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Honda Tr200 Fatcat Service Manual Repair 1986-1987 TR 200 Fat Cat
Honda Tr200 Fatcat Service Manual Repair 1986-1987 TR 200 Fat Cat
:'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
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
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.
1-2
GENERAL INFORMATION
SPECIFICATIONS
ITEM SPECIFrCA TfONS
1-3
GENERAL INFORMATION
ITEM SPECIFICATIONS
1-4
GENERAL INFORMATION
TORQUE VALUES
ENGINE
FRAME
1-5
GENERAL INFORMATION
Torque
Item O'ty
Thread Dia
(mm)
N-m kg-m ft -Ib
-- Remarks
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 .
1-6
GENERAL INFORMATION
TOOLS
SPECIAL
COM MON
1-7
GENERAL INFORMATION
Valve seat cutters are commercially available in the USA Therefore , the following cutters are not required in the USA
1-8
GENERAL INFORMATION
• Keep wire harnesses away from the exhaus1 pipe and other
parts that get hot.
1-9
GENERAL INFORMATION
n) THROTTLE CABLE
n ) THROTTLE CABLE
(9) BATTERY GROUND W IRE
('
Aft er ' 86 :
(12) CUPS
1-10
GENERAL INFORMATION
' 86 :
( 11 WIRE BANDS
(2 ) CHOKE CABLE
(4 ) SPARK PLUG
)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
WIRE HARNESS
(6) CRANKCASE
BREATHER TUBE;:;r---">
1-12
GENERAL INFORMATION
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
121 CR,'NKSH,"T
m lOlL
FILTER
(4 ) MAIN$HAFT
(5) COUNTER$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
TORQUE VALUES
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
(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 .
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 .
2-2
LUBRICATION
CAUTION
Do nOI alfow dust or dirt (Q enter the crankshafT oil passage.
DonOI useco~,,~,p:,~~
::od
~: u:
~C'____________________________
2-3
LUBRICATION
OIL PUMP
REMOVAL
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
Remove the oil pump drive shaft and measure the pump end
clearance.
2-5
LUBRICATION
/
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.
)
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.
CABLE END
--1-_,
(4 ) REAR BRAKE PEDAL PIVOT SHAFT
AND DUST SEAL
/
--- 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
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
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)
· 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.
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
· CARBURETOR-CHOKE
AIR CLEANER NOTe 1
1 3-5
C 3 -5
SPARK PLUG 1 3 -6
· HEADLIGHT AIM
CLUTCH SYSTEM
1 3-13
1 1 3- 1 3
· SUSPENSION I, L 3 -14
• 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.
3-3
MAINTENANCE
CAUTION
After installing, turn the fuel valve ON and check that there are
no fuel leaks .
Check for smooth throttle grip full opening and automatic full
closing in all steering positions.
3-4
MAINTENANCE
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.
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.
Measure the gap with a wire -type feeler gauge and adjust if
necessary by cafefully bending the side electrode.
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.
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.
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
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 .
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.
DRIVE CHAIN
'IRwaN
Nel'er irupect or aajust the ,Iril·e chaill while the engine is ",n-
lIing.
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
3-8
MAINTENANCE
\~
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.
CAUTION
Be careful nOllO lose Ihe a-rings when fhe clip and masler fink (
are relllo~'ed.
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.
,
3-9
MAINTENANCE
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
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 .
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)
At the tip of the brake lever, measure the distance the lever
moves before the brake starts to take hold.
NOTE
Make sure the cut~out on the adjusting nut is seated on the
brake arm pin.
REAR BRAKE
Check the cable, brake lever and brake pedal for loose connec-
tions, excessive plaV or other damage.
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.
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 .
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.
•
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 _
NOTE
Adjust the brake pedal free play after adjusting the brake
pedal height.
3-12
MAINTENANCE
NOTE
Make sure the cut-out of each adjusting nul is seated on the
brake arm pin.
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.
After adjustment. start the engine and check for proper clutch
operation.
3-13
MAINTENANCE
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 .
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
SUSPENSION
'" %
/)0 not ride a IIIQlOrqcle with fault)' SUl"pens;on. I. oose. worn
or domagnt suspension porrs impair motorc}'cle sfObility and
cottrrol.
3-14
MAINTENANCE
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.
