mm (0.08 in)
Fork oil capacity 195.5 - 200.5 cc j6.6 - 6.8 US oz, 6.8 - 7.0 Imp ozl
Fork oil level '86161 mm 16.3 in) After '86 182 mm (7.2 in)
Fork spring free length '86: 558.6 mm (21.99 in) 547.4 mm (21.55 in)
A 120.4 mm (4 .74 in) 118.0 mm (4.65 in)
After '86:
B 437.1 mm 117.21 in) 428.3 mm (16.86 in)
Fork tube runout -- 0.20 mm (0.008 in)
TORQUE VA LUES
Wheel hub nut 60- 70 N·m 16.0 - 7 .0 kg ·m, 43 - 51 ft -Ibl

Axle nut 55-65 N·m j5.5 - 6.5 kg -m, 40 - 47 ft -Ib)
Fork upper bolt 50 - 60 N -m 15.0 - 6.0 kg-m, 36 - 43 ft -Ib)
Fork lower pinch bolt 30 - 40 N -m (3.0 - 4 .0 kg-m, 22 - 29 ft -Ib)
Fork socket bolt 15 - 30 N·m 11.5 - 3.0 kg -m, 11 - 22 ft-lbJ
Steering stem nut 70 - 90 N-m 17.0 - 9.0 kg -m. 51 - 65 ft·lbl
Steering bearing adjustment nut , Initial 25 - 35 N·m 12.5 - 3.5 kg-m, 18 - 25 ft -Ib)
Final 5.5 - 6.5 N·m 10.55 - 0.65 kg -m, 4 .0 - 4 .7 ft-lbJ
Brake arm bolt 8 - 12 N·m (0.8 - 1.2 kg -m, 6 - 9 ft -Ib)
Handlebar lower holder mounting nut 40 - 48 N·m 14 .0 - 4.8 kg -m. 29 - 35 ft -Ibl
Handlebar upper holder bolt 18 - 30 N'm (1.8 - 3.0 kg-m, 13 - 22 h -Ib)
Fork tub e boll 15 - 30 N·m 11.5 - 3 .0 kg-m, 11 - 22 It-Ib)
Front brake drum mounting bolt 25 - 35 N·m 12.5 - 3.5 kg -m. 18 - 25 fl -Ib)
11-1
TOOLS
Special
Universal bead breaker GN-AH-958-BB1 ! U.S.A. only)
Steering stem socket 07916-4300000
Ball race remover 07953 - 3330000
Attachment 07946 - 3290000 Use a steering head races
Steering stem driver 07946 - 4300101
Bearing remover shaft 07GGD - 0010 100 or Equivalent commercially available in U.S.A.
Common
Fork seal driver 07747 - 0010100
Fork seal driver attachment 07747 - 0010400
Bearing remover head , 15 mm 07746 - 0050400 or Equivalent commercially available in U.S.A.
Driver 077 49 - 0010000
lock nut w rench, 30 )( 32 mm 07716 - 0020400 or Equivalent commercially available in U.S.A.
Attachment, 42)( 47 mm 07746 - 0010300
Piolt, 15 mm 07746 - 0040300
Tife bead breaker set 07772 - 0050000
Breaker arm 07772 - 0050200 not available in U.S.A.
Breaker arm compressor 07772-0050100
TROUBLESHOOTING
Hard steering Front suspension noise
Steering stem nut too tight. loose steering stem bearing
Faulty steeting stem bearings. loose front fork fa steners
Damaged sleering slem inner and /or outer face. Insu ffic ient fluid in forks
Insufficient tire pressure .
Poor brake performance
Steer. to one side or does not track straight Improper brake adjustment
Bent front forks . Worn brake shoes
• Bent front a)l:;le, wheel installed incorrectly. Brake linings oily, greasy or dirty
Worn brake cam
Front wheel wobbling Worn brake drum
Bent rim . Brake arm serrations improperly engaged
Worn wheel bearing.
Faulty tire. Brake drags
Axle not tightened properly. Incorrect brake adjustment
Incorrect tire installation. Sticking brake cam
Sticking brake cable
Soft suspension
Weak fork springs
Insufficient ftuid in front forks
Incorrect fork oil weight
Hard suspension
Incorrect fluid in Iront forks
Fork damaged
Incorrect fork oil weight
11-2
HANDLEBAR 111 REAR BRAKE (2) FRONT BRAKE

LEVER HOLDER HOLDER
REMOVAL

- w ire bands
j
- throttle grip housing and disconnect the throttle cable from
the throttle pipe.
- front and rear brake lever holders and brackets.
- handlebar switch
(5) THROTTLE
141 HA"DLE.',R GRIP
SWITCH HOUSING
- handlebar upper holders

- handlebar
INSTALLATION 0) LEFT HANUC",'AH GRIP
If the left handlebar grip or throttle pipe from the right handle'
bar grip has been removed:
Apply Honda Bond A or Honda Hand Grip Cement (U.S.A.
only) 10 the inside surface of the grips and to the clean surface
of the left handlebar and throttle pipe.
Wait 3 - 5 minutes and install the grips. Rotate the grips for
even application of adhesive.
NOTE
• Allow the adhesive to dry for an hour before using.
Place the handlebar on the lower holders.
Align the handlebar punch mark with the top of the right
handlebar lower holders.
Install the handlebar upper holders on the handlebar.
11-3
FRONT WHEEUBRAKE/SUSPENSION/STEERING
Tighten the forward bolts lirst, then tighten the rear bolts.
TORQUE: 18- 30 N·m 11 .8 - 3.0 kg. m, 13- 22 h · lb)
Align the handlebar switch locating lab with the hole in the n f SWITCH REAR
handlebar and install the handlebar switch. COVER
121
Tighten the upper screw first, then tighten the lower screw.
Install the rear brake bracket and holder on the handlebar with
the dot mark up .
Align the end of the holder with handlebar punch mark .

Apply grease to the throttle cable and connect the cable to the CABLE END
throttle pipe.
I
121 TH ROTTLE PIPE
1
11-4
FRONT WHEEU BRAKE/SUSPENSION/ STEERING
Align the end of the throttle cover with the handlebar punch
mark and install the throttle grip housing.
Install the front brake bracket and holder on the handlebar with
the dot mark up.
A lign the end of holder with the handlebar punch mark.

Tighten the upper screw 'irst, and tighten the lower screw .
Install the wire bands securely.
NOTE
After installing the handlebar, check tha t the throttle grip
rotates freely in atl steering positions.
Perform the following inspections and adjustments;

- Throttle operation (page 3 -41
- Brake lever free -play (page 3-101
•
FRONT WHEEL
REM OVAL
Raise the front wheel off the ground by placing a box or

workstand under the engine.
Move the front wheel sideways with force to see if the hont
wheel bearings are worn.
Refer to page 11 -6 fo r front wheel bearing inspection and re-
placement.
,
Remove the front brake adjusting nut and disconnect the brake
cable from the brake arm.
Remove the 8)Cle nut, 8)Cle and front wheel.

Remove the brake panel from the f ront wheel.
Remove the a)Cle side collar from the wheel hub.
2l~:2:'lJSlrlNG NUT
INSPECTION
Axle
Set the ade in V blocks and measure the runout.
SERVICE LIMIT : 0 .2 mm (0 .01 in l
11-5
W HEEL
Check the rim runout by placing the wheelan a truing stand .

Ten turn the wheel by hand, and read the runout using a dial in-
dicator.
SERVICE LIMIT:
Radial : 2 .0 mm (0.08 in)
A xial : 2.0 mm (0 .08 in)
W heel bearing
Remove the dust seal.
Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the hub.
Remove and discard the bearings jf the races do not tUfn

smoothly , quietly , or if they fit loosely in the hub.
NOTE
• Replace wheel bearings in pairs.
Install the dust seal.

For replacement of bearings. see page 1 ' -7.
DISASSEMBL Y/ASSEMBLY (1) FRONT WH"tJ.
Remolle the front wheel hub nuts and hub from the front
wheel.
Remove the from brake drum (page 11 - 13).
NOTE
Only the front wheel can be installed on the front wheel
hub .
Assemble the front wheel with the FRONT mark and front
hub.
(1 ) WHEEL HUB NUT
) BEARING
BEARING
,
OUST SEAL
,8) I:"NTF'R O<Ol","
11-6
FRONT WHEEL/BRAKE/SUSPENSION/ STEERING
Insert the bearing remover head into the bearing.

From the opposite side install the bearing remover shaft and
11\ BEARING REMOVER <",'"
drive the bearing out of the wheel.
Remove the center collar and drive out the other bearing.
TOOLS :
Bearing remover head , 15 mm 07746 - 0050400
available in U.S.A .
Bearing remo ver shaft 07GGO - 0010100 ,21 BEARING \OVER ~H~E';"O~'~1~5 mm
available in U.S.A.
Drive in the bearing squarely until seated. 11 DRIVER

Install the center collar and drive in the other bearing squarely
until seated.
TOOLS:
Drive r 07749 - 0010000
Attachment, 42 x 41 mm 07746 - 0010300
Piolt, 15mm 07746-0040300
NOTE
• Do not allow the bearings to tilt while driving them in.
CAUTION 121 ATTACHME'NT AND PILOT

Nel'ef ins/all the old bearing. Once the bearing is remo~'ed, the
bearing musr be rep/aced wirh a new one,
Apply grease to the inside of the dust seat

Install the dust seal onto the right side hub.
Install the front wheel hub onto the front wheel,
Tighten the hub nuts.
TORQUE : 60 - 70 N·m 16.0 - 7 .0 kg -m . 43 - 5 1 ft -Ibl
Install the front brake drum,

Refer to page 11 - 13 for the brake drum installation_
Install the side collar.
INSTALLATION
I
Install the brake panel,
Align the groove on the brake panel with the lug on the front
fork. Apply a thin coat of grease to the axle. Install the front
wheel by inserting the axle from the right side.
\ (2) GROOVE
11-7
FRONT WHEEU BRAKE/SUSPENSION/STEERING
InSlalilhe axle nut and tighten the axle nut ,
TORQUE : 55 - 65 N·m 15 .5 - 6 .5 kg-m. 40 - 47 ft-Ibl
Connect the brake cable and install the fr ont brake adjusting
nut.
Adjust the front brake (page 3- 1 , L I
•
TIRES
(2) AXLE NUT
!
Remove the wheel (page' ' ·5). (1) FRONT WHEEL HUB
Remove the wheel hub from the rim.
REMOVAL (U.S.A. ONLY)
NOTE
This service requires the Universal Bead Breaker IGN-AH-
958· 881) available in U.S. A . only_
Remove and install tires from the rim side opposite the
-
valve st em.
Remove the core from the valve stem.
CAUTION
Use oj the Bead Breaker 100/ is required jor tire remOl'ol.
Do nOf damage the bead sealing Ufeo o/Iile rim.
Usr a COOIS}10 Tire Changer or l'quH'ufent /0 remol'(! the fire
from /he ,im, If a lire changer is 110f available, rim protectors
and lire irons may be used.
V....
(1) PRESS BLOCK
(2) BREA7R ARM ASSEMBLY
Install the blade for 9"111 " rims onto the breaker arm assemb·
I,. !-J
CAUTION (3) BLADE

Use oj an improper size blade ma)' reslill in damage 10 Ihe rim,
lire or blade.
Place the proper size adapter onto the threaded shaft and then 13) BREAKER ARM ASSEMBLY
put the wheel over the threaded shaft and adapter, I II TIRE --'.
12\ RIM
. .. '
lube the bead area with water , pressing down on the tire side-
.'',:. .. .. '
wall/bead area in several places, 10 allow the water to run into
\- \
and around the bead. Also lube the area where the breaker arm
Will contact the sidewall of the tire,
11JJ.ij'WII~11
. ..J _ .J
'"
USt ollly k'altr as a lubricant k'hNI rtmol';ng or mounting tires .
Soap or some mount;ng lubricants moy leo I'e a slippery " sitlut
k'hlch can COIISt' the tire to shift on the rim ami lose a;r prt'sSIlre
(4) ~'REAOEO SHAFT
during rid;"g, 15) ADAPTER
11 -8
FRONT WHEEl/ BRAKE/SUSPENSION /STEERING
While holding the breaker arm assembly at an approximate

45 0 position. insert the blade of the breaker arm between the
tire and rim . Push the breaker arm inward and downward until
it is In the horizontal position with it s press block in con tact
with the rim.
With the breaker arm in the horizontal position, place the

breaker press head assembly oller the breaker arm press
block.
Make sure the press head boll is backed out all the way and
then position the nylon buttons on the press head against the
inside edge of the rim
Insert the threaded shaft through the appropriate hole in the

breaker press head assembly and then tighten the lever nut
until both ends of the breaker press head assembly are in firm
contact with the rim.
(5) PRESS HEAD
ASSEMBLY
n) PRESS HEAD BOL T - ,"",,=,,
(2) LEVER NUT
Tighten the press head bolt until the reference mark on the
(3) 1'" RIM
press block is aligned with the top edge of the press head.
(7) 9" RIM (6) 7" RIM

