2004-2009A Few Words About Safety Service Information “The service and repair information contained in this manual is intended for use by qualified, professional technicians, [Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition, ‘This manual describes the proper methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. you nead to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior qualty. For Your Customer's Safety ; FETT Proper service and maintenance are essential to the customer's safety and the reliably of the vehicle. Any error or oversight while servicing a vehicle | Improper service ot repairs can create an ‘can result in faulty operation, damage to the vehicle, or injury to others. Unsafe condition that can cause your customer or others to be seriously hurt or killed For Your Safety Follow the procedures and precautions in this Because this manual is intended for the professional service technician, we manual and other service materials carefully. do not provide warnings about many basic shop safety practices (e.g,, Hot parses! gts). yu hve ralecehed sho sty anno: dor ume ye feet confident about your knowledge of sale servicing practice, we recommended that you do not attempt to perform the procedures described Failure to properly follow instructions and inthis manual precautions ean cause you to be seriously hurt ‘Some of the most important general service salely precautions are given oF Killed. below. However, we cannot warn you of every conceivable hazard thal can Follow the procedures and precautions in this arise in performing service and repair procedures. Only you can decide manual carefully ‘whether or not you should perform a given task = Important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and Using safety equipment. When performing any service task, be especially careful ofthe following + Read all ofthe instructions before you begin, and make sure you have the too's, the replacement or repair parts, and the skills required to perform the tasks sately and completely * Protect your eyes by using proper safety glasses, goggles or face shields any time you hammer, dil, grind, pry oF work around pressurized air or iquids, and springs or other stored-energy components. If there is any doubt, put on eye protection, * Use other protective wear when necessary, for example gloves or safety shoes. Handing hot or sharp parts can cause severe ‘bums or cuts. Before you grab something that looks like ican hurt you, stop and put on gloves. * Protect yourself and others whenever you have the vehicle up in the air. Any time you lit the vehicle, either with a hoist or a jack, ‘make sure that it's always securely supported. Use jack stands, Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. ‘This wil help eliminate several potential hazards: * Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. * Burns from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. * Injury from moving parts, I the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hyerogen gases rom bates ae explosive To rede the possibilty of re or explosion, be careful w working around gasoline or batteries. pose miplesens ce “wren * Use only a nonflammable solvent, not gasoline, to clean pars. * Never drain or store gasoline in an open container. + Keep all cigarettes, sparks and flames away trom the battery and all fue-related parts,HOW TO USE THIS MANUAL procedies ‘or the Follow the Mantansace Sehecile (Section 4) reammendations 1 it scheduled maintenance 18 very portant Sections 1 and 4 apply tothe whole motores, Section 3 tates poveles br remowiesilaten of eompenene that a be {Baured ope corece descrbed nthe tlomng sections. Sekton § tough 1? deserbe pets of the materge. grouod stcodng locaton 36 secon you want en this page, then im tthe table Most soctons eat wit an assembly ot sytem iusaton. sence hiormaten and Voubleshactng forthe section ‘The. sutsoquc ages pve orale procedue yo aro rr it is ote, ad Tail Fst Ir you" cont know the source of the woutle, go to secton 18 Thetoshacn Your eal. andthe salty of ors, very Inportant To heb You mate hermes decions wa nave prvded salty meteagee {Shimer intomaton throughout Wis manual. Ot coutee, fet Yeu must ee ou! on good ude Yeu tnd portant salty information 1 a arey of ors Ireing * Salty Labels ~ on he wore + Gaiety Messages ~ prececod by a8 tne of tee Sra words, DANGE Fon. ESI ee nse’ ORT you dor alow natetons ‘ACAUTION ory aie syrbot ard WARING. or CALE ou CAN be KILLED or SERIOUSLY HORT tos don flew instrortons You CAN be HURT if you dont flo ENGINE __|_BALANGEH CONTENTS GENERAL INFORMATION TECHNICAL FEATURE SYSTEM. MAINTENANCE LUBRICATION SYSTEM FUEL SYSTEM ‘COOLING SYSTEM | ENGINE REMOVAL/INSTALLATION CYLINDER HEAD/VALVES CYLINDER/PISTON | CLUTCHIKICKSTARTER/GEARSHIFT LINKAGE [ETI ‘CRANKCASE/CRANKSHAFT/TRANSMISSION/ Ea FRONT WHEEL/SUSPENSION/STEERING REAR WHEEL/SUSPENSION HYDRAULIC BRAKE ELECTRICAL SYSTEM WIRING DIAGRAM + instuctons now 1 serie this vehicle corecty and sally |_ TROUBLESHOOTING EZ INDEX ‘As youread tha mania you wil filma that is preceded by 8 NOIKE synod The purpoce of nse meseage 10 help prevent (dire to You vei, cher propery, ofthe erwronmentSYMBOLS ‘The symbols used throughout this manual show specific service procedures. if supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols. fod Replace the part(s) with new one(s) before assembly. 