@ HONDA MOTOR CO, {TD. 1989INTRODUCTION ‘This service manual describes the service procedures for the CB400F This Model Specific Manual includes every service pro- cedure that is of 2 specific nature to this particular model. Basic service procedures that are common to other Honda Motoreycles/Motor Scooters Common Service Manual. This Model Specific Service Manual should be used together with the Common Service Manuatin order to provide complete service information fn all aspects of this motorcycle. Follow the Maintenance Schedule (Section 3) recom: ‘mendations to ensure that the vehicle is in peak operst ing condition and the emission levels are within the standards set by the U.S. Environmental Protection Agoncy and the California Air Resources Board. Performing the first scheduled meintenance is very im- nt. It compensates for the initial wear that occurs 19 the break-in period. ou ‘Section 1 and 3 apply to the whole motorcycle, section 2 ilustretes procedures for removal/inetallation of com- ponents that may be required to perform sorvice de: scribed in the following sections. While section 4 through 18 describe parts of the motor cycle, grouped according to locations. Find the saction you went on this page, then turn to the table of contents on the first page of the section. Most sections describe the service procedure through @ system illustration. Refer to the next page for details on how to use this manual. I you don’t know the source of the trouble, go to see- tion 19, TROUBLESHOOTING. ALL INFORMATION, ILLUSTRATIONS, DIREC. TIONS AND SPECIFICATIONS INCLUDED IN ‘THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING, HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATEVER. NO PART OF THIS PUBLI- CATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRIT- TEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES OR MOTOR SCOOT- ERS. CONTENTS GENERAL INFORMATION Ez FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE | LUBRICATION EZ ” " COOLING SYSTEM El "FUEL SYSTEM Ea ENGINE REMOVAL/INSTALLATION Ea CYLINDER HEAD/CYLINDER/PISTON Ez CLUTCH/GEARSHIFT LINKAGE Ex ” CRANKSHAFT/TRANSMISSION E 10 | FRONT WHEEL/SUSPENSION/STEERING E I | REAR WHEELISUSPENSION E Ea BRAKES Ez | CHARGING SYSTEM/ALTERNATOR a IGNITION SYSTEM a E Ea ELECTRIC STARTER/STARTER CLUTCH E I oe “ucHrsmerersswircies AE WIRING DIAGRAM Ea ‘TROUBLESHOOTING [19 i INDEX ENGINE AND DRIVE TRAIN CHASSIS. ELECTRICAL Date of Issue: August, 1989 © HONDA MOTOR CO., LTD.HOW TO USE THIS MANUAL FINDING INFORMATION YOU NEED ‘+ This manual is divided into sections which cover each of the major components of the motorcycle To quickly find the section you are interested in, the first page of each section is marked with a black tab that lines Lup with one of the thumb index tabs before this page. ‘The first page of each section lists the table of contents within the section, ead the service information and troubleshooting related to the section before you begin working, ‘+ An index of the entire book is provided in the last chapter 10 directly locate the information you need. (NOTE ON THE EXPLANATION METHOD OF THIS MANUAL +The removal and installation of parts are for the most parti reader with visual aid in understanding the major polnt for servicing. + The system illustrations are augmented by callouts whose numbers or letters indicate the order in which the parts should bbe removed or installed + The soquence of steps represented numerically are dif reader that they must perform these steps seperately. For example, if the steps prior and up to camshaft removal are performed with the engine installed, but the subsequent steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders. + The illustrations may contein symbol marks to indicate necessary service procedures and precautions that need to be ‘akon. Refer to tho next page for the meaning of each symbol merk. + Also in the illustration is a chart that ists information such as the order in which the partis removedtinstalled, the name of ‘the part, and some extra notes that may be needed. + Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces- ‘sary or llustrations alone would not suffice. + Service procedures required before or after the procedure described on that particular page, or inspection/adjustment pro- ‘cedures required following the installation of parts, are described under the ttle Requisite Service. + Standard workshop procedures and knowledge covered in the Comman Service Manual are abbreviated in this manual lustrations that should provide tho rentiated from the ones represented elphebeticelly to notify the Detailed descrintion ‘Symbol mark ‘Systm illustration of the procedure step sequonce inumerale or alphabets) name Number of Extra notes or precaution felated to the service proced:Symbols ‘The symbols used throughout this rranual show specitic service procedures. If supplementary information is raquired pertain- ing to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the part(s) with new one(s) before assembly ge Use epee Use optional tool. These tools are abtainad as you order parts. Torque specification. 