If the rest of the bead cannot be pushed down into the center
of the rim by hand. loosen the press head bolt and the lever
nut. Rotate the breaker arm assembly and breaker press head
assembly l i B to 1/4 the circumference of the rim. Tighten the
(2) TOP EDGE OF
lever nut and then tighten the press head bolt as described.
PRESS HEAD
(1) REFERENCE MARK
Repeat this procedure as necessary until the remainder of the
bead can be pushed down into the center of the rim.
Assemble the Universal Bead Breaker on the other side o f the

wheel and break the bead following the same procedures.
Remove the tire from the rim using a tire changer machine or
tire irons and rim protectors.
Remove tire from rim that has the smallest shoulder area to
(3) RIM BEAD LOCKS
simplify removal.
REMOVAl lEXCEPT U.S.A.I (1) BREAKER ARM
NOTE
This service require s the Tire Bead Breaker Set 107772 -
0050000) not available in U.S.A .
CAUTION
Do nOI apply waler, soapy waler, oil elc. to the lire, om and
roof when removing 'he /Ire. The toof breaker arm may slip ojj
the I;re and rhe bead cal! nOI be broken ojf Ihe rire.
Do flot damage the bead seating area oj the rim.
Fol/o ...· the breaker manujacwrer's instructioll. (2) NARROW END (A SIDE)
11-9
lnsen the narrow end !A sidel of the breaker arm between the
(1) RIM CENTER (2) BREAKER ARM
tire and the rim.
COMPRESSOR
TOOL;
Brea ker arm 07772 - 0050200
Position the breaker arm compressor onto the rim center as

shown.
TOOL:
Breaker arm compressor 07772 - 0050 100
Keep the breaker arm horizontal and align the end of t he com -
pressor bolt with the arm hole.
Screw in the breaker arm compressor bolt to break the bead

from the tlfe.
If the rest of the bead cannot be pushed down into the cen ter
01 the rim, remOlle and reposition the compressor and arm' 18
to 1 (4 the circumference of the rim. T ighten the compressor
bolt to break the bead. Repaat this procedure as necessary
until the remainder of the bead can be pushed down into th e
center of the rim.
If the bead breaking is difficult With the narrow end (A side) of

the breaker arm, use the wide end (B side of the arm and (1) WIDE END (B SIDE)
repeat the procedure above.
11-10
TIRE REPAIR
NOTE
Use the manufacturer's instructions for the tire repair kit
you are using. If your kit does not have instructions. use the
procedures provided here.
Check the tire for puncturing objects. Chalk mark the punc-
tured area and remove the puncturing object.
Inspect and measure the injury. Tire repairs for injuries larger
than 15 mm (5/8 inl should be a section repair. Section repairs
should be done by a professional tire repair shop.
If the injury is smaller than 15 mm (51B in), proceed with the
repair as described here.
Install a rubber plug into the injury as follows:

, Apply cement to a plug inserting needle and work the needle
into the injury to clean and lubricate it. Do this three times. Do
not let the cement dry.
Insert and center a rubber plug through the eye of the inserting
needle.
Apply cement to the rubber plug.
Push the inserting needle with plug into the injury until the plug
is slightly above the tire. Twist the needle and remove it from
the tire, the plug will stay in the tire.
NOTE
Be careful not to push the plug al! the way into the tire to
prevent it from falling inside.
Trim the plug 6 mm (1/4 in) above the tire surface.

Repeat the above procedure if the puncture is large.
Do not use more than two plugs per injury.
Allow the repair to dry. Drying time will vary with air tempera-
ture. Refer to the tire repair kit manufacturer's recommenda-
tions.
Inflate the tire and test the seal by dabbing a small amount of
cement around the plug. Escaping air will cause a bubble in the
cement. If there is leakage, remove the tire (page 11·8) and
apply a cold patch to the inside of the tire as described.
If a plug has been inserted, trim it even with the inner tire sur-
face.
Temporarily place a rubber patch that is at least twice the size
of the puncture over the injury. Make a mark around the patch,
slightly larger than the patch itself.
Remove the patch.
Roughen the area marked inside the tire with a tire buffer or a
wire brush . Clean the rubber dust from the bulled area.
11-11
Apply cement over the area marked and allow it to dry.

Remove the lining from the patch and center it over the injury.
Press the patch against the injury using a special roller.
NOTE
Allo w cement to dry until tracky before applying patch .
• Do not touch the cement with dirty or greasy hands.
ASSEMBLY
Install the tire onto the rim, where the rim shoulder width is the
most narrow, to simplify installation.
Clean the rim bead seat and flanges.

Apply clean water to the rim flanges. bead seat and base.
Use only woter as a lubricant when removing or mounting tire.

Soap or some mounting lubricants may leal'e a slippery residue
which can cause the tire 10 Shift on the rim and lou air pressure
during riding.
Install the tire and inflate it to seat the tire bead.

Install the valve core in the valve stem.
Deflate the tire. Wait 1 hour and inflate the tire to the specified
pressure.
TIRE PRESSURE (Front and Rear) :

4 .3 ± 0.4 psi (30 ± 3 kPa, 0 .3 ± 0.03 kg{cm 2 )
-
Check for air leads and install the valve cap.
Install the wheel hub into the wheel rim.

Tighten the hub nuts.
TORQUE: 60 - 70 N·m (6.0-7.0 kg -m. 43 - 51 ft -Ib)
Install the front wheel (page 11- 7).
11-12
FRONT WHEEl/BRAKE/SUSPENSION/STEERING
FRONT BRAKE
Remove the front wheel (page 11 · 5).
Remove the front brake panel.
BRAKE DRUM
Measure the brake drum 1.0.
SERVICE LIMIT: 111 mm 14.4 in)
Bend down the lock washer tabs.

Remove the drum mounting bolts and lock washer.
Remove the brake drum from the front hub.
Install the brake drum in the reverse order of removal.
Install a new lock washer and tighten the bolts.
TORQUE : 25 - 35 .N·m 12.5-3 .5 kg.m, 18 -25 ft·lbl
Bend up the lock washer tabs against the bolt head.
BRAKE LINING
Measure the brake lining thickness .
SERVICE LIMIT : 2.0 mm 10.08 in)
Contaminated brake linings lettuce slOpping power. Keep

grease off the linings.
Brake dust contains asbeslM which can be harmful 10 your
health. Do not Wit compressed air 10 clean brah parts. Use
I'Qcuum with Q sealed dust t:oflecror. Wear a protecti"e lace
mask and wlllh )'our hands "'hen finished.
(1) BRAKE SHOES

BRAKE PANEL DISASSEMBLY
Put marks on the brake shoes before removing them so that

they can be installed in their original positions.
Remove the brake shoes.
NOTE
• Replace brake shoes in pairs.
11-13
Remove the washer from the brake panel by bending up the SEAL
washer tab, if necessary .
Remove the brake arm, wear indicator plate, return spring and
brake cam.
Remove the dust seal.
Check the dust seal for wear or damage and replace if neces-
sary.
7-
(1) WASHER
BRAKE PANEL ASSEMBLY
Apply grease to the dust seal .

InSlall the dust seal onto the brake panel.
Apply silicone grease to the brake cam sliding surface and

anchor pin.
, it!
Wipt txcess grease off the cam. A contaminated brake lining
rl'lfllces stopping power. Keep grease off the lining.
Install the brake cam. (1) ANCHOR~ ~I BRAKE CAM
Install the return spring . 131 PU'I,H MARKS

Place the wear indicator plate onlO the brake cam by aligning
lhe wide tooth on the plate with the wide groove on the brake
cam .
Install the brake arm with aligning the punch marks on the
brake cam and arm.
Torque the bolt.
TORQUE: 8 - 12 N'm (0.8 - 1.2 kg-m, 6 - 9 ft -Ibl
121 REllURN SPRING
Install the washer and bend down the washer tabs.
11-14
FRONT WHEEl/BRAKE/SUSPENSION /STEERING
Install the brake shoes and springs. _~I1~I~~'(E SHOES
NOTE
• InSlall the brake shoes with the marks facing up.
Place the brake panel in the fr ont wheel .

Install the front wheel (page 11 -7\,
(2) SPRINGS
FRONT FORK
REMOVAL
Remove the front wheel (page 11 -5\
Remove the clamp bolts and disconnect the front brake cable
from the fork tub.
Remove the front fork upper bolt and loosen the lower pinch
boilS.
Remove the front fork slowlV .
NOTE
Do not turn the Iront fork upside down before the fork oil is
drained.
CAUTION
The Jork caps are under spring pressure. Be care/ul when re-
mO I'ing and ...ear eye and jocI! pro/(!('rion del'ices.
(2) LOWER
DISASSEMBLY )11 FOjUBE BOLT
Remove the front fork boot.

Hold the fork tube in a vise. with soft jaws or shop towel and
remove the frok lube bolt.
CAUTION
• Do not damage the fork tube sliding stlrface.
11-15
FRONT WHEEL/BRAKE/SUSPENSION/ STEERING
Remove the fork spring . (1) SPRING

Drain the fork oil by pumping the fork up and down several
times.
Hold the lug of the fork slider in a vise with soft jaws or a shop
towel.
Remove the socket bolt.
NOTE
Temporarily install the spring and fork tube bolt if difficulty
is encountered in removing the socket boll.
111 SOC ET BOLT
Remove the dust seal and stopper ring . 111 DUST
(2) STOPPER RING
Remove the lork tube and oil lock piece from the fork slider. m FORK TUBE
/
Remove the piston from the fo rk tube.
/
{31 PISTON
/
(2) OIL LOCK PIECE
11-16
FRONT WHEEL/BRAKE/SUSPENSION/STEE RING
Remove the oil seal and back-up ring from the fork slider with a
screwdriver .
NOTE (1) OIL

Be careful not to damage the inside of the slider bushing or SEAL
fork slider during removal.
(2) BACK-UP
RING
(3) SUDER
(1) OIL BUSHING
INSPECTIO N ' 86:
Fork spring free length

Measure the fork spring free length.
SERVICE LIMIT: '86 : 547 .4 mm (21 . 55 in )

After ' 86 : "U"'t!l'IIIUllttllllllflmfnMlllllllllffi
A: 118.0 mm 14.65 in )
B: 428 .3 mm (16.86 in)
J
Fork tube /fork slider/piston 111 FOR1 SLIDER
Check the f ork tube, slider and piston for score marks, scratch-
es or excessive or abnormal wear. Replace if necessary.
-;; .,
\
(31 PISTON
(4) PISTON RING
Bushing/back-up ring
Check the bushing for excessive wear or scratches.
If copper appears on more t han 3/4 of the entire surface. re- (1) SLIDER BUSHING
place the bushing . (3) BACK -UP
RING
NOTE
The slider bushing cannot be removed f rom the slider.
If the slider bushing requires replacement, replace the slid-
".
(41 CHECK POINTS
Replace the back-up ring if it is distorted at the check points (21 COPPER
shown. SURFACES
Check the fork piston ring for wear or damage.

Check the rebound spring for fatigue or damage.
11-17
FRONT WHEELI BRAK EI SUSPENSIONI STEERING
FORK TUBE
Sel the fork tube in V blocks and check its funout.
SERVICE LIMIT : 0 .20 mm 10.008 in)
ASS EMBLY
Before assembly, wash all parts with a high f lash point or non-
flammable solvent and wipe them off completely.
111 UPPER FORK BOLT

(191 BOOT BAND
(18) BOOT BAND SCREW
(3IWASHER \ (12) STOPPER
(4) FORK TUBE BOLT y .f2) D-RING RING
12) O-F'!!'(
(6) PISTON RING
A FTER '86:
,- - - -- ,
(7) PIST~
(2 1) FORK
SPRING (AI
I
---,f----.
(23) SPRING
SEAT
I
I I (20) BOOT
I (15) FORK SUDER
I I
(10) FORK TUBE
19) OIL LOCK PIECE

--.- (161 WASHER
"--- 117) SOCKET BOLT
(22) 181 REllOlJNO SPRING

SPRING iB)
11 -18
FRONT WHEELfBRAKEfSUSPENSION fSTEERING
Install the rebound spring on the fork piston, then slip the 111 FiK TUBE
piston into the fork tube.
Install the oil lock piece onto the pist on.
(2)
/
PISTON
./
(31 Oil LOCK PIECE
Insert the fork tube into the s lider.

Hold the lug of the fork slider in a vise with soft jaws or a shop
towel.
Apply a locking agent to the socket bolt and th read it inlO the
piston . Tighten the socket bolt.
TORQUE : 15- 30 N·m 11.5-3. 0 kg-m. 1' - 22 ft-Ibl
NOTE
Temporarily install the fork spring and fork tube bolt to
tighten the socke t bolt. (11 SOCKET BOLT
Install the back-up ring.

