Honda Rebel Cmx250 Manual 85-87

HONDA
e
IMPORTANT SAFEW NOTICE
indicates u strong possibih'ty of severe personal injury or loss of life if insiructions are not followed.
CAUTION: Indicates a possibility of personal injury or equipment damage if instructions are not foliowed.
NOTE: Gives helpful information.
Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is
important t o note that this manual contains some warnings and cautions against some specific service methods which
could cause PERSONAL INJURY t o service personnel or could damage a vehicle or render it unsafe. Please understand
that those warnings could not cover ail conceivable ways in which service, whether or not recommended by Honda
might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all
such ways.
Anyone using service procedures or tools, whether or not recommended by Honda must satisfy himself thoroughly
that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected.
HOW TO USE THIS MANUAL CONTENTS
Follow the Maintenance Schedule (Section3)
recommendations to ensure that the motor-
cycle is in peak operating condition and the
emission levels are within the standards set
by the U.S. Environmenatal Protection
Agency and the California Air Resources
Board. Performing the first scheduled mainte-
nance is very important. It compensates for
the initial wear that occurs during the break-in
period.
Sections 1 through 3 apply to the whole CYLINDER HEADIVALVES

motorcycle, while section 4 through 18
describe parts of the motorcycle, grouped ac-
CYLlNDERlPlSTONS
cording to location.
Find the section you want on this page, then

turn to the table of contents on page 1 of that
section. ALTERNATORISTARTER CLUTCH
Most sections start with an assembly or

system illustration, service information and
troubleshooting for the section. The subse-
quent pages give detailed procedures.
a REAR WHEELIBRAKEISUSPENSION
If you don't know the source of a problem, go
to section 19, TROUBLESHOOTING.
iO
HYDRAULIC BRAKE
All information, illustrations, directions and speci- BATTERYICHARGING SYSTEM

fications included in this publication are based an
the latest product information available at the
time of approval for printing. HONDA MOTOR
CO., LTD. reserves the right to make changes at
ii2 ELECTRIC STARTER SYSTEM
any time without notice and without incurring any +
obligation whatever. No part of the publication
may be reproduced without written permission. LIGHTSISWITCHESIHORN
W
HONDA MOTOR CO., LTD. WIRING DIAGRAM

Service Publications Office
TROUBLESHOOTING
INDEX
Date of Issue: Dec., 1986

O HONDA MOTOR CO., LTD.
1. GENERAL INFORMATION
SERVICE RULES a 1-1 EMISSION CONTROL SYSTEM
(U.S.A. only)
MODEL IDENTIFICATION 1-2
EMISSION CONTROL INFORMATION
SPEClFlCATlONS
LABEL {u.s.A. only)
TORQUE VALUES 1-5
s
GENERAL SAFETY
"
If the engine must be nrnning to do some work, make sure the The battery electrdyte contains suEfuric acid. Protect your
area is well-ventilated. Never run the engine in a closed area. eyes, skin and clothing. In case of contact, flush thoroughly
The exhaust contains poisonous carbon monoxide gas that with water and call a doctor i f electrolyte gets in your eyes.
may cause loss of consciousness and lead to death.
The battery gerierateshydrogen gas which can be highly explo-

Gasolineis extremelyflammable and is explosive under certain sive. Do not smoke or allow flames or sparksneaithe battery,
conditions. Do not smoke or allow flames or sparks in your especially while charging it.
working area.
SERVICE RULES
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don't meet Honda's design
specifications may damage the motorcycle.
2. Use the special tools designed for this product.
3. Install new gaskets, O-rings, cotter pins, lock plates, etc. When reassembling.
4. When torquing a series of bolts or nuts, begin with larger-diameter or inner bolt first, and tighten to the specified torque di-
agonally in 2-3 steps, unless a particular sequence is specified.
5. Clean parts in non-flammable or high flash point solvent upon disassembly. Lubricate any sliding surfaces before re-
assembly.
6. After reassembly, check all parts for proper installation and operation.
7. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English
fasteners. The use of incorrect tools and fasteners may damage the motorcycle.
8. Route all electrical wires as shown on pages 1-8 through 1-11 Cable and Harness Routing.
GENERAL INFORMATION
MODEL IDENTIFICATION
The carburetor serial number is stamped on the left side of

the carburetor body.
(4) VEHICLE IDENTIFICATION NUMBER
The engine serial number is stamped on the lower left side The vehicle identification number (VIN) is on the left side
of the crankcase. of the steering head.
(5)COLOR LABEL.
The frame serial number is stamped on the right side of the The color label is attached on the air cleaner case cover,
steering head.
GENERAL INFORMATION
SPECIFICATIONS
ITEM SPECIFICATIONS
DIMENSIONS Overall length 2,115 mm (83.3 in)

Overall width 81 5 mm (32 in)
Overall height 1,100 m m (43.3 in)
Wheelbase 1,460 m m (57.5 in)
Seat height 660 m m (26 in)
Footpeg height 286 mm (1 1.2 in)
Ground clearance 140 mm (5.5 in)
Dry weight 136 kg (300 Ib)
Curb weight 146 kg (322 Ib)
FRAME Type Semi double cradle
Front suspension, travel Telescopic fork, Travel 140 mm (5.5 in)
Rear suspension, travel swingarm,-s ravel 70 mm (2.8 in)
Gross vehicle weight rating 304 kg (670 Ib)
Vehicle capacity load 156 kg (345 Ib)
Front tire size 3.00- 18-4PR
Rear tire size 130190- 15-66P
Up to 9 0 kg Front 2 0 0 kPa (2.00 kglcm2, 2 8 psi)

(200 Ibs) load 200 kPa (2.00 kglcmz, 2 8 psi) a
Cold tire
pressures Up to vehicle Front 200 kPa (2.00 kglcm2, 2 8 psi)
capacity load
Front brake, lining swept area Single disc brake, lining swept area 179.8 cm2
(27.9 sq in)
Rear brake, lining swept area Drum brake, lining swept area 123 cm2 ( 19.1 sq
in)
Fuel capacity 10.5 liter (2.8 US gal, 2.3 Imp gal)
Fuel reserve capacity 2.5 liter (0.7 US gal, 0.5 Imp gal)
Caster angle 32'
Trail 120 mm (4.7 in)
Fork oil capacity 238 cc (8.1 US oz)
ENGINE TYpe Air cooled 4-Stroke OHC engine
Cylinder arrangement 2-cylinder, inclined 15O from vertical
Bore and stroke 53 x 53 mm (2.1 x 2.1 in)
Displacement 234 cc ( 14.2cu in)
Compression ratio 9.2 : 1
Valve train Chain drive, OHC, 2 valves per cylinder
Oil capacity 1.8 liter (1.9 US qt, 1.6 Imp qt) after disassembl)
1.5 liter (1.6 US qt, 1.3 Imp qt) after draining
Lubrication system Forced and wet sump
Air filtration Oiled polyurethane foam
Cylinder compression 1400 kPa (14 kglcm2, 199 psi)
Intake valve Opens 5O ATDC \
Closes
Exhaust valve Opens
~ioses 50 BTDC J
Valve clearance (Cold) IN: 0.05 mm (0.002 in)
EX: 0.05 mm (0.002 in)
Revised: August 1987

8 1987 American
-. - - - -Motor
Honda - - - All Rights Reserved
- - -- -Co.;
- Inc. 1-3
GENERAL INFORMATION
ITEM SPECIFICATIONS
ENGINE Engine weight (Dry) 39.0 kg (86.0 Ib)
Idle speed 1,300 e l 0 0 rpm
Cylinder numbering No. I-Left
No. 2-Right
CARBURETION Carburetor typelthrottle bore VE type128 mm (1.1 in)
Identification number See page 4-1
Pilot screw initial setting See page 4-1
Float level 18.5 mm (0.73 in)
DRIVE TRAIN Clutch Wet, multi-plate type
Transmission 5-speed
Primary reduction 3.631 (69119)
Final reduction 2.357 drke sprocket 1 4 7 driven sprocket 33T
Gear ratio I 2.846 : 1 (37113)
Gear ratio I1 1.777 : 1 (32118)
Gear ratio Ill 1.333 : 1 (28121 1
Gear ratio IV 1.083 : 1 (26124)
Gear ratio V 0.913 : 1 (21123)
Gearshift pattern Left foot operated return system (1-N-2-3-4-5)
ELECTRICAL Ignition CDI
Ignition timing "F" mark 5 O BTDC at 1,300 rpm
Full advance 30° BTDC at 3,500 rpm
Starting system Starter motor
Alternator 0.19 kw/5,000 rpm
Battery capacity
Spark plug
- -
12V-9Ah
----_I
NGK ND
Standard CR6HS U20FSR-U
For extended
CR7HS U22FSR-U
high speed riding
Spark plug gap 0.6-0.7 mm 40.024-0.028 in)
FuseIMain fuse 7A x 211 5A
LIGHTS Headlight (HighILow) 12V-36.5135W
Taillbrake light 12V-4/32 CP (8127W3
Turn signal FrontlRear 12V-32/32 CP (23123W) SAE No. 1073
Instrument light 12V-2CP (3.4W)
License plate light 12V-4CP (8W)
Turn signal indicator 12V-2CP (3.4W)
Neutral indicator 12V-2CP (3.4W)
High beam indicator 12V-2W
GENERAL INFORMATION
TORQUE VALUES
ENGINE
I ltem
Engine oil drain bolt

I /
'Ity
Thread
Dia (mm) / Torque N-m (kg-m, ft-lb) Remarks
Drive sprocket bdlt

Cylinder head bolt
Cylinder headhamshaft holder nut
Cam sprocket bolt
h Cylinder head cover bolt
Clutch lock nut
Clutch/oil pump drive gear lock nut
Drum stopper plate bolt
Flywheel bolt
Crankshaft mounting nut
Crankshaft mounting bolt
Oil through plate attaching screw Apply a locking agent.
Valve adjuster lock nut
Starter clutch screws Apply a locking agent.
FRAME
Thread
ltem Torque N*m (kg-m, ft-lb) Remarks
Dia (mm)
Front engine mounting bolt
Rear engine mounting bolt
Engine hanger plate bolt
Footpeg mounting bolt
Exhaust muffler mounting nut

Handlebar upper holder bolt
Handlebar lower holder nut
Axle holder nut
Brake disc mounting bolt

Fork top pinch bolt
Fork bottom pinch bolt
Steering stem nut
Steering stem adjustment nut (First)
>see page 11-17
Apply a locking agent.