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.
SPARK ARRESTER
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.
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
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
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
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 .
""
~ 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
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 .
4-4
FUEL SYSTEM
Slide the air cleaner case backward and remove it hom the
frame.
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.
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.
I
(4 ) RETAINER
4-6
FUEL SYSTEM
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.
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.
• ••
\
\
(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.
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
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
\" ~
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
With the float valve seated and the float arm just touching the
valve, measure the float level with the float level gauge as
shown.
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.
/p::
(2) FLOAT CHAMBER SCREWS
Install the jet needle into the throttle valve and secure it w ith
the needle clip retainer.
(3 1 RETAINER
4 -9
FUEL SYSTEM
I
CARBURETOR INSTALLATION
Install the carburetor between the intake manifold.
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.
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.
4 -10
FUEL SYSTEM
Below
6,000 ft (1,800 ml
Above
5,000 ft 11,500 ml
L •
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
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
5-1
,,
,
ENGINE REMOVALIINSTALLATION
.,
.. 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.
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 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
ENGINE REMOVAL/INSTALLATION
ENGINE INSTALLATION
NOTE
Be sure to use the engine mounting bolts in their correct po-
sitions.
Install the front lower hanger plates . 8 mm and 10 mm bolts 111 B mrn BOLTS
and nuts .
Tighten the nuts lightly.
5-4
ENGINE REMOVAL/INSTALLATION
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
NOTE
Route the wires and cables properly (page 1-9) ,
Fill the crankcase to proper level with recommended oil
(page 2-21.
5-5
CYLINDER HEAD/V ALVES
~~
.
" 14N·m
<I f~-Ib)
10 - 14Kg-m .
t 1.0 -
7-
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
TORQU E VA LUES
6-1
CYLINDER HEAD/V ALVES
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)
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
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.
6-3
CYLINDER HEAD/V ALVES
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
<31 DECDM'>RES.sOR
14 , S P R I N G / LEVER
Rocker arm
Inspect the rocker 8fms lor wear or damage to the camshaft
/
contact surfa ce or for a clogged oil hole.
6-4
CYLINDER HEAD/V ALVES
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
SERVICE LIMITS;
INTAKE : 34.19 1 mm )1. 3461 inl
EXHAUST : 34.062 mm (1.3410 in)
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)
6-5
CYLINDER HEA D/V ALVES
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.
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.
6-6
....
-
CYLINDER HEAD/VALVES
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 .
SERVICE LIMITS:
IN : 5 .45 mm (0.215 in)
EX: 5 .43 mm 10.214 in)
TOOL :
Valve guide reamer 07984 - 2000000
6-7
CYLINDER HEAD/VALVES
NOTE
Rafaee the valve seats whenever the valve guides are re -
placed.
'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.
/
(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
6-8
CYLINDER HEAD/VALVES
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.
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.
NOTE
Follow the reface r manufacturer's operating instructions.
"'"
6-9
CYLINDER HEAD/V ALVES
'/ \
32 0
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
CYLINDER HEAD/V ALVES
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.
NOTE
• Do not allow lapping compound to enter the guides.
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.
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.
6-12
CYLINDER HEAD/V ALVES
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.
NOTE
• Be careful not to drop foreign material into the crankcase.
6-13
CYLINDER HEADIV ALVES
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 .
NOTE
The tensioner is projected by spring force when it is re-
leased.
\ ·'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
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.
Install new O-rings onto the oil orifice bosses of the cylinder
head 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 gasket, dowel pins, cam chain guide and cylinder.
NOTE
• Be careful not to damage the gasket surface.
INSPECTION
7-2
CYLINDER/PISTON
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
SERVICE LIMITS:
Top/ Second: 0 .09 mm 10.004 in )
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
7-4
CYLINDER/PISTON
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).
OJ TOP RING
151
SIDE RAIL
PISTON INSTALLATION
NOTE
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
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.
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 '~~ . ___ _
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)
TORQUE VALUES
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 .
Hard to shift
Clutch does not disengage
Bent gearshift spindle
Oamaged drum shifter
Damaged gearshift plat e
8-2
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
••
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.
8-3
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
Check the kick starter shaft end needle bearing on the right
crankcase cover for 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
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
(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
8-5
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
TOOL:
Clutch holder 07HMB - HB70100
NOTE
• The lock nut has left hand threads.
TOOL:
Clutch puller D7GM C- HB30100
AFTER 'S6
IN SPECTION
Weight lining
Measure the weight lining thickness.
8-6
CLUTCH/ KICK STARTER/GEARSHIFT LINKAGE
Check the weight spri ngs for wear or damage. and replace if
necessary_
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
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
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
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
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
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 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.
TOOL:
Clutch holde, 07GMB - HB30 100
NOTE
• The lock nut has left hand threads.
8-9
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
MANUAL CLUTCH
REMO VA L
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.
8-10
CLUTCH/ KICK STARTER/GEARSHIFT LINKAGE
TOOL:
Clutch center holder 07923 - 9580000
INSPECTION
Check the slots of the clutch outer for damage or wear caused
by the clutch discs. Replace if necessary.
8-11
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
IN ST A LLATI ON
8-12
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
,
(2) CLUTCH PRESSURE PLATE
center.
Install the clutch center holder as shown, and tighten the lock (2) CENTER
nut.
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
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
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).
GE.'R';HIIFT SPINDLE
8-14
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
/
(4) DRUM STOPPER BOLT
8-15
CLUTCH /KICK STARTER/GEARSHIFT LINKAGE
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
KICK STARTER
REMOVAL
NOTE
• Refer to page 8 -4 for kick starter drive gear removal.
8-16
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
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
Inspect the kick starter gear needle bearing for damage and /or
e)( cessive play. \
NEEDLE
BEARING
ASSEMBLY
Install the starter gear onto the shaft, washer and snap ring.
8-17
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
Align the punch marks and install the ratchet over the shalt . ~') O'.T;:;:;:";;;7,;;'
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
CLUTCH/KICK STARTER/GEARSHIFT LINKAGE
I
(1) SKID PLATE
8-19
ALTERNATOR/STARTER CLUTCH
~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
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
ALTERNATOR/STARTER CLUTCH
!
14) SKID PLATE
Remove
cover. the nine left crankcase cover mounting boils and r'I~111~~~~~~~~t1~~~~~\-~j-l
9-2
AL TERNATORI STARTER CLUTCH
, STATOR REPLACEMENT
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
AL TERNATORI STARTER CLUTCH
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
9-4
ALTERNATOR/STARTER CLUTCH
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.
FLYWHEEL INSTALLATION
9-5
ALTERNATOR/STARTER CLUTCH
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.
\.
(2) DOWEL
9-6
AL TERNATORI STARTER CLUTCH
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 left footpeg bracket to the frame and tighten the
foot peg bolts.
9-7
CRANKCASE/CRANKSHAFT/TRANSMISSION
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
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
CRANKCASE/CRANKSHAFT/TRANSMISSION
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
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
Hard t o shift
Incorrect clutch adjustment
Shift fork bent or damaged
Shift fork shaft bent
10-2
CRANKCASE/CRANKSHAFT/TRANSMISSION
CRANKCASE SEPARATION
NOTE
Put the transmission in neutral before separating the crank-
case,
NOTE
Make sure that the tab in the neutral indicator plate is in-
stalled facing down.
10-3
CRANKCASE/CRANKSHAFT/TRANSMISSION
TRANSMISSION
DISASSEMBLY
Remove the shift fork shaft, shift drum and shift forks.
10-4
CRANKCASE/CRANKSHAFT/TRANSMISSION
INSPECTION
Inspect the shift fork guide pin for wear or damage. (1) GUIDE PIN
I
Measure the shift fork claw thickness.
Measure the shift fork shaft 0.0 . at the shift fork sliding sur~
faces.
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
CRANKCASE/CRANKSHAFT/TRANSMISSION
Check the gear dogs. dog hotes and teeth for abnormal wear, tl)M5
or lack of lubrication.
Measure the 1.0. and 0.0. of each gear bushing and the
countershaft collar .
BEARING REPLACEMENT
NOTE
• Replace the transmission bearings in pairs.
10-6
CRANKCASE/CRANKSHAFT/TRANSMISSION
Right crankcase :
Remove the mainshaft bearing set plate.
Drive the mainshaft and countershaft beari ngs out o f the right
crankcase.
TOOLS :
Mainshaft bearing :
Driver 07749 - 0010000
Attachment, 42;1147 mm 07746 - 0010300
Pilot, 20 mm 07746 - 0040500
TOOLS: ) DRIVER
Countershaft bearing:
Driver 07749 - 0010000
Attachment, 32 x 35 mm 07746 - 0010100
Pilot, 15 mm 07746 - 0040300
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
CRANKCASE/CRANKSHAFT/TRANSMISSION
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
TOOL:
Driller 07749 - 0010000
Attachment, 52 x 55 mm 07746 - 0010400
Pilot, 22 rnm 07746 - 004 1000
ASSEMBLY
Coat each gear and bushing with clean engine oil. and check
for smooth movement.
C1
(44T)
C4 (2ST) C3 (31T) ~
910 ~7DcD'41 NO CHAMFER SIDE
W C5
(2ST) C2134T)
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 shift forks with their marks facing down Heft crank·
case).
10-9
CRANKCASE/CRANKSHAFTITRANSMISSION
CRANKSHAFT
REMOVAL
TOOL:
Universal bearing puller 07631 - 0010000 or
Equivalent co mme rcially
available In U.S.A .
TOOLS:
Driver 07749 - 0010000
Attachment , 42 It 47 mm 07746 - 0010300
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
10-10
CRANKCASE/CRANKSHAFT/TRANSMISSION
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
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 right crankcase bolts and tighten the bolts. CRANKCASE
10-12
CRANKCASE/CRANKSHAFT/TRANSMISSION
NOTE
Make sure that the t ab in the neutral position indicator plate
is installed facing down .
10-13
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
I,
I
j
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
• 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
TORQUE VA LUES
11-1
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
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
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
(5) THROTTLE
141 HA"DLE.',R GRIP
SWITCH HOUSING
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.
Align the handlebar punch mark with the top of the right
handlebar lower holders.
11-3
FRONT WHEEUBRAKE/SUSPENSION/STEERING
Tighten the forward bolts lirst, then tighten the rear bolts.
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 .
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.
Tighten the upper screw first, then tighten the lower screw.
Install the front brake bracket and holder on the handlebar with
the dot mark up.
NOTE
After installing the handlebar, check tha t the throttle grip
rotates freely in atl steering positions.
,
Remove the front brake adjusting nut and disconnect the brake
cable from the brake arm.
2l~:2:'lJSlrlNG NUT
INSPECTION
Axle
Set the ade in V blocks and measure the runout.
11-5
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
W HEEL
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.
NOTE
• Replace wheel bearings in pairs.
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.
) BEARING
BEARING
,
OUST SEAL
11-6
FRONT WHEEL/BRAKE/SUSPENSION/ STEERING
TOOLS :
Bearing remover head , 15 mm 07746 - 0050400
or Equivalent commercially
available in U.S.A .
Bearing remo ver shaft 07GGO - 0010100 ,21 BEARING \OVER ~H~E';"O~'~1~5 mm
or Equivalent commercially
available in U.S.A.
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.
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
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.
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.
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
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
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.
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
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
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
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.
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.
11-10
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
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.
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.
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
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
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.
Deflate the tire. Wait 1 hour and inflate the tire to the specified
pressure.
-
Check for air leads and install the valve cap.
11-12
FRONT WHEEl/BRAKE/SUSPENSION/STEERING
FRONT BRAKE
Remove the front wheel (page 11 · 5).
Remove the front brake panel.
BRAKE DRUM
BRAKE LINING
NOTE
• Replace brake shoes in pairs.
11-13
FRONT WHEEL/BRAKE/SUSPENSION/STEERING
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
, it!
Wipt txcess grease off the cam. A contaminated brake lining
rl'lfllces stopping power. Keep grease off the lining.
11-14
FRONT WHEEl/BRAKE/SUSPENSION /STEERING
NOTE
• InSlall the brake shoes with the marks facing up.
(2) SPRINGS
FRONT FORK
REMOVAL
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
CAUTION
• Do not damage the fork tube sliding stlrface.
11-15
FRONT WHEEL/BRAKE/SUSPENSION/ STEERING
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.
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 .
(2) BACK-UP
RING
(3) SUDER
(1) OIL BUSHING
-;; .,
\
(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
11-17
FRONT WHEELI BRAK EI SUSPENSIONI STEERING
FORK TUBE
ASS EMBLY
Before assembly, wash all parts with a high f lash point or non-
flammable solvent and wipe them off completely.