(1) OIL SEAL
Wrap a piece of tape around the groove at the top of the lork
tube . This will protect the oil seal from damage when it is in-
stalled.
Coat a new oil seal wi t h ATF and inst all it with the seal mark- .0-__ (2) BACK -
ings fac ing up. Drive the seal in with the seal driver. UP
RING
TOOL:
Fork seal driver 07747 - 0010100
Fork seal driver attachment 07747 - 0010400 (3) SUDER
BUSHING
(21 ATTAC HME NT
(1) DUST SEAL

Install the stopper ring into the groove in the slider.
Be sure the stopper ring is seated in the groove aU the way

around.
~\
(2) STOPPER RING
11 -19
FRONT WHEEU BRAKE/SUSPENSION/STEERIN G
Pour the specified amount of ATF inlo the fork tubes.

.£ .£
MN
RECOMMENDED OIL: ATF or equivalent <o~
/~
EE
CAPACITY; 195.5 -200.5 cc EE
16.6- 6 .B US oz, 6 .8 - 7 .0 Imp ozl _N
<oro
Pump the front fork several times to stabilize the oil level.
Compress the front fork and measure the oil level from the top "''''
ro ro
of the tubes. §
l i ;(
SPECIFIED lEVEL: '86 161 mm 16.3 in) --
After ' 86 182 mm (7.2 in)
Wipe all any excess oil from the fork spring. 86 : After ' 86 :
Install the fork spring with the tapered end facing down.
11) FORK SPR)NG~ ~A
~
I 1
I I
I I I I
131 TAPERED END~ ~B

12) DOWN
I
DOWN
Install the O-ring onto the lork tube bolt .

Hold the fork tube in a vise, with soft jaws or shop lowel and
InSlali the fork tube bolt .
Tighten the fork tube bolt .
TORQUE : 15 - 30 N·m 11 .5 - 3 .0 kg-m, 11 - 22 It-fbi
121 a -RING
In Slall the lork boot and the boot band with the band screw III FORWARD
121 BOOT BOOT
facing rear, and the screw head facing outside as shown.
(4) SCREWS
11 -20
FRONT WHEELI BRAKEI SUSPENSIONI STEERING
INSTALLATION
Install the fork and temporarily tighten the lower pinch bolts.
Install the fork upper bolt with the O-ring and loosen the lower
pinch bolts, then tighten the fork upper bolt.
TORQUE : 50 - 60 N·m (5.0 - 6 .0 kg-m. 36 - 43 ft -Ibl
T ighten the lower pinch bolt.
TORQUE: 30 - 40 N-m (3 .0 - 4.0 kg-m , 22 - 29 ft -Ibl
(3) FORK PINCH BOLTS
Push up the fork boot until it just touches the bottom of the
steering stem then tighten its clamp.
Install the front wheel Ipage 11-71.

Connect the front brake cable to the cable clamps and install
them onto the fork tub. Tighten the clamp bolts.
STEERING STEM
REMOVAL
Remove the headlight case from the headlight bracket Ipage

, 7-21.
Remo ve the headlight bracket by removing two bolts.
Remove the handlebar lower holder mounting nuts and handle-
bar from the fork top bridge.
Remove the front fender (page 13-2). (11 FRONT FENDER

I
11 -21
FRONT WHEEL/BRAKE/SUSPENSION /STEERING
Bend down the tonged washer tab.

Remove the st eering stem nut.
TOOL:
l ock nu t w re nc h 077 16 - 00204 00
available in U.S.A . pi
Remove the front fork tube assemblies (page 11-15) and the
fork top bridge. •
I~
•
· ""'...,;~
(3) TONGED WASHER
loosen the steering bearing adjustment nut and re move the (1) STEERING STEM
nut, dust seal and upper bearing inner race. Then remove the
steering stem, being careful not to drop the steel baUs.
TOOL:
Steering stem s ocket 079 16 - 4300000 or
07916 - 37 10 100
• /"""'121
r <'- ADJUSTMENT NUT ~(BS
BEARING RACES INSPECTION 11) UPPER OUTER RACE
Check the steering stem inner and outer races for wear or dam-
age.
NOTE
• Replace the steel ball bearings and races as a set .
121 LOINEf
BEARING RACES REPLACEMENT
Remove the upper and lower bearing races from th e frame

using the special tool:
TOOL :
Ball race remover 07953 - 3330000
11 -22
FRONT WHEEL/ BRAKE/SUSPENSION /STEERING
Drive new upper and lower outer ra ces into the steering head. (2) ATTACHMENT
TOOLS :
Driver 07749 - 0010000
Attachment 07946-3290000
•
131 DAI'VEA
Install the washer and dust seal 01'110 the steering slem and
press a new lower inner race over the stem with the special
tool:
TOOL:
Steering stem driver 07946 - 4300101
0'
Attachment 07946 - MBODOOO with
6N - HT - 54 [U .S.A . only)
111 STEM DRIVER

~-
INSTALLATION
Apply grease to the upper and lower outer races and install the
18 steel ball bearings for both the upper and lower races. (1) STEERING BEARING
ADJUSTMENT NUT
(4) STEEL BAll

(18PIECES) /
I
~~
~
~ ___ (21 OUST SEAL
15) UPPER OUTER R7E~~

~
-
_ _ _ 131 UPPER INNER RACE
(6) LOWER OUTER RACE '-......_ ~§'=f

(7) STEEL BALL BEA~INGS ~
(18 PIECES) ---0
(91 DUST SEAL

1101 WASHER
11-23
FRONT WH EEUB RAKE/SUSPENSION/STEERING
Slide the steering stem t hrough the st eering head from the bot -
10m .
Install the upper inner race and st eering head bearing adjust-
ment nut. 1/
(l) UPPER INNER RACE (2) STEEL BALLS
•
Tighten the steering head bearing adjustment nut t o the initial
torque.
TORQUE : 25 - 35 N'm 12.5-3 .5 kg-m, 18- 25 ft -Ibl
TOOL:
Steering stem socket 07916 - 4300000
••
07916 - 3710100
STEM SOCKET .....
Turn the steering st em all the way to right and teft 2 or 3 times • ~:'R'~~B~~E~ARING ADJUSTMENT NUT
to seat the bearings.
Retighten the steering bearing adjustment nut to the final
torque.
TORQUE : 5.5 - 6 .5 N·m (0 .55 - 0.65 kg-m , 4 .0 - 4 .7 ft·lbl
Instatl the for k top bridge.

TemporarllV Install the tonged washer by filling the hook on the
washer in the hole on the top bridge, then install the steering
stem nut .
Install the front forks (page 11 -21).
Tighten t he steering stem nut .
-- • -'J
-'
I
. (3 ) LOCK TAB
TORQUE: 70 - 90 N·m 17. 0 - 9 .0 kg-m . 5 1 - 65 ft -Ibl
TOOL:
\
Lock nut wrench 07716 - 0020400
or Equivalent commer -
ciallv available in U.S .A .
Bend up one lock tab of the tonged washer. (2) TOP BRIDGE
11 -24
FRONT WHEELIBRAKE/SUSPENSION/STEERING
Install the handlebar onto the fork top bridge.

InSlall the washer and handlebar lower holder nut.
Tighten the nut .
TORQUE: 40 - 48 N·m (4.0 - 4 .8 kg -m, 29 - 35 ft·lb)
Inslall the following:

- headlight bracket
- headlight
- ftont fender
- front wheel
11-25
REAR WHEEL/BRAKE/SUSPENSION
80-100 N·m 10.0 kg-m, 58 - 72 ft-Ibl
28 - 34 N·m ( kg -m
kg_~)~~~~~~~E~:i~;z
20 - It-lb)
70 - 80 N.m t7.0 - 8 .0
51 -58 ft -Ib)
12-0
12. REAR WHEEl/BRAKE/SUSPENSION
SERVICE INFORMATION 12-1 REAR BRAKE 12-7
TROUBLESHOOTING 12-2 REAR SHOCK ABSORBER 12- 10
REAR WHEEL 12-3 SWINGARM 12-13
SERVICE INFORMATION
GENERAL
Ilruke llust muy COn/ain asbestos which cun be harmful to )'0/11 health. Do lIor use compressed ai' to clean brake drums or brake
punels. VSf'1I I'QeIlUm with a sealed dust collector. Wear a pratte/iI't! face mask anti (1lOrollgh ly wush J'our hllT/lls 'H'hen jin;shell.
A comulI/inuled brake /ining reduces stopping power. Keep grease off the linillgs.
The shock absorber con tains nitfogen gas /lnder high pressure. 1)0 nor allow f ire or htat luar the shock absorber.
Bejorf' disposal oj ,he shock absorber, release the Ititrogen, (see page !l- I I) ,
• This section covers maintenance of rear wheel, rear brake panel and drum, rear shock absorber and swingarm.
• A workstand or block is required to support the motorcycle.
• Refer to SectIOn 11 f or tire removal and repair.
SPECIFICATIONS
A)(le runout 0.2 mm (0.008 in) If)

Wheel rim runout
Radial -- 2.0 mm (0.08 in)
A)(ial -- 2.0 mm (0.08 m)
Rear brake drum 1.0 . 110 mm (4.3 in) 111 mm (4.4 in)
Rear brake lining thickness 4 mm (0.2 in) 2 mm (0. 1 in)
Rear shock absorber spring free length 147.8 mm (5.8 in) 144.8 mm (5.70 in)
TORQUE VA LUES
Wheel hub nut 60 - 70 N·m (6.0- 7.0 kg -m, 43 - 51 ft -Ib)

Driven sprocket nut 28 - 34 N·m (2.8 - 3.4 kg -m , 20 - 25 ft-Ib) - Apply oil to the threads .
A)(le nut 80 - 100 N·m (8.0 - 10.0 kg -m, 58 - 72 ft·lb)
Brake arm bolt 8 - 12 N·m (0.8 - 1.2 kg-m, 6 - 9 ft-Ib)
Damper rod lock nut 38-60 N·m (3.8 - 6.0 kg·m, 27 - 43 ft -Ib)
Shock absorber mounting bolt upper 70-80 N'm (7.0-8.0 kg·m, 5 1-58 ft·lb)
lower 70 - 80 N'm (7.0- 8.0 kg·m. 51 - 58 ft -Ibl
Swingarm pivot nut 80 - 100 N·m (8.0 - 10.0 kg ·m, 58 - 72 ft-Ib)
Rear brake drum mounting bolt 25 - 35 N·m (2.5 - 3.5 kg -m. 18 - 25 ft -Ibl
12-1
REAR WHEEL/BRAKE/S USPENSION
TOOLS
Special
Bearing remover shaft 07GGO - 001010a or Equivalent commercially available in U.S.A.
Common
Driver 07749-0010000
Attachment , 42 x 47 mm 07746 - 0010300
Bearing remover head, 15 mm 07746 - 0050400 or Equivalent commercially available in U.S.A.
Pilot, '5 mm 07746 - 0040300
TROUBLESHOOTING
Wobble o r vibration in motorcycle Poor brake perf o rm an ce
Bent rim Improper brake adjustment
Worn wheel bearing Worn brake shoes
Faulty tire Brake lining oily, greasy, dirty
Axle not tightened properly Worn brake cam
Swing arm bushing worn Worn brake drum
Incorrect tire installation Brake arm serrations improperly engaged
Soft suspension Brake drag

Weak spring Incorrect brake adjustment
• Faulty shock absorber Sticking brake cam
Sticking brake cable
Hard suspen sion
Bent shock absorber rod
Improperly adjusted rear shock absorber
Faulty swing arm bushing
Suspension noise
Shock case binding
• Loose fasteners
12-2
REAR WHEEl/BRAKE/SUSPENSION
REAR WHEEL
REMO VAL
Raise the rear wheel off the ground with workstand or block
under the engine.
Remove the rear brake adjuster nuts and disconnect the brake
cables from the brake arms.
Remove the axle nut. III DRIVE CHAIN ADJUSTING NUT

Loosen the drive chain adjusting nut s an d remove the axle nut
and rear axle.
." "
Push the wheel for ward and remove the drive chain from the
driven sprocket. Remove the rear wheel.
( -
.I ~
Remove the axle side collar from the wheel hub .
I
_ '0
(2 ) AXLE NUT
INSPECTION
Axle
Place the rear axle in V blocks and measure the runout.
SERVICE LIM IT : 0 .2 m m (0.08 in )
Rea r wheel rim runout

Check the rim runout by placing the wheelan a truing s tand .
Turn the wheel by hand and measure t he runout using a dial in-
dicator.
SERVICE LIMIT :
Radial: 2 .0 mm 10.008 in)
Axial : 2 .0 mm (0.008 in)
12-3
Wheel bearings
Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the hub.
Remove and discard the bearings If the races do not turn

smoothly, quietly. or if they fit loosely in the hub .
NOTE
• Replace hub bearings in pairs.
For replacement of bearings, see page 12-5.
OISASS EM BL Y
Remove the driven sprocket by removing the six socket bolts.
Remove the four wheel hub nuts and remove the wheel hub
from the rim . r
Bend down the lock washer tabs.