Front turn signal mounting nut
Headlight mounting nut
Driven sprocket nut
Brake torque link arm nut
Brake arm bolt

Brake pedal bolt
Rear shock absorber lock nut Apply a locking agent.
Swingarm pivot bolt

Rear fender attaching bolt
Caliper mounting bolt
Master cylinder holder bolt
Torque specifications listed above are for specific t ~hteningpoints. If a specification is not listed, follow the standard torque
values on the next page.
GENERAL INFORMATION
Thread
Itern Q'ty Torque N-rn (kg-rn, ft-lb) Remarks
Dia (mm)
Caliper pin 2 8 15-25 (I .5-2.5, 1 1 - 18)
Caliper pin A 2 8 20-25 (2.0-2.5,14-18)
Pin plug 1 10 2-4 (0.2-0.4,1.5-2.9)
From master cylinder cap 1 4 1-2 (0.1-0.2, 0.7-1.5)
Brake lever pivot bolt 1 6 4-7 (0.4-0.7,2.9-5.1 )
Rear shock absorber bolt 2 14 80-100 (8.0-10.0,58-72)
Taillight 1 6 3-4 (0.3-0.4,2-2.9)
Exhaust pipe clamp 2 7 24-30 (2.4-3.0,17-22)
Gear shift pedal 1 6 7-11 (0.7-1.1,5-8)
Torque specifications listed above are for specific tightening points. If a specification is not listed, follow the standard torque
values.
STANDARD TORQUE VALUES
TYPE TORQUE Nern (kg-m, ft-lb) TYPE TORQUE N-rn (kg-m, ft-lb)
5 rnm bolt, nut 4.5-6.0 (0.45-0.6,3.3-4.3) 5 m m screw 3.5-5 (0.35-0.5,2.5-3.6)
6 mm bolt, nut 8-12 (0.8-1.2,6-91 6 mrn screw, 6 rnrn
8 rnm bolt, nut 18-25 (I .8-2.5, 13-18) bolt with 8 mrn head 7-1 1 (0.7-1.1,5-8)
10 mrn bolt, nut 30-40 (3.0-4.0,22-29) 6 rnm flange bolt, nut 10- 14 (1.0-1.4,7- 10)
12 mm bolt, nut 50-60 (5.0-6.0,36-43) 8 mrn flange bolt, nut 24-30 (2.4-3.0,17-22)
10 mm flange bolt, nut 30-40 (3.0-4.0,22-29)
GENERAL INFORMATION
I
TOOLS
@ SPECIAL
I / REF.SEC I
--
DESCRIPTION NUMBER ALTERNATIVE NUMBER

Vacuum pump (U.S.A. only) ST-AH-260-MC7
Pressure pump (U.S.A. only) ST-AH-255-MC7
Valve guide reamer, 5.47 mm 07984-0980000
Piston ring compressor 07954-2350000
Piston base 07958-3000000
Clutch center holder 07923-9580000
p Bearing remover, 15 mm 07936 -KC 10500
Remover weight 07936-371 0200
Steering stem socket 0791 6-3710100
Ball race driver 07944- 1 150001
Steering stem driver 07946 -GC40000 Steering stem driver 07946- MBOOOOO
Attachment (u.S.A: only) 07946 -GC4000A
Hex wrench, 6 mm 0791 7-3230000 Equivalent commercially
available in U.S.A.
Shock absorber compressor
attachment
Needle bearing remover
Bearing remover handle
Bearing remover, 20 mm
Snap ring pliers
Valve adjustment wrench
COMMON
e- II ' DESCRIPTION
Spoke wrench C, 5.8 x 6.1 mm
1 ALTERNATIVE I NUMBER / REF.SEC (
I Valve adjusting wrench, 8 x 9 mm
Float level gauge

Equivalent commercially
available in U.S.A.
Valve spring compressor

Valve guide driver 5.5 mm
Gear holder
Lock nut wrench, 2 0 x 2 4 mm
Extension Equivalent commercially
available in U.S.A.
Flywheel puller Rotor puller
Flywheel holder Equivalent commercially
a / Driver
Attachment, 6 2 x 68 mm
available in U.S.A.
Pilot, 25 mm
Attachment, 52 x 55 mm
Pilot, 2 0 mm
Attachment, 32 x 3 5 mm
Pilot, 22 mm
Lock nut wrench, 3 0 x 32 mm
Attachment, 37 x 4 0 mm
Pilot, 15 mm
Bearing remover shaft
Bearing remover head, 15 mm
5 Equivalent commercially
available in U.S.A.
Fork seal driver
I ~ o r seal
k driver
Attachment
Shock absorber compressor
Timing hole cap wrench
GENERAL INFORMATION
CABLE & HARNESS ROUTING

Note the following when routing cable and wire harnesses.
A loose wire, harness or cable can be a safety hazard.

After clamping, check each wire t o be sure it is secure.
Do not squeeze a wire against the weld or end of its clamp

when a weld-on clamp is used.
Secure wires and wire harnesses t o the frame with their re-
spective wire bands at the designated locations. Tighten
r
the bands so that only the insulated surfaces contact the
wires or wire harnesses.
Route harnesses so they are not pulled taut or have exces-

sive slack.
Protect wires and harnesses with electrical tape or tubes if

they contact a sharp edge or corner.
Clean the attaching surface thoroughly before applying
tape.
Do not use wire or harness with a broken insulator.

Repair by wrapping them with protective tape or replace
them.
Route wire harnesses to avoid sharp edges or corners. Also

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

not interfering with any moving or sliding parts.
Wire harnesses routed along the handlebars should not be

pulled taut, have excessive slack, be pinched, or interfere
with adjacent or surrounding parts in all steering positions.
After routing, check that the wire harnesses are not twisted ,.
or kinked.
Do not bend or twist control cables. 0:CORRECT

Damaged control cables will not operate smoothly and may x : INCORRECT
stick or bind.
I GENERAL INFORMATION
CARBURETOR OVERFLOW TUBE MOTOR CABLE

AIR CLEANER CASE DRAIN TUBE
CRANKCASE BREATHER TUBE (121 BRAKE HOSE
HARNESS
GENERAL INFORMATION I
,(I) CLUTCH CABLE

9
(2) CHOKE CABLE
CABLES (3) MAIN WIRE HARNESS
(5) BRAKE OIL (41 SPEEDOMETER
(7) CONNECTION BOX

GENERAL INFORMATION
(1) MAIN WIRE

- HARNESS
(2) STARTER MOTOR CABLE

GENERAL INFORMATION
EM ISSlON CONTROL SYSTEM (U.S.A. only)

The U.S. Environmental Protection Agency and California Air Resources Board (CAR61 require manufacturers t o certify that
-
their motorcycles comply with applicable exhaust emissions standards durina their useful life, when operated and maintained
9
according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emis-
sion standards for one year or 6,000 km (3,730 miles) after the time of sale t o the ultimate purchaser, when operated and
maintained according t o the instructions provided. Compliance with the terms of the Distributor's for Honda Motorcycle
Emission Control Systems is necessary in order to keep the emissions system warranty in effect.
SOURCE OF EMISSIONS
b
7
The combustion process produces carbon monoxide and 11) dr~l',l~hons.Control of hydrocarbons is very important because,
under certain conditions, they react to from photochemical smog when subjected to sunlight. Carbon monoxide does not
react in the same way, but it is toxic.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, t o reduce carbon monoxide and hydro-
carbons.
0
EXHAUST EMISSION CONTROL SYSTEM
The exhaust emission control system is composed of lean carburetor setting, and no adjustments should be made except idle
speed adjustment with the throttle stop screw.
CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner and into the
combustion chamber. Condensed crankcase vapors are accumulated in a storage tank which must be emptied periodically.
See the Maintenance Schedule in section 3.
(1) CARBURETOR
(2)AIR CLEANER
I I
0( 6 ) FRESH AIR )5(' DRAIN PLUG

(7) BLOW-BY GAS
GENERAL INFORMATION
EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)
This model complies with California Air Resources Board requirements for evaporative emission regulations.
Fuel vapor from the fuel tank is routed into a charcoal canister where it is adsorbed and stored while the engine is stopped.
When the engine is running and the purge control diaphragm valve is open, fuel vapor in the charcoal canister is drawn into
the engine through the carburetor.
(1) FUELTANK
@ (5) FRESH AIR
( 6 ) FUELVAPOR
4 NOISE EMISSION CONTROL SYSTEM
TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing
thereof: ( 1 1 The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replace-
ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior t o its sale or
delivery t o 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 ACTRS LISTED BELOW:
1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
2. Removal of, or puncturing of any part of the intake system.
4 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.
GENERAL INFORMATION
EMISSION CONTROL INFORMATION LABEL (U.S.A. only)

An Emission Control Information Label is located on the air cleaner case cover as shown. It contains basic tune-up specifica-
tions.
(1) EMISSION CONTROL INFORMATION LABEL
VACUUM ~ O S ROUTING
E
DIAGRAM LABEL LABEL
EMISSION CONTROL INFORMATION UPDATE LABEL
After making a high altitude carburetor adjustment (Page 4-1 1), attach an update label on the frame down tube as shown.
Instructions for obtaining the update label are given in Service Letter No. 132.
VACUUM?WSEROUTING DIAGRAM LABEL (California model only)
The Vacuum Hose Routing Diagram ~ a b e l i sattached to the air cleaner case cover. Route the vacuum hoses as shown on this
label.
After '85:
1 CANISTER / KR3
OPEN t ,50 1
MEMO
LUBRICATION
2. LUBRICATION
INFORMATION
SE~ICE 2-1 OIL FILTER SCREEN CLEANING 2-2
TROUBLESHOOTING 2-1 OIL PUMP 2-3
ENGINE OIL 2-2 LUBRICATION POINTS
'SERVICE INFORMATION
I GENERAL
* This section covers maintenance of the oil pump and engine oil. This service can be done with the engine iktalled in the
frame.
Q 0
When removing and installing the oil pump use care not to allow dust or dirt to enter the engine and oil line.
When the oil pump clearances are not within specification, replace the oil pum@as an assembly.
SPECIFICATIONS
Engine oil
1.5 liter (1.6 US qt, 1.3 Imp qt) at change a
Oil capacity
1.8 liter (1.9 US qt, 1.6 Imp qt) at disassembly
Oil recommendation OIL VISCOSITIES
Use Honda 4-Stroke Oil or equivalent.

API Service Classification: SE or SF
Viscosity: SAE 1OW-40
1 I 1
I 1
b I1
I
i
Other viscosities shown in the chart may be
used when the average temperature in your
riding area is within the indicated range.
-20 -10 1
0 20 30 40 *C
ITEM STANDARD mm (in) SERVICE LIMIT mm (in)
,tor tip clearance 0.1 5 (0.0006) 0.20 10.008)

Pump body clearance 0.1 5-0.1 8 (0.006-0.007) 0.25 (0.010)
4 -
Pump end clearance 0.01 -0.07 (0.0004-0.0028) 0.12 (0.005)
TORQUE VALUE
Engine oil drain bolt 30-40 N.m (3.0-4.0 kg-m, 22-29 ft-lb)
Oil level too l o w Low oil pressure

External oil leaks. Oil level too low.
Worn valve guide or seal Clogged oil filter, screen or oil through.
- Worn piston rings. Faulty oil pump.
Oil contamination
Oil not changed often enough.
Faulty head gasket.
* Worn piston rings.
2-I
LUBRICATION
OIL CHANGE
NOTE
Change the engine oil w i t h the engine warm and the motor-
cycle o n its side stand t o assure complete and rapid drain-
ing.
Place the oil pan under the engine.