10 Nem (1.0 kam, 7.2 fttb) Use recommendad engine oil, uniass otherwise specifieg Use molybdenum ail solution (mixture of the engine oll and molybdenum grease with the ratio 1 : 11, Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) ‘Use molybdenum disuli ‘grease (containing more than 3% molybdenum disulfide, NLGI #2 or ‘Multi-purpose M-2 manufactured by Mitsubishi Oil Japan Use moivbdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) Example: Molykote* G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 45 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Paste manufactured by Sumico Lubricant, Japan Use silicone grease | 7 A =m ie Sa _— Apply @ locking agent. Use the agent of the middie strength, unless otherwise specified. SED Apply seatane Se a ee Sse Fork oF Suspension Fi1. GENERAL INFORMATION GENERAL SAFETY 1-1 LUBRICATION AND SEAL POINTS: 1-18 MODEL IDENTIFICATION 1-3 CABLE AND HARNESS ROUTING 119 SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS 1-25 TORQUE VALUES 1-14 EMISSION CONTROL INFORMATION Tools 1-16 LABELS (U.S.A. Only) 1-28 GENERAL SAFETY Carbon Monoxide Used Engine Transmission Of must be running to do some work, make sure 8 well vetlated. Never tun the engine nar er a closed ares. * Used engine oll (or transmission oil in two-stokes) | + The exhaust contains polsonous carbon monoxide ‘gas that can cause loss of consciousness and may lead to death Run the engine in en open ares or with an exhaust evacua: tion system in an enclosed are Gasoline Work in a well vontileted area. Keep cigerettes, flames or sparks away from the work area or where gasoline is stored. + Gasoline is extremely flammable and is explosive ‘under certain conditions. KEEP OUT OF REACH OF ‘CHILDREN. ‘+ Engine and exhaust system parte become very hot ‘and remain hot for some time aftor the engine is run. ‘Wear insulated gloves or wait until the engine and ‘exhaust system have cooled before handling these parts. may causa skin cancer if repeatedly lett in contact ‘with the skin for profonged periods. Although this is unlikely unless you handle used oll on a daily basis, it ts stil advisable to thoroughly wash your hands with ‘soep and water as soon as possible after handling used oll. KEEP OUT OF REACH OF CHILDREN. Brake Dust lever use an aic hose or dry brush to clean brake assemb- lies, Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers, Broke Fluid CAUTION + Spilling fluid on painted, plastic or rubber parts will damage them. Place a clean shop towel over these arts whenever the system is serviced. KEEP OUT ‘OF REACH OF CHILOREN. 1-1GENERAL INFORMATION Coolant Under some conditions, the ethylene glyco! in engine cool ant is combustible and its flame is not visible. lf the ethyl 12 glycol does ignite, you will not see any flame, but you can be burned, Wl * Avoid spilling engine coolant on the exhaust system | or engine parts. They may be hot enough to cause | the coolant to ignite and burn without a visible | flame, + Coolant {ethyione glyco!) can cause some skin ierita tion and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN. + Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. + Koop hands and clothing away from the cooling fan, 2s it starts automatically. If it contacts your skin, wash the affected areas immedi- ately with soap and water. It it contacts your eyes, flush them thoroughly with fresh water and get immediate medi- attention. If it is swallowed, the vietim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical attention, Because of these dan- gers, always store coolant in 2 safe place, away from the teach of children, Nitrogen Pressure For shock absorbers with a gas-filed reservoir sion resulting in serious injury. + Tho shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock ab- sorbor could lead to an explosion that could result in serious injury. + Failure to reloase the pressure from a shock absorber