Remove the drum mounting bolts and lock washer.
Remove the brake drum from the rear hub.
12-4
(2 BEARING
(3) REAR BRAKE DRUM (5) CENTER COLLAR
(2) BEARING
(4) REAR WHEEl HUB
(7) DRIVEN SPROCKET

(6) DUST SEAL
Insert the bearing remover head into the bearing. (11 BE,'RI~G REMOVER HEAD, 15 mm
From the opposite side install the bearing remover shalt and
d rive the bearing out of the wheel.
Remove the center collar and drive out the other bearing.
TOOLS :
Bearing remo ver head, 15 mm 07746 - 0050400
Bearing remover shaft 07GGD-00 10100
available in U.S. A .
Drive in the bearing squarely until sea ted.

Install the center collar and drive in the other bearing squarely
until seated.
-
SHAFT
TOOL:
Driver 07749 - 0010000 (1) DRIVER
Attachment , 42 x 47 mm 07746 - 0010300
Pilot, 15 mm 07746 - 0040300
NOTE
• Do not allow the bearings to tilt while driving them in.
CAUTION
New>r inSlal/the old bearing. Once (he bearing is removed, the
bearing II1I1S{ be replaced wifh II new one.
(21 ATTACHMENT AND PILOT
12-5
ASSEMBLY 111 LOCK W~ ~H"A S
Install the brake drum in the reverse ord er 01 removal.

Inst all new lock washers and tighten the bolts .
TORQUE: 25 - 35 N·m 12. 5 - 3 .5 kg -m, 18 - 25 ft -fb l
Bend up the lock washer tabs against the boll head.
Install the rear wheel hub ont o the feaf wheel.

Tighten the wheel hub nuts.
T ORQUE: 60 - 70 N·m (6 .0 - 7 .0 kg -m , 43 - 5 1 it-fb i
Install the driven sprocket onto the hub.
Tighten Ihe driven sprocket nut.
TORQUE: 28 - 34 N·m (2.8-3.4 kg-m , 20 - 25 ft- fbl
Apply grease to the inside of the dust seal and install it into the
hub.
Install the side collar.
I,
INSTALLATION 111 j
Install the fear brake panel.
NOTE
• Refer to Section l ' for the rear tire removal /repair.
Align the groove on the brake panel with the lug on the swing
arm . Install the drive chain on the driven sprocket.
Apply thin coat of grease to the axle.
Install the rear wheel by inserting the axle wi t h chain adjust er
through from the right side.
12-6
Install the left chain adjuster and t ighten the axle nut lightly.
Adjust the drive chain slack (page 3-71. •
STANDARD: 25 - 35 mm (1 - 1·3 18 In)
Tighten the axle nut .
TORQUE: 80 - 100 N·m (8 .0 - 10.0 kg-m . 58 - 72 it-fb i
~
~
.- 'v
(2) LEFT CHAIN AO~JU':S~T::EO:;R
..:..
Connect the brake cables and install t he rear brake adjusting CABLES
~
nuts. Adjust the rear brake (page 3- 11'.
# •
m~W1;mt!G NUTS •
REAR BRAKE
Remove the rear wheel (page ' 2-31.
Remove the brake panel.
BRA KE DRUM IN SPECTION
Measure the brake drum 1.0 .
SERVICE LIMIT: 11 ' mm 14.4 In)
BRAK E LINI NG IN SPE CTI ON
Measure the brake lining thickness.
SERVICE LIMIT: 2 .0 mm 10.08 in)

111 BRAKE SHOES
BRAKE PANEL DI SA SSEMBLY
Put marks on the brake shoes before removing them so that

they can be installed in their original positions.
NOTE
• Replace brake shoes in pairs .
12-7
REAR WHEEL/BRA KE/SUSPENSION
Remove the dust seal. 111 SEA L
Check the dust seal for wear or damage and replace it if neces-
sarv·
•
•
BRAKE PANEL ASSEMBLY (1) WASHER ( I DUST SEAL
Install the washer and bend down the washel tabs.

•
•
Apply grease \0 the dust seal and install it .

Apply grease to the brake cam sliding surface and anchor pin .
Install the brake cam.
'm
Wipe exuss grease off the cam. A comaminated brab lining
reduces slOpping power. Keep grease off the linings.
13) pu"eH MA,BKS
•
Install the return spring.
Place the wear indicator plate onlo the brake cam by aligning
the Wide tooth on the plate with the wide groove on the brake
cam.
Install the brake arm with aligning the punch marks on the
brake cam and arm .
-.,-
TorQue the bolt.
TORQUE : 8 - 12 N·m {O.8 - 1.2 kg-m . 6 - 9 ft -Ib!
P
121 RETURN SPRING
12-8
REAR WHEEL/ BRAKE/SUSPENSION
Install the brake shoes and springs. (1) BRAKE SHOES
NOTE
• Install the brake shoes with the marks facing up.
Place the brake panel in the rear wheel .

InSlall the rear wheel Ipage 1 2 ·6) .
REAR BRAKE PEDA L REMOVAL
Remove the brake pedal adjusting nut and unhook the retun
spring from the swing arm.
Remove the rear brake pedal bolt and pillot shaft.
Remove the brake pedal and brake rod by removing the cotta
pin .
(3) ADJUSTING NUT
~~
(8) RUBBE PROTECTOR
~ (4) SPRING
(1) PIVOT SHAFT
' \ 9 1 COTTER PIN
(7) REAR BRAKE PEDAL

16) BRAKE PEDAL BOLT
REAR BRAKE PEDAL INSTALLATION
Install the brake pedal in the reverse order of removal.

Apply grease to sliding surface of the pivot shaft, then instal
the pillot shaft with dust seals.
Adjust the reat brake lever play (page 3- 11 ).
NOTE
• 00 not forget to install the inner dust seal.
12-9
REAR WHEEL/BRAK E/SUSPENSION
REAR SHOCK ABSORBER

REMOVAL
Remove the seat and side covers.

Remove the reBr shock absorber upper mounting nut and bolt.
Remove the rear shock absorber lower mounting nut and bolt
and remove the shock absorber downward through the open-
ing of the swingarm.
OISASSEMBl Y (2 ) COLLAR
, it '
Thr damper unil is filled with ,,{trogen gas under high pressurr,
do 110/ try do disassemble.
Remove the coliar from rear shock absorber lower mount.

,
Set the reBr shock absorber in a hydraulic press as shown and

press the shock absorber to remove the stopper ring.
Remove the shock absorber from the hydraulic press.
12-10
loosen the damper rod lock nut and remove the lower joint.
Remove the spring, damper rubber. spring seat and spring seat
III DAMPER ROD cu'"'."U
stopper.
(2IlQWER JOINT
SPRI NG INSPECTION
Measure the spring free length.
SERVICE LI MIT: 144.8 mm (5.70 in)
SHOCK ABSORBER DISPOSAL PROCEDURE
Center punch the damper case to mark the drilling point, ap-
(2) PL.""C BAG
proximatelv 10 mm (0.4 in) from the top surfase.
Wrap the damper unit inside a plastic bag. in)
Support the damper unit upright in a vise as shown.
Through the open end of the bag. insert B drill motor with a
sharp 2 - 3 mm (5 /64 - 1' 8 in) drill bit .
·iI.
Do 1I0/1lS~ a dull drill bit which could couu Q build-liP of exces-
sil't heat and pressure inside the damper. leading to explosion
and sel'ere personal injllr)'.
The shock absorber conrains nitrogen gas and Qilunder high
prnsuu. /)0 not drill any farther down the damp~r case than
Ih~ m~asur~m~nt gil'en abol'~, or you ma)' drill inlo the oil
chamber; oil ~scaping under high preSJ'ure may ca/lse seriou)'
persollal injury,
Always "'~ar ~)'e prolfilion 10 al'oi(/ gelling m~/al sha"'ngs in
),ollr tJ'u "'h~n the gas pr~ssur~ is re/~as~d. Th~ pJaslir bag is
onl)1inunded 10 shield )'011 from Ih~ ~sraping gas,
Hold the bag around the drill motor and briefly run the drill
motor inside the bag; this will inflate the bag with air from the
motor and help keep the bag from getting caught in the bit
when you start.
12-11
REAR WHEEL/ BRAKE/SUSPENSION
Apply locking agent to the damper rod threads, and instali lhe (1) LOWER JOINT
.~
lock nut and lower joint .
Tighten the damper rod lock nut .
TOROUE : 38 - 60 N·m (3.8-6.0 kg-m. 27 - 43 ft -tbl
DAI~PE: R ROD LOCK NUT
Set the rear shock absorber in a hydraulic press in the same (1) SPRING PRELOAD
manner as during disassembly. ADJUSTMENT
Install the stopper ring into the spring preload adjustment GROOVES
groove.
Remove the rear shock absorber from the hydraulic press.
(
-
(2) HARD ....
13)
STANDARD
(4) SOFT
I
Apply grease to t he lower mount bushing and collar and install
the collar into the lower mount.
IN STALLATION
Install the rear shock absorber onto the Itame .

Install the upper and lower mounting bolts and nut s.
Torque the nuts .
TORQUE: 70 - 80 N-m 17.0 - 8 .0 kg-m , 51 - 58 h -Ibl
12-12
SWINGARM
REMOVAL
Remove the following :

- rear wheel (Page 12-3).
~ drive chain cover .
- drive chain guide .
- rear shock absorber lower mounting bolt and nut .
c::.."
, ,b
(3 ) SHOCK ABSORBER
LOWER MOUNTING BOLT
- brake pedal return spring and unhook the rear brake cable
from the swing arm .
- swingarm pivot nut and bolt.
- swingarm from the frame .
- drive chain slider and rubber protector. 11 1 RUBBER SLIDER

- dust seal caps and pivot collar .
SEAL CAPS
INSPECTION 111 PIVOT CO~t2 ) BUSHINGS
Check the 5wingarm for damage and replace if necessary. (

Check the swingarm pivot collar. bushings and dust seals for
wear or damage.
(31 DUST SEAL CAPS
12-13
PIVOT BU SHING REPLA CEMENT
Drive out the swingarm pivot bushings.

Drive in new pivot bushings.
TOOLS : / '
Driver 07749 - 0010000
Attachment, 42 )( 47 mm 07746 - 0010300
121 ATTA6<MEINT
•
INSTALLATION
Apply grease to the cotlar end dust seals.
,
t21 PIVOT cuee,,"
Install the drive chain slider using the bolts.

inst all the rubbe r protector . ,
(11 DAIVE SLIDER
Install the coller and dust seal caps.
(2) RUBBER PROTECTOR
Install the swingarm into the frame and install t he pivot bolt
and nut .
Tighten the pivot nut.
TORQUE: 80 - 100 N·m 18 .0 - 10.0 kg -m. 58 - 72 ft -Ibl
Check t he swingarm for proper operation.
12-14
Install the rear shock absorber mounting bolt and nut.

Tighten the nut.
- CHAIN COVER
(2) DRIVE CHAIN
I
TORQUE: 70 -80 N·m 17.0-8.0 kg-m , 51 -58 fH b )
Install the drive chain covet using the bolts.

Install the drive chain guide to the swingarm.
13)
"~",
. .'"
SHOCK ABSORBER
LOWER MOUNTING BOLT
Install the brake pedal return spring.

Hook the rubber protector end to the feBr brake rod.
Install the rear brake cable to the hook of the swingarm.
Install the rear wheel (Page 12·6).
)
;.L.
(3) BRAKE PEDAL RETURN
SPRING _ • (4)HOOK~
12-15
MEMO
13. FENDERS/EXHAUST MUFFLER
SERVICE INFORMATION 13· 1 FRONT AND REAR FENDER 13· 2
SEAT 13· 1 EXHAUST MUFFLER 13·3
SIDE COVERS 13· 1
SERVICE INFORMATION
GENERAL
• Refer to Section 3 for spark arrester cleaning.
14WPiii!5
• Do not sen 'ice the exhaust s)'sum while it is hot.
(1) SEAT RElEA!;E
SEAT
REMOVAU INSTALLATION
Release the seat lock bV moving the lever in the direction

shown, unhook the seat and remove it.
Install in the reverse order of removal.
SIDE COVERS
r~..;:(1) SIDE COVER
REMOVALI INST ALLATION
Remove the seat.