Remove the oil filler cap/dipstick and oil drain bolt and allow
t h e oil t o drain thoroughly.
Make sure that the sealing washer on the drain bolt is in good
condition and install the bolt.
TORQUE: 30-40 N*m (3.0-4.0kg-m, 22-29 ft-lb)

#
Pour the recommended engine oil (Page 2-1) through the oil
filler hole.
ENGINE OIL CAPACITY:

1.5 liter (1.6 US qt, 1.3 Imp qt) a t change
1.8 liter. (1':9us qt, 1.6 Imp qt) a t disassembly
Reinstall the oil filler cap/dipstick and start the engine and let it
idle for f e w minutes.
Recheck the oil level.
Check for any oil leaks.
OIL FILTER SCREEN CLEANING

Drain the engine oil.
Remove t h e oil pump (Page 2-3).
Remove the oil filter screen from the oil pump.
Clean the oil filter screen b y washing it in clean solvent and
blowing it dry w i t h compressed air.
Reinstall the oil filter screen onto the oil pump.
Install the oil pump (Page 2-5).
NOTE
During installation check the seating of the O-ring.
LUBRICATION
I
OIL PUMP
REMOVAL
Drain the engine oil (Page 2-21.
Remove the right (Page 8-31 and left crankcase covers.
Rotate the flywheel counterclockwise until the cutout of the
oil pump gear aligns with the screws.
Remove the three screws, and remove the oil pump.
Remove the oil filter screen and clean it (Page 2-21.

Remove the oil pump cover.
Measure the rotor tip clearance.
SERVICE LIMIT: 0.20 rnrn (0.008 in)
Measure the rotor-to-body clearance.

LUBRICATION
Measure the rotor-to-cover clearance with a straight edge.
Remove the inner and outer rotors.

Remove the gear cover and the pump gear and pull the rotor
shaft out.
(4) PUMP BODY (51 PUMP COVER
(3) 'PUMP GEAR

I I I
(2) ROTOR SHAFT
OUTERROTOR
ASSEMBLY
lnstall the rotor shaft and the pump gear into the pump body.
NOTE
Align the pump gear cutout with the rotor shaft cutout.
lnstall the gear cover.
k -
43,
) .-
GEAR
* ,.. -
-, , , .- COVER ,
-
.a,
lnstall the outer and inner rotors.
NOTE
Align the inner rotor cotout with the rotor shaft cutout. (2) OUTER ROTOR
lnstall the gasket and cover.

Check for smooth operation.
lnstall the oil filter screen.
INSTALLATION
Install's new O-ring into the crankcase.
lnstall the oil pump.

lnstall the left and right crankcase covers (Page 8-10).
Fill the crankcase with the recommended engine oil (Page 2-1 I.
LUBRICATION
LUBRICATION POINTS
Use general purpose grease when not specified otherwise.
Apply oil grease t o sliding surfaces not shown here.
CONTROL CABLES
Periodically, disconnect the throttle and clutch cables at their upper ends. Thoroughly lubricate the cables and their pivot
points with a commercially available cable lubricant or a light weight oil.
CABLE LUBRICANT 2
6Gm
THROTTLE CABLE CLUTCH AND
CHOKE CABLE BRAKE LEVER PIVOTS
CLUTCHCABLE
SPEEDOMETER CABLE 1
REAR BRAKE PEDAL

PIVOT SHAFT
STEERING
HEAD
BEARINGS 1
-
BRAKE
CALIPER PIN -
AND BOOT A
l"-
DUST SEAL
SPEEDOMETER
\
DUST SEAL.
I
" GEAR SIDESTAND PIVOT NEW WHEEL BEARINGS
NEW WHEEL AND
FINAL DRIVEN FLANGE
*
BEARINGS GEARSHIFT PEDAL
NEW BEARING AND DUST
PIVOT SWINGARM
6 PIVOT BUSHING
AND CENTER COLLAR
SEAL
6
DUST SEAL
3. MAINTENANCE
SERVICE INFORMATION 3- 1 DRIVE CHAIN 3-1 1
MAINTENANCE SCHEDULE a 3-3 BATTERY 3-1 2
FUEL LINE 3-5 BRAKE FLUID 3-13
FUEL STRAINER 3-5 BRAKE SHOEIPAD WEAR 3-13
THROTTLE OPERATION 3-5 BRAKE SYSTEM 3-14
CARBURETOR CHOKE 3-6 BRAKE LIGHT SWITCH 3-15
, AIR CLEANER 3-7 HEADLIGHT AIM 3 3-15
CRANKCASE BREATHER 3-8 CLUTCH 3-15
SPARK PLUGS 3-8 SIDE STAND 3-16
VALVE CLEARANCE 3-9 , SUSPENSION ' - 3-17
CARBURETOR IDLE SPEED 3-9 NUTS, BOLTS, FASTENERS 3-17
IGNITION TIMING 3-10 WHEELSISPOKES 3-18
CYLINDER COMPRESSION 3-10 STEERING HEAD BEARINGS 3-18
EVAPORATIVE EMISSION CONTROL
SYSTEM (California model only) 3-1 1
SEIRVlCE INFORMATION
GENERAL
Engine oil See page 2-2.
Engine oil filter screen See page 2-2.
SPECIFICATIONS
Throttle grip free play: 2-6 mm (118- 114 in)

Spark plugs:
- --
Standard For extended high speed riding
NGK ND NGK ND
CR6HS U2OFSR-U CR7HS U22FSR-U
-
Spark plug gap: 0.6-0.7 mm (0.024-0.028 in)
Valve clearance: IN
Idle speed:
EX
0.05 mm (0.002 in)
0.05 mm (0.002 in)
1,300 +- 100 rpm
I k?
Ignition timing: "F" mark 5 O BTDC at 1,300 rpm

Advance mark 30° BTDC at 3,500 rpm
Compression pressure: 1,400 + 200 kPa (14 + 2 kg/cm2, 199 + 28 psi)
Drive chain slack: 15-25 mrn (518- 1 in)
Replacement drive chain: DID 520VC6, RK520MO
Rear brake pedal free play: 20-30 mm (314- 1-114 in)
Clutch lever free play: 10-20 mm (318-314 in)
Tire pressure:
Front Rear
*-
Rider only 200 kpa (2.0 kglcm, 28 psi) 200 kpa (2.0 kglcm, 28 psi)
Rider and one passenger 200 kpa (2.0 kglcm, 28 psi) 200 kpa (2.0 kglcm, 28 psi)

(9 1987 American Honda Motor Co.. Inc. - All Rights Resewed
MAINTENANCE I
TORQUE VALUES
Fuel strainer cup 3-5 Nam (0.3-5.0 kg-m, 2-4 ft-lb)

Valve adjuster lock nuts 8- 12 N-m (0.8- 1.2 kg-m, 6-9 ft-lb)
Rear axle nut 80-100 N-rn (8-10.0 kg-m, 58-72 ft-lb)
Headlight mounting nut 30-40 New 13.0-4.0 kg-m, 22-29 ft-lbl
TOOLS
Common
Spoke wrench C, 5.8 x 6.1 mm
07701 -0020300>~r Equivalent commercially available in U.S.A.
Valve adjustment wrench, 8 x 9 mm 07708-00301 0 0
Valve adjustment wrench
I- MAINTENANCE SCHEDULE
MAINTENANCE
I ) '85 and '86
Perform the Pre-ride Inspection in the Owner's Manual at each scheduled maintenance period.
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN
- R: REPLACE
) A: ADJUST
L: LUBRICATE
I WHICHEVER II) / ODOMETER READING [NOTE (311 1
I VICE DATA AND IS MECHANICALLY QUALIFIED.

* I N THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEAL-
@ ER.
NOTES (1) Service more frequently when riding in dusty areas.

(2) Service more frequently when riding in rain, or at full throttle.
(3) For higher odometer reading, repeat at the frequency interval established here.
f4) California tvwe onlv.
MAINTENANCE
After '86:
Perform the Pre-ride Inspection at each scheduled maintenance period.

I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN
R: REPLACE
A: ADJUST
L: LUBRICATE
1 WHICHEVER I ODOMETER READING [NOTE (311
* SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SER-
>
VICE DATA AND IS MECHANICALLY QUALIFIED.
" "IN THE tNTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA D ~ A L -
ER.
NOTES (1) Service more frequently when riding in dusty areas.

(2) Service more frequently when riding in rain, or at full throttle.
(3) For higher odometer reading, repeat at the frequency interval established here.
(4) California type only.
MAINTENANCE
FUEL LINE
Inspect the fuel line for damage or deterioration gnd has
clamps at each connection.
Replace any parts that are damaged, leaking or show signs of
deterioration.
FUEL STRAINER
Keep gasoline away from flames or sparks.
Wipe up spilled gasoline at once.
Turn the fuel valve "OFF" and remove the fclel cup, O-ring and
filter screen.
Wash the cup and filter screen in clean non-flammable or high
flash point solvent.
Reinstall the filter screen, new O-ring and fuel cup.
Hand tighten the fuel cup and torque t o specification.
CAUTION
Do not overtighten the fuel cup.
TORQUE: 3 - 5 N-m (0.3-0.5 kg-m, 2 - 4 ft-lb)
TurrI the fuel valve "ON" and check for leaks.
(1) SCREEN
(2)O-RING
GP--
f9- (3) FUELCUP
THROllLE OPERATION
Check for smooth throttle grip full opening and automatic full
closing in all steering positions.
Make sure there is no deterioration, damage, or kinking in the

throttle cables. Replace any damaged parts.
Lubricate the throttle cables (Page 2-6), if throttle operation is
not smooth.
Measure throttle grip free play at the throttle grip flange.
FREE PLAY: 2 - 6 m m (118- 314 in)

MAINTENANCE C
Throttle grip free play can be adjusted at either end of the

throttle cable. Minor adjustments are made with the upper ad-
juster,
Major adjustments are made with the lower adjuster.
Adjust free play by loosening the lock nut and turning the ad-
juster. Tighten the lock nut.
Recheck throttle operation in all steering positions,
CARBURETOR CHOKE
This model choke system uses a fuel enrichening circuit con-
trolled by a starter valve. The starter valve opens the
enrichening circuit via a cable when the choke lever on the
handlebar is pushed up.
Check for smooth upper choke lever operation.

Lubricate the choke cable if necessary.
,
Remove the choke cable boot and loosen the valve nut.
Remove the starter valve from the carburetor.
Push the choke lever on the handlebar all the way down to
fully closed and make sure the distance between the nut's
threads and valve is 10.5 mm (0.41 in).
mm
.41 in)
MAINTENANCE * h
O L
Adjust within specificatjons by loosening the lock nut and
turning the cable's elbow at the clutch housing. Tighten the
lock nut. Recheck the distance.
Thread the starter valve in by hand and then tighten the starter
valve nut 114 turn with a 14 m m wrench.
Install the choke cable boot.
Reinstall the removed parts in the reverse order of removal.
?!
j
' AIR CLEANER
Remove the left side cover.
Remove the air cleaner case cover attaching screws then
B remove the case cover.
I
Remove the set spring and air cleaner element.
Remove the element from the element holder.