7” Use the recommended engine ol, unless otherwise species. A ‘Use molyedenum ol solution (mixture of he engine oll and molybdenum grease in rato of 1:1) Sima, __US0-mull-purposo grease (lithium based mult-purpose grease NLGI #2 or equivalent Use molybdenum disulfide grease (containing more than 3% molybdenum alsulide, NLGI #2 or equivalent, ARB Example: Molykote® BF-2 pus manutactured by Dow Corning U.S.A Muli-purpose M-2 manutactured by Mitsubishi Oil, Japan —— — = { Use molyodenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or ‘equivalent. Eramle: Nobile? Ga Past malate by Dow Coming USA ie Hoa oy 8 (8A. ony) | Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manulactured by Sumico Lubricant, Japan Sal Use silicone grease. Am Apply a locking agent. Use a medium strength locking agent unless otherwise specified. we ‘Apply sealant. Use DOT 4 brake fluid. Use the recommended brake fuid unless otherwise specified. Use fork or suspension fluid oe e1. GENERAL INFORMATION SERVICE RULES - 12 MODEL IDENTIFICATION: GENERAL SPECIFICATIONS -+--e1-seseeee 1-4 LUBRICATION SYSTEM ‘SPECIFICATIONS -~ FUEL SYSTEM SPECIFICATIONS. COOLING SYSTEM SPECIFICATIONS «1-7 CYLINDER HEAD/VALVES SPECIFICATIONS-~- CYLINDER/PISTON SPECIFICATIONS -----1-8 CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS --- 1-8 CRANKCASE/CRANKSHAFT/TRANSMIS- SION/BALANCER SPECIFICATIONS ------- 1-9 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS 110 REAR WHEEL/SUSPENSION SPECIFICATIONS --- TAT HYDRAULIC BRAKE SPECIFICATIONS 1-11 ELECTRICAL SYSTEM SPECIFICATIONS «== STANDARD TORQUE VALUES -~ ENGINE & FRAME TORQUE VALUES-- 1-13 LUBRICATION & SEAL POINTS 1-19 CABLE & HARNESS ROUTING 1-22 OPTIONAL PARTS: 1-30 1-1GENERAL INFORMATION SERVICE RULES Use genuine Honda or Honda-recommended parts and lubricants or their equivalents, Parts that do not meet Honda's design specifications may cause damage to the motorcycle. Use the special tools designed for this product to avoid damage and incorrect assembly. Use only metric tools when servicing the motoroycle, Metric bolts, nuts and serews are not interchangeable with nglish fastener. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental steps unless 8 particular sequence is specified. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly, After reassembly, check all parts for proper installation and operation, Route all electrical wires as shown in the Cable and Harness outing page 1-22). MODEL IDENTIFICATION “04 model shown: After 08: eoGENERAL INFORMATION The Vehicle Identification Number (VIN) is stamped on the right side of the steering head, © © wy oa ‘VEHICLE IDENTIFICATION NUMBER (VIN) The engine serial number is stamped on the left side of the lower aay © crankcase. ‘The carburetor identification number is stamped on the left side of the carburetor body. ,. ha ___ CARBURETOR IDENTIFICATION: NUMBER]GENERAL INFORMATION GENERAL SPECIFICATIONS Tem DIMENSIONS | Overall fengih Overall width Overall height Wheelbase Seat height Footpeg height Ground clearance Frame type Front suspension Front suspension axle travel Front suspension cushion stroke Rear suspension Rear wheel travel Rear damper Front tire size Roar tire size Tire brand (Duntop) Front brake Front brake swept area Rear brake Rear brake swept area Caster angle Tra length Fuel tank capacity Toa "O7) (After ‘07) (oa) (After 04) (04-07) (alter 07) (04) (After 04) (oa) (ator 04) (oa) (0-07) (after '07) (oa) (after 04) ('04) (After 04) (04 -'06) (After 08) 04) (ater 04) 04) (95-07) (after ’07) SPECIFICATION 2,172 mm (85.5 in) e 2.470 mm (85.4 in) 827 mm (32.6 in) 1,263 mm (49.7 in) 1,277 mm (50.3 in), 1479 mm (58.2 in) 1477 mm (68.1 in) 957 mm (37.7 in} e 985 mm (38.0 in) 434 mm (17-1 in) 446 mm (178 in) 389 mm (137 in) 361 mm (14.2 in) See wane {|o Telescopic fork 280 mm (11.0 in} 279 mm (11.0 in} 315 mm (12.4 in} Pro-Link 312 mm (12.3 in) 313 mm (12.3 in) Decarbon type with nitrogen gas filled damper ‘80/100-21 51M 100/90-19 57M Front: D742F/Rear: D756 Front: D742FA/Rear: D756 Hydraulie single dise e 334.5 om? (51.8 in’) Hydraulic single dise 391.1 om? (60.6 in’) 2744 27°60" 112 mm (44 in) 323 mm (48 in) 125 mm (4.9 in) 723 liter (1.93 US gal, 1.61 Imp gal)CARBURETOR DRIVETRAIN ELECTRICAL Bore and stroke Displacement Compression rat Valve t Intake valve Exhaust valve Lubrication syster Oil pump type Cooling system Air filtration Crankshaft type io opens closes opens closes m Engine dry weight Cylinder arranger ment Carburetor type Venturi diameter Clutch system Clutch operation system Transmission Primary reduction Final reduction Gear ratio Gearshift pattern (04 -"07) (after ‘07) (04 and After 07) (05-07) (04-07) 08) (ater 08) at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift at 1 mm (0.04 in) lift ‘at 1 mm (0.04 in} lift (04, “05) (08) (07) (After ’07) ("04, 05) _ (after '08) ast 2nd ard ath 5th GENERAL INFORMATION ‘SPECIFICATION "78.0 x 52.2 mm (3.07 x 2.06 in) 249.4 cm? (16.21 cu-in) 12911 Bad 13.0:1 Chain drive and OHC with rocker arm 16° BTDC. 20° BTDC 0° ABDC 50° BBDC 20° ATOC 18° ATDC Forced pressure and wet sump Trochoid Liquid coolea Oiled polyurethane foam Assembled type 23.90 kg (52.68 lbs) 24.05 kg (83.02 Ibs) 24.08 kg (53.09 Ibs) 24.10 kg (63.13 Ibs) Single cylinder, inclined 10 from vertical Piston valve type 37 mm (15 in) 40 mm (1.6 in) Multi-piate, wet Cable operated Constant mesh, 5-speed 3.166 (57/18) 3.923 (5113) 2.142 (30/14) 1.750 (28/16) 1.450 (29/20) 1.227 (27122) 1.041 (25/24) Left foot operated return system, 1-N-2-3-4-5 TCM (ignition Control Module)GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS TEM Engine oll capacity Transmission oil capacity At draining "Ai disassembly Recommended engine oll Recommended transmission oll Oil pump rotor FUEL SYSTEM SPECIFICATIONS Tem Fuel tank capacity Carburetor identification number Main jet Slow jet Jet noodle | det needle clip position | (Standard) Pilot screw initial opening ‘At draining At filter change At disassembly "04 ‘After 04 "oa ‘After "04 Tip clearance Body clearance Side clearance Om ry 06 0 "08 After "08 [After "08 “Od and ‘06 "06 and After ‘06 C7 5 "06 ‘O7 "08 ‘Afar "08 08 ‘After 04 "04 and ‘07 ‘05 and ‘06 8 Carer "08 Float level (Tale speed Throttle grip freeplay Hot starter lever freeplay Unit: mm (in) ‘STANDARD ‘SERVICE LIMIT (0.68 litor (0.70 US qt, 0.58 Imp at) = 0.69 liter (0.73 US qt, 0.61 Imp at) 0.85 liter (0.80 US qt, 0.75 Imp at) 0.72 liter (0.76 US qt, 0.63 Imp at) 0.60 liter (0.63 US qt, 0.63 Imp qi) - 0.77 liter (0.81 US qt, 0.68 Imp at) = 0.70 liter (0.74 US at, 0.62 Imp at) = Pro