Remove the side cover mounting bolts.
Oisconnect the tang CD by slightly bending the side cover.
Disconnect the pin ® from the side cover.
Remove both right and left side covers by turning the side
covers clockwise , centering around the hook @.
Install the side covers in the reverse order of removal.
CAUTION
(2) SIDE COVER
Be careful not to damage (Ill' hooks all the CQl'ers during re-
MOUNTING BOLT
11101'01 Qnd installation.
13-1
FENDERS/EXHAUST MUFFLER
FRONT AND REAR FENDER

RE MOVAl/INSTA LLATI ON
Remove the front fender mounting bolts. Remove the front

lender by releasing it from the tabs on the headlight case.
Install the tront fender in the reverse order of removal .
111
\21 FRONT FENDER

Disconnect the taillight wire connectors .
Remove the rear fender from the frame.
n) REAR FENDER --"ia~:-::?<::~~~~
121 TAILLIGHT WIRE CONNECTORS
13-2
FENDERS/EXHAUST MUFFLER
EXHAUST PIPE/ MUFFLER

, It
Do not .ten 'ice (he exhaust pipe or m llffler when they are hot.
REMOVAl/INSTALLATI ON
Remove the exhaust pipe joint nuts .
Loosen the exhaust clamp bolt and remove the exhaust muf-
fler mounting bolts.
Remove the exhaust muffler and pipe.
Check the gasket and pipe seal for wear and replace them if
(t) EXH AUST MUFFLER
I
m
..
EXHAUST CLAMP BOLT
necessary.
Install the exhaust pipe and muffler in the reverse order of re -

moval.
NOTE
• Make sure there are no exhaust leaks after installation.
It) EXHAUST MUFFLER

(2) EXHAUST PIPE
.,.. .. ~
.• .. 131 lPIP~E
S~:~ EXHAUST CLAMP /
.,..
.,.. ..
•
• • '----,oiD,
(5) GASKET
'"
(6) EX HAUST MUFFLER MOUNTING BOLTS
13-3
IGNITION SYSTEM
__ ·m IGNITION SWITCH
(3) COl UN IT
(8) IGNITION COIL
{71 PULSE GENERATOR
161
(5) NEUTRAL SWlre:H
(9) BI: Black

(10) W: White
(1')Y: Yellow
(12) G: Green
, - - - 8I1R --+-j---, (13) R: Red
BI/W BIIW Bu/Y (14) Bu: Blue
(15) Lg: light green
SI/ A BIIY
Bu/Y G BI / A
G
(3) COl UN IT
/
(2) IGNITION
SWITCH
181 IGNhlON
COIL 7 ;
~
-7
I -=
\
(1) ENGINE 14) SPARK PLUG m PULSE (61 ALTERNATOR
STOP SWITCH GENERATOR
14-0
14. IGNITION SYSTEM
SERVICE INFORMATION 14-1 ALTERNATOR EXCITER COIL 14-3
TROUBLESHOOTING 14- 1 PULSE GENERATOR 14-4
COl UNIT 14-2 IGNITION TIMING 14-4
IGNITION COIL 14-3
SERVICE INFORMATION
GENERAL
• Ignition timing does nOI normally need to be adjusted since the COl (Capacitive Discharge Ignition 1 unit is factory preset.
• For spark plug inspection, refer to page 3-6.
• For pulse generator and stator coil removal, refer to Section 9 .
• Inspection should be made in sequence referring to page 19-6 for troubleshooting of the system .
SPECIFICATIONS
ITEM STANDARD
Ignition timing At idle lOa:!: 2° BTDC at 1.400 ~ 100 rpm

Full advance 28 ° 'j: 2° BlOC at 3,500 ~ 100 rpm
Ignition coil/20oe, 68 ° F) Primary coil resistance 0.1 - 0.3U
Secondary coil resistance
3.7 - 4.5 kG
(Without spark plug cap)
EICciter coil resistance (20 0 e, 68°F) 100-3000
Pulse generator resistance (20°C, 68°FI 290 - 360 n
T OOLS
COl tester inspection adaptor (KKO) 07508 - 0012300 INot available in U.S.A .)
COl tester spark adaptor Q7GGK - 0010100 (Not available in U.S.A .)
TROUBLESHOOTING
Engine starts but stops Engine starts but run s poorly
No spark at plug Ignition primary circuit
Improper ignition timing - Faulty ignition coil
Faulty spark plug - Loose or poorly contacted terminals
- Faulty alternator exciter coil
No spark at plug - Faulty COl unit
Engine stop switch or 19nilion swilch "OFF " - Faulty pulse generator
Poorly connected, broken or shorted wires Ignit ion secondary cirCUit
- Between alternator and COl unit - Faulty plug
- Between COl unit and engine Stop switch or Ignition - Faulty spark plug wire
switch - Loose or poorly contacted spark plug wire
- Between ignition coil and spark plug Improper ignition timing
- Between pulse generator and COl unit - Faulty pulse generator
Faulty ignition coil - Faulty COl unit
Faulty COl unit
Faulty pulse generator
Faulty alternator exciter coil
14-1
IGNITION SYSTEM
COl UNIT
COl UNIT
Remove the fue l tank (page 4 -3\.
Check the spark plug condition before system inspection (page
3-5).
Disconnect and test the 2P and 4P couplers from the COl unit
couplers according to the following chart-
ITEM TERMINAL STANDARD

G
BI/ R
BIIWn
Ignition coil primary 0.1 - 0.30 G
BIIY and G
coil (at 20 o C/68"F)
Bu/Y G BlIR BI/W Bt/W
Ignition coil Blry and spark 3.7-4.511
n~g~NE
secondary coil plug wire (at 20"Cf68°F)
100-30011
"-_',LG/N,tt
Alternator exciter coil BIIA and G
Pulse generator
Ignition and engine

Bu/ Y and G
(at 20 c e /68°Ft
290- 360 n
(at 20ce/68°F) 1
IGN ITION PULSE ALTEANATUR
SWITCH 1 1wITCH
stop switches (Set COIL GENERATOR

the ignition switch No continuity
BI/W and G
ON. and engine stop 100 1
switch RUN posi-
tions)
If there IS no problem, replace the COl unit.
If there is indication of abnormality , inspect the related circuit:
- Ignition coil primary coil (page 14--3).
- Ignition coil secondary coil (page 14·3).
- Alternator exciter coil (page 14·3).
- Pulse generator (page 14·41 .
- Ignition and engine stop switches {page 17A l.
PERFORMANCE TE ST IExce pt U.S.A .I III AC ELECTRIC

SOURCE
Inspect the COl unit with COl tester.
NOTE (2) COl TESTER
• Follow the COl tester manufacturer'S instructions.
TOOL:
Inspection adaptor (KKO) 07508 - 0012300
(not available in U.S.A .)
Connect the special adapter to the COl unit and COl tester
TESTER SWITCH COl UNI T COl UNIT

POSITION GOOD FA ULTY
1. OFF No spark --
2. P 1 --
3. EXT t Spark s
4. aNt Sparks No spark
5. ON2 t t
Replace the COl unit with a new one If necessary .
14-2
IGNITION SYSTEM
IGNITION COIL ) IGNITION COil
PRIMA RY CI RCU IT INSPECTI ON

Remove t he fuel tank (page 4-3).
Disconnect the 4 P coupler from the COl unit.
Check the COl unit couplers for loose connections or rusted
terminals.
Measure the resistance of the Black/ Yellow and Green wire
terminals of the COl unit 4P coupler.
STANDARD: 0 .1 - 0 .3 0 (20 ° C/G8 ° F)
If standard resistance is not obtained, remove the ignition coil

as follows:
Remove the spark plug cap from the spark plug.
Disconnect the ignition primary wires and remove t he ignition
coil. (j IJ
Measure Ihe primary coil resistance at the ignition coil wire ter-
minals. E1l
STANDARD: 7 .4 - 11 .0 n (20 ° C/68 ° F)
,
- :l 01
If the resistance is within range, check the primary wire termi·
nals of the ignition coil for loose wires, poor connect ions or an
open circuit in the wire harness.
-f? ~(
'1 ,
If there is no continuity, replace the ignition coil.

W ~
(1) SPARK PLUG CAP
SECONOARY CIR CUIT INSPECTI ON
Remove the spark plug cap from the wire and measure the sec-
ondary coil resistance. (1) COl TESTE,R:r--rc==it-..,.-E~
STANDARD: 3 .7- 4 .5 kfl (20 °C/68 ° F)
PERFORM ANC E TEST (Except U.S.A.I 13) IGNITION

COIL
Install the spark plug cap to the ignition coil.
Check the ignition coil with a COl tester.
NOTE
• Follow the tester manufact urer's instructions.
121 SPARK ADAPTOR (5) INSPECTION ADAPTOR

TOOL:
Spark adaptor
07GGK - 0010l00 Not available in U.S.A.
Inspection adapter
07508 - 0012304 Not available in U.S.A .
If sparks fail to jump across the electrodes in the tester inspec-

tion window , replace the ignition coil with a new one.
ALTERNATOR EXCITER COIL

Disconnect the alternator wire terminals.
Measure the resistance between t he black/red wire and
ground.
RESISTANCE: 100 - 300 n (20 ° CI68 ° F)
14-3
IGNITION SYSTEM
PULSE GENERATOR
Disconnect the alternator coupler.
Measure the resistance between the blue/yellow terminal and
ground.
RESISTANCE; 290- 360 0 (20 0 C/ 68 D F)
IGNITION TIMING
NOTE
The Capactive Discharge ignition syst em is f actory pre-set
and cannot be adjusted. Ignition timing inspection proce-
dures are given to inspect the function of the COl compo-
nents.
Warm up the engine and remove the timing hole cap.

Connect the timing light and tachometer.
The liming is correct if the "F" mark on the flywheel aligns (1) tNDEX MARK
with the index mark on the left crankcase cover at 1,400 :!:
100 rpm.
To check the advance, raise the engine speed to 3,500 ± 100

rpm; the index notch should be between the advance marks.
If the ignition timing is not correct. check the COl unit wi t h a

continuity test and test t he pulse generator.
(2) F MARK (3) A DVANCE MARKS
14-4
MEMO
BATTERY/CHARGING SYSTEM
,...C-L;""(-- - --(1) IGNITION SWITCH
FUSE 10 A
131 R.",,,,RV
(5( Al TEANATOA
(8) 81 : Black
(91 A: Red
11 0) G: Green
e (11 ) Y: Yellow
(4) REGULATOR/ RECTIFIER
(2( MAIN FUSE 10 A 81 R L _ _ _ G _ _ _ _lc::5:c,1;LA::.

lT :..:ERNATOR
"'-" L - _ y _---,"'-_
-=-
-=- L
(31 BATTERY,
'86 12V9AH
Aher '86 12V7AH
~ (7) TO ELECTRICAL _.+_ --' L-_ _ _ y -----'V-=o
- LOADS
(1) IGNITION
.I SWITCH
(61 CHARGING COIL
15-0
15. BATTERY/CHARGING SYSTEM
SERVICE INFORMATION 15-1 CHARGING SYSTEM 15-2
TROUBLESHOOTING 15-1 REG ULATOR/RECTIFIER 15-3
BATTERY 15-2 CHARGING COIL 15-3
SERVICE INFORMATION
GEN ERA L
• Quick charging should be restricted to emergencies only. Slow charging is preferred .
• Remove the battery from the motorcycle for charging. If the battery must be charged on the motorcycle, disconnect the
battery cables.
• The banery on this motorcycle is permanently sealed type. Never remove the filler hole caps even when Ihe battery is
being charged.
• Be sure to charge the battery with the amount of current and for the time indicated on the battery label and as given below .
Charging with excessive current and/or too fast may cause battery failure .
iii
Do not smoke around a battery being charged. A lwu)'J keep spark" a way fro m a balter},. The gas prodllud by a battery ....iII ex-
plode if /la mes or spurks are brOllght /lear.
• Use only a sealed-type battery on this motorcycle.

• All charging system components can be lested on the motorcycle.
SPECI FICATI ONS
ITEM STANDARD
Battery Capacity ' 8612 V - S AH After '86 12 V - 7 AH

·860.S
Charging current Standard: After '860.6 A /5 hours Maximum : 4 Al l hour
'865.0
Charging time At Standard: Aher '86 3 .0 hours At Maximum: 1 .0 hour
Alternator capacity 120 W/5,OOO rpm

Voltage regulator Type Transistorized non-adjustable regulator
Charging voltage 14 .3 V - 15.1 V
Charging coil resistance 0.1 - 1.0n
TROUBLESHOOTI NG
No power - key turned on Intermittent power
Dead battery Loose battery connection
Disconnect ed battery cable Loose charging system connection
Main fuse burned out Loose starting system connection
Faulty ignition switch
Charging sy stem failur e
Low power - key turned on Loose, broken, or shorted wire or connection
Weak battery Faulty voltage regulator
• Loose battery connection Faulty ahernator
Low power - engine running

Ba ttery undercharged
Charging system failure
Loose connection or short circuit in lighting system
15-1
BATTERY ~OI_D'R BOLTS

(2) NEGATIVE CABLE
REMOVAL/INSPECTION

Remove the battery holder boils.
Disconnect the negative cable and then the positive cable and
remove the battery.
Measure the battery voltage using the digital voltmeter.
VOLTAGE: Fully charged: 13. 1 V .,

-
Under charged: Below 12.8 V
CHARGING
Connect the charger positive (+) cable to the battery positive

1+1 terminal, and charger negative 1-) cable to the battery neg-
ative 1-) terminal. • After '86:
Standard Maximum
Charging current 0.9 A, '0.6 A 4A
Charging time 5 hours • 3 hours 1 hour
;I
Keep flames and sparks away from Q charging ball")',
Turn pOK'''' ON/OFF at the charger. I/ ot 01 the battery (e,,,,i-
nals.
CAUTION
Quick-charging should only be done in an emergency; slow-
charging is pre/erred.
For ballery charging, do nOI exceed Ihe charging current and
lime specified on Ihe ballery cover. Using excessive currenl or
eXlending the charging lime may damage Ihe bal/cry.
INSTALLATION
Install the battery In the reverse order 01 removal.
After installing the battery, coat the terminals with clean

grease.
CHARGING SYSTEM
LEAKING TEST
J
If undercharged , disconnect the negative (-) cable from the
battery and connect the voltmeter to the battery terminal and
battery ground cable.
There should be no voltage with the ignition switch turned
OFF.
If there is voltage, check the wire harnesses, couplers and
connec tos for short circuit and the main swit ch for function.
15-2
BATTERY I CHARG ING SYSTEM
CHARG ING VOLTAG E IN SPECTION
NOTE
Be sure that the battery is fully c harged before peforming
this test.
Warm up the engine.