MAINTENANCE
1
Wash the element in non-flammable or high flash point sol-
vent, squeeze it out and let it dry.
Soak the element in gear oil (SAE #80 or #90) and sbueeze
out the excess.
Install the removed parts in the reverse order of removal.
(1 (2) (3) (4)

WASH IN SQUEEZE THE SOAK IN SQUEEZE
SOLVENT SOLVENT OUT GEAR OIL OUT THE
THOROUGHLY (SEA #80-#go) EXCESS OIL
CRANKCASE BREATHER
Remove the plug from the drain tube to empty any accumula-
tion.
lnstall the drain plug.
NOTE
- -
Service more frequently when riding in rain or at full throt-

tle, or if any accumukeion can be seen in the transparent
section of the drain tube.
SPARK PLUGS
SPECIFIED SPARK PLUGS
ELECTRODE
Standard CR6HS
For extended
CR7HS U22FSR-U
high speed riding
Disconnect the spark plug caps and clean any dirt from around ..
the spark plug bases.
Remove and discard the spark plugs.
Measure the qew spark plug gaps using a wire-type feeler

gauge.
SPARK PLUG GAP: 0.6-0.7 mm (0.024-0.028 in)
Adjust the spark plug gap b y bending the side electrode care-
a
fully.
With the plug washer attached, thread each spark plug in by
hand to prevent crossthreading. Tighten the spark plugs an-
other 112 turn with a spark plug wrench t o compress the plug
washer. Connect the spark plug caps.
MAINTENANCE
I
- VALVE..CLEARANCE
NOTE
lnspect or adjust the valve clearance while the engine is
cold (below 35OC195OF).
Remove the fuel tank (page 4-1 1).
I
) Rerrlove the cylinder head cover.
Rerrlove the crankshaft and timing mark hole caps.
Rotrate the flywheel counterclockwise to align the "T" mark
..
wltn the index mark on the left crankcase covkr.
1 . Check the valve 'clearances at the right or left cylinder on the
2
compression stroke (the rocker should be loose) by inserting a
feeler gauge between the adjusting crew and valve stem.
*. 'I VALVE CLEARANCE:
Intake: 0.05 mm t0.002 in)
-xhaust: 0.05 mm (0.002 in)
Adjust the clearance by loosening the lock nut and turning the
adjusting screw until there is a slight drag on the feeler gauge.
Hold the adjusting screw and tighten the lock nut.
LUE: 8- 12 N-m (0.8- 1.2 kg-m, 6-9 ft-lb)
jck the valve clearance.

Rotate the flywheel counterclockwise one full turn (360') and
align the "T" mark with the index mark.
Check the clearance of the opposite cylinder in the same
sequence as above.
Install the cylinder head cover.
CARBURETOR IDLE SPEED

NOTE
Inspect and adjust the idle speed after all other engine ad-
justments are within specifications.
The engine must be warm for accurate idle inspection and
adjustment.
Ten minutes of stop and go riding is sufficient.
Warm the engine, shift t o NEUTRAL, and hold the motorcycle
upright.
Adjust the idle speed with the throttle stop screw.
IDLE SPEED: 1,300 + 100 rpm

B 1987 American Honda Motor Co.. Inc.
ISCII
- All Rights Resewed
a n r e r n m n * r n r m-. I ~ R ~ V ' I C ~ ~
MAINTENANCE
NOTE
* This Capacitive Discharge Ignition system is factory pre-set
and cannot be adjusted, Ignition timing inspection proce-
dures are given t o inspect the function of the CDI compo-
nents.
Remove the timing hole cap.

Connect the tachometer and timing light t o the engine.
Start the engine.
The timing at idle is correct if the index mark aligns with the
"F" mark at idle of 1.300 rom.
To check the advance, raise the engine speed t o 3,500 rpm;

the index mark should be between advance marks. I (1) 1NDE.X MARKS
If the ignition timing is incorrect, check the ignition compo-
nents as described in the Troubleshooting section ( 1 5) and re-
place any faulty parts. If all of the other components check out
OK, replace the CDI unit.
Refer t o Section 15.
(2) "F" MARK (3) ADVANCE MARK
CYLINDER COMPRESSION
Warm the engine.
Stop the engine and remove the spark plug caps and spark
plugs.
Insert the compression gauge.
Fully open the throttle and crank the engine.
NOTE
* Crank the engine until the gauge reading stops rising.
The maximum reading is usually reached 4-7 seconds,
COMPRESSION PRESSURE:
1,400 +- 200 kPa (14 ~r-2 kglcm2, 1 9 9 +. 28 psi)
#
If comprdssion is low, check for the following:

- Improper valve clearance
- Leaky valves
- Leaking cylinder head gasket
- Worn pistoniringlcylinder
If compression is high, it indicates that carbon deposits have
accumulated on the combustion chamber and/or the piston
crown.
II
MAINTENANCE
EVAMRATIVE EMISSION CONTROL '85:
SYSTEM
(California model only)
Check the hoses between the, fuel tank, charcoal canister,

PCV, carburetor and the air cleaner for damage or loose con-
) :GYaTis necessary. '
DRIVE CHAIN After '85:
INSPECTION *
EVAPORATIVE FAMILY IDENTIFICATION - 86 YC
ENGINE FAMILY IDENTIFICATION - GHN023441CO
Never inspect or lubricare the drive chain while the engine is
running.
Stop the engine.

Support the motorcycle with its side stand.
Shift theYransmission into neutral.
Measure the drive chain slack in the chain run midway be-
tween the sprockets.
CHAIN SLACK: 15-25 mm (518- 1 in)
,UTION
Excessive chain slack, 50 mm (2 in) or more, may damage the
frame.
ADJUSTMENT
Loosen the axle nut.

Loosen the adjuster lock nuts.
Turn both adjusting nuts an equal number of turns until the
correct drive chain slack is obtained.
CAUTION
Check sure that the same alignment marks on both adjusters
align with or are the same distancefrom the rear edge of the ad-
justing slots.
MAINTENANCE
Tighten the adjuster lock nuts.
Tighten the rear axle nut.
TORQUE: 80- 1 0 0 N-m (8.0- 10.0 kg-m. 58-72 ft-lb)
Recheck chain slack and free wheel rotation.

Lubricate the drive chain with SAE #80 or #90 gear oil.
Check the chain wear label. If the red zone on the label and the
index mark on the adjuster align or overlap after adjustment,
the chain must be replaced and the sprockets will probably
need to be replaced as well.
REPLACEMENT CHAIN: DID520VC6, RK520MO
lnspect the sprocket teeth for excessive wear or damage.

Replace if necessary.
NOTE
* Never install a new drive chain on worn sprockets or a worn
chain on new sprockets. Both chain and sprockets must be
in good condition, or the new replacement chain or sprock-
ets will wear rapidly.
Clean the drive chain with a non-flammable or high flash point

;@I
DAMAGED
NORMAL
solvent that will not damage the O-rings, and wipe dry.
,'-- I
CAUTION
* Do not use a steam cleaner, high pressure washers or solvents as
these witl%damagethe O-rings.
u
Lubricate the drive chain with SAE #80 or #90 gear oil. (2) WIPE DRY
3 5 1
CAUTION
Do not use commercial aerosol chain lubricants. They contain #80
solvents which could damage the O-rings.
(3) LUBRICATE
0RSAE#90
GEAR OIL 1
Support the motorcycle upright on level ground.
lnspect the battery electrolyte level.
When the electrolyte level nears the lower level line, remove
the battery and add distilled water t o the upper level as fol-
lows: Remove the right side cover.
Remove the battery (Page 14-2).
Remove the filler caps and add distilled water t o the upper
level line.
NOTE
- Add only distilled water. Tap water will shorten the service
life of the battery.
MAINTENANCE
The battery electrolyte contains sulphuric acid. Prptect your

eyes. skin, and clothing.
If electrolyte gets in your eyes, flush them thoroughly with
water and get prompt medical attention.
Replace the battery, if the sulfation forms or sediments

accumulate on the bottom.
Reinstall the right side cover.
BRAKE FLUID
Support the motorcycle upright on level ground.
Check the front brake fluid reservoir level. If the level nears the
lower level mark, remove the cover and diaphragm. Fill the res-
ervoir with DOT 3 or 4 brake fluid t o the upper level mark locat-
ed inside the reservoir.
Check the entire system for leaks, if the level is low.
CAUTION
Be careful not to let dust or water enter the hydraulic system
when filling the reservoir.
Do not remove the cover unless the handlebar is turned so that
v
rlre reservoir is level.
Avoid spilling fluid on painted, plastic or rubber parts.
Piace a rag over these parts whenever the system is serviced.
BRAKE SHOE/PAD WEAR

FRONT BRAKE PAD
Inspect the front brake pads for wear.
Replace the brake pads when the wear groove in the pads
reaches the edge of the brake disc.
CAUTION
A [ways replace the brake pads as a set to assure even disc pres-
sure.
Refer to Page 13-3 for brake pad replacement.

7
MAINTENANCE
REAR BRAKE SHOE
Replace the brake shoes if the arrow on the wear indicator

aligns with index mark on the brake panel when brake is ap-
plied.
BRAKE SYSTEM
lnspect the front brake hose and fittings for deterioration,
cracks or signs of leakage. Tighten any loose fittings.
Replace hose and fittings as required.
lnspect the rear brake pedal and rod for loose connections,
excessive play or other damage.
Replace or repair if necessary.
BRAKE PEDAL FREE PLAY
Measure the rear brake pedal free play from the top of the
brake pedal.
FREE PLAY: 20-30 mm (314-1-114 in)
To adjust, turn the adjusting nut.

After adjustment, check the rear brake light switch and adjust
if necessary.
MAINTENANCE
I
Adjust brake pedal height so the pedal is 10-20 m m (318-31

4 in) above the top of the footpeg.
CAUflON
.
- Incorrect brake pedal height can cause brake drag.
To adjust:
Loosen the stopper bolt lock nut and turn the stopper bolt.
fietighten the lock nut.
NOTE
After adjusting the brake pedal height, check the rear brake
light switch and brake pedal free play and adjust if neces-
sary.
BRAKE LIGHT SWITCH

Adjust the brake light switch by holding the switch body and
turning the adjusting nut. Do not turn the switch body.
Turn the adjusting nut clockwise if the brake light comes on

too late.
HEADLIGHT AIM
Adjust the headlight vertically by loosening the adjusting bolts.
Adjust the headlight horizontally by loosening the mounting
nut.
Tighten the bolts securely after adjustment.
Tighten the mounting nut after adjustment.
HEADLIGHT MOUNTING NUT
TORQUE: 30-40 Norn (3.0-4.0kg-rn, 22-29 it-lb)
NOTE
Adjust the headlight beam as specified by local laws and
regulations.
,-
4- nitimproperly
may fail toadjusted
light the
headlight
road properly.
may blind oncoming drivers,
CLUTCH
Measure the clutch free play at the lever end.
FREE PLAY: 10-20 rnm (318-314 in)

MAINTENANCE
Perform the major adjustments with the lower adjuster.