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 I
(10) FORK TUBE
11 -18
FRONT WHEELfBRAKEfSUSPENSION fSTEERING
Install the rebound spring on the fork piston, then slip the 111 FiK TUBE
piston into the fork tube.
(2)
/
PISTON
./
(31 Oil LOCK PIECE
NOTE
Temporarily install the fork spring and fork tube bolt to
tighten the socke t bolt. (11 SOCKET BOLT
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
~\
(2) STOPPER RING
11 -19
FRONT WHEEU BRAKE/SUSPENSION/STEERIN G
/~
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
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.
Push up the fork boot until it just touches the bottom of the
steering stem then tighten its clamp.
STEERING STEM
REMOVAL
11 -21
FRONT WHEEL/BRAKE/SUSPENSION /STEERING
TOOL:
l ock nu t w re nc h 077 16 - 00204 00
or Equivalent commercially
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
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
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)
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
-
_ _ _ 131 UPPER INNER RACE
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.
TOOL:
Steering stem socket 07916 - 4300000
••
07916 - 3710100
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.
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
11-25
REAR WHEEL/BRAKE/SUSPENSION
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
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
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
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.
( -
.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 LIMIT :
Radial: 2 .0 mm 10.008 in)
Axial : 2 .0 mm (0.008 in)
12-3
REAR WHEEL/BRAKE/SUSPENSION
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.
NOTE
• Replace hub bearings in pairs.
OISASS EM BL Y
Remove the four wheel hub nuts and remove the wheel hub
from the rim . r
12-4
REAR WHEEL/BRAKE/SUSPENSION
(2 BEARING
(2) BEARING
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
or Equivalent commercially
available in U.S. A .
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.
12-5
REAR WHEEL/BRAKE/SUSPENSION
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
REAR WHEEL/BRAKE/SUSPENSION
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)
~
~
.- '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.
NOTE
• Replace brake shoes in pairs .
12-7
REAR WHEEL/BRA KE/SUSPENSION
Check the dust seal for wear or damage and replace it if neces-
sarv·
•
•
•
•
'm
Wipe exuss grease off the cam. A comaminated brab lining
reduces slOpping power. Keep grease off the linings.
•
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.
P
121 RETURN SPRING
12-8
REAR WHEEL/ BRAKE/SUSPENSION
NOTE
• Install the brake shoes with the marks facing up.
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 .
~~
(8) RUBBE PROTECTOR
~ (4) SPRING
NOTE
• 00 not forget to install the inner dust seal.
12-9
REAR WHEEL/BRAK E/SUSPENSION
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.
12-10
REAR WHEEL/BRAKE/SUSPENSION
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
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 .
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
12-12
REAR WHEEL/BRAKE/SUSPENSION
SWINGARM
REMOVAL
- brake pedal return spring and unhook the rear brake cable
from the swing arm .
- swingarm pivot nut and bolt.
- swingarm from the frame .
SEAL CAPS
12-13
REAR WHEEL/BRAKE/SUSPENSION
TOOLS : / '
Driver 07749 - 0010000
Attachment, 42 )( 47 mm 07746 - 0010300
121 ATTA6<MEINT
•
INSTALLATION
,
t21 PIVOT cuee,,"
Install the swingarm into the frame and install t he pivot bolt
and nut .
Tighten the pivot nut.
12-14
REAR WHEEL/BRAKE/SUSPENSION
13)
"~",
. .'"
SHOCK ABSORBER
LOWER MOUNTING BOLT
)
;.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
14WPiii!5
• Do not sen 'ice the exhaust s)'sum while it is hot.
(1) SEAT RElEA!;E
SEAT
REMOVAU INSTALLATION
SIDE COVERS
r~..;:(1) SIDE COVER
REMOVALI INST ALLATION
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
111
13-2
FENDERS/EXHAUST MUFFLER
REMOVAl/INSTALLATI ON
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.
NOTE
• Make sure there are no exhaust leaks after installation.
.,.. .. ~
.• .. 131 lPIP~E
S~:~ EXHAUST CLAMP /
.,..
.,.. ..
•
• • '----,oiD,
(5) GASKET
'"
13-3
IGNITION SYSTEM
__ ·m IGNITION SWITCH
(3) COl UN IT
161
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
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-
n~g~NE
secondary coil plug wire (at 20"Cf68°F)
100-30011
"-_',LG/N,tt
Alternator exciter coil BIIA and G
Pulse generator
TOOL:
Inspection adaptor (KKO) 07508 - 0012300
(not available in U.S.A .)
Connect the special adapter to the COl unit and COl tester
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
,
- :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 ,
Remove the spark plug cap from the wire and measure the sec-
ondary coil resistance. (1) COl TESTE,R:r--rc==it-..,.-E~
NOTE
• Follow the tester manufact urer's instructions.
14-3
IGNITION SYSTEM
PULSE GENERATOR
Disconnect the alternator coupler.
Measure the resistance between the blue/yellow terminal and
ground.
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.
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.
14-4
MEMO
BATTERY/CHARGING SYSTEM
FUSE 10 A
131 R.",,,,RV
(5( Al TEANATOA
(8) 81 : Black
(91 A: Red
11 0) G: Green
e (11 ) Y: Yellow
"'-" L - _ y _---,"'-_
-=-
-=- L
(31 BATTERY,
'86 12V9AH
Aher '86 12V7AH
~ (7) TO ELECTRICAL _.+_ --' L-_ _ _ y -----'V-=o
- LOADS
(1) IGNITION
.I SWITCH
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.
ITEM STANDARD
'865.0
Charging time At Standard: Aher '86 3 .0 hours At Maximum: 1 .0 hour
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
15-1
BATTERY/CHARGING SYSTEM
CHARGING
;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
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
NOTE
Be sure that the battery is fully c harged before peforming
this test.
NOTE
• Avoid short circuiting 10 the teste r during the test .
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.
15-3
BATTERY/CHARGING SYSTEM
15-4
MEMO
STARTER SYSTEM
131 lOA
BATTERY
181 ""RT IFR";WI'TCH
BI/W 81 --jII~~S=~~:;,
(S ) STARTER SWITCH
t-------<...- 0 -_ _ _ _ _ Y / R ----'I'~-_J:
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 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.
NOTE
00 not use emery or sand paper on the commutator.
16-2
STARTER SYSTEM
CASE INSPECTION
ASSEMBLY
16-3
STARTER SYSTEM
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 rear cover white aligning the slot on the reaf cover
with the pin on the brush holder.
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.
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.
• 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
17-1
LIGHTS/SWITCHES
HEADLIGHT
BULB REPLACEMENT
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.
17-2
LIGHTS/SWITCHES
TAILLIGHT
BULB REPLACEMENT
Remove the taillight lens mounting screws from the rear fend -
eL
Remove the taillight lens.
•
NEUTRAL INDICATOR LAMP (1) NEUTRAL INDICATOR LAMP
NEUTRAL SWITCH
Remove the seat and side covers.
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:
17-3
LIGHTS/SWITCHES
INSPECTION
REMOVAL
HANDLEBAR SWITCH
NOTE
The handlebar switch (lighting, dimmer, engine stop, and
starter switches) must be replaced as an assembly.
COLOR G BIIW
OFF 0 0
RUN
., .,
SWI TCH
COLOR ., LIGHTING DIMMER
.0 W
COLOR
RELEASED
.~
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
j
2. Try spark test WEAK OR NO SPARK
tube
I
151 Damaged cylinder head gasket
161 Incorrect valve seat contact
(7) improper valve timmg
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
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
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
I
bustion chamber
)5) Ignition timing too advanced
IFault y COl unit or pulse gener-
ator)
18-2
TROUBLESHOOTING
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
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
Faulty pulse generator
I
5 . Check ignition timing and valve
clearance
INCORRECT -----------.~ 11)
16)
(7)
Incorrect valve seat contact
Improper valve timing
18-3
TROUBLESHOOTING
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
CORRECT
I
5. Check valve spring tension WEAK - - - - - - - - - - - -_. Faulty spring
NOT WEAKENED
I
6. Check camshaft A8NORMAL - - - - - - - - - - -
.. Worn camshaft
I
(2) Damaged steering races or steel
ball bearings
(3) Cables interfering
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
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
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
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
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
19-2 1202)