bofore disposing of it may lead to a possible oxplo: sion and serious injury if it is heated or pierced. To prevent the possibility ef an explosion, release the ni- trogen by pressing the valve core. Then remove the valve stem from the shock sbsotber reservoir. Dispose of the oil in-@ manner acceptable to the Environmental Protection Agency (EPAY. Before disposal of the shack absorber, release the nitrogen by pressing the valve core. Then remove the valve stem {ram the shock absorber. Battery Hydrogen Gas & Electrolyte ‘The battery gives off explosive gases: keep sparks, flames and cigarettes away, Provide adequate venti: lation when charging + The battery contains sulfuric acid (electrolyte). Con- tact with skin or eyes may cause sovere bums. Wet protective clothing and a face shield = If electrolyte gets on your skin, flush with water = If electrolyte gets in your eyes. flush with wat {or at least 15 minutes and call a physician, | + Electrolyte is poisonous, | =f swallowed, drink large quantities of water or milk and follow with milk of magnesia or vagata- bile oil and call a physician. KEEP OUT OF REACH (OF CHILDREN. 1-2MODEL IDENTIFICATION GENERAL INFORMATION ‘The {rame serial number is stamped on the right side of the steering head. “The engine serial number is stamped on the tight side of the crankcase. The Vehicle Identification Number (VIN) is located on tho satety cortification label on the right side of the frame tube. (4) CARBURETOR IDENTIFICATION \ a A | ‘The carburator identification number is on the rear side of ‘each carburetor, The color code label ig attachad on the lft frame tube tunder tho seat. When ordering a color coded part, always spocity its designated color code,GENERAL INFORMATION SPECIFICATIONS Displacement Compression ratio Valve train Intake valve opens at 1 mm litt Intake valve close at 1 mm litt Exhaust valve opene at 1 mm litt Exhaust valve close at 1 mm litt Lubrication system il pump type Coofing system Air fitration Crankshott type Engine wei Firing order Cylinder [General rem ‘SPECIFICATIONS DIMENTIONS | Overall length 2,035 mm (80.1 in) ‘Overall width 705 mm (27.8 in) ‘Overall height 1,025 mm (40.4 in} Whes! base 1.370 mm (53.9 in} Seat height 775 mo (30.5 in) Foot pag height 335 mm (13.2 in) Ground clearance 130 mm (5.1 in) Dry weight 170 kg (375 lbs) Curb weight 183 kg (403 Ibs) Maximum weight capacity 157 kg (247 Ibs) FRAME Frome type Diamond Front suspension Telescopic fork Front wheel travel 130 mm (5.1 in) Rear suspension Swingarm Rear wheel travel 110 mm (4.3 in) Rear damper Gos-flled damper Front te size 110/70—17 5H Rear tire sia 140/70—17 66H ‘Tire brand (Bridgestone) FrontRear | G547/G548 Tire brand (Dunlop) Front/Rear KSOSF/KE05 Tire brand {Yokohama} Front/Rear | — Tire brand (IRC) Front/Rear Front brake Hydraulic diee brake Rear brake Hydraulic dise brake Caster angle 25°30" Taail length 99 mm (3.9 in) Fusl tank capacity 11.5 lit (3.04 US gal, 2.53 Imp gal) Fuel tank reserve capacity 3.5 lit (0.92 US gal, 0.77 Imp gall ENGINE Bore and stroke 56.0 x 42.0 mm (2.17 x 1.65 in) 999 om? (24.3 cu in) 16:1 Gear driven DOHC, 4 valves per cylinder 5° ATOC 33° ABDC. 33° BBDC, 38° BBDC (California) 5° BTDG, 10° BTDC (California) Forced pressure and wet sump Trochoid-type Liquid cooling system with cooling fan Paper fit Unit-type, 6 main journals 57 kg (126 Ibs) 12-43 Vertical 30° Jo line fourGENERAL INFORMATION [General (Cont'd) irem SPECIFICATIONS. CARBURETOR | Carburetor type | veos Throttle bore 32.5 mm (1.28 in) DRIVE TRAIN | Clutch system Wer, mut ‘Clusch operation system Mechanical type Tranamission speed constant-mesh Primary reduction 2.181 (36/44) Secondary reduction — Third reduction — Final reduction 2.733 (41/15) Geer ratio 1st 3.307 (43/13) | Gear ratio 2nd 2.352 (40117), Goor ratio 3rd 1,876 (30/16) Goar ratio 4th 1,590 (36/22) Gear ratio 5th 1.434 (33/23) 1,393 (32/24) Left foot operated return system 1—N—2~-3~4—-5~6 Gearshift pattem ELECTRICAL | Ignition system Full transistor ignition Starting system Starter motor Charging system Triple phase output alternator Regulator/rectifier type SCA shorted/trile phase full- wave rectification Lighting system Bottery AC regulator type ie 1-5GENERAL INFORMATION Unit: mm sin) [= Lubrication a tom Standard Sorvice limit Engine oil capacity at draining 2.9 t (9.06 US at, 2.55 Imp at) — ‘at disassembly 3.5 € (3.70 US gt, 3.08 Imp at) — ‘at oll filter change | 8.11 19:28 US at, 2.73 imp ad oe Recommended engine ail HONDA 4-stroke oil or equivalent, ~ OU VISCOSITES. APL service classification SF or SG SENS { tcl | The viscosities shown in the chart may SE bbe used when the average temperature in your siding area is within the indicated range. O35 406080 Too oF <2 686 tO | Oit pressure et oil pressure switch | 490 kPa (8 kg’em?, 71 psih — il pump roter tip clearance (?) 0.10 (0.004) 0.18 10.008) body clearance @ 0.15~0.22 (0,006—0.008) 0.36 10.014), end clearance 0.02-0.07 {0.001 0.003) 0.10 10.008), Pilot screw high altitude adjustment Air screw initial opening (California) Air screw high altitude adjustment Float level Carburetor vacuum difference Base carburetor (For carburator synchronization) Idle speed (California) Choke type Throttle grip free play Accelarator pump clearance Secondary air supply system Ar injection control valve vacuum pressure 41/2 turn in from initial opening 6.0 10.24) Within 30 mmHg (1.2 ing) No. 2 carourotor 1,300 = 100 rpm 1,400 = 100 rom Manual by starter 2-6 (0.08-0.24) Reed valves are built into the ASV 380 mmHg (14.2 inHg) [—_ Fucl system - 1 Carburetor identification number vcos — (California) veoec — Main iet #105 os (High altitude) — — (2,3) — — 4 =~ — (Front) — — Rear) — — ‘Stow jot #38 — Jet needle clip position = — Pilot serew initia opening ‘See page 6-13, =GENERAL INFORMATION Rocker arm ID. IN EX Rocker arm shaft 0.0. IN Rocker arm-to-racl Valve lifter 0.0. Valve lifter bore 1.0. Hydraulic lash adjuster assist spring free length Hydraulic lash adjuster compression stroke with kerosene rit: mm [ vlinder nea tom Standard Service ii Cylinder compression 1280-1,820 KPa (12.8132 kglem®, | —— 182~ 188 psii400 ror Cylinder compression aiferonce Within 30 mm (1.2 inHg) of each other | — Valve clearance IN 0.12-0.18 (0.005--0.007) — (cole ex 0.17 -0.23 (0.007-0.008) |— Cylinder head warpage —_ 0.1 ©.008 Cam tobe height IN 38.070-33.230 (1.9020-1.3083) | 33.02/1.300) IN (California moda — — Ex 99.120--99.280 (1.3039-1.5102 | 33.07 (1.3029 EX (Caltomia model — — ‘Camshaft runout (2) aor | 0.05 (0,002) nce 0.020-0.082 10.0008-0.0024) 0.10 (0.008) Comshaft journal 0.0. 22.959~22.980 (0.5039-0.9047) 22.97 (0.904) Comshaft holder LD. — i Valve stem 0.0. 1N 3.775~3.790 10.1486-0.1492) | 3.70 (0.148) ex 3.755—3.770 10 1478-0.1484) 3.69 (0.145) Valve guide 10. 1N 31800 3.812 10.1496 0.1253) | 3.89 (0.183) 3.600-3.812 (0 1498-0.1253) "3.89 (0.183) = 0.04 (0.002) — 0.05 10.002) | Valve guide projection above eviner head (IN 19.7-19.77 10.526-0.542) me ex 11152-1182 (0.454-0.468) [1 F_ Betore guide instaation | fp Chit te valve guides inte fer 1 LS, er section af a relrigerator for a Y about an hour, 1 (7/2. Hoat the cylinder head t6 j 130°C—-140°C (278°F--290°F) Valve coat wieth 0.9-1.1 0.035~0.083) | 1510.08) Valve sping free length IN 39.40 (1.551) 38.6 (1-52) &x 39.40 (1.581) 38.6 (1.52) inner IN — — inner EX _ = outer IN _ — outer EX — aGENERAL INFORMATION —eeeeaoaoaoaououaoaou— SSS F erinten tm sented sere Share as Siw oe te = 338 i 096 00m TEL G1 fume UU a in en oe Sioras os : ° : =GENERAL INFORMATION Unit: mm find j- Transmission thom Standerd | Service timit Transmission gear |.D. M5. 25,000-25.021 (0.9843-0.9851) | 25.05 (0.986) Me 25.000-25.021 (0.9843-0.9851) 25.08 (0.986) cz 28.000-28.021 (1.1024~1.1032) 28.08 (1.104) 3 28,000~28.021 (1.1024 1.1032) 28.05 (1.104) ca 28.000-28.021 (1,1024—1.1032) 28.05 (1.104) ‘Transmission gear bushing 0.0. MB 24.959 -24.980 (0.9826-0.9835) | 24:92 10.981) Me 24,959-24.980 (0,9826-0.9835) 24.92 (0.981) ce 27.959—27.980 (1.1007— 1.1016) 27.92 (1.099) 3 27.988 —27.980 (1.1007 1.1016) 27.92 (1.099) ca 27.959 27.980 (1.1007— 1.1016) 27.92 (1.098) ‘Transmission gear busing |.D. MS 21,985—22.006 (0.8655—0.8664) 22.07 (0.869) c2 24,985 ~25.006 (0.9837—0.9845) 25.07 (0.987) Gear-to-bushing clearance at M5 gear 0,020~0.062 10.0008-0.0024) 0.10 10.004) ‘ot M6 gear (0.020-0.062 {0.0008—0.0024) 0.10 10.004) at C2 gear 0.020—0.062 {0.0008 0.0024) 0:10 (0.004) at C3 gear 0.020-0.062 {0.0008—0.0024) | 0.10 10.004) at C4 ger 0.020-0.062 (0.0008~-0.0024) 0.10 10.004) Mainshaft 0.0. at MS gear bushing @ 21.959—21.980 (0.8645—0.8654) 21.93 (0.863) at clutch outer guide @ 21.987~21.980 (0.8648 0.8654) 21.93 (0.863) ® © 24.967 24.880 (0.9830—-0.9835) | 24.93 10.981) Gear-to-shett clearance — j— Gear bushing-to-shaft clearance at M5 geer 19.020-0.062 (0.0008-0.0024) 0.10 (0.004) at C2 gear 0.005—0.039 (0.0002—0.0015) 0.06 (0,002) ‘Shift fork claw thickness L 5.93-6.00 {0.233-0.236) | 5.60 (0.220) i. 5,936.00 (0.233 -0.236) 5.60 (0.220) R 5.93~6.00 {0.233-0.236) 5.60 (0.220) Shift fork LO. L 12.000— 12.018 (0.4724 0.4731) 12.08 (0.475) c 12.000 12.018 {0.4724—0.4731) 12.08 (0.478) R 12,000-12.018 (0.47240.4731) | 12,06 10.475 Shift fork shaft 0.0. 11,969— 11.980 10.4712—0.4717) {11.90 (0.489)GENERAL INFORMATION Contritugal clutch drum 1.0. bushing 0.0. Centrifugal olutch center guide I.D. 0.0. Centrifugal clutch center guide collar height Centrifugal clutch waight lining thickness Centrifugal clutch spring free length Clutch fining thickness Crankshaft 0.D. at clutch center Unit: mm (int [= Clutch system tem Standard Service limit Clutch lever free play 10-20 (0.40.8) — Recommended cluteh fluid — — Clutch master cylinder 1.0, — a Clutch master piston 0.0. ae as Clutch outer 1. 37.008~-37.030 (1,4569— 1.4578) 37.08 (1.460) Clutch outer guide 0.0. 29,984—30.007 (1,1809—1.1814) 29,95 (1.179) Lo. 21,980~22.007 (0.8654~0.8664) 22.08 (0.868) Mainshaft 0.0. at clutch outer guide 21.967 ~ 21.980 (0.8648-0.8654) 21.93 (0.863 il pump drive sprocket ID. 30,025~30.075 (1,1821—1.1841) 30,13 (1.186) Clutch spring free height — — Clutch spring free length 37.5 (1.48) 36.0 (1.42) Clutch disc thickness 3.22-3,38 (0,127-0.133) 2.9 10.11) 8 3.22-3.38 (0.127-0.133) 2.9 (0.11) c 3.42—3.58 (0.135-0.141) 3.1 10.12) Clutch plate warpage: — 0:3 10.01) = Cooling system Coolant capacity (Radiator and engine) (Reserve tank) Radiator cap rellaf pressure ‘Thermostat begins to open ‘Thermostat fully open Therenostat valve litt 1.8 £ (0.40 US gal, 0.33 Imp gal) 0.3 £ (0.08 US gal, 0.07 imp gal) 93-123 kPa (0,951.25 kglom?, 1418 psid 80-84°C (176—183°F) 95°C (203°F) 8.0 (0.315) min r_ Drivetrain Recommended final drive oil Final drive gear oil capacity at disassembly ‘at draining Final drive gear backlash Ring gear-to-stop pin clearance (A) ‘Stop pin shim ing gear spacer Pinion spacer ‘Output gear backlash ‘Output gear |.D. ‘Output gear bushing 0.0. ho. ‘Output drive sheft 0.0. ‘Output gear damper spring free length ‘Output shaft adjustment shim Countershaft drive shaft adjustment shim 1-10GENERAL INFORMATION Unit: men tind [— Wheels/tires tom Standard Service limit ‘Minimum tre tread depth (FR) 1.5 (0.06) (RR) -— 2,0 (0.08) Cold tire pressure Up to 90kg {200Ib) load (FA) 225 kPa (2.26 kg/cm, 33 psi} oe Up to 80kg (2001b) load (RA) 225 kPa (2.25 kg/omé, 33 psi} = Up to maximum weight capacity (FR) | 225 kPa (2.25 kgiom?, 33 psi) _ Up to maximum weight capacity (RR) | 250 kPa (2.50 kgicr?, 36 psi) — Front and rear axle runout — 0.2 (0.011 Front and rear wheel rim runout (Radial) _ 2.0 (0.08) (axial —_ 2.0 (0.08) Front whee! hub-to-rim distance — — Front wheel hub standard surface — — Rear wheel hub-to-rim distance — an Floar wheel hub standard surface — — Wheel balance weight Front/Rear — 60 g (2.1 02) Drive chain slack {on the lower chain run} 15—25 (5/81) — Drive chain size/link (DID) oiDs26var104 a (Re) RK25SMa/104 = — Front suspension —— Fork spring free length 324.5 (12.78) 318 (12.5) Fork spring free length & 8 Fork spring direction With tightly wound coll end facing down | — Fork tube runout 0.2 10.01) Recommended fork oll Fork Fluid — Fork oil level 9513.7) Fork oll level (R) a wu |- Fork oil capacity 810 cc (17.2 US o7, 17.9 Imp o2) a Fork oil capacity (R) — 1.0-1.6 ka ae [Rear suspension ‘Shock absorber spring free length 178.0 (7.01) 1746.9) Shock absorber spring tree length (Al — 8 —_ Domper gas pressure — Damper compressed gas —_ | Damper rod compressed force at 10 mm (0.4 in} compressed —_— Damper driling point | f 20mm (0.8 im | Shock absorber spring installed length (Standard) ‘Adjuster position it — (Adjustable range) | Position VII - Shock absorbar spring diraction With the taper end facing to adjuster — Recommended shock absorber ol! ‘Shock absorber oil capacity pressure — | 1-11GENERAL INFORMATION — Brakes: Unit: ene find Standard Service limit Front brake fluld brake lever free play bbrake pad wear indicstor itl brake disc thickness: brake dise runout ‘mester cylinder .D. ‘master piston 0.0. caliper cylinder 1.0. Caliper cylinder 1.0.{Upper) (Lowen) caliper piston 0.0. caliper piston O:D.(Upper (Lower) brake drum ILD, bbreke lining thickness. Reor brake fluid brake pedal height brake pedal free play brake pad wear indicator i Ai! brake disc thickness ‘master cylinder 1.0. ‘master piston 0.0, ‘caliper cylinder 1.0. caliper piston 0.0. broke drum 1,0. brake lining thickness ota 5.8-6.0 10,220.24) 11,000—11.043 (0.4331—0.4348) 10.957—10.984 (0.4314~0.4324) 27.000~27-080 (1.0830—1,0850) 26.918-26.968 {1.0598— 1.0617) 4.8 -5.2 (0.18-0.20) 14.000— 14.043 10.5512—0.5529) 13.957 ~ 13.984 (0.5495 0.5506) 38.180~38.230 (1.6031 —1.5051) 38,098-38.148 (1.4999— 1.5019) to the groove 5.0 (0.20) 0.4 10.02) 11.08 (0.438) 10.95 (0.431) 27.08 (1.065) 26,91 (1.059) to the step ® 4.0 10.18) 0.4 (0.02) 14,08 (0.554) 13.98 (0.549) 38.24 (1.506) 38.09 (1.500) [—_ Battery/charging system Alternator charging coil resistance (At 20°C/68°F) Regulator/rectifier regulated voltage/amperage Battery capacity Battery specific gravity (Fully charging) (Needs charging) Battery charging rate (Normal (Quick) Battery voltage (Fully charged 20°C/6°F) (Needs charging 20°C/68°F) Alternator lighting coil resistance (At 20°C/68°F}) ‘AC regulator regulated voltage (With analogue type) [With digital type! 0.10.50 14.0-16.0 V/0--8 A at 5,000 rpm 12V-8 AH 0.8 A (5~10 hours) 4A (1 hourh Over 12.8 V Below 12.5 V =. Starting eystom Starter driven gear 0.D. Starter clutch outer 1.0. Starter motor brush spring tension brush length 42.175—42.200 (1.6804— 1.6614) 920 + 140 g (82.4 = 4.9 02) 12,5 (0.49) 42.12 (1.658) 8.5 10.33) ea 1-12GENERAL INFORMATION Unit: mm fin) [— Hanition system tam Standard Service limit Spark plug (Standard NGK) CREEH-S — (Standard ND) U2aFERS — {For cold climate/below 5°C/41°F NGK) — — For cold climate/below 5°C/41°F ND) — _— (For extended high speed riding NGK! cRoEH.S — (For extended high speed riding ND) U27FERS _ Spark plug gap 0.8-0.9 (0.031-0.035) — Ignition timing ““F”*mark 16° BTOC at idle — Advance start 1,700 rpm —_ stop —_ oe Full advance — — Alternator exciter coil resistance (At 20°C/68°F) — — Ignition coil rasistance (Primary: at 20°C/68°F) 2-40 —_ {Secondary with plug cap) 23-27 ka. — (Secondary without plug wire) | 13-17 kD —_ Pulse generator resistance (At 20°C/68°F) 340-420 0 = [= Lights/meters/switches Main tuse 304 Fuse 1OAx4 == Headlight (high/low beam) 12 V 60155 W — Tailbrakelight 12.v 3/32 CP — License light — —_ Position light bulb — — Front turn signel/runing light — — Front turn sigaal light 12V 32. CP x2 — Rear turn signal light 12V 32. CP x2 — Instrument lights 12VIIWS il proscure warning indicator 12vi7W Tailrakelight warning indicator ae Side stand indicator 2vi7W Low fuel indicator — Coolant temperature indicator Oil temperature indicator : High beam indicator 2vi2W Turn signal indicator viaWw Neutral indicator 12v1.7W Reverse indicator ‘Overdrive indicator Oil temperature sensor resistance Fuel unit resistance (at full level) (at low level) Fuel pump flow capacity (min./minute) Coolant temperature sensor resistence 80°C (176°F) 120°C (248°F) Starts to close (ON) Stops to open (OFF) Fan motor switch 660 cc (22.3 US oz, 23.2 Imp oz\ min, 47-570 14-180 98—102°C (208—216°F) 93~87°C (199-207°F) HPTTEPEE EE 1-13GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES fon Torque tem Torque Nem (kgem, ft-lb) Nem (kgm, ft) '5 mm bolt and nut 510.5, 3.5) 5 mm screw T 404,38) 6 mm bolt and aut 1011.0, 7) 6 mm screw | s10.9, 7) 8 mm bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm hoad) | 90.9.7) 10 mm bolt and nut 35 (3.5, 25) 6 mm flange bolt (10 mm head) and nut 1241.2, 9) 12 mm bolt and nut, 55 (5.5, 40) & mm flange bolt and nut | 27427 20) 10 mm flange bolt and nut L__40 (4.0, 29) Torque specifications listed below are for important fasteners, Others should be tightened to standard torque values listed above. NoTES: 1. Apply a locking agent to the 2. Apply sealant to the threads. 3. Stake. threads. 4. Apply silicone grease to the sliding surface. ENGINE vay | Thread Torque ae a oy | aaimm | nem | tom | tem | emer Lubrication: il pump driven sprocket bolt 1 6 | 15 15 11 | Note Oil pressure switen 1h 12 12 3 | note2 Oil drain Boke 1 12 35 36 25 Oil fiter boss 1 20 18 18 13 Oil iter 1 20 10 10 7 Cylinder heed/eyinder piston Cylinder head cover bolt 8 6 10 10 7 Gamsheft holder bolt 168 6 12 12 8 Cylinder head cover breether plate bolt 2 6 12 12 8 | Notet Grinder head soecal nut 2 8 30 30 2 Gylinder head mounting bolt 2 6 12 12 8 | Ghrinder mounting bolt 1 6 10 10 7 Gylinder stud bott 12 8 28 26 18 Spork plop loa 10 "1 ia 8 Ciutchigearshit linkage: Crankshatt hole cap 1 30 7 07 5 Timing hole ap 1 14 tone eT 7 Clutch center lock nut 1 20 86 a5 61 | Notes Gearshift spindle return spring pin 1 8 23 23 7 Crankcase/erankshatttransmission: Connecting rod mt 8 7 24 24 7 Grankcase bolt (8 ram) 12 8 24 24 7 (8 mmx 85) 1 8 | 2 27 20 (6 mm) 19 8 12 12 9 Sealing bolt \lower crankcase) 1 20 30 3.0 22 Special bolt (ower crankcase) Jeet 14 28 28 1a | note2 Neutral switch 1 10 18 18 13 | NoTe2 Drive sprocket bolt 1 10 55 55 40 Altornstor: | Fiywheei bolt 1 10 85 85 6 Starter clutch: Starter clutch bolt 1 10 85 86 61 1-14GENERAL INFORMATION FRAME tem Frame/exhaust system: Exhaust pipe joint nut ‘Muffiar mounting bolt Side stend pivot bolt Side stand pivot lock nut Side stend switch mounting bolt Gearshift pedal joint bolt Gearshift pedal mounting bolt Footpeg stay bolt Right footpeg mounting bolt Cooling system: ‘Tempersture sensor Fan motor switch Fuel system: Fuel valve nut Fuel tank cap mounting bolt Engine mount: Engine mount nut (front) Engine mount nut {rear/upper) Engine mount nut (rear/lower) Adjusting bolt ‘Agjusting bolt lock nut Engine sub frame nut Engine bracket bolt Front: Handlebar pinch bolt Hendlebar weight screw Aale bolt ‘Axle pinch bolt Fork pinch bolt (upper) Fork pinch bolt lower! Fore cap bolt Fork socket bolt ‘Steering stem nut ‘Steering head bearing adjustment nut Ignition switch mounting bolt Re Axle nut Drivon sprocket put ‘Shock absorber mounting nut (upper) ‘Shock absorber mounting mut (lower) ‘Shock absorber lower joint lock nut ‘Swingarm pivot nut 8 Front caliper pad pin plug pad pin bracket bolt pin bolt bracket pin bolt Front master cylin Front brake dise bott Rear caliper pad pin plug pad pin ‘mounting bott pin bolt Rear master cylinder push rod joint lock nut Roar brake disc bolt 89 After ‘89 Brake hose bolt Thread ‘i (oom) 2 10 10 10 20 20 10 16 10 10 10 14 14 Torque | Nem kom | fel 12 12 9 | 22 22 16 10 10 7 27 27 20 30 3.0 22 12 1.2 9 27 27 20 27 27 20 38 38 27 10 1.0 7 18 1B 13 23 23 ” 3 03 2 40 40 29 60 5.0 36 | 0 5.0 36 13 | 15 W 65 66 a7 4 4s 3a 4 | 40 29 | 27 27 20 10 10 7 | 60 6.0 43 | 22 22 16 1 [a 8 50 5.0 36 23 23 7 20 20 14 108 108 76 25 25 18 25 25 18 20 9.0 65 65, 85 47 45 45 33 45, 45 a3 6B oe 49 110 110 80 25 | 028 18 18 138 13 27 27 20 23 23 "7 13 13 9 | 6 0.6 4 | 30 3.0 22 25 | 025 18 18 18 13 23 23 v7 23 23 7 iF fa 12 4 | 40 29 43, 43 a 35. 3 25 Remarks NoTE1 NoTE 2 NOTE 2 NOTE 1 Note 1 Nore 1 NoTe1 NOTE 1,4 NOTE 1,4 NoTE 1,4 1-15GENERAL INFORMATION TOOLS ‘The tools for the ball bearing removal and installation are not contained in this list Refer to section 1, Ball Bearing Replacement, of the Common Service Manual ‘The newly designed tools are indicated with * mark in the list Description filter wrench Vecuum gauge Oil pressure gauge Oil pressure gauge attachment Rotor holder Antifreeze tester Cooling system tester Float level gauge Vecuum pump Pressure pump "Valve guide driver (guide removal Instaltion) “Valve bucket hole protector alve spring compressor Valve spring compressor attachment “Valve guide resmer, 3.8 mm Valve seat cutter, 22 mm (45° IN, EX) Valve flat cutter, 22 mm {32° IN} Volve tlet cutter, 21.5 mm (32° EX) Valve interior cutter, 22 mm (60° IN, EX! “Cutter holder Piston ring compressor Piston base Compression gauge “Compression gauge attachment “Clutch center holder ‘Too! number ‘O7HAA—PJ70100 074040030000 075063000000 075104220100 077250040000 Commercially available 07401 0010000 ST—AH—260—MC7 ST—AH~265-MC7 07JMD—K¥20100 07JMG—KY20100 977570010000 07JME~KY20100 O7JMH-KY20100 97780-0010701 077800012601 07780—0012800 077800014202 O7JMH—KY20200 079542500000 07958~4130000 97305—0010000 O7JMJ—KY20100 07GMB—KTBO100 Alternative tool We equivalent commer. | cially available in USA. |-U.S.A. only U.S.A. only O7JMH-KY20108 (US.A. only! or equivalent commer- clally avilable in USA. 07954 2350000 |-07958-2500001 (U.S.A. only) [To eauivalent commer cially aveilable in USA. |-Not available in U.S.A. O7HGB--001000A (U.S.A. only! Ref. section(s) 14, 16 1-16GENERAL INFORMATION (Cont’a) Description “Tool number ‘Alternative tool | Ref. section(s) {Boaring remover head, 20 mm. Boaring remover shaft Driver Attachment, 42 x 47 mm, Attachment, 62 x 55 mm Pilot, 20 mm Fork seal driver Fork seal driver attachment Lock nut wrench, 30 x 32 mm Steering stem socket Ball race remover attachment driver Bearing race remover Driver Attachment, 37 x 40 mm Steering stem criver Bearing remover head, 17 mm Attachment, 24 x 26 mm Pilot, 17 mm Pilot, 22 mm ‘Shock absorber compr raw assembly ‘Shock absorber compressor attachment *Driver pin Driver shatt ‘Needle bearing remover attachment Attachment, 28 x 30 mm Attachment, 32 x 36 mm Pilot, 18 mm ‘Snap ring pliers Rotor puller Christie battery charger Battery tester Digital mutttester (KOWA) Analogue tester Torx bit (740) (07746 0080600 077460050100 07748—0010000 077460010300 077460010400 977460040800 07947 —-KA60100 07947 —KF00100 (07716 0020400 97916-3710100 (07983—MJ10000 (07983—MJ10100 (07953—MJ10200 (07946—3710600 07349-3710001 07748~0010200 (07946—MB00000 (977460060500 077460010700 (077460040400 (077460041000 (07GME—0010000 (076MeE—0010100 (07959—MB10000 07GMD—KTB0100 (07946100100 07GMD—KT70200 (07946~ 1870100, 077480010100, 07748--0040300 07914~3230001 077330020001 Me10122 BM—210 (074110020000 (073080020001 (SANWA) ‘or TH—5H (KOWA} 077030010100 7 7 Wa We q ihe 7 7 0 0 tachment (07959~ | 11 twto0o8h er | cr tersco-s7t0001) | tnd tect, Sra tom (07746 soios0o " " q | q | a | 8 | 8 G Ll acc Us| 18 O79s8e 3200008 hag Ae Ln metas tsa 1 Pane St wen areas Gosigoo) ons Dever ‘o7re0" opr0000) Nor oveue oe. | 12 Diver ores" sr10007 neuen (ie Suing rover ) (367x038 — XXXXX) 12 2 j 12 12,13 |-07e33~2160000 | 14 } U.S.A. only! } 14 | 14 KS—AHM—32—003 | 14,15, 16, | U.S.A. only) 7 14,15, 16, 7 [et equivalent commer- | 17 | aly avelabe in [Usk 1-17GENERAL INFORMATION LUBRICATION AND SEAL POINTS ENGINE Point Material Remarks + Intake and Exhaust valve stem sliding surface + Camshaft journal + Transmission gear shifter groove + Connecting rod bearing sliding surface + Connecting rod small end-piston pin sliding eurtace + Crankshaft main journal bearing sliding surface ‘Molybdenum solution (mixture fof tho engine oil and molyba ‘num disulfide grease with the ratio 1: 1) * Upper crankcase mating surface Liquid Do not apply sealant to the oil passeges and near the ‘rain journal ba pressure ewitch + Fan motor switch + Thermo sensor Neutral switch Sealant Do nat apply sealant to the ol pressure switch thread bead as shown, = Gear teeth + Shaft journals + Siding surface FRAME Point Material Remarks + Center stand pivot + Side stand pivot + Brake pedal pivot + Gearshift pedal pivot + Steering head bearings + Dust seal lips + Clutch lever pivot + Throttle cable ends + Swingarm pivot bssrings + Seat locking tab ‘Rear wheel driven flange bearing + Wheel bearings ‘Spoadometer gear Brake caliper seals + Caliper-piston sliding surface + Master cylinder piston cups + Master cyiinder-piston sliding surface + Brake caliper pivots + Brake caliper pivot boots + Rear brake master cylinder push rod head Muttipurpose grease DOT 4 Brake fhuid Silicone grease * Speedometer cable + Throttle cable + Choke cable + Clutch cable Light weight olf Handlebar grip inside surface Honda Bond A or Honde Hand Grip Cement (S.A. only) 1-18GENERAL INFORMATION CABLE AND HARNESS ROUTING (1) 6P-WHITE CONNECTOR 2) 6P-RED CONNECTOR (METER) (METER) (3) 6P-BLACK CONNECTOR (TURN SIGNAL SWITCH! 16) SP-BLACK CONNECTOR (IGNITION SwiTCH) 4} 6P-GREEN CONNECTOR (TURN SIGNAL SWITCH) (6) SP-RED CONNECTOR (STARTER SWITCH, ENGINE STOP SWITCH) (7) BRAKE HOSE (8) CLUTCH CABLE (15) THROTTLE CABLE (4 cut HANDLEBAR Tio) cHoxe caste swircn Tr | I ° L (3) FRESH AIR mt |e | (4) cahusreR : << (SI FRESH AIR =m (6) FUEL VAPOR 2) AiR VENT CONTROL VALVE (aveV) NOISE EMISSION CONTROL SYSTEM ‘TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof (1/ The removal or randaring inoporstive by any person, other than for purposes of maintenance, repair of replace- ment, of any device or element of design incorporated into any naw vohicla for the purpose of naise control prior to its sale or dolivary to the ultimste purchaser or while it isin use; or (2) the use of the vehicle atter such device or element ot design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1, Removal of, oF puncturing the muffler, baffles, header pipes or any other component which conducts exhaust 4: 2. Removal of, oF puncturing of any part of the intake system. 3. Lack of proper maintenance, 4, Replacing any maving parts of the vechile, or parts of the exhaust or intake system, with parts other than those specified by the manufactur 1-27GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. Only) ‘An Emission Information Label is located on the rear fender {5 shown, The seat must be removed to read i. It gives basic tune-up specifications. VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL Aiter making a high altitude corburetor adjustment, attach an update label on the rear fender as shown VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) ‘The Vacuum Hose Routing Diagram Label is on the reat fender as shown, The seat must be removed ta read i. Route the vscuum hoses as shown on this label 1-28 (1) EMISSION INFORMATION ai Geoate LABEL 3) VACUUM Hose ROUTING DIAGRAM LABEL (Californie model only) vacuum NOSE ROUTING TLAGSAM ve “rawicy. FRONT OF