Loosen the lock nut and turn the adjuster nut.
Tighten the lock nut.
Check the clutch operation.
SIDE STAND
(1) GOOD (2) REPLACE
Check the rubber pad for damage or wear.
Replace the rubber pad if wear extends to the wear line.
f 3 ) -WEAR
0
LINE @
x
Check the side stand spring for damage or loss of tension and
the side stand assembly for freedom of movement.
Make sure the side stand is not bent.
Measure the amount of force required to lower side stand.
It should be within 2.0-3.0 kg (4.4-6.6 Ib).
MAINTENANCE
I
SUSPENSION
"D not ride a vehicle with faulty suspension.
pose, worn or damaged suspensionparts impair vehicle stabil-
1 and control.
FRONT
Check the action of the front forks by compressing them sev-
eial times.
Check the entire fork assembly for leaks or damage.
Replace damaged components which cannot be repaired.
Tighten all nuts and bolts.
REAR
Check the action of the rear shock absorber by compressing
them several times.
Check the entire shock absorber assembly for damage.
Replace damaged components which cannot be repaired.
Raise the rear wheel off the ground by placing a box or work
stand under the engine.
Move the rear wheel sideways with force t o see if the swing
arm bushings are worm.
Replace the swingarm bushings if there is any looseness.
Tighten all rear suspension nuts and bolts.
NUTS, BOLTS, FASTENERS

Check that all chassis nuts and bolts are tightened t o their cor-
rect torque values (Section 1) at the intervals shown in the
Maintenance Schedule (Page 3-3 or 3-41.
Check all cotter pins, safety clips, hose clamps and cable
stays,
Check the front and rear wheels for trueness.
Measure the tread depth at the center of the tires.
Replace the tires i f the tread depth reaches the following lim-
its:
Minimum tread depth:

Front: 1.5 mm (0.06 in)
Rear: 2.0 mm (0.08 in)
Tighten the wheel spokes periodically.
TORQUE: 2.5-5 N.m (0.25-0.5 kg-m, 1.8-3.6 ft-lb)
NOTE
* Check that the control cables do not interfere w i t h handle-
bar rotation.
Raise the front wheel o f f the gound and check that the handle-
bar rotates freely.
If the handlebar moves unevenly, binds, or has vertical move-
ment, adjust the steering head bearing (Page 11-16).
MEMO
I
I
FUEL SYSTEM
4. FUEL SYSTEM
SERVICE INFORMATION 4-1 PILOT SCREW ADJUSTMENT 4-9
TROUBLESHOOTING 4-2 LIMITER CAP INSTALLATION 4-9
CARBURETOR REMOVAL 4-3 HIGH ALTITUDE ADJUSTMENT 4-1 0
ACCELERATOR PUMP 4-3 FUELTANK 4-1 1
VACUUM CHAMBER 4-4 AIR CLEANER CASE 4-12
FLOATIFLOAT VALVEIJETS 4-6 CRANKCASE BREATHER 4-14
, FLOAT LEVEL INSPECTION 4-7 PURGE CONTROL VALVE
'
INSPECTION (CALIFORNIA MODEL) ' 4-15
CARBURETOR INSTALLATION 4-8
L
SERVICE INFORMATION
GENERAL
Emm Gasoline is extremely flammable and is explosive under certain conditions. Work in'a well ventilated area. Do not smoke or allow
flames or sparks in the work area.
CAUTION
Do not bend or twist control cables. Dammaged control cables will not operate smoothly and may stick or bind.
When disassembling the fuel system parts, note the location of the O-rings. Replace them with new ones on reassembly.
Before disassembling the carburetor, drain the fuel in the float chamber by opening the drain screw.
California model:
Refer t o the label attached t o the air cleaner case cover for proper hose connections of the evaporative emission control
system.
SPECIFICATIONS
ITEM 49- STATE model California model

Identification number VE08A VE18A
-
1 Venturi dia. 1
I
25.2 mm (1 in) I I
18.5 i 1.0 mm (0.73 +- 0.04 in)
Main jet number '85: #I
35, After '85: # I 2 8 c---
' @ .I-----
Slow jet number #35
Idle speed 1,300 i 100 rpm f---
2- 114 turns out

--Pilot screw opening (initial) C---
Throttle grip free play 2-6 mm (118-114 in) ..c------
lh -
TOOLS
Special
Vacuum Dump
. . ST-AH-260- MC7 (U.S.A. only)
Pressure pump ST-AH-255-MC7 (U.S.A. only)
) Comnton
Float Ilevel gauge
FUEL SYSTEM
TROUBLESHOOTING
Engine cranks but won't start
No fuel in tank
* No fuel to carburetor
Engine flooded with fuel
No spark at plug (faulty ignition system)
Clogged air cleaner
lntake air leak
lmproper bystarter adjustment
lmproper throttle operation
Hard starting or stalling after starting

lmproper bystarter adjustment
Ignition malfunction
* Faulty carburetor
Contaminated fuel
lntake air leak
lncorrect idle speed
Rough idle
Faulty ignition system
lncorrect idle speed
Faulty carburetor
Contaminated fuel
Misfiring during acceleration

* Faulty ignition system
Backfiring
= Faulty carburetor
Poor performance (drivability) and poor fuel economy

Clogged fuel system
Faulty hose, of the emission control system (California model only)
Lean mixture
Clogged fuel jets
Stuck vacuum piston
Faulty float valve
Low float level
Blocked fuel cap vent
Clogged fuel strainer screen
Restricted fuel line
Clogged air vent tube
lntake air 1,eak
Rich mixture
* Clogged air jets
Faulty float valve
Flo-at level too high
Faulty bystarter adjustment
Dirty air cleaner
FUEL SYSTEM
CARBURETOR REMOVAL
Remove the throttle cable cover.
Loosen the throttle cable lock nut and adjuster nut and discon-
nect from the carburetor.
Turn the fuel valve "OFF" and disconnect the fuel line. ..
Drain the carburetor.
Remove the starter valve from thicarburetor body.
Loosen the connecting tube band and insulator band.
Remove the fuel tank (Page 4-1 1).
Remove the carburetor.
Check the starter valve and spring for damage.
ACCELERATOR BUMP
DISASSEMBLY
Remove the accelerator pump cover, pump rod and spring.
Remove the boot.
INSPECTION
Check the diaphragm for deterioration and tears.

Check the boot for tears or pin holes.
ASSEMBLY
Assemble the removed parts in the reverse order of disassem-

bly.
Check the accelerator pump for smooth operation.
FUEL SYSTEM
ADJUSTMENT
Loosen the throttle stop screw, so that the butterfly valve is
closed. Measure the clearance between the accelerator pump
rod and adjusting arm w i t h the butterfly valve closed.
CLEARANCE: 0 mm (0in)
Adjustment is made by bending the arm.
Measure the clearance between the adjusting arm and stopper

on the carburetor body.
CLEARANCE: 6.5 mm (0.26 in)
Adjustment is made by bending the arm.
VACUUM CHAMBER
DISASSEMBLY
Loosen the drain screw and drain the fuel from the float cham-
ber.
Remove the four vacuum chamber cover screws and cover.
Remove the compression spring and the vacuum piston. (1) VACUl
FUEL SYSTEM
Push the needle holder in and turn it 60° using an 8 mm sock-

et.
Then remove the needle holder, spring and jet needle,from the
piston.
Inspect the vacuum piston for wear, or other damage.

lnspect the needle for excessive wear, bending, or other dam-
age.
Check the diaphragm for deterioration and tears.
ASSEMBLY
lnstall the jet needle, spring and needle holder into the vacuum
piston, push the needle holder in and turn it 60°.
lnstall the vacuum piston in t o the carburetor body and align

the tab on the diaphragm with the vacuum passage in the car-
buretor body.
Install the compression spring.
Install the vacuum chamber cover and tighten it with the

screws.
-
NOTE
Be careful not t o move the diaphragm.
If the diaphragm can not be positioned correctly because of
- its expansion, dry the diaphragm before installation.

FUEL SYSTEM
I
FLOAT/FLOAT YALY E/ J ETS
DISASSEMBLY
Remove the float chamber screws and the float chamber.
Remove the float pin, float and float valve.
FLOATIFLOAT VALVE INSPECTION
lnspect the float valve for damage and wear.

lnspect the operation of the float valve.
Remove the main jet, needle jet holder and needle jet.
Remove the slow jet.
Turn the pilot screw in, carefully counting the number of turns
before it seats lightly. Make a note of this to use as a reference
when reinstalling the pilot screw.
CAUTION
Damage to the pilot screw seat wilI occur if the screw is tight-
ened aminst the seat.
Remove the pilot screw.

Check each part for wear or damage.
FUEL SYSTEM
Blov3 open the all passages with compressed air before as-
sembling.
ASSEMBLY
Clean the main jet, needle jet holder, slow jet and pilot screw in
cleaning solvent and blow them open with compressed air.
lnstall the needle jet and needle jet holder.
lnstall the main jet and slow jet.
Install the pilot screw and return it t o the original position as
noted during removal.
Perform pilot screw adjustment if a new pilot screw is installed
(Page 4-91.
NOTE
Do not install the limiter cap on new pilot screw until after
adiustment has been made (Page 4-91.
lnstall the float valve, float and float pin.
FLOAT LEVEL INSPECTION

Measure the float level with the float tang just touching the
float valve.
FLOAT LEVEL: 18.5 i 1.0 mm (0.73 -r 0.04 in)
Replace the float if the level does not meet the specification.
Reinstall the float chamber.
FUEL SYSTEM
CARBURETOR INSTALLATION
install the carburetor.
Install the fuel tank (Page 4-1 1).
Tighten the connecting tube band and insulator band.
lnstall the starter valve onto the carburetor body.
Connect the fuel line.
Connect the throttle cables to the carburetor.

Adjust the throttle cables (Page 3-5).
Adjust the idle speed (Page 3-9).
Check the fuel leaks.
Install the throttle cable cover.

FUEL SYSTEM
PILOT SCREW ADJUSTMENT

IDLE DROP PROCEDURE (U.S.A. ONLY) -
NOTE
The pilot screw is factory pre-set and no adjustment is nec-
essary unless the pilot screw is replaced.
Use a tachometer with graduation of 100 rpm or smaller
that will accurately indicate a 1 0 0 rpm change.
7. Turn the pilot screw clockwise until it seats lightly and back
it out t o the specification given. This is an initial setting
prior t o the final pilot screw adjustment.
) INITIAL OPENING: 2-1 14 turns out
CAUTION
Damage to the pilot screw seat will occur if the pilot screw is
ti~htenedagainst the seat.
2. Warm up the engine t o operating temperature. Stop and go

driving for 1 0 minutes is sufficient.
3. Attach a tachometer according t o the manufacturer's in-
structions.
4. Adjust the idle speed with the throttle stop screw.
IDLE SPEED: 1,300 k 100 rpm
, b 5. Turn the pilot screw in or out slowly to obtain the highest

engine speed.
6. Readjust the idle speed with the throttle stop screw.Turn
the pilot screw in gradually until the engine speed drops
100 rpm.
7. Turn the pilot screw 1 turn out from the position obtained in
Step 6.
8. Readjust the idle speed with the throttle stop screw. Install
a new limiter cap.
LIMITER CAP INSTALLATION

If the pilot screw is replaced, a new limiter cap must be in-
stalled after pilot screw adjustment is completed.
After adjustment, cement the limiter cap over the pilot screw,
using LOCTITEm 601 or equivalent.
The limiter cap should be placed against its stop, preventing
further adjustment that would enrich the fuel mixture (limiter
cap position permits clockwise rotation and prevents counter-
clockwise rotation).
NOTE
DO not turn the pilot screw when installing the limiter cap.
FUEL SYSTEM
HIGH ALTITUDE ADJUSTMENT

NOTE
These adjustments must be made at high altitude to ensure
proper high altitude operation.
When the vehicle is to be operated continuously above 6,500

ft (2,000 m) the carburetors must be readjusted as described
below to improve driveability and decrease exhaust emissions.
1. Warm up the engine t o operating temperature.