Stop the engine and remove the seat.
Connect the voltmeter across the battery terminals.

Start the engine, gradually raise the engine speed and measure
the voltage.
NOTE
• Avoid short circuiting 10 the teste r during the test .
VOLTAGE: 14.3 - 15. 1 V /500D rpm
REGULATOR/ RECTIFIER
Disconnect the regulator /rectifier coupler.
Make following inspections at each terminal of the harness
side coupler.
Make sure that the battery voltage appears between the Red
1+1 and Green 1-) terminals of the regulator/ rectifier couplers.
Check the Red and Green wires for open circuit jf voltage does
nOt appear.
Make sure that the battery voltage appears between the Black
(+1 and Green (-I wires of the regu lator/ rectifier coupler .
Check the Black and Green wires lor open circuit If voltage
does not appear with ignition switch turned ON.
Check the resistance between the coupler terminals (stator

side).
STANDARD : O. , - ' .0 fl{2 0 ° C/ 68 ° F)
If the above Items are abnormal, check the wire harness of

abnormal line for an open circuit and the coupler for loose or
poorly contact.
If the wire harness is normal. check the part of abnormal line.
Replace the regulator/ rectifier if th e above items are satisfied.
CHARGING COIL INSPECTION
Disconnect the 2P regulator/rectifier coupler .

Measure the resistance between the coupler terminals {stator
side).
STANDARD : 0 . ' - ' .0 flI 20 oC/68 ° F)
15-3
Replace the alternator stator if there is no continuity or if any

lead has continuity to ground.
Refer to Section 9 for stator removal .
If there is no problem, check the wiring .
If OK, disconnect the 3P regulator/rectifier coupler .
15-4
MEMO
STARTER SYSTEM
III NEUTRAL INDICATOR LIGHT
- (21 IGNITION SWITCH
131 lOA
BATTERY
181 ""RT IFR";WI'TCH
121 IGNITION SWITCH

13 1 FUSE lOA
i~--------- 81 --~~~.------ R ----~~4----
BI/W 81 --jII~~S=~~:;,
(S ) STARTER SWITCH
t-------<...- 0 -_ _ _ _ _ Y / R ----'I'~-_J:
L-~~~~~~~-c~--c--- l9/R ---____-'~__________==~

( 1) NEUTRAL INDICATOR LIGHT
__--<
19/ R
(4) BATTERY -
12V 9A -
1
(B) BI: Black. (7) STARTER MOTOR
(9) Br : Brown (6) NEUTRAL SWITCH
!1 0) R: Red
{l1l Y: Yellow
(12 1 Lg : Ught green
(l3 ) G: Green
16-0
16. STARTER SYSTEM
SERVICE INFORMATION 16-1 STARTER MOTOR 16-2
TROUBLESHOOTING 16-1 STARTER RELAY 16-4
SERVICE INFORMATION
GENERAL
• The starter motor can be removed with the engine in the fame.
SPECIFICATIONS
Starter motor Brush spring tension 680 9 (24.0 ozl 545 9 {19.2 ozl
Brush length 12.5 mm (0.49 in) 6.5 mIT] (0.26 in)
TROUBLESHOOTING
Starter motor will not turn
Dead battery
Faulty ignition switch
Faulty starter switch
Faulty neutral switch
Faulty starter relay switch
loose Of disconnected wire or cable
Starter motor turns engine slowly

Low battery
Excessive resistance in circuit
Binding in starter motor
Loose or poorly contacted battery or starter motor cable
termina ls
Starter moto r turns, but engine does not turn

Faulty starter clutch
Faulty starter motor gears
Faulty starter motor or idle gears
Starter motor and engine turn, but e ngine does not s tart
Ignition system problems
Engine problems
Fuel syst em problems
16-1
STARTER SYSTEM
STARTER MOTOR
REMOVAL
II L _ _ _ _ __ _ _ _ __ _ _ _ __ _
With rhe igllilioll switch OFF. remOl't /lIe lIegaril'l;' cable at the
battt'f)' before serl'icing 'he slIIrter 11I0/or.
Remove the fuel tank lpage 4·3), carburetcr (page 4 ·6) and left
crankcase cover (page 9-2).
Disconnect the starter motor cable from the starter motor.
Remove the two mounting bolts and sta rter motor.
o I BRUSH LENGTH
BRUSH INSPECTION
Remove the two starter motor case screws and the hont and
feaf covers.
Remove the armature and the brushes.
NOTE
Record the location and number o f thrust washers for cor-
rect assembly.
Inspect the brushes and measure the brush length .
SERVICE LIMITS : 6 .5 mm (0 .26 in )
Measure the each brush spring tension with a spring scale.
SERVICE LIMIT : 545 9 n 9 .2 oll
COMM UTATOR INSPECTION
Inspect the commuta t or bars for discoloration. Bars discolored

in pairs indicate grounded armature coils, in which case the
starter motor must be replaced.
NOTE
00 not use emery or sand paper on the commutator.
16-2
STARTER SYSTEM
Check for continuity between pairs of commutator bars; there

should be continuity.
Also, check for continuity between individual commutator

bars and the armature shalt; there should be no continuity.
CASE INSPECTION
Check for continuity between th e cable terminal and the motor

case.
There should be no cont inuity.
Also, make a continuity check between the cable terminal and

the insulated brush terminal.
There should be continuity.
ASSEMBLY
16-3
STARTER SYSTEM
Install a new O-ring onto the case . (1) THRUST WASHIERS

Insert the commutator into the St8rter motor case.
(2) BURSH HO'LD~~~~
Install the brushes into the brush holder.
Compress the brushes into their holders and slip the brush
holder over the commutator while aligning the case notch with
the brush holder tab.
Install the thrust washers onto the commutator shaft .
NOTE
Be sure the proper number and location of the thrust wash -
ers, as previouslV noted, have been placed on the shaft.
(51 BUI'SH I CASE
Install the front cover.
Install the rear cover white aligning the slot on the reaf cover
with the pin on the brush holder.
Install and tighten the starter motor screws.
STARTER RELAY
Depress the starter relay swit ch button with the Ignition
sWitch ON. The coil is normal if the starter relay clicks.
Check the battery starter motor cables and starter relay switch
couplers f or loose or poor connections.
Disconnect the starter relay switch coupler from the wire har-
ness.
Measure the volt age between the Yellow /Red 1+1 and Green/
Red (-) of the wire harness side coupler.
The battery voltage should appear when the ignition switch is
ON, starter switch is pushed and the transmission is shifted
into neutral.
If the battery voltage does not appear, check the ignition
switch, starter switch, neutral switch or open circuit in wire (11 STARTER RELAY (3) YELLOW/RED
harness . I (2) GREEN/ REO
If it is OK, check the starter relay switch as follows :
Connect an ohmmeter to the starter cable terminal.
Connect the Yellow / Red wire to a 12 V battery positive (+1 ter -
minal and Green/Red wire to the negative (-) terminal.
The relay switch is normal If there IS continui ty with the bat-

tery connected and no continuity With the battery disconnect-
ed.
(5) BATTERY
(4) OHMM ETER
16-4
17. LIGHTS/SWITCHES
SERVICE INFORMATION 17-1 NEUTRAL SWITCH 17-3
TROUBLESHOOTING 17-1 IGNITION SWITCH 17-4
HEADLIGHT 17-2 HANDLEBAR SWITCH 17-4
TAILLIGHT 17-3 WIRING DIAGRAM 17-5
NEUTRAL INDICATOR LAMP 17-3
SERVICE INFORMATION
GENE RA L
• Some wires will have different colored bands around them near t he connector. These are con nected to o t her wires which
correspond with the band color.
• All plastic plugs have lock.ing tabs that must be released before disconnecting and must be aligned when reconnecting.
• The following color codes used are indicat ed throughout this section and on the wiring diagram.
81 Black G Green L9 Light green R R,d

80 Blue G, Gray a Orange W White
• To isolate an electrical failure, check the continuity of the circuit or part. A continuity check can usually be m ade without
removing the part from the motorcycle. Simp ly discon nect the wires and connect a continuity t ester Of volt -ohmmeter to
the terminal or conn ector .
• A continuity tester is useful when checking to find out whether or not t here is an electrical connection between two
poin t s. An ohmm eter is needed to measure the resistance of a circuit, su ch as w h en t h ere is a specific coil resistance in-
volved , or when checking for high resistance caused by corroded connections.
Headlight 12 V 45 /4 5 W
Taillight 12V3.4W
Neutral indicator 12V3.4W
TROUBLESHOOTING
Ught do es not c ome o n w he n light switch is turned o n (En -
gine is runnin g)
Bulb burned out
Faulty switch
Wiring to that component has open circuit
Headlight beams do not shift when hi ·lo switch is operated

m
Faulty dimmer switch
Bulb burned out
Wiring to th at component has open circuit
17-1
LIGHTS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
Remove the two headlight case mounting bolts.
loosen the two headlight bracket flange bolts on the top

bridge.
CASE MOUNTING BOl lSt.
Pull out the bulb socket rubber and turn the bulb socket.
Replace the bulb with a new one.
Install the headlight bulb in the reverse order of removal.
HEADLIGHT CASE REMOVAL/INSTALLATION
Remove the headlight bulb and disconnect the ignition switch

wires and coupler (page 17-4). handlebar switch coupler and
wires, and the neutral indicator coupler.
Disconnect the choke cable at the carburetor and free the
choke cable from the f ra me.
Remove the headlight case.
Install the headlight case in the reverse order of removal.
(1) NEUT,RAL INDICATOR LIGHT • (2) IGNITION SWITCH
(3) HEADLIGHT CASE
(4) CHOKE CABLE
17-2
LIGHTS/SWITCHES
TAILLIGHT
BULB REPLACEMENT
Remove the taillight lens mounting screws from the rear fend -
eL
Remove the taillight lens.
OlTAILLIGHT MOUNTING SCREWS
Replace the taillight bulb with a new one. (1) TAIL

I LI(;HT BULB
•
NEUTRAL INDICATOR LAMP (1) NEUTRAL INDICATOR LAMP
Remove the headlight case mounting bolts.

Remove the neutral indicator lens and holder rubber.
Replace the indicator bulb with a new one.
NEUTRAL SWITCH
Disconnect the alternator 4P coupler.
Check the continUity between the Light Green/ Red terminal of
the alternator 4P coupler and body ground. The neutral switch
is funClional il continuity exists with the transmission in neu-
tral.
Check the neutral switch before replacement as described
below:
Remove the drive sprocket cover and disconnect the neutral

switch wire.
Check for continuity between the switch terminal and ground.
The neutral switch is functional if continuity exists with the
transmission in neutral.
17-3
LIGHTS/SWITCHES
IGNITION SWITCH ;NITION SWITCH
INSPECTION
Remove the headlight case mounting bolts.

Oisconnect the ignition switch wires (Green and Black/While)
and the 2P coupler IBlack and Redl.
•
Check the switch for continuity between the black / white and
green wires with the switch "OFF", and th e red and black
with the switch "ON" .
The switch is norm al if there is continuity between the circuits

marked " 0---0 ".
REMOVAL
Disconnect the Green and Black/While wire connectors and

the 2P coupler.
Push the lugs on th e ignition swit ch in and remove the ignition
switch from the headlight case.
HANDLEBAR SWITCH
NOTE
The handlebar switch (lighting, dimmer, engine stop, and
starter switches) must be replaced as an assembly.
Remove t he headlight case mounting bolts and disconnect the

4P coupler and the Black/ White wire.
Check for continuity between the terminals.

Continuity should exist between the color coded wire termi -
nals in each chart .
ENGINE STOP SWITCH
COLOR G BIIW
OFF 0 0
RUN
LIGHTING/DIMMER SWITCHE S STARTER SWITCH
., .,
SWI TCH
COLOR ., LIGHTING DIMMER
.0 W
COLOR
RELEASED
.~
Off HI C PUSHED -=--

ON INI
lo
INTERCONNECTIONS
17-4
LIGHTS/SWITCHES
WIRING DIAGRAM
'86 :
<::)
<::)
<::)
<::)
I
r-
ca
:c
I
N
<::)
Ct')
<::)
<::)
~
o
u irQ
g•
••
;•
u
• •-
i• u
~
, ----
..
.-
17-5
LIGHTS/SWITCHES
After '86:
, ~
o
o
• ~
• lfr'~ , '/
~/~t:>CJIfJII
r-...
,~,
u
• •
I <0
!i g'" i ·- -~ --
•
,,
, ~
~1DJt,.~ I
r-...
.1" ,, !..1tjCJ<f~J7l
1.._-:-0
•
CQ
:z:
~.~ ':
,,r--~" <
I
!
~
r .
, "
:,
Lr;~ q;J
~
N
o
=
,, o
.. __ J
•
I"''i:'
;"-,
L_~
•
o
,
>
,
. 0 ,
II:; 01 ; -
>
_J
'
ig
~.
.,
;;
u .19
,.,' - ,r- = -'
0
••
I! -, •
6
u
,,
L
'-- ;::~ 5•
,,
0,,
:~ ~:
0
• •"
r-'
,, .., .... ~j-£>CJ-iII ~
,,11
u
•
J 1, •
~
• •
-
.
jfl?-. I ,. .• ,. , .
~
:
I ~~: It==-l~ ~i:-t::;;;l:
_____J . · . .I•
~ . ; • •
~
§
is g! ~
17-6
18. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR HANDLING 18-4
HARD TO START 18- 1
UNDER CHARGE/OVER CHARGE OF THE
ENGINE LACKS POWER 18-2 8ATTERY 18-5
POOR PERFORMANCE AT LOW WEAK OR NO SPARK 18-6
AND IDLE SPEEDS 18-3
POOR PERFORMANCE AT HIGH SPEEDS 18-4
ENGINE DOES NOT START OR IS HARD TO START

Probable Cau se
1. Check if fuel is getting NO FUEL TO - - - - - -- -_ • (11 No fuel in fuel tank

to carburetor CARBURETOR 121 Clogged fuel hose or fue l filter
131 Clogged IIoa1 valve
GETTING TO CARBURETOR 141 Clogged fuel tank cap breather
j
2. Try spark test WEAK OR NO SPARK
tube
• (11 Faulty spark plug

121 Fouled spark plug
GOOD SPARK 131 Faulty COl unit
141 Broken or shorted spark plug
wire
151 Faulty alternator
161 Broken or shorted ignition coil
171 Faulty pulse generator
181 Poorly connected, broken or
shorted wires
191 Pulse generator rotor gap incor-
rect
(10) Faulty Ignition or engine stop
switch
3 . Test cylinder compression LOW COMPRESSION - - - - -_· 0) low battery charge

121 Valve clearance too small
COMPRESSION NORMAL 131 Valve stuck open
141 Worn cylinder and piston rings
I
151 Damaged cylinder head gasket
161 Incorrect valve seat contact
(7) improper valve timmg
4. Start by following normal st arting

procedure
ENGINE STAATS BUT
SOON STOPS
• 111 Restricted fuel tine
121 IncorreCt choke cable free play
1m
131 Improperly adjusted air screw
ENGINE DOES NOT START 14 1 Air leaking past carburetor insu-
lator
I
5 . Remove spark plug
DRY
WET PLUG
15' Improper ignition timing (COl unit
121
131
or pulse generator faulty)
161 Fuel/ aIr mixture too lean
• 111 Carburetor flooded

Choke valve stuck closed
Fuel/air mixture too rich
14, Air cleaner dirty
I
151 Improperly adjusted air screw
18-1
TROUBLESHOOTING
6 Remove spark plug, pour ENGINE STAATS BUT - - -- - -_. (1) Clogged carburetor
small amount of fuel into cylinder STOPS SOON 121 Faulty carburetor
and try to start engine (3) Restricted fue l line
IL-- - - - - -- - - - - -- ENG INE DOES NOT - -- - -- - -•• (1) Incorrect ignition timing
START
ENGINE LACKS POWER

Probable Ca use
1. Raise wheels off ground and spin WHEEL DOES NOT SPIN - - - - -__ (1) Brake dragging
by hand FREELY (2) Worn or damaged wheel bearing
(3) Wheel bearing needs lubrication
WHEEL SPINS FREELY (4) Incorrect drive chain adjustment
I
2. Check lire pressure wi t h the gauge PRESSU RE TOO LOW - ------. 0) Punctured 'ire
(2) Faulty tire valve
PRESSURE NORMAL
I
3. Remove spark plug FOULED OR DISCOLORED - - - -- . 111 Plug not serviced frequently
enough
121 Use of plug with improper heat
NOT FOULED OR DISCOLORED range
I
4 . Remove oil level gauge and OIL lEVEL INCORRECT - - - - -_ .. ( 1) Oil level too high
check oil level (21 Oil level too low
(3) Contaminated oil
CORRECT
I . .
5 . Check clutch slipping CLUTCH SlIPS-- -- -- - -... {1) Weak clutch spring
121 Worn clutch disc/ plate
NORMAL 13) Warped clutch disc/ plate
I
)4) Engine oil mixed with additive
IS) Centrif ugal clutch incorrectly ad-
justed
6. lightly accelerate engine ENGINE SPEED NOT -----~~ .. (1) Air /fuel mixture too rich or lean
INCRE AS ED SUFFICIENTLY )2) Clogged air cleaner
ENGINE SPEED INCREASED )3) Restricted fuel line
)4) Clogged fuel tank breather tube
I
7. Accelerate or run at high speed ENGINE KNOCKS -------~
)5) Clogged muffler
.. (11 Worn piston and cylinder

)2) fuel-air mixture too lean
ENGINE ODES NOT KNOCK )3) Use of improper grade 01 fuel
)4) Excessive carbon build-up in com -
I
bustion chamber
)5) Ignition timing too advanced
IFault y COl unit or pulse gener-
ator)
8 . Check if engine overheats OVERHEATED - - - - - - -_ • 111 Excessive carbon build-up in com -

bustion chamber
NOT OVERHEATED 121 Deteriorated fuel
13) Clutch slipping
I )4) Fuel-air mixture too lean
18-2
TROUBLESHOOTING
9. Check ignition timing INCORRECT - - - - - - - - -_. (11 Faulty COl unit

(2) Faulty pulse generator
CORRECT (3) Improper flywheel installation
I
10. Test cylinder compression using TOO LOW - - - - - - - - - - -•• 11) Low battery charg e
a compression gauge 12) Valve clearance to o small
(3) Valve stuck open
NORMAL (4) Worn cylinder and piston rings
I
(5) Damaged cylinder head gasket
(6) Incorrect valve seat contact
(7) Improper valve timing
11 . Check carburetor for clogging CLOGGED - - - - - - - - - -- ... Carburetor not serviced frequently
enough
NOT CLOGGED
I
12. Check valve clearance INCORRECT - - -- - -- - - -_ .. (1) Improper valve adjustment
(21 Worn valve seat
CORRECT
I
13. Remove cylinder head cover and VALVE TRAIN NOT LUBRICATED _ (1) Clogged oil passage
inspect lubrication PROPERLY (2) Clogged oil strainer
VALVE TRAIN LUBRICATED

PROPERLY
POOR PERFORMANCE AT LOW AND IDLE SPEEDS

Probable Cause
1. Check carburetor air screw adjust- INCORRECT - - - - - - - - - - _. Improperly adjusted air screw
ment
CORRECT
2. Ch\ Ck jf air is leaking past LEAKING - - - - -- - -- - -_. (1) Deteriorated insulator O-ring
carburetor insulator (2) Loose carburetor
NOT LEAKING
I
3. Try spark test W EAK OR INTERMITTENT--- - -•• (1) Faulty, carbon or we I fouled spark
SPARK plug
GOOD SPARK (2) Faulty COl unit
(3) Alternator faulty
I
4 . Test cylinder compression using
a compression gauge
LOW COMPRESSION -------.~
(4)
(5)
11)
(2)
13)
Faulty Ignition coil
Low battery charge

Valve clearance too small
Valve stuck open
COMPRESS ION NORMAL (4) Worn cylinder and piston rings
(5) Damaged cylinder head gasket
I
5 . Check ignition timing and valve
clearance
INCORRECT -----------.~ 11)
16)
(7)
Incorrect valve seat contact
Improper valve timing
Improper valve clearance

(2) Improper ignition timing IFaulty
COl unit or pulse generator)
CORRECT
18-3
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEEDS

Probable Cause
1. Remove spark plug and check DISCOLORED OR DIRTY - - - - --- (11 Use of plug with improper heat
condition range
(2) Plug not cleaned property
NORMAL (3) Rich or lean air/ fuel mixture
(4) Clogged air cleaner
(5) Poor flow in fuel line
(6) Air coming in through insulator
P) Clogged carburetor
2. Check clutch slipping CLUTCH SLIPS - - - - - - - -__ (1) Weak clutch spring
(2) Worn centrifugal clutch shoe
NORMAL (3) Warped clutch disc / plate
(4) Engine oil mixed wi th additive
I
3. Check ignition timing and valve
clearance
INCORRECT - - - - - - - - - -__ (1)
(2)
(3 )
(5) Centrifugal clutch incorrectlv ad-
justed
Improper valve clearance

Faulty COl unit
CORRECT (4 ) Improper flywheel installation
4 . Chteck valve timing INCORRECT----------- . Cam sprocket not installed properly
CORRECT
I
5. Check valve spring tension WEAK - - - - - - - - - - - -_. Faulty spring
NOT WEAKENED
I
6. Check camshaft A8NORMAL - - - - - - - - - - -
.. Worn camshaft
L I_ _ _ _ _ _ _ _ _ __ • NORMAL - - - - - -- -- _. Go to " ENGINE LACKS POWER"

(page 18-2)
POOR HANDLING - - - - C h e o k "" ,,,,,U,,

Probable Cause
1. If steering is heavy - - - - - - - - - - - - - - - - - - - - - - -•• ( 1) Steering bearing adjustment nut

t oo tight
I
(2) Damaged steering races or steel
ball bearings
(3) Cables interfering
2. If either wheet is wobbling - - - - - - - - - - - - - - - - - - - -... (1) Excessive wheel bearing play

(2) Bent rim
(3) Improperly installed wheel hub
• Loose swing arm pivot
• Improperly installed tire
(4 1 Bent frame
(5) Bent swing arm
3 . If the motorcycle pulls to one side - - - - - - - - - - - - - - - - _.. (11 Front and rear wheels not aligned
(2) Bent front fork
(3) Bent swing arm or frame
18-4
TROUBLESHOOTING
UNDER CHARGE/ OVER CHARGE OF THE BAITERY

NOTE: Make sure that the battery is in good condition, use a known -good battery if necessary.
Possible Ca s e
, . Test the battery for DRAIN - - - - - -- - - -- - - •• (11 Shorted wire harness
current drain (See page 15-21. (2)Faulty ignilion switch
NO DRAIN
I
2. Start the engine and check the
charging voltage at the battery
terminals (See page 15-3).
1 STANDARD - - - - -- - -- -, •• (1 )Faulty regulator/ rectifier
HIG HER THAN STANDAAD ----~•• (' )Faulty bat tery

Battery out of life
VOLTAGE IS NOT ABOVE (2) Faulty reg ulator/rectifier
BATTERY VOLTAGE (3)Short or open circuit in (Black) wire
(4(Loose or poorly contact of regula-
tor/ rectifier coupler .
3. Check the regulator / rectifier ABNORMAL - - - -- - - - - -... (1lPoor contact

coupler for loose connection.
NORMAL
I
4 . Check the regulator/ recti f ier NORMAL - -- - - - - - - - -_ .. (l)Faulty regulator/ rectifier
(See page 15-3).
ABNORMAL
I
5 . Inspect the tau Ity .Items. ABNORMAL - - - - - - - - - -_ . (1 )Open or short circuit in (Red, Black
or green wiresl of wire harness
(2)Faulty charging coil
18-5
TROU BLES HOOTING
WEAK OR NO SPARK
1. Try spark test with known good GOOO SPARK --------~•• {1)Faulty spark plug
spark plug.
I
WE t K OR NO SPARK
2 . Check spark plug wire for loose or

poor con t act at the spark plug cap - GOOO SPARK - - - - - - - - -_. (1 )Loose or poor con t act of spark plug
then try spark test again. wire
I
WEAK OR NO SPARK
3 . Check COl unit coupler for loose or -ABNORMAL - - - - - - - - - -__ (1)Loose or poor con t act of COl unit
coupler
4 . Check the resistances or continuity at the COl unit coupler of the wire harness side (See page 14-2).
I I
AB ~ORMAL NORMAL
5. Check part of abnormal line

{See page 14-3, 14-41. I I
GOOD SPARK WE 1 K OR NO SPARK
I
NORMAL ABNORMAL
I
(1) Faulty ignition coil (1 ) Faulty COl unit
I I
, __L _ _ ____'======;-- - - - - - - - - -______•• n IFaulty part
6 . Check the wire harness for open or -ABNORMAL - - - - -______.~ ( 1 )Faulty wire harness
short circuit between the COl unit .
I
NORMAL - - - - - - - - - - - - -- - - - - -- •• (l)Loose or poor contact connec t ors
of the ignition related part
18-6
19. INDEX
Air Cleaner ......................... . 3-5 Handlebar ......................... ............................ . 11 -3
Case 4-4 Switch ................. ..... ............ ... ........... . 17-4
Air Screw Adjustment ... .... ........... ... ... .. 4 - 10 Headlight .................................... .. 17-2
Alternator /Starter Clutch ... ........... .. ........... .... g . " 9 -3 Aim ........ .. 3-13
Exciter Coil .................. ... ............... .. ..... 14-3 High Altitude Adjustment ................................. . 4- 11
Batterv/Charging System ......... ........................ 15-' Ignition System ............................................ . 14- 1
Battery .............. ................. .......................... 15-2 Coil .... .... ............. ................................ . 14-3
Brake Lock Lever 3· 13 Switch ... 17-4
Shoe Wear ....... ............. .............. . ........ . 3· 10 Timing ................................................ . 14 ·4
System ................. . 3·11 Kick Starter ................................................... . 8 · 16
Cable & Harness Routing ........ .. ............... . 1-9 Left Crankcase Cover Installation ...................... . 9-6
Camshaft Installation ........................ .. 6 -13 Removal ... ......... .... .......................... . 9-2
Removal ......................................... . 6 -5 lights/Switches ........... . 17-1
Carburetor Assembly ..... .. ....................... . 4-B Lubrication ......... . 2-1
Disassembly .......... .... ........ .................... . 4-6 Points ............................................... .. 2-7
Installation ..................................... ...... . 4-10 Maintenance ... ..... ............ .. ............ ...... ........ . 3- 1
Removal ........ .......... ........ ..... ............ . . 4-6 Schedule ............................................ . 3-2
Carburetor-Choke ...................... ... ........ . 3-5 Manual Clutch ................................................ . 8-10
Carburetor-Idle Speed ................... ................... . 3-6 Model Identification ........................................ . 1-2
COl Unit .. .. ............. .. .................................... . 14-2 Neutral Indicator Lamp ................................. .. 17-3
Centrifugal Clutch ................................. .. . B-5 Switch ..... .......... ...... ......... .. 17-3
Charging Coil ..................... ......... ........ .. . , 5-3 Noise Emission Control System ....... . .. 1· 13
Charging System ........................... .... ... . 15-2 Nut , Bolt . Fastener ....................................... .. 3· 15
Clutch/ Kick Starter/Gearshift linkage ......... .. .... .. 8- 1 Oil Filter AOlor and Screen ........................ .. 2-2
System ............................. ... ........... ... .. 3-13 Pump ................................................. . 2-4
Crankcase fCrankshaft/Transmission .................. . 10· 1 Piston ....... ......... ...... ........ ..... ...... . 7-3
Assembly ..... ...... ................................ . , 0 -12 Pistonl Cylinder Installat ion .............................. .. 7-5
Separation .......................................... . 10-3 Pulse Generator ....................................... . 14-4
Crankshaft ............................... ..... ...... .. 10-10 Rear WheelfBrake/ Suspension ........ ...... ..... .. 12· '
Cylinder HeadfValves .. ............ ...... ........ .. . 6- 1 Brake ...... ........ ....... .......... .... ............ . 12-7
Cylinder fPiston ... ...... .. .. ... . .. ......... .. 7-1 Shock Absorber .. .. 12 · 10
Cylinder .... ...... .. .............. . 7-2 Wheel ............................................... . , 2-3
Compression ...... .. ................. .. 3-16 Regulator fRectifier ........................................ .. 15-3
Head Assembly ............... .... ................ . 6 · 11 Right Crank case Cover Installation ... .......... . 8-19
Cylinder Head Cover Assembly ........................ .. 6 · 15 Removal ... ..... ... . .. ... ...... . 8-3
Disassembly .. . ................................... . 6-4 Seat ...................................... .. 13· ,
Installation ................................. .. 6-15 Service Information
Removal .. ............. .................... . 6 -3 Alternalor /Staner Clutch . 9-1
Cylinder Head Disassembly ........ ....... .............. . 6-6 Banery/ Charging System ...... .. .. 15-1
Installation 6 · 12 Clutch / Kick Slarter/ Gearshift Linkage 8- 1
Removal ... ... ... ............ .. 6 -6 Crankcase/ CrankshaftlTransmission ..... . 10· 1
Drive Chain ........... .................. ...................... . 3-B Cylinder Head/Valves ............................. . 6-1
Slider ......................... . 3-10 Cylinder/Piston ..................................... . 7-1
Engine Removal/Installation . 5- 1 Engine Removal/Installation ..................... . 5- 1
Installation ....... .................................. .. 5-4 Fenders/ Exhaust Muffler ......................... . 13· 1
Oil ...................................................... . 2-2 Front WheellBrake/ Suspension/ Steering .... . 11 - 1
Removal ... .. 5-2 Fuel System ............................ .. ........... . 4- 1
Exhaust Muffler .... ....... . ............ .. .. ........... ... .. .. 13-3 Ignition System .......... ... ............ ..... ...... . 14- 1
Fenders/ Exhaust Muffler 13· ' Lights/ Switches ....... . ....................... .. 17· '
Front Wheel/ Brake/SuspensionfSteering ............. . 1 1· 1 Lubrication ............................... .. ........... . 2-1
and Aear Fender .................................... . 13-2 Maintenance ...... 3- 1
Brake
Fo~k ............................................ ..... ..
11 - 13
, 1· ' 5
Rear Wheel/Brake/ Suspension ................. .
Starter System ..................................... .
'2·'
, 6-1
Wheel 11 -5 Service Rules ................................................. . 1- 1
Fuel System ........................ . 4-1 Side Covers ........................................... . 13- 1
Line ................ . 3-4 Stand. 3- 14
Strainer Screen ...... .. 3-4 Spark Arrester . 3-15
Tank ......... .. 4 -3 Plug .. 3-6
Gearshift Linkage .. .. 8-14 Specifications .............................................. .. 1-3
Pedal Pivot ........................................ .. 3· 14 Staner System ............................................... . 16-'
General Information ...................................... .. 1- 1 Motor ...... .. ................. .. 16-2
Safety .................................................. . 1- 1 Relay ... ........ ...... .... ......... . 16-4
19-1
INDEX
Steering Head Bearings ........ ... _, ". 3- 16

Stem ............ ........ .. .. ..... . .. 1 1-21
Suspension ......................... ... .. .. .. ....... . . 3- 14
Swingarm ........................... . . .... .. .. . . 12- 13
Taillight ................... . .. ..... ............. ......... . 17-3
Throttle Operation ............. .. .................. ......... . 3-4
Throttle Valve ........ ..... .... .. ... .................. ....... . . 4 -9
Disassemblv ..... ,- 4-6
Tires .... . .. ........................... ..... ... ......... .. . 11 ·8
Tools .... ..... .......................... .... .... ....... .. . 1-7
Torque Values .......................... .......... . 1-5
Tran sm ission ........................ .... ............. ..... .. .. . 10-4
Troubleshooting
Altemat or/Start er Clutch .................... .... . 9-1
Battery/Charging System ........ ........ . 15- 1
Clutch/ Kick Starter /Gearshift linkage . ...... . 8-2
CfankcaselCrankshaft/Transmission ....... . .. 10-2
Cylinder HeadlValves . ............ . ... .. ... ... .... . 6-2
Cylinder/ Piston ... .................................. . 7- 1
Front WheellBrake/ Suspension/ Steering ... . . 11 · 2
Fuel System ....... .............................. ... .. . 4-2
Ignition System ........... ........................ .. . 14· 1
lights/ Swi tches ................ ................. . 17· 1
Lubrication .. ..... .. ... ... .. ... ......... .. ..... ..... .. . 2-1
Rear Wheel / Brake / Suspension .......... . . 12· 2
Starter System ............. .. .................. ... .. . 16· 1
Under Charge/ aver Charge
of The Banery .......... . ................... .. ... .. .. . 1B· 5
V alve Clearance ....... .. ................................... . 3-7
Guide Repla cement ................................ . 6-8
Seat Inspection and Relaclng ........ .. . 6-9
Weak or No Spark ........... .... .. .. ................. ...... . lB-6
Wheel .............................. ... ... .. .. .......... .... ..... . 3- 16
W iring Diagram .................. ..................... .. .. ... . 17· 5
19-2 1202)

Honda Tr200 Fatcat Service Manual Repair 1986-1987 TR 200 Fat Cat

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Honda Tr200 Fatcat Service Manual Repair 1986-1987 TR 200 Fat Cat

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8S-B7

U I FENDERS/ EXHAUST MUFFLER

FR'<ME SERIAL NUMBER

The carburetor identification number is on the right side of

DIMENSIONS Overall length 2,020 mm (79.5 in)

DRIVE TRAIN Clutch Wet multi-plate, semi-automatic

Thread Dia Torque

Engine oil drain bolt 1 12 35-40 3.5-4.0 25-29

Thread Dia Torque

Gearshift pedal adjuster lock nut 2 6 8-12 0.8-1.2 6-9

Gearshift pedal arm bolt

STANDARD TORQUE VALUES

Item Torque N ·m {kg-m, ft-Ibl hem Torque N ·m {kg-m, ft -Ib)

5 mm bolt, nut 4.5 - 610.45-0.6,3 - 4) 5 mm screw 3.5 - 510.35-0.5,2 - 4)

DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER REF. PAGE

DESCRIPTION TOOL NUMBER ALTERNATE TOOL TOOL NUMBER REF. PAGE

Float level gauge 07401 - 0010000 4 -9

DESCRIPTION TOOL NUMBER AL TEANATE TOOL TOOL NUMBER REF . PAGE

~Not available in U.S.A.

VALVE SEAT CUTTER

DESCRIPTION TOOL NUMBER REF. PAGE

Valve seat cutter, 27.5 mm (EX 45°) 07780-0010200 6-9

CABLE & HARNESS ROUTING

• A loose wire . harness or cable can be a safety ha~ard . A ft er

• Do not squeeze a wi re against a weld or end of it s clamp

• Route harnesses so they are not pulled taut or have exces-

• Protect wires and harnesses with electrica l tape or tubes if

• Do not use a wire or harness with a b roken insulator . Repair

• Route wire harnesses to avoid sharp edges or corners. Also

• Be sure grommets are seated in their grooves properly.

• After clamping, check each harness to be certain that it is

• Wire harnesses routed along t he han dlebars should not be

• After routing, check that the wire harnesses ar e not twisted

• Do not bend or twist control cables.

' - - - (21 lEFT HANDLEBAR SWITCH WIRE

(6) INOICATOR LIG HT

(8) CHOKE CABLE

After '86 : -.."I.JI

110) GROUND W IRE

n 11 REAR BRAKE PEDAL ROO

:':>_--- (31 MAIN W IRE HARNESS

(6 ) ALTERNATOR COUPLERS , CONNECTORS )5 ) R.TT " RY GROUND CABLE

(8) BATT ERY

(1) FUEL TUBE

STARTER MOTOR CABLE

~';S~~)~====:;. (4) WIRE

NOISE EMISSION CONTROL SYSTEM (U.S.A. only)

(11 ROCKER ARM SHAFT ---tAtai~~t.~

(3) Oil PUMP

(8) OIL TER SCREEN

• " " " .,

ITEM STANDARD SERVICE LIMIT

Engine oil drain bolt 35 - 40 N·m (3.5-4.0 kg~m, 25-29 It-Ib)

Start the engine and allow it to idle for 2 or 3 minutes.

TORQUE: 35 - 40N ·m (3 .5 - 4 .0 kg -m , 25 - 29 ft -Ibl

OIL FILTER ROTOR AND SCREEN

Remove the centrifugal clutch cover by removing three bolts.

Clean the centrifugal clutch cover and inside of the centrifugal

Reinstall the centrifugal clutch cover with a new gasket align-

TORQUE : 10 - 12 N·m 11.0 - 1.2 kg-m . 7 - 9 ft-Ib )

Remove the oil filter screen from the right crankcase.

Install the dowel pins and a new gasket .

Install the right crankcase cover and disassembled parts !page