Honda GNA 4-stroke oil (U.S.A. and Canada} or equivalent motor ail API service classification: SG or higher JASO T 903 standard: MA, Viscosity: SAE 10W-30 Pro Honda GNA 4-stroke oll (USA. and Canada) or equivalent motor oil APL service classification: SG or higher JASO T 903 standard: MA, Viscosity: SAE 10W-30 10.15 (0.008) (0.15 - 0.20 (0.008 - 0.008) {0.05 = 0.22 (0.002 - 0.008) = (0.20 (0.008) SPECIFICATIONS 7.3 liter (1.83 US gal, 1.61 Imp gall FCROIA FCROIB FCROIC FCROID. FCROTE FCROTE #160 #72 #175 #188 #185 #40 wa? NCYR i NYO (HFS NKET NMIGU NNNSU ath from the top Srl from the top 7-74 turns out 8.0 mm (0.31 in) 6.0mm (0.24 in) 4,700 100 rpm 3=8 mm (1/8 - 3/16 in} 2—3mm (1/16- V8 in} SS 1-6 oe SoGENERAL INFORMATION Sesser COOLING SYSTEM SPECIFICATIONS ITEM ‘SPECIFICATIONS: Q | costentcsnaciey ‘At change {0.93 liter (0.98 US qt, 0.82 Imp qi) At disassembly 7.00 liter (1.06 US qt, 0.88 Imp at) Radiator cap relief pressure ‘93-123 kPa (0.95 — 1.25 kaflom’, 13.5 - 17.8 psi) Recommended antifreeze Pro Honda HP Coolant or en equivalent high quality ethylene glycol antifreeze containing silicate-free corrosion inhibitors. ‘Standard coolant concentration TET mixture with distilled water © CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mn Cin) Tem | STANDARD SERVICE LIMIT @ | rere 392 KPa (@ Okgifem?, 57 pail - 231 800 rpm Cylinder head warpage = 10,05 (0.002) Valve Valve clearance |_IN 0.12003 (0.005 + 0.001) = andvelve ex 0.28 £0.03 (0.011 = 0.001) = guide Vaive stem 0.0. IN 4.975 ~ 6.990 (0.1959 - 0.1965] = ex 4.966 - 4.980 (0.1955 - 0.1961) 4.955 (0.1961) 4.465 - 4.480 (0.1758 — 0.1764) 4.455 (0.1754) | Valve guide. IN 5.000 - 6.012 (0.1969 - 0.1973) 5.052 (0.1989), ex 5.000 6.012 (01969 0.1873) 5.052 (0.1989) 4.500 4.612 (0.172 0.1776) 4.552 (0.1792) Stemvto-gquide IN {0.010 - 0.037 (0.0004 - 0.0015) clearance ex 0.020 - 0.047 (0.0008 = 0.0019) Vaive guide iN 74,8 - 16.0 (0.58 - 0.59) | projection above EX | "04-07 19.8 -20.0 (0.78 0.78) = © oylinderhead |_| “Afier'07_| 19.8 = 20.1 (0.78 0.78) = |__| Valve seat width INEX 0.90 - 1.10 (0.035 = 0.043) 17 (0.07) Valve spring free length IN | 708-707 39.47 (1.532) 365 (1.52) ‘Afier'07 | 3851 (1.516) 37.7148) TEX 04-707 43.07 (1.696), 42.4(1.66) ‘Alter'07 | 43.03 (1.654), 42.2(1.66) Rocker [Rocker arm LO. 12.016 ~ 12.034 (0.4731 - 0.4738) 12.07 (0.475) aim Rocker atm shaft 0.0. 11.977 = 11.986 (0.4715 - 0.4719) 11.93 (0.470) Rocker arm-to-shaft clearance 0.031 ~ 0.057 (0.0012 - 0.0022) (0.11 (0,004) Camshaft Cam lobe | IN’ | ‘04-06 26,000 - 36,240 (1.4173 ~ 1.4268) 35.86 (1.412) height "7 | 36.200 - 36.440 (1.4262 ~ 1.4348) 36.06 (1.420) ‘After'07 36 280 - 36.360 (1.4283 - 1.4915) 36.44 (1.473) ex | "04 and 06 25,667 - 25 907 (1.0105 — 1.0120) 25.56 (1.006) (05 25,501 - 26741 (1.0040 - 1.0134) 24.40 (0.861) ‘07 125.501 = 25.721 (1.0040 1.0126) 24.40 (0.861) ©e ‘After "07 25.750 - 25.830 (1.0138 1.0163) 25.64 (1.009) Valve lifter 0.0. 22.478 - 22.493 (0.8850 — 0.8855) 22.47 (0.885), Valve lifter bore 1. 22.510 22.526 (0.8862 — 0.8669) 22.54 (0.857)GENERAL INFORMATION CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) : “Tem. SERVICE MIT Cylinder [1D - Out of round “Taper = iZ Warpage t Piston, | Piston mark direction t piston ‘O" mark facing toward ring Piston OD. . |" 77.870~ 77.980 (3.0697 - 3 Piston 0.0. measurement paint 7.0 mmm (0.28 Piston ring o-ring groove Piston ring end gap on elearané “Connecting rod small end 0. Connecting rod-to-piston pin clearances 4-707 | 0.068 = 0.100 (0.0026 - 0.0038) | 0.175 (0.0045) ‘After‘07 | 0.035 ~ 0.086 (0.0014 - 0.0026) 0.08 (0.003) 16.016 = 16,084 (0.6305 0.6313) ~ [0.016 = 0.040 (0,0006- 0.0016) 116.08 (0.631) 0.08 0.002) CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE SPECIFICATIONS Unit: mm (in) Trem (“Clutch Tevertreeplay Clutch spring free length Clutch dise thickness Clutch plate warpage 1-8 SERVICE Ln 363 (1.43) 37.2 (1.46) 71.48) 2.850.112) (0.10 (0.008) 6.55 (0.652) "16.46 (0.648) 17.06 (0.672) 16.97 (0.668) | ~ 16.516 - 16.534 (0.6502 - 0.6509) 16.466 — 16.484 (0.6483 - 0.6430), (034 (0.6699 - 0.6706) 76.883 = 16.994 (0.6686 - 0.6881) oe e eo oeGENERAL INFORMATION CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER SPECIFICATIONS a Unit: mm tin} trem STANDARD ‘SERVICE LiMr Crankshaft | Side clearance ;30= 0:75 [0.01 - 0.03) 0.8 (0.03) Radial clearance {0.006 - 0.018 (0.0002 - 0.0007) 0.05 (0.002) Funout a = = (0.08 (0.002) "23,020 - 23.041 (0.9063-0.9071] 23.07 (0.908) 20.020 - 20.041 (0,7882 0.7890) 20.07 (0.790) 27.020 = 27.041 (1.0638 1.0646) 27.07 (1.066) 25.020 25.041 (0.9850-0.9859)_|_ 25.07 (0.987) ‘Transmission Bushing. | Ma, ME 22.979 2,000 (0.9047 -0.9055) 22.98 0.904) ci 18.979 - 20.000 (0,7866-0.7874)_ 19.95 (0.785) ce 26.979 = 27.000 (1.0622 - 110630) 26.95 (1.061), a 24.979 26,000 (0.9834 -0.9643) 24.96 (0.983) Bushing LO. |M 20,000=20,02' (0.7874 0.7882) 20,04'0.788) ci 17.08 (0.671) c 24.04 (0.948) ca 22.04 (0.868) Gearto- M4, Mi t 0.12 (0.005) bushing 1,02, 0:12 (0.005) Mainshaft | M6 bushing 19.960 (0:7858=0.7865) 18:94 (0.785) oD. Countershatt > CY bushing 16,983 = 16.994 (0,6686- 0.6691) | 16.97 (0.668) | 00. ‘ter"06| 16,981 = 16,992 (0.6685 -0.6690)_|16.970.668), G2 bushing ad 23.94 (0843) 3 bushing 21,94 (0.868) Bushingto- MS [0.12 (0.006) shaft cr 0 0.07 (0.003) elearance ‘After 05 ‘0003 = 0.0015) | 0.07 (0.003) aca 0.020 = 0.062 (0,0008 - 0.0024) | 0.120.005) ‘Shift fork Fork claw thickness 4.93 - 6.00 (0.194 -0.197) 48 (0.19) shift fork Shift fork D.C 7.008 -11.024 (0.4392 0.4340) | 11.04 0.435) shaft c 1207 (0.478) Fork shat —[c 70.97 (0.432) 0.0. RL ~|_11,966 - 11.984 (0.4711 - 0.4718) 17.95 (0.470)GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS iTeM Coid tire pressure ‘Axle runout Wheel rim Radial runout Axial ‘Wheel hub-to-rim distance - Fork ‘Spring free length Slider runout —— Recommended fork ol Oilievel Fluid] Fork capacity tube Fork damper Compression damping adjuster standard position Rebound damping adjuster standard position HPSD_ (after ‘07) "04-07 ‘After ‘07 04 05 08 07 "08 ‘Afior’08 "04, "05 "06,07 ‘After ‘07 "04 ‘05 (06, 07 After ‘07 "04, 05 After ‘05 Recommended damper oil Free piston depth at 20°C (68°F) Damping force adjuster standard position 1-10 ‘STANDARD 98 KPa (1.0 katiem’, 14 psi) 1 280= 7011.10 0.04) z 113.6) 494 (19.4) Pro-Honda HP Fork Oil 6W or equivalent 42 - 47 mm (1.65-1.85 379 em® (12.8 US oz, 13 371 em® (12.5 US oz, 13.1 Imp o2) 369 em" (12.5 US oz, 13.0 mp o2) 372 em" {12.8 US oz, 13.1 Imp oz) 4408 em? (13.8 US o2, 14.4 Imp o2) "368 cm" (12.4 US oz, 13.0 Imp o2) 195 om (6.6 US 02, 6 Imp 02) 192 om" (6.5 US 02, 68 Imp 02) i Imp 02] 187 em" (6.3 US 0, 6.6 Imp oz) Y2 clicks out from full in 410 clicks out from full in “B clicks out from full in clicks out from full in 8 clicks out from full in clicks out from full in Pro:Honda HP Fork Oil BW or ‘equivalent 21.3 ~27.9(1.07- 1.10) 7 clicks out from full in 487 (19.2) 0:20 (0.008) Unit: mm (in) ‘SERVICE LIMIT o 10:20 (0.008) 2.0 (0.08) 2.0 (0.08) 88 (19.2) o ©GENERAL INFORMATION REAR WHEEL/SUSPENSION SPECIFICATIONS ITEM Axle runout ‘Wheel rim runout Radial Es ‘Wheel hub-to-rim distance Drive chain slack Drive chain sizelink DID ‘04="08 Aer 08 RK (ater Drive chain slider thickness Drive chain roller | “0d — on. | Atir'08 Upper Lower ‘Shack absorber Damper gas pressure Damper compressed gas Recommended shock oil Damper rod compressed force at 12 mm compressed Spring “08 installed 05 length 06-07 (standard) = after"07 High speed side compression damping "04 adjuster standard position Low speed side compression damping adjuster standard position Rebound damping adjuster standard position ‘STANDARD ‘98 kPa (1.0 kgficm’, 14 psid 48,75 £1.00 (191820039) 25 - 35 (1.0- 1.4) 520DMA2 - 114 520DMA4- 114 S20TXZ- 114 ‘980 KPa (10.0 ka/em’, 142 psi) Nitrogen gas Pro:Honda HP Fork oil SW or equivalent 20.0 ~ 24.0 kaf (4.1 ~ 62.9 Ibt) 260.1 (10.24) 261.3 (10.28) 259.0 (10.20) 259.6 (10.22) 258.1 (10.16) 4-7/2 - 2-112 turns out from full in 4-314 = 2-1/4 turns out from full in 1-5/6 - 2-1/3 turns out from full in 7 clicks out from full in 9 clicks out from full in 14 clicks out from full in 11 clicks out from full in "clicks out from full in 710 clicks out from full in 12 clicks out from full in HYDRAULIC BRAKE SPECIFICATIONS rem Brake fluid Brake pad wear indicator Brake disc thickness Brake disc runout Master cylinder 1D. Master piston 0.0. Caliper cylinder LD. Caliper piston O.D. Rear Brake fluid [Brake pad wear indicator Brake disc thickness Brake disc runout Master cylinder ID. Master piston 0.0. Caliper cylinder 1D. Caliper piston 0.0. 1 Front ‘STANDARD bora 3.00.12) 1.022 (0.4339), 10.971 (0.4319), 27.025 (1.0640) 26.878 (1.0582) Dota 4010.18) ‘9.647 (0.3759) ‘9.491 (0.3737) 22.675 (0.8827) 22.6002 (0.8898) Unit: mm (in) ‘SERVICE LIMIT 0:20 (0.008) 2.0 (0.08), 2.0 (0.08) 50 (2.0) 5010.2) 39 (1.5) 38 (1.5) 31 (1.2) Unit: mm (in) ‘SERVICE LIMIT 1.0 (0.04) 2.5 (0.10) 0.18 (0.008) 17.050 (0.4350), ‘0.840 (0.4268), 277.060 (1.0654) 26.863 (1.0572) 7.0 (0.04) 3.5 (0.14) 10.18 (0.008) 9.575 (0.3770) 9.465 (0.3726) 22.712 (0.8942) 22.573 (0.8887)GENERAL INFORMATION ELECTRICAL SYSTEM SPECIFICATIONS WMS Standard | (NGR} % ‘Spark plug __1DENSOT ‘Optional GK) TMRSCOH 009 8. Spark plug gap [Directignition colt inition cofl input voltage CKP (crankshaft position) sensor peak voltage Exciter coil peak v 1-12GENERAL INFORMATION STANDARD TORQUE VALUES ToRQUE a ToRQUE FASTENER TYRE Nem (kgf-m, Ibf-ft)_ FASTENER TYPE Nem (kgf-m, Ibf-ft) © sre toirana nr Beles 38) Sm aow Tze 3) mm bolt ane ut io) smmscew 20109,68) Emm bolt and et 22(22,18) Smmflange bot (&mm head small | 1011071 tanec! tam bot and rut 34(35,25) Brnmlonge bolt (8mm hese lage 1212.8) fiangel CO) wombat antna (85,40) Bmmflange bolt (10 mm head) and | 12112,8) Bm flange bolt an nt 21129, 29 : i tom fonge bolt and nut lao, 2) (& ENGINE & FRAME TORQUE VALUES Terauo specications sted below are or specified forener + Gina afouid oe Sghtonod to sendard org vluss sted above nore 1) Apply ot the threads and satng surface 3 Apply stocking auont io te threads F aeEnY a Neh sheet ecin agent io the threads & Abplyareee tothe tence, & sue & Unt 5: Lethon threos. & ALOC bolero replace with a new one 5 Gasbotmur ENGINE © manrenance mn THREAD TORQUE ITEM aay: DIA, (mm) Nem (kgf-m, Ibfft) femines Engine oi an bot (08-05) 1 3 Dea i NOTET Enene el dan bolt (ter) 1 3 welts 12 NOTE! Trangmloson ol oan bat (04-08) 1 3 222.18 NOTE! Transmission olan bolt (Ato 08) : 3 telnet NOTE! Ting ole cop ' i Gowese | NOTES Crontshatt hte cap : % stt8.11 NOTE Spark plug joa 10 16(1.6, 12) Luaricarion ———— THREAD “TORQUE | ne arty DIA. (mm) Lm (kgf-m, Ibf-ft) REMARKS aro —— i 3 ZOUzis) | NOTED O [ilethrcuming bot ater‘) 1 $ foro.) NOTE?GENERAL INFORMATION FUEL ITEM Throttle drum cover bolt Needle jet Main jet Slow jet Slow air jot ('04 -'07) Starter jot Maintenance cover bolt Top cover bolt Throttle shaft screw ('04-‘06) Throttle shaft torx screw (After 06) Float chamber screw Accelerator pump cover screw Carburetor drain plug SE valve lock nut Hot start valve lock nut Jet needle holder Throttle position sensor torx screw ‘Acs. pump bypass jet COOLING sysTEM Tem Water pump impaller CYLINDER HEAD/VALVES Tem Cylinder head cover bolt Camshaft holder mounting bolt Decompressor cam stopper plate bolt Cylinder head nut Cam chain tensioner bolt Rocker arm shaft cap (CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE rem Gearshift drum center pin Gearshift drum stopper arm bolt Clutch center lock nut Clutch spring bolt Clutch cover bolt Gearshift return spring pin Gearshift pedal pinch bolt Kickstarter pedal bolt (CRANKCASE/CRANKSHAFT/TRANSMISSION/BALANCER rem Crankshaft bearing set plate screw Countershaft bearing set plate screw Gearshift drum bearing set plate bolt Mainshatt bearing set plate bolt Balancer shaft bearing set plate bolt, Drive sprocket bolt Primary drive gear bolt Crankcase orifice (07 only) Balancer shaft nut 1-14 THREAD DIA. (mm) THREAD DIA. (mm) THREAD DIA. (mm) TORQUE ‘Nem (kgfm, Ife) 3.4 (0.3, 25) 1.8 (0.2, 1.3) 1.5 (0.2, 1.1) 1.5 (02, 1.1) 1.0 0.1, 0.7) 15 (0.2, 1.1) 2.10.2, 15) 2.1 (0.2, 1.5) 2.1 (0.2, 1.5) 2.1 (0.2, 1.5) 2.1 (0.2.1.5) 2.1 (0.2, 1.5) 49 (0.6, 3.6) 2.1 (0.2, 1.5) 2.1 (0.2, 15) 2.410.215) 3.4(0.3,2.5) 0.3 (0.03, 0.2) TORQUE Nem (kgf-m, ibf ft) 12(1.2, 3) TORQUE ‘Nem (kgfm, Ibf-ft) 10 (1.0, 7) 16 (1.6, 12) 1011.0, 7) 39 (4.0, 29) 12(12,8) 6.00.8, 44) TORQUE Nem (kgm, Ibf-t) 22(2.2, 16) 12(1.2, 9) 68 (70, 51) 12(1.2, 9), 1011.0, 7), 22 (2.2, 16) 1211.2, 9) 38 (3.9, 28) TORQUE Nem (kgm, tf t) 20 (2.0, 16} 10 (1.0, 2) 10 (1.0, 7) 10 (1.0, 7) 10 (1.0, 7) 31 (3.2, 23) 108 (11.0, 80) 2.0 (0.2, 1.) 44 (4.5, 32) REMARKS NOTE 2 NOTE 2 NOTE 2 REMARKS. NOTE? REMARKS. NOTE? NOTE2 NOTE1 NOTE 2 NOTE 4 REMARKS. NOTE2 NoTE 1 REMARKS NOTES NOTE 2 NoTE 2 NOTE 2 NOTE 2 NOTE 9 NOTE 1 NoTE 8 NOTE 1 e eo eo o o o eoGENERAL INFORMATION ‘ALTERNATOR a 7 . THREAD — TORQUE T eM. BT pia temm) nem tkgtim, ttt) REMARKS CQ Eerieat nat 7 12 64 (65,47) NOTET KP sensor mounting bolt 2 5 5.2 (05,38) NOTE 2 Stator mounting screw 3 4 2510.3, 19) NOTE 2 Insulator clamp: Carburetor si ‘04 'G7: 12.0 1.0 mm (0.47 + 0.04 in) After '07: 11.0: 4.0 mm (0.43 + 0.04 in) oe Engine side: 9.0 + 10 mm (0.36 + 0.04 in) ue Teh © ff a Cylinder head stud bolt: © 22.0 £0.5 mm (0.87 + 0.02 in) Cylinder stud bolt: 12204 1.0mm (5.00 + 0.04 in) 1-15GENERAL INFORMATION FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TORQUE) rem OTY | piatmm) | Nmtigtm,tbeny | REMARKS | GQ ‘Seat mounting bolt 2 S 26 (2.7, 19) T Sub-frame mounting bolt (upper) 1 8 30 (3.1, 22) | (lower 2 to 260.3) | Seat bracket screw a 5 4.0 (0.4, 3.0) Ful tank band hook serew 1 5 4010430) Muffler joint band bolt "04-05: 1 8 21(2.1, 15) eo wttor'08, | 2 8 204,18) Muffler mounting bot 2 3 28.2719) Exhaust pipe joint nut 2 8 22.1, 18) Muller protector bolt (04) 2 6 12(12,8) Exhaust joint pipe mounting bolt (After 5) 1 8 zen Exhaust pipe joint band bolt (after"05) 1 | 8 2.1.48) Shroud mounting bot fuel tank side) 4 5 £0105 37) e Exhaust pips protector bot 2 6 2012.8) ‘Side cover bolt 2 | 6 10 (1.0, 7) | Stop bracket {upper 2 2 sea) | (lower) 2 a 30 (3.1, 22) Roar fender mounting bolt 4 6 1313.10) ‘Mudguard mounting screw fe |g | iitetos | MAINTENANCE 7 ” THREAD | = = TORQUE 7 | - eM TY ta temm)_| Nm (kgm, tt) REMAN ‘Throttle cable upper adjuster lock nut (After ‘06) | 1 7 40 (0.4, 3.0) — Throtle cable lower adjuster lock nut (after‘06)_| 1 6 | 4010430) ENGINE MOUNTING THREAD TORQUE e rem DIA {rmm)——_Namthgtm, bgt) REMARKS hanger plate nut \engnasitel 1 10 54165, 40) {frame side) 04 2 8 28 27,20) ater'os | 2 8 34138, 25) Engine mounting nut (front) 1 10 64 (6.5, 47) tower 1 | eee an 1-16GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING THREAD TORQUE rest oy | REA ore ey REMARKS | © Front axle nut 1 16 ‘88 (9.0, 65) Front exle holder bolt 4 8 20 20,15) Front spoke se | Beas 37104 2.7) Frent im lock 1 8 12012, 9) Front brake dsc nut 6 8 18(16.12) notes Steering stom nut 1 2 108 (110,60) | Steering stom adjusting nut 1 30 See page 1357 CO eericp bse inch bor 4 e 2222.16) Fork bottom bridge pinch bolt 4 a 20 (20.18) Forkeap 2 2 30 (8.1.22) Fork center bolt z 22 69 (7.0, 51) Fork center bolt lock nut 2 2 22 (22.16) Fork air plug bolt # 5 1.2 (0.1, 0.9) © Fork damper 2 50 34 (3.5, 25) Fork protector mounting bolt é . 701027,52) Note 2 Front brake dlee cover bolt ‘08 2 6 1313.10) iter08 | 6 1313.10) Handlebar upper holder bolt 4 8 2212216) Handler lower holder nut 2 0 aa(as.32) Notes Clutch lever pivot bolt i 6 2010218) | Loosenthe | bettas 90° oer tightening Clutch lever pivot nut 1 6 10(10,7) NOTES Tighten wate Molding the pivot batt Cluten lever nolder bolt 2 6 88(09,65) @ | au 2 : uae Engine stop button scrow i 4 15 (02.11) _Stouring damper bolt (ater‘07) i 2 7 20 (20.15) NoTe2 REAR WHEEL/GRAKE/SUSPENSION vy) THREAD ToRauE ies QTY DIA. (mm) Nem (kgfim, bese) REMARKS Rear axle nut i 1 22 128 (13.1, 94) NOTE 6 Reet spoke 2 aS 37 (00,27) Rear rm lock 1 6 213.9) Rear brake dise nut 4 6 318.12) Notes Driven sprocket nut 6 8 3253.2) Noves Rear vinee! bearing retainer 1 Ps dala. 32) NOTES Swingarm pivot nut 1 14 33 (80,65) NOTES vo ‘Shock arm nut (swingarm side) 1 12 53 (5.4, 39) NOTE 1,6 {shock ink side) 1 % 2364.39) NOTE 1.6 Shock ink nut (rome sie) + 1 53 (54.39) NOTE 6 Shock absorber upper mounting nut 1 10 24 (45,32) NOTE 6 Shock absorber lower mounting nut 1 0 aa (as, 30) NOTES ‘Shock absorber spring adjuster lock nut x 60 44 (4.5, 32) Drive chln alder eorew 3 ° 390,29) Nove 2 ) Drive chain upper roller bolt 1 8 12 (1.2, 9) Drive chain lowor roller nut 1 8 2112.9) notes Dive chan guide mounting aut 3 8 ia) NOTE 6 Drive chain adjusting bolt tock nut 2 a 27 (28.20) Note 8 Shock absorber damper rod end nut i 2 57 (38.27) NOTES Shock absorber damping adjuster 1 Zz 30 (31.22) 1-17GENERAL INFORMATION HYDRAULIC BRAKE i Water hose clamp: Lg 4 0-10 mm (0-0.04in) rem any ‘ REMARKS. | Brake hose oil bolt a 34 (35, 25) Brake lever adjuster lock nut 1 5 59106, 44) Brake lever pivot nut 1 6 59 (0.6, 44) Brake lever pivot bolt 1 6 1.0 (0.1, 0.7) Front brake hose guide bolt 1 6 52 (05, 38) Rear brake hose guide screw 2 5 1.2 (0.1, 09) Front master cylinder reservoir cover screw 2 4 1.0 (0.1, 0.7) Front master cylinder holder bolt 2 6 99(10,73) | Front brake caliper mounting bolt 2 8 30 (3.1, 22), NOTE 2 Caliper bleed valve 2 8 54 (0.6, 40) Rear master cylinder mounting bolt 2 6 13(13, 10) Rear master cylinder reservoir cover bolt 2 4 10 (0.1, 0.7) Front caliper pin bolt 1 8 22 (2.2, 16) NoTE 2 Rear caliper pin bolt 1 2 27 (2.8, 20) Brake caliper pad pin 2 10 18 (1.8, 13) Front brake caliper pad pin plug 1 10 25 (03, 18) Front caliper bracket pin bolt 1 8 22(2.2, 16) NoTE 2 Rear caliper bracket pin bolt 1 a 12(1.2,9) NOTE 2 Brake pedal pivot bolt “04: 1 8 25 (2.6, 19) NOTE 2 After ‘04: 1 10 36 (3.7, 27) NOTE 2 Rear master cylinder push rod lock nut 1 6 5.9 (0.6, 44) 1-18GENERAL INFORMATION LUBRICATION & SEAL POINTS ENGINE oo LOCATION Camshaft lobes Rocker arm (shaft hole inner surface and vaive stem fend contact area) Valve stem (valve guide sliding surface) Valve stem end sliding surface Valve lifter outer surface Clutch outer guide sliding surfaces Clutch outer needle bearing rolling area Cluteh liter lever eam area Kickstarter pinion gear sliding surface Kickstarter spindle spline area and gear rolling area Connecting rod small end inner surface Connecting rod big end (side sliding area) Mainshaft spline area and gear rolling area Countershatt spline area and gear rolling area Transmission gear and sliding surfaces Shift fork gear guide area and guide pin area Shift fork sliding surface Shift fork shaft outer surface Each gear sliding area Engine oil drain bolt threads and seating surface ‘Transmission oil drain bolt threads and seating surface Camshaft holder mounting bolt threads and seating surface Cylinder head nut threads and seating surfaces Balancer shaft nut threads and seating surface Piston outer surface and piston pin hole Piston pin outer surface Piston ring whole surfaces Cylinder bore Clutch lifter and lifter rod sliding area Clutch lifter needle bearing Clutch disc linings Clutch center lock nut threads and seating surface Primary drive gear bolt threads and seating surface Flywheel nut threads and seating surface Crankshaft (oil seal contact area) Kickstarter spindle (crankcase contact area) Decompressor cam sliding area Transmission gear teeth Plug hole seal Clutch outer sliding surface Shift drum guide grooves Shift spindle servation area il pump rotors sliding area Each bearing rolling area Each O-ring Crankshatt hole cap threads ‘Timing hole cap threads Rocker arm shaft cap threads Camshaft set ring Oil seal lips it filter spring contact area Water seal lips MATERIAL — REMARKS — ———Mraiybdenum oil solution (mixture of the engine oll and molybdenum sulfide grease with the ratio 100g :70 cm’) Engine oil Milti-purpose grease 1-19GENERAL INFORMATION Cc LOCATION - MATERIAL “REMARKS Shift drum center pin bolt threads Locking agent Coating wicth: 6527. 0mm Oiljet threads (04) (0.26 + 0.04 in); except Oil jet mounting bolt threads (After ‘04) 12mm (0.04- 0.08 in) e Decompressor cam stopper plate bolt threads from tip Cylinder head cover breather plate bolt threads |L_Oil guide plate bolt threads Cam chain tensioner pivot bolt threads Locking agent eae | ee om & o | stator screw threads Coating with 30 1.0mm rz 04 nl Fort CRF seneor mowing He has Coating wath 451.0 mm (ere b04 nl rom tp Countrshat bearing sot plate screw threads Coating witn'3.51.0 mm [_Soumirshe - (Gia 04 inl om to Shift drum beering set plate bolt threads | Balancor shat bearing ae late bolt treads Throttle shaft screw tread Thistle postion ssnear meurtng exw thread : Ceara Dasrig x lee toi oan ROD Tonka agar | coatina wid 6 510mm (Pro Honda Hondalock 3 (0.26 + 0.04 in); except trequivaont igh Sa nm (0.02 from L _ ___| strength locking agent) tip. ian ee TG I tea sea Air cleaner housing connecting surface Cylinder head surface 1-20© © © GENERAL INFORMATION OS FRAME — LOCATION “MATERIAL ———~|~—SSSSREMARKS ‘Steering head bearing (upper and lower rolling area Ureabased multi-purpose | Apply each 3-5g Steoring head dust seal lips ‘grease with extreme Pressure (example: EXCELITE EP2 manufactured by KYODO YUSHI, Japan), Shell Stamina EP2 or equivalent Multi-purpose grease ‘Apply 36 | Wheel bearing dust seal ips Wheel bearing rolling area ‘Swingarm pivot bolt sliding surface ‘Swingarm pivot needle bearing rolling area ‘Swingarm pivot thrust bearing rolling area Apply 3.4 | ‘Swingarm pivot dust seal lips, Shock linkage needle bearing rolling area ‘Shock linkage dust seal lips ‘Shock arm side collar inside (bearing side) Rear shock absorber spherical bearing rolling area Rear shock absorber dust seal lips Brake pedal pivot bolt sliding area Gearshift pedal sliding area of pin Throttle cable slider (cable sliding area) Throttle cable end (throttle grip side) Clutch cable end adjuster inside surface _ — bolt sliding area Silicone grease er bracket pin bolt sliding area Brake caliper dust seal lips Brake caliper and brake pin boots inside surface Brake lever pivot bolt sliding surface Brake lever adjusting bolt tip Clutch lever pivot bolt sliding surface Clutch lever adjusting bolt tip Clutch cable end adjuster inner sliding surface Rear master cylinder push rod rounded surface Rear master cylinder boot fitting area Brake lever spring contact area Brake lever pivot bushing sliding surface (After 06), Brake lever push rod sliding surface (After 06) _ Drive chain slider mounting screw threads Locking agent Front fork protector bolt threads Front disc cover bolt threads Front brake caliper mounting bolt Caliper slide pins thread Brake pedal pivot bolt threads |_ Steering damper bolt (After 07) Brake caliper piston seal lips Brake caliper piston outer surface ~ DOTA brake fluid Master cylinder inner surface Master cylinder piston outer surface _ 7 _ ee Handlebar grip rubber inner surface Honda Bond A or Honda Hand Grip Cement (U.S.A a - only) - Fork cap O-rings Pro-Honda HP Fork Oil 5W Fork center bolt O-rings Fork oil seal lips Fork dust seal lips Damping adjuster O-rings Steering damper plug bolt O-ring (After 07) Steering damper rod O-ring (After ‘07) Steering damper free piston O-ring (After 07) Steering damper end cap O-ring (After ‘07) ‘Shock link nut threads and seating surfaceGENERAL INFORMATION CABLE & HARNESS ROUTING ‘04-07: CLUTCH CABLE HOT START CABLE ‘THROTTLE CABLES ENGINE STOP BUTTON WIRE Atter’07: CLUTCHCABLE HOT START CABLE THROTTLE CABLES ENGINE STOP BUTTON Wine H\ LNT T) womoncomarnsous \/ |) if] \ | /\ | / mokrenmevose J\\ \J LAy/ |) * | NJ LM | 1-22GENERAL INFORMATION CLUTCH CABLE THROTTLE CABLES: HOT START CABLE FUEL CAP BREATHER HOSE ENGINE STOP BUTTON CONNECTORS ‘04 -'07: THROTTLE CABLES STATOR 2P. CONNECTOR CKP (CRANKSHAFT. POSITION) SENSOR 2P CONNECTOR GROUND TERMINAL THROTTLE POSITION SENSOR 3P CONNECTOR RADIATOR OVERFLOW HOSE 1-23GENERAL INFORMATION ‘After ‘07: CKP (CRANKSHAFT ‘THROTTLE CABLES POSITION) SENSOR 2P CONNECTOR GROUND TERMINAL THROTTLE POSITION SENSOR 3P CONNECTOR RADIATOR ALTERNATOR2P ~~ OVERFLOW HOSE CONNECTOR 04-07: HOT START CABLE CLUTCH CABLE encine stor BUTTON CONNECTORS FRONT BRAKE HOSE 1-24After ‘07: © GENERAL INFORMATION HOT START CABLE IGNITION CONTROL MODULE CLUTCH CABLE 4P CONNECTOR ENGINE STOP <— BUTTON CONNECTORS: IGNITION CONTROL MODULE 6P CONNECTOR FRONT BRAKE HOSE AIR VENT HOSES 1-25GENERAL INFORMATION After ‘07: CRANKCASE BREATHER DRAIN HOSE 1-26 WIRE CLIP, ‘TRANSMISSION BREATHER HOSE ‘TRANSMISSION BREATHER HOSE REAR BRAKE HOSEGENERAL INFORMATION RADIATOR OVERFLOW HOSE THROTTLE CABLES THROTTLE POSITION SENSOR WIRE CRANKCASE BREATHER HOSE © “05 and ‘06: RADIATOR OVERFLOW HOSE RADIATOR HOSE THROTTLE CABLES © DIRECT IGNITION COIL © HOT START CABLE CKP SENSORISTATOR WIRE © CRANKCASE BREATHER HOSE07: RADIATOR HOSE DIRECT IGNITION COIL, HOT START GABLE CRANKCASE BREATHER HOSE After ‘07: RADIATOR HOSE DIRECT IGNITION COIL HOT START CABLE CRANKCASE BREATHER HOSE 1-28 GENERAL INFORMATION RADIATOR OVERFLOW HOSE THROTTLE CABLES RADIATOR OVERFLOW HOSE ‘THROTTLE CABLES: THROTTLE POSITION SENSOR WIREGENERAL INFORMATION ‘04-07: CRANKCASE BREATHER, DRAIN HOSE ‘TRANSMISSION BREATHER HOSE CRANKCASE / oe BREATHER HOSE ain vetrnoses cansdfeTon ovenrow Hose © awn roatclmner | CRANKCASE BREATHER DRAIN HOSE CRANKCASE < BREATHER HOSE TRANSMISSION BREATHER HOSE oe CKP SENSORSTATOR WIRE AIR VENT HOSES CARBURETOR OVERFLOW HOSE 1-29GENERAL INFORMATION OPTIONAL PARTS ENGINE Main jet Jet needle 1-30 __TEM CARBURETOR: = Standard (04) (06 and 06) con) (08) (After 08) (04) (05 end 06) (on) (08) (after 08) Optional Standard (04) _ ‘Specific flow characteristics at 176 10 14 throttle Rich General flow characteristics {at 1/16 to 1/4 throttle) [bean Standard (05) Specific flow characteristics at 1/6 to 14 throttle Fi General flow characteristics {fat 1/16 to 14 throttle) | bean "Standard (06) Specific flow character to 1/4 throttle tics at 16 Rich Gonoral flow characteristics (at 1/16 to V4 throttle) Lean #160 #172 #175 #188 #185 #150 ~ 170 (increments of 2 or 3) ‘#162 ~ 182 (increments of 2 or 3) #165 ~ 185 (increments of 2 or 3) | #178 ~ 198 {increments of 2 or 3) || #176 ~ 195 (increments of 2 or 3) CYR (02.755 mm) Jet needle number ‘| Jet (Standard series) edie number (1/2 clip position leaner than _standard series) 735 mm) NCVQ (92.745 mm} NCVR (62.755 mm} NCYP (927 NCYO (02.745 mm) NCYR (02.755 mm) (Standard needle) 765 mm) ‘NCYT (62.775 mm) NCYO (62.745 mm] ‘Jet needle number ‘Standard series) Jet needle number (1/2clip position leaner than __standard series) [CNCWN (62.725 mm NCVP (62.735 mm) NCVG (62.746 mm} NVA (92.755 mm) NGVS (92.765 mm) ‘Jet needie number (Standard series) [INH R (62.755 mm)____|_ NHGR (¢2.765 mm) 'NHFS (o2.765 mm) NAGS (62.765 mm) TC NAGT 775 mim) | NHGU (02.785 mm)_ Explanation of the jet needle numbers (Example)Le © © ‘CARBURETOR: TEM ‘Standard ('07) Specific flow characteristics at 16 10 1/4 throttle Rich General flow characteristics (at 1/16 to 1/4 throttle) Lean ‘Standard (08) Specific flow characteristics at 1/6 to 1/4 throttle Rich General flow characteristics (at 1/16 to 1/4 throttle) Lean GENERAL INFORMATION REMARKS NNKBT (¢2.775 mm) Jet needle number (Standard series) NKBR (62.755 mm) NKBS (02.765 mm) NKBT (62.775 mm) (Standard needle) NKBU (02.785 mm) NKBY (¢2.795 mm) NMGU (02.785 mm) Jet needle number {Standard series) NMGS (62.765 mm) NMGT (02.775 mm) NMGU (02.785 mm} (Standard needle) NMGV (62.795 mm) NMGW (62.805 mm) Jet needle number (1/2 clip position leaner than standard series) NKUR (02.756 mm] NKUS (62.765 mm] NKUT (92.775 mm) NKUU (62.785 mm) NKUY (02.735 mm) Jet needle number (1/2 clip position leaner than standard series) NMUS (02.765 mm) NMUT (92.775 mm) NMUU (62.785 mm) NMUV (92.795 mm) NMUW (62.805 mm) Standard (After 8) NSU (02.785 mm) Specific flow characteristics at 116 to 14 throttle Rich General flow characteristics (at 1/16 to 1/4 throttle) Lean Jet needle clip standard position Slow jet (0a) (after 04) Standard (04 and ‘o6) ((05 and After 08) Optional (04 and ’06) (05 and After 06] ‘Ace. pump bypass jet Stendard (04,05) (08) (After 06) Optional 08) (after 06) Jet needle number (Standard series) NNSS (62.765 mm) NNST (02.775 mm) NNSU (62.785 mm) (Standard needle) NNSV (92.795 mm) NNSW (62.805 mm) Explanation of the jet needle numbers (Example) 4th groove 3rd groove #40 #42 #35 ~ 45 (increments of 2 or 3) #38 — 48 (increments of 2 or 3) #70 #55 #70 #40 — #50 (increments of 6) #60 - #80 (increments of 6) Jet needle number (W2clip position leaner than standard series) NNWS (62.765 mm) NNWT (62.775 mm) NNWU (2.785 mm) NNW (92.785 mm} NNWW (62.805 mm) 1-31GENERAL INFORMATION FRAME Tem MAINTENANCE: Work stand Pin spanner DRIVE CHAIN & SPROCKET: Driven sprocket /chain link Standard Optional HANDLEBAR LOWER HOLDER: Standard Optional 20 INCH FRONT WHEEL (04, 05): Front wheel sub assembly = Rim (20 x 1.85) = Spoke (226.5 mm) = Distance = Wheel b = Dust seal Rim lock (1.85), Tire (Dunlop D739A 90/100-20) Tire flap Tire tube Front wheel assembly, (page 13-13) ‘+ Brake disc, disc bolts and side collars using the original parts. Inthe top surface of the top bridge with the line in the outer tube. REMARKS For maintenance Pin spanner Ax 2 For shock absorber spring installed length (preload) adjustment (two required) 51T (Aluminum)/114 507 (Aluminumy/114 527 (Aluminumy/114 3mm offset no offset 1-32~ FORK (04 Spring — TEM a7 TRE - SPRING RATE Light 422 Nimm i (0.43 kgtimm) O i 9 scribe marks ‘Standard 7457 Nim . (0:48 kgtmm aN CY WZ 1 scribe mark (after market parts) GENERAL INFORMATION REMARKS OIL CAPACITY 04: Standard 376 cm’ (12.7 US oz, 13.2 Imp 02) Maximum 413 cm? (14.0 US oz, 145 Imp 02) Minimum 317 em? (10.7 US or, 11.2 Imp o2) ae Standard 368 cm? (12.4 US oz, 13.0 Imp 02) Maximum 414 cm? (140 US oz, 146 Imp 02) Minimum 318 om? (10.8 US oz, 11.2 Imp 02) "06: Standard 366 cm? (12.4 US oz, 12.9 Imp 02) Maximum 410 em? (13.9 US 02, 144 Imp o2) Minimum 314m? (10.6 US oz, "07: Standard 369 cm? (12.8 US oz, 13.0 Imp oz) Maximum 410 cm? (13.9 US 02, 14.4 Imp 02) Minimum 314 cm" (10.6 US oz, 11.1 Imp 02) "04: Standard 379 cm? (12.8 US 02, 13.3 Imp 02) Maximum 416 om (14.1 US 02, 14.6 Imp 02) Minimum 320 cm? (10.8 US oz, 11.3 Imp 02) "08: Standard 371 cm? (12.5 US oz, 13.1 Imp 02) Maximum 417 cm? (14.1 US 02, 14.7 Imp 02) Minimum 321 cm? (10.9 US oz, 11.3 Imp 02) "06: Standerd 369 cm? (12.6 US oz, 13.0 Imp oz) Maximum 413 cm? (14.0 US 02, 14.5 Imp 02) Miniemum 317 cm? (10.7 US oz, 11.2 Imp 02) ‘07 Standard 372 em? (12.6 US oz, 13.1 Imp 02) Maximum 413 cm® (14.0 US oz, 14.5 Imp 02) Minimum 317.cm? (10.7 US oz, 11.2 Imp o2) mp 02) 1-33GENERAL INFORMATION TEM — a Heavy 461 Nim (0.47 kgtimm) yy a } aL 1 scribe mark and 3 seribe marks 75 degrees apart ‘SPRING RATE Light 4.31 Nmm — (0.44 kgfimm) O 4 scribe marks ‘Standard 4.51 Nimm (0.46 kgtimm) O 5 scribe mark (after market parts) REMARKS ne Standard 419 cm? (14.2 US 02, 14.7 Imp o2) » Maximum | 382 cm’ {12.9 US oz, 13.4 Imp oz) Minimum | 323 om! (10.9 US oz, 11.4 Imp 02) 05: Standard 374 om’ (12.6 US oz, 13.2 Imp oz) Maximum Oo 420 em? (14.2 US oz, 14.8 Imp 02) Minimum 324.¢m® (11.0 US oz, 11.4 Imp 0 Tr St $ewttaousce sim | @ vos 416 cm’ (14.1 US oz, 14.6 Imp oz) ts US 07, 11.3 Imp oz) Standard 375 cm? (12.7 US oz, 13.2 Imp 02) Maximum’ 416 cm (14.1 US oz, 14.6 Imp oz) Minimum 320 om” (10.8 US oz, 11.3 Imp oz) iL caPaciTY a Standora fsemP(140US oz 145impo) Maximum 21 em? (142 US ot, 148 Imp o2) Minimum 325 em’ (11.0 US oz, 11.41mpoz)__| ater 08 Standard 379 em (12.6 US o7, 13.1 Imp 02) Maximum 419 cm? (14.2 US 07, 14.7 Imp oz) Minimum 323 cm* (10.9 US oz, 11.4 Imp oz) “08 Standora 408 cm? (13.8 US oz, 14.4 Imp oz) a e NG cm’ (14.1 US 07, 146 mp2) Minimurn 320 cm? (10.8 US oz, 11.3 Imp oz) cater'0g Standard 368 cm’ (12.4 US oz, 13.0 Imp oz) Minor e 414 cm? (14.0 US 02, 14.6 Imp oz) Minimum _318 cm’ (10.8 US oz, 11.2 Imp o2) 1-34‘SHOCK ABSORBER (04 - ‘08 model A, CM type): Spring ‘SHOCK ABSORBER (After 08 and 08 modal IA, NOM type): Spring 3 scribe marks Tem TYPE Light Standard Heavy TYPE Light ‘Standard Heavy 471 Nimm (0.48 kgtimm) SPRING RATE 50.0 Nimm (6.1 kgfimm) 52.0 Nim (6.3 kgfimm) 53.9.Nimm (6.5 kgtimm) 55.9 Nimm (6.7 kgfimm) SPRING RATE 50.0 Nimm (5.1 kgtimm) 52.0 Nimm (6.3 kgtimm) 9 Nimm (5.5 kgfimm) GENERAL INFORMATION REMARKS "08: Standard 402 em" (1.6 US 02, 14.2 Imp 02) Maximum 410 em? (13.9 US oz, 144 Imp 02) Minienum 31d em? (10.6 US 02, 11.1 imp 02) ‘Aer "08: Standard 382 em? (12.2 US oz, 12.7 Imp o2) Maximum 408 cm* (13.8 US 02, 14.4 Imp 02) Minimum 313 em? (10.6 US oz, 1.0 Imp oz) REMARKS IDENTIFICATION MARK White paint Blue paint Red paint Pink paint IDENTIFICATION MARK White paint Blue pain Red paint The standard fork and shock springs mounted on the motoreycle when it leaves the factory are not marked. Before replacing the springs, be sure to mark them so they can be distinguished from other optional springs. 1-352. TECHNICAL FEATURE 7 © = Se HPD (Honda Progressive Btearing Damper/ ( Atter ‘07) 2-1TECHNICAL FEATURE HPSD (Honda Progressive Steering Damper/After ‘07) ‘The steering damper is installed on the steering head pipe and the bottom bridge. HPSD utilizes the angle change of the bottom Bridge relative to the steering head pipe to compress or extend the damper rod. Th 1 steering damper can be serviced, however the damper rod/piston is not serviceable, Each component of HPSD functions as follows: Damper rod/piston The damping force is generated by the extension or the compression of the damper rod, Adjuster piece/Plug bolt ‘The damping force can be adjusted with the adjuster piece by turning the plug bolt. The adjuster piece adjusts the damping force of both compression and extension. Turning the plug bolt clockwise will increase damping force and turning it counterclockwise will decrease damping force. Free piston/Reservoir/Spring When compressing the damper rod, damper oil moves temporarily into the reservoir. The damper oil stored in the reservoir is pushed back by the fre piston. The free piston is moved by the spring tension and damper ol pressure. Jamper case ‘There is a groove inside the damper case. Progressive damping force is controlled by the configuration of the groove within the damper case. RESERVOIR 6 ADJUSTER PIECE FREE PISTON GhOOWE eTECHNICAL FEATURE HPSD CHARACTERISTICS ‘+ The required steering torque when turning the handlebar fully (within angle 8) is greater than the required steering torque when turning the handlebar slightly (within angle A), Angle: A=B NEUTRAL POSITION Stroke: C :Low damper rod speed herd ii £5 2. ° ai . tard Full <0 — © 2-4TECHNICAL FEATURE ay :High damper rod speed =-== :Low damper rod speed (Steering angle) 2-53. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION see Bod ENGINE GUARD... wy ‘TROUBLESHOOTIN 32 NUMBER PLATE-- SEAT- 3-3 SUB-FRAME 36 SIDE COVER errsrneneennnenee 8 FUEL TANKovssnsesessetn 37 RADIATOR SHROUD --scrssesneensnnenee $e EXHAUST SYSTEM eveeees 3-9 wv wv ww 3-1FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL «Thiet oversold intalsion of eka al nk an exhaust tom ) + Sutuirurary rent fue btu aysum nee skSana ca tte amore ts romovad or sec 1 Site gett etn pe gas arterials ease eso he oo «Ait apc nox trae ser ratlaton TORQUE VALUES Seat mounting bt 20Nim (27 kot, 19 16H) oe Subtramemeuntngbok (upped) SOM Koes 321) joel eee esti io fant 2 htm tote, a6 ioe eso ame ee sama tosses Lines eee Eineat recipe ourtng bier ‘05) JN a ates abe) Exnuet pene band ok tera) EN te 1 Ray pro eoberrneey diem Gan arene sees toner iatoe ey Ston!mocring bo ual tnksise) gam ostgira ae eed Mudguard mounting screw: 1.1. Nem (0.1 kgfm, 0.8 Ibf-ft), TROUBLESHOOTING Excessive exhaust noise * Broken exhaust system + Exhaust gas leak Poor performance + Dforned ereust estar eo 5 mele mae