Stop and go driving for 1 0 minutes is sufficient.
2. Turn the pilot screw clockwise 1/2 turn.
3. Adjust the idle speed to 1,300 & 100 rpm with the throttle
stop screw.
4. Attach the Vehicle Emission Control Information Update
Label (See service letter # 132 for information on obtaining
labels).
NOTE
Do not attach the label to any part that can be easily
removed from the vehicle.
CAUTION
Operation at an altitude lower than 5,000 ft (1,500 mJ with the
carburetors adjusted for high altitudes may cause the engine to
idle roughly and stall.
When the vehicle is to be operated continuously below 5,000 ft
(1,500 m), turn the pilot screw counterclockwise to its original
position against its stop and adjust the idle speed to 1,300 +. 100
rpm. Be sure to do these adjustments at low altitude.
FUEL SYSTEM
FUEL TANK
REMOVAL
Remove the passenger seat mounting bolts and passenger
seat.
Remove the seat mounting bolts and seat.
. no notupallow
Wipe
flames or sparks near gasoline.
spilled gasoline at once.
'
Turn the fuel valve "OFF" and disconnect the fuel line.
Remove the fuel tank mounting bolts, then remove the fuel
tank.
Check that fuel flows freely from the fuel valve.
Remove the fuel valve and clean the fuel strainer if fuel flow is
restricted.
INSTALLATION
install the fuel tank.

Connect the fuel line.
Install the seats.
After assembly, make sure there are no fuel leaks.
CAUTION
Du not overtighten the fuel valve.
FUEL SYSTEM
CRANKCASE BREATHER
Route the crankcase breather tube as shown.
BREATHER SEPARATOR
REMOVAL/INSTALLATION
Remove the air cleaner case (Page 4-1 2).

Remove the breather separator from the air cleaner case.
Disassemble the breather separator.
Wash the separator element i n non-flammable or high flash
point solvent, squeeze out the solvent thoroughly and allow t o
dry.
Assemble the breather separator and install it.
Install the air cleaner case (Page 4-13).
FUEL SYSTEM
PURGE CONTROL VALVE INSPECTION (1) PURGE CONTROL(2) VACUUM PUMP

ST-AH-260-MC7 (U.S.A. only)
(CALIFORNIA MODEL)
NOTE
The purge control valve should be inspected if hot restart is
difficult.
Check all fuel tank, Purge Control Valve (PCV), and charcoal
canister hoses t o be sure they are not kinked and are securely
connected.
Rkplace any hose that shows signs of damage or deterioration. (5) CARBURETOR
NOTE
The PCV is located on the right side of the air cleaner case.
Disconnect the PCV hoses from their connections and remove

the PCV from its mount. Refer t o the routing label on the fuel
tank for hose connections.
-260-MC7, (U..S.A. only)

Connect a vacuum pump to the 8 mm I.D. hose that goes to
the air cleaner. Apply the specified vacuum t o the PCV.
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuum should be maintained.

Replace the PCV if vacuum is not maintained.
Remove the vacuum pump and connect it to the hose that

goes to the carburetor.
Apply the specified vacuum to the PCV. ) VACUUM PUMP
SPECIFIED VACUUM: 250 mm (9.8 in) Hg
The specified vacuum should be maintained.

Replace the PCV if vacuum is not maintained.
Connect a pressure pump to the 8 mm I.D. hose that goes to

the charcoal canister. While applying the specified vacuum to
the PCV hose that goes to the carburetor, pump air through (2) PRESSURE
the canister hose. Air should flow through the PCV and out the ST-AH-255-MC7 (U.S.A. only)
hose that goes to the air cleaner. Replace the PCV if air does
not flow out.
CAUTION
To prevent damage to the purge control valve, do not use high
air pressure sources. Use a hand operated air pump only.
Remove the pumps, install the PCV on its mount, route and re-
connect the hoses according to the routing label.
FUEL SYSTEM
'85 :
Route the vacuum hoses as shown on the Vacuum Hose Rout-
ing Diagram Label.
NOTE
Be careful n o t t o bend, t w i s t or kink the hose$ when install-
ing.
Slide the end of each hose onto its fitting fully and secure
w i t h the hose ciamps.
Secure w i t h the hose clamps whenever specified.
Check that the hoses are not contact sharp edges or cor-
ners.
After '85:
MI LY IDENTIFICATION - GHN023441CO
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MEMO
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ENGINE REMOVALIINSTALLATION I
'85, '86: 24-30 N-m

7- 11 N.m (2.4-3.0 kg-m, 17-22 ft-lb)
(0.7- 1.1 kg-m,
5-8 ft-lb) 24-30 N-m (2.4-3.0 kg-rn, 17-22 ft-lb)
After '86:
12-15 N-m
(1.2-1.5 kg-m,
9- 11 ft-lb)
80-100 N-m
'(8.0- 10.0 kg
58-72 ft-lb)
22-29 ft-lb) I
55-70 N-rn
(5.5-7.0 kg-rn, 40-51 ft-lb)
5. ENGINE REMOVAL/INSTALLATION
SERVICE INFORMATION 5-1 ENGINE INSTALLATION 5-4
ENGINE REMOVAL 5-2
SERVICE INFORMATION
GENERAL
0 The engine must be removed from the frame to service the following parts:
,Cylinder head (Section 6)
Cylinderlpistons (Section 7)
CrankshaftiTransmission/Crankcase (Section 10)
SPECIFICATION
Engine dry weight
TORQUE V A L U E S
Front engine mounting bolt (10 mm) 55-70 N*m (5.5-7.0 kg-m, 40-51 ft-lb)
Rear engine mounting bolt (10 mm) 80- 100 N-m (8.0- 10.0 kg-m, 58-72 ft-lb)
Engine hanger plate bolt (8 mm) 24-30 Nwm (2.4-3.0 kg-m, 17-22 ft-lb)
Drive sprocket bolt 10-14 N-m (1.O-1.4 kg-m, 7-10 ft-lb)
Footpeg mounting bolt 35-40 N-m (3.5-4.0 kg-m, 22-29 ft-lb)
Exhaust pipe joint nut '85, '86: 7-1 IN-m (0.7-1.1 kg-m, 5-8 ft-lb)
After '86: 12- 15 N.m (1.2- 1.5 kg-m, 9- 1Ift-lb)
Exhaust muffler mounting nut 18-25 N-m (1.8-2.5 kg-m, 13-18 ft-lb)
Exhaust muffler joint bolt 24-30 N-m (2.4-3.0 kg-m, 17-22 ft-lb)
ENGINE REMOVAL/INSTALLATION
ENGINE REMOVAL
Drain the engine oil (Page 2-21.
Remove the following:
- fuel tank (Page 4-1 1).
- exhaust pipe joint nuts.
- exhaust muffler mounting nuts.
- exhaust pipeslmufflers.
Disconnect the starter motor positive cable.
Disconnect the crankcase breather tube from the crankcase

side.
Remove the left side cover and disconnect the alternator
wires.
Loosen the carburetor insulator clamp.
Remove the h i v e sprocket cover.

Loosen the drive chain (Page 3-1 1).
Remove the drive sprocket cover and drive sprocket.
ENGINE REMOVALIINSTALLATION
Remove the right footpeg mounting bolts and right footpeg.
1
Remove the spark plug caps.
Disconnect the clutch cable at it s lower end.

- engine hanger plates.
- front and rear mounting bolts.
- engine from the right side.
Note the direction of the mounting bolts.

ENGINE INSTALMION
lnstall the engine in the frame and tighten the engine
bolts and hanger plate bolts.
TORQUE:
FRONT ENGINE MOUNTING BOLT (10 mm):
55-70 N-m (5.5-7.0 kg-m, 40-51 ft-lb)
REAR ENGINE MOUNTING BOLT (10 mm):

80- 100 N.m (8.0- 70.0 kg-m, 58-72 ft-lb)
ENGINE HANGER PLATE BOLT (8 mm):

24-30 Nom (2.4-3.0 kg-m, 17-22 ft-lb)
Install the drive sprocket and tighten the bolts.
TORQUE: 10-14N.m (1.0-1.4 kg-m, 7-loft-lb)
Install the drive sprocket cover and gearshift linkage arm.

Install the left footpeg and tighten the mounting bolts.
TORQUE: 35-40 N.m (3.5-4.0 kg-m, 22-29 ft-lb)
lnstall the removed parts in the reverse order of removal.

Route the cables and wires properly (Page 1-81.
Adjust the clutch cable lever free play (Page 3-1 5).
Adjust the drive chain slack (Page 3-1 1).
Fill the recommended engine oil (Page 2-2).
EXHAUST MUFFLER INSTALLATION
Loosely install the exhaust pipeslmufflers.

Tighten the exhaust pipe joint nuts.
TORQUE: '85, '86: 7- 11 N*m

(0.7-1 .Ikg-m, 5-8 ft-lb)
After '86: 12- 15 N-m
(1.2-1.5 kg-m, 9-11 ft-lbl
Tighten the exhaust muffler mounting nuts.
TORQUE: 18-25 N-m (1.8-2.5 kg-m, 13-18 ft-lb)

MEMO
CYLINDER HEADIVALVES
8-12 N-m
(0.8-1.2 kg-m, 6-9 ft-lb)
2.1 -2.5 kg-m, 15- 18 ft-ib)
10-14 N.m
(1.0-1.4 kg.
7-10 ft-lb)
17-23 N.m
(1.7-2.3 kg-m, 12- -17 ft-lb)
-
6. CYLINDER HEAD/VALVES
SERVICE INFORMATION 6- 1 VALVE SEAT INSPECTIONIREFACING 6-9
TROUBLESHOOTING 6-2 CYLINDER HEAD ASSEMBLY 6-12
ROCKER ARMICAMSHAFT REMOVAL 6-3 CYLINDER HEAD INSTALLATION 6-1 3
CYLINDER HEAD REMOVAL 6-6 CAMSHAFT AND ROCKER ARM
6-7 INSTALLATION 6-13
CYLINDER HEAD DISASSEMBLY
VALVE GUIDE REPLACEMENT 6-9
SERVICE lNFORMATION
I) h
GENERAL
The rocker arms and camshaft citn be serviced w i t h the engine installed in the frame.
Camshaft lubricating oil is fed t o the cylinder head through oil passages in the cylinder head. Be sure the oil passages are
not clogged and the stud seals and dowel pins are in place before installing the cylinder head.
Pour clean engine oil into the oil pockets in the cylinder head t o provide initial lubrication.
SPECIFICATIONS
SERVICE LIMIT
ITEM STANDARD m m (in)
m m (in)
Compression pressure 1,400+- 200 kPa (1 4 +- 2 kg/cm2, 199 -+ 28 psi)
Camshaft Cam lobe height IN 27.437 (1.0801) 27.2 (1.07)
EX 27.263 (1.0733) 27.0 (1.06)
Runout - 0.05 (0.002)
Journal O.D. 19.967- 19.980(0.7861-0.7866) 19.92 (0.784)
Camshaft bushing I.D. 20.063-20.083 (0.7899-0.7907) 20.20 (0.795)
Rocker arm Rocker arm I.D. 10.000- 10.015 (0.3937-0.3943) 10.1 (0.40)
Rocker arm shaft O.D. 9.978-9.987 (0.3928-0.3922) 9.17 (0.361)
Valves and Valve stem O.D. IN 5.450-5.465 (0.2146-0.2152) 5.42 (0.213)
valve guides EX 5.430-5.445 (0.2138-0.21 44) 5.40 (0.213)
Valve guide I.D. 5.475-5.485 (0.2156-0.21 59) 5.50 (0.217)
Stem-to-guide clearance IN 0.010-0.035 (0.0004-0.0014) 0.08 (0.003)
EX 0.030-0.055 (0.0012-0.0022) 0.10 (0.004)
Valve seat width 1.1-1.5 (0.04-0.061 1.8 (0.07)
Valve springs Free length Inner 29.9 (1 .I8) 29.0 (1 .I41
Outer 38.2 (1.50) 37.0 (1.46)
Cylinder head warpage - 0.1 (0.004)
TORQUE VALUES
Cylinder head bolt 10-14 Nom (1.0-1.4 kg-rn, 7 - l o f t - l b )

Cylinder head/camshaft holder nut 21 - 2 5 Nom (2.1 -2.5 kg-rn, 15-18 ft-lb)
Cam sprocket bolt 17-23 Nern (1.7-2.3 kg-m, 12- 17 ft-lb)
Cylinder head cover bolt 8 - 12 N-m (0.8-1.2 kg-m, 6 - 9 ft-lb)
TOOLS
Special
Valve guide reamer, 5.47 mm
Common
Valve spring compressor
Valve guide driver, 5.5 rnm
Engine top-end problems usually affect engine performance. These problems can be diagnosed by a compression test, or by
tracing engine noises t o the top-end with a sounding rod or stethoscope.
Low compression Excessive noise

Valves: lncorrect valve adjustment
- lncorrect valve adjustment Sticking valve or broken valve spring
- Burned or bent valve Damaged or worn rocker arm or camshaft
- lncorrect valve timing Worn or damaged cam chain
- Weak valve spring Worn or damaged cam chain tensioner
Cylinder head: Worn cam sprocket teeth
- Leaking or damaged head gasket
- Warped or cracked cylinder head Poor idling
Cylinder and piston (Section 7) Compression too low
High compression
Excessive carbon build-up on piston crown
or on combustion chamber
CYLINDER HEADffALVES
ROCKER ARM/CAMSHAFT REMOVAL

NOTE
The rocker arm'and camshaft servicing can be performed
with the engine installed in the frame.

Remove the spark plug caps.
Remove the cylinder head cover.
Loosen the cylinder head hold down bolts and nuts in the s6-.
quence shown in 2-3 steps.
Remove the nuts and camshaft holders.
Remove the dowel pins.
Thread a 5 mm screw into the rocker arm shaft and pull the
rocker arm shaft out of the camshaft holder.
Remove the rocker arms and rocker arm springs,
NOTE
Mark each part t o insure they are replaced in their original
places.
Remove the flywheel cap. (3) CAM CHAIN TENSIONER ."*

Remove the cam sprocket bolt.
Turn the crankshaft counterclockwise one turn, and remove
the other cam sprocket bolt.
NOTE
Be careful not t o drop the cam sprocket bolts into the crank-
case.
Pull the wedge A of the cam chain tensioner straight up while

holding the wedge B down.
Secure wedge A with a 2 mm pin.
Slide the cam sprocket off the camshaft flange and remove the
cam chain from the sprocket.
Remove the camshaft from the right side and remove the cam
sprocket.
Hang the cam chain with a piece of wire t o prevent it from fall-
ing into the crankcase.
Remove the' snap ring, spacer and bushings from the cam-
shaft.
NOTE
The snap ring and spacer are installed at the left side only.
INSPECTION
lnspect the rocker arms for wear or damage t o the-camshaft

contact surface and for a plugged oil hole.
NOTE
* If the camshaft contact surface of the rocker arm is dam-
aged or abnormally worn, check the cam lobes for damage.
Measure the I.D. of each rocker arm.
Inspect the rocker arm shafts for wear or damage.

Measure the O.D. of each rocker arm shaft.
SERVICE LIMIT: 9.17 rnm (0.361 in)
lnspect the camshaft bushings for wear or damage.

Measure the I.D. of each bushing.
SERVICE LIMIT: 20.20 mrn (0.795 in)
Support both ends of the camshaft with V-blocks and measure

the camshaft runout with a dial indicator.

Measure the camshaft journal O.D.
SERVICE LIMIT: 19.92 mm (0.784 in)
Measure the height of each cam lobe.
SERVICE LIMITS:
Intake: 27.2 rnm (1.07 in)
Exhaust: 27.0 mm (1.06 in)
CYLINDER HEAD REMOVAL

Remove the engine from the frame (Section 5).
Remove the camshaft (Page 6-31.
Remove the intake manifold from the cylinder head.
Remove the cam chain tensioner upper bolt and loosen the
lower bolt.
Remove the cylinder head bolts and the cylinder head.
NOTE
* The front cylinder head bolt nut may fall from the cylinder.
Do not lose the nut.
CAUTION
Do not strike the cylinder head fins to remove the head.
Remove the dowel pins, stud seals and cylinder head gasket,
b
CYLINDER HEAD DISASSEMBLY
Remove the spark plugs from the cylinder head.
Remove the valve spring cotters, retainers, springs and valves.
CAUTION
To prevent loss of tension, do not compress fhe valve springs
more than necessary to remove the cotters.
NOTE
Mark all parts during disassembly so they can be placed
back in their original locations.
Remove carbon deposits from the combustion chamber.

Clean off the head gasket surfaces.
ITE
Avoid damaging the gasket surfaces.
Gasket will come off easier if soaked in sofvent.
INSPECTION
Check the spark plug hole and valve areas for cracks.
Check the cylinder head for warpage with a straight edge and
a feeler gauge.
SERVICE LIMIT: 0.1 mm (0.004in)
Measure the free length of the inner and outer valve springs.
SERVICE LIMIT:
Inner: 29.0 mm (1.I4in)
Outer: 37.0mm (1.46in)
Inspect each valve for bending, burning, scratches or

abnormal stem wear.
Check the valve movement in the guide.
Measure and record each valve stem O.D.
SERVICE LIMIT:
Intake: 5.42mm (0.213in)
y: '1,
Exhaust: 5.40mm (0.213in)
NOTE
* Ream the guides t o remove any carbon deposits before
checking valve stem-to-guide clearance.
Measure and record each valve guide I.D.
Subtract each valve stem O.D. from the corresponding guide

I.D. to obtain the stem-to-guide clearance.
SERVICE LIMIT:
Intake: 0.08mm (0.0031in) I
Exhaust: 0.10mm (0.0039in)
If the stem-to-guide clearance exceeds the service limits, de-

termine if a new guide with standard dimensions would bring
the clearance within tolerance. If so, replace any guides as
necessary and ream t o fit.
If the stem-to-guide clearance exceeds the service limits with

new guides, also replace the valves.
NOTE
Reface the valve seats whenever the valve guides are re-
place.
CYLINDER HEADfVALVES
VALVE GUIDE REPLACEMENT

f
(1) VALVE GUIDE DRIVER, 5.5 mm
Heat the cylinder head to 100°-1 50°C (212°-3000F) with

a hot plate or oven.
To avoid burns, wear heavy gloves when handliqg the heated

cylinder head.
CAUTION
*" Do not use a torch to heat the cylinder head; it may cause
warping.
Support the cylinder head and drive out the old guides from the +
combustion chamber side of the cylinder head. ( 1 ) VALVE GUIDE DRIVER, 5.5 mm
NOTE
- Avoid damaging the cylinder head.
Drive new guides in from the rocker arm side of the cylinder
head.
Ream the new valve guides after installation.
NOTE
Use cutting oil on the reamer during this operation.
* It is important that the reamer always be rotated in the
same direction when it is inserted or removed.
Clean the head thoroughly after reaming the valve guides.
VALVE SEAT INSPECTION/REFACING

Clean all intake and exhaust valves thoroughly to remove
carbon deposits.
Apply a light coating of Prussian Blue to each valve seat.

Lap each valve and seat using a rubber hose or other hand-
lapping tool.
Remove and inspect each valve.
CAUTION
The valves cannot be ground. If a valve face is burned or badly
worn or i f it contacts the seat unevenly, reduce the valve.
Inspect the width of each valve seat.
STANDARD: 1. I - 1.5 mm (0.04-0.06 in)

If the seat is too wide, too narrow or has low spots, the seat
must be ground.
VALVE SEAT CUTTERS
Honda Valve Seat Cutters, grinder or equivalent valve seat

refacing equipment are recommended t o correct a worn valve
seat.
NOTE
- Follow the refacer manufacturer's operating instructions.
( I -
VALVE SEAT REFACING
Use a 45 degree cutter t o remove any i,oughness or irregulari-

ties from the seat.
NOTE
Reface the seat with a 4 5 degree cutter when a valve guide
is replaced.
Use a 32 degree cutter t o remove the top 114 of the existing

valve seat material.
Use a 60 deg;ee cutter t o remove the bottom 114 of the old

seat. Remove the cutter and inspect the area you have
refaced.
CYLINDER HEADIVALVFS
Install a 45 degree finish cutter and cut the seat to the proper
width. Make sure that all pitting and irregularities are removed.
) Refinish if necessary.
Apply a thin coating of Prussian Blue t o the valve seat. Press

the valve through the valve guide and onto the seat t o make a
clear pattern.
NOTE
The location of the valve seat in relation t o the valve face is
very important for good sealing.
I
I 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 low on the valve, the seat must be (1) CONTACT TOO LOW
raised using a 60 degree inner cutter.
Refinish the seat to specifications, using a 45 degree finish

cutter.
After cutting the seat, apply lapping compound t o the valve

face, and lap the valve using light pressure.
After lapping, wash all residual compound off the cylinder
head and valve.
NOTE
Do not allow lapping compound t o enter the guides.
CYLINDER HEADIVALVES I
CYLINDER MEAD ASSEMBLY

Install the valve spring seat and a new stem seal.
Lubricate each valve stem w i t h molybdenum disulfide grease
and insert the valve into the valve guide.
To avoid damage t o the stem seal, turn the valve slowly when
inserting.
Install the valve springs and retainers. The springs tightly

wound coils should face i n toward the combustion chamber.
install the valve cotters.
CAUTION
To prevent loss of tension, do not compress the valve springs
more than Scessary to instau the valve cotters.
Tap the valvei stems gently w i t h a soft hammer t o firmly seat

the cotters.
CAUTION
Support the cylinder head above the work bench surface to pre-
venf possible valve damage.
CYLINDER HEAD INSTALMTION

Clean the cylinder head gasket surfaces of any gasket materi-
al.
Make sure that the cam chain guide is installed properly.
lnstall the dowel pins, new stud seals and a new gasket.
lnstall the cylinder head.

lntall the cam chain tensioner upper bolt and sealing washer.
Tighten the cam chain tensioner bolts.
lnstall new O-rings into the grooves in the intake manifold and
install the manifold onto the cylinder head.
lnstall the camshaft, rocker arms and rocker cover.

lnstall the engine in the frame (Section 5).
CAMSHAFT AND ROCKER ARM

INSTALMTIOFI
Apply thin coat of oil t o the rocker arm shafts.
lnstall the rocker arms and springs in the camshaft holder, and
install the rocker arm shafts with the threaded end facing out.
lnstall the camshaft bushings onto both ends of the camshaft.

lnstall the spacer by placing its tab into the groove in the left
end of the shaft and secure it with the snap ring.
Pass the camshaft through the cam chain and sprocket and in-
stall it in the cylinder head.
NOTE
lnstall the cam sprocket with the timing marks (index lines)
facing toward the left side.
Position the knock pins of the camshaft bushings into the

grooves in the cylinder head.
Remove the timing hole cap, turn the crankshaft counter-

clockwise and align the "T" mark on the flywheel with the
index mark on the left crankcase cover.
Align the timing marks (index lines) on the cam sprocket with d'
;,,;
the top of the cylinder head and install the cam chain over the I
sprocket.
,
lnstall the cam sprocket on the camshaft flange and align the
I
cam sprocket bolt holes in the sprocket and camshaft.
Apply locking agent to the threads of the cam sprocket bolts,

(I:
and install and tighten the sprocket bolt.
TORQUE: 17-23 Nsm (1.7-2.3 kg-rn, 12- 17 ft-lb)
Turn the crankshaft counterclockwise 360° and install the

other bolt.
Make sure that the timing marks on the sprocket align with the
top of the cylinder head.
lnstall the dowel pins into the cylinder head.
Loosen the valve adjusting screws fully and install the cam-
shaft holders with the "F" mark toward the front. e
lnstall the cylinder head bolts, nuts and washers.

Tighten the nuts and bolts in the sequence shown in 2-3 steps.
TORQUE:
Nut: 21 -25 N.m (2.1-2.5 kg-m, 15-18 ft-lb)
Bolt: 10- 14 N-m (1.0-1.4kg-m, 7- I0 ft-lb)
I
I
Pour fresh oil into the oil pockets in the cylinder head until the
cams are submerged.
Adjust the valve clearance (Page 3-91.
Inspect the cylinder head cover gasket for damage or deterio-

ration and replace with new one if necessary.
Install the cylinder head cover and tighten the cover bolts.
lnstall the spark plug caps t o the plugs.

lnstall the fuel tank (Page 4-1 11.
SERVICE INFORMATION 7-1 PISTON 7-3
TROUBLESHOOTING 7-1 PISTONICYLINDER INSTALLATION 7-5
CYLINDER 7-2
' 1' SERVICE INFORMATION

GENERAL
Cylinder head lubricating oil is fed through an oil passage in the cylinder.
*
Be sure this oil passage is not clogged and that the O-rings and dowel pins are in place before installation.
Refer t o section 10 for the cam chain tensioner removal and inspection.
SPECIFICATIONS
Cylinder I.D.
Taper 0.05 (0.002)
1 Out of round I / 0.05 (0.002) 1
Warpage across top - 0.05 (0.002)
Piston, Piston O.D. 52.97-52.99 (2.085-2.086) 52.9 (2.08)
piston pin, Piston pin bore 15.002- 15.008 (0.5906-0.5908) 15.05 (0.593)
piston rings
Piston pin O.D. 14.994- 15.000 (0.5903-0.5906) 14.98 (0.590)
/ Piston-to-pin clearance / 0.002-0.01 4 (0.0001 -0.0006) 1 0.07 (0.003) 1
Piston ring-to-ring TOP 0.01 5-0.040 (0.0006-0.001 6) 0.1 (0.004)
groove clearance SECOND 0.01 5-0.045 (0.0006-0.001 8) 0.1 (0.004)
Piston ring end gap TOPISECOND 0.1 5-0.35 (0.006-0.014) 0.5 (0.02)
OIL/SIDE RAIL 0.2-0.9 (0.008-0.036) -
1 Cylinder-to-piston clearance I 0.01 -0.04 (0.0004-0.001 6) 1 0.1 (0.004) 1
I Connecting rod small end 1.0. 1 '1 5.01 6- 15.034 (0.591 2-0.591 9) / 15.08 (0.594) /
TOOLS
Special
) Piston ring compressor
Piston base
TROUBLESHOOTING
) Low or unstable compression Knocking or abnormal noise
Worn cylinder or piston rings Worn piston and cylinder
Cylinder head and valves (Section 6) Excessive carbon build-up
bcessive smoke
') Worn cylinder, piston, or piston rings

Improper installation of piston rings
Scored or scratched piston or cylinder wall
Overheating
Excessive carbon build-up on piston or
combustion chamber wall
CYLINDER
REMOVAL
- cylinder head (Page 6-61.
- cam chain tensioner lower bolt (Page 6-61.
- tensioner guide
- stud seals, dowel pins and the cylinder head gasket.
- cylinder
Remove the dowel pins and cylinder gasket.
Clean off the gasket material from the cylinder surface.
NOTE
Be careful not to damage the gasket surface.
INSPECTIO~I
Inspect the top of the cylinder for warpage.

Inspect the cylinder walls for scratches and wear.
Measure and record the cylinder I.D. at three levels in both an
X and Y axis. Take the maximum reading t o determine the cyl-
inder wear.
SERVICE LIMIT: 53.1 mm 12.09 in)
Calculate the piston-to-cylinder clearance. Take the maximum

reading to determine the clearance.
Refer to page 7-4 for measurement of the piston O.D.
SERVICE LIMITS: 0.05mm (0.002

in)
Calculate the cylinder for taper at three levels in an X and Y

axis. Take the maximum reading t o determine the taper.
SERVICE LIMIT: 0.05mm (0.002in)
Calculate the cylinder for out-of-round at three levels in an X

and Y axis. Take the maximum reading t o determine the out-
of-round.
The cylinder must be rebored and oversize piston fitted if the

service limits are exceeded.
The following oversize pistons are available:
in) and 0.75mrn (0.030

0.25mm (0.010in). 0.50mm (0.020
in), I .OO mm (0.039in)
The cylinder must be rebored so that the clearance t o an over-

size piston is 0.01 8-0.048 mm (0.0007-0.001 9 in).
PISTON
REMOVAL
Remove the piston pin clip with pliers.
NOTE
Do not let the clip fall into the crankcase.
Press the piston pin out of the piston and remove the piston.
INSPECTION
Remove the piston rings.
NOTE
Do not the damage the piston ring during the removal.
Measure the piston ring-to-groove clearance.
SERVICE LIMIT:
Top: 0.1 mm (0.004in)
Second: 0.I rnm (0.004in)
Measure the O.D. of the piston 10 mm from the bottom and
90° t o the piston pin hole.
Compare this measurement against the service limit and calcu-

late piston-to-cylinder clearance.
Refer t o page 7-3 for measuring the cylinder.
Measure the piston pin hole I.D.
Measure the piston pin O.D.
Compare this measurement against the service limit and calcu-

late piston pin-to-piston pin hole clearance.
Measure the connecting rod small end I.D.

PISTON RlNG INSTALLATION
Clean the piston ring grooves thoroughly and install the piston
rings.
NOTE
Avoid piston and piston ring damage during installation. In-
stall the piston rings with the marking facing up.
Do not the mix top and second rings.
,
Space the piston ring end gaps 120 degrees apart.

Do not align the gaps in the oil rings (side rails).
After installation, the rings should be free to rotate in the
grooves.
(3) O I L RING
-
CY LINDERIPISTON
PISTONICYLINDER INSTALLATION
Apply molybdenum disulfide grease to the connecting rod

small ends.
lnstall the pistons and piston pins with the "IN" mark on the
piston crown positioned toward the intake side.
lnstall new piston pin clips with the end gap away from the
cutout of the piston, being careful not to drop them into the
crankcase.
lnstall the dowel pins and a new cylinder gasket.
.W? ,
Coat the cylinder bores and piston rings with clean engine oil. (1 PISTON RING COMPRESSOR
Place piston bases under the pistons, compress the piston

rings with piston ring compressors and slide the cylinder over
the pistons.
Remove the piston ring compressors and piston bases.
lnstall the tensioner guide, stud seals, dowel pins and a new
cylinder head gasket.
lnstall the cam chain tensioner lower bolt.
lnstall the cylinder head (Page 6-1 5). -
MEMO
CLUTCHIGEARSHIFT LINKAGE
8. CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION 8-1 CLUTCH AND OIL PUMP DRIVE GEARS 8-7
TROUBLESHOOTING 8-2 GEARSHIFT LINKAGE 8-8
RIGHT CRANKCASE COVER REMOVAL 8-3 RIGHT CRANKCASE COVER
INSTALLATION 8-10
CLUTCH 8-4
SERVICE INFORMATION
GENERAL
This section covers removal and installation of the clutch, clutch drive gear, oil pump drive gear, and gearshift linkage.
Clutch maintenance can be done with the engine in the frame.
SPECIFICATIONS
ITEM STANDARD mm (in) SERVICE LIMIT rnm (in)

Clutch Lever free play 10-20 (318-314)
Spring free length 37.8 (1.49) 36.0 (1142)
Disc thickness 2.8-2.9 (0.11-0.1 141 2.6(0.10)
Plate warpage 0-0.10 (0-0.004) 0.2 (0.01)
Outer guide O.D. 25.959-25.980 (1.022-1.023) 25.9 (1.02)
Outer guide I.D. 20.000-20.021 (0.7874-0.7882) 25.05 (0.986)
Outer I.D. 26.000-26.021 (1.0236-1.0244) 26.04(1.0252)
TORQUE VALUES
Clutch lock nut 50-56 Nsm (5.0-5.6kg-m, 36-40 ft-lb)
Clutchioil pump drive gear lock nut 48-60 N-m (4.8-6.0kg-m, 35-43 ft-lb)
Drum stopper plate bolt 10-14 N-m (1 .O-1.4kg-m, 7-10 ft-lb)
Gearshift pedal 7- 1 1 N-m (0.7-1 .I kg-m, 5-8 ft-lb)
TOOLS
Special
Clutch center holder
Common
Gear holder 07724-001 0200
Lock nut wrench, 20 x 24 mm 07716-00201 00
Extension 0771 6-0020500 - Equivalent commercially available in U.S.A.
TROUBLESHOOTIPIG
Faulty clutch operation can usually be corrected by adjusting the free play.
Clutch slips when accelerating

* No free play
Discs worn
* Springs weak
Clutch will not disengage

Too much free play
Plate warped
Motorcycle creeps with clutch disengaged

Too much free play
Plates warped
Excessive lever pressure

Clutch cable kinked, damaged or dirty
Lifter mechanism damaged
Clutch operation feels rough

Outer drum slots rough
Hard shifting
* Stopper plate bent or worn
* Improper clutch adjustment
Gearshift pedal won't return

Return spring broken
Shift spindle interferring with crankcase or cover
Jumps out of gear

Stopper arm spring broken or weak
RIGHT CRANKCASE GOVER REMOVAL

Drain the oil from the engine.
Remove the right crankcase cover bolts and disc6nnect the
clutch cable from the clutch lever.
Remove the right crankcase cover.
Remove the gasket and dowel pins.
CLUTCH LIFTER LEVER DISASSEMBLY

!1) CLUTCH LIFTER CAM
Remove the pin from the clutch lifter cam and pull out the
clutch lifter lever.
CLUTCH LIFTER LEVER ASSEMBLY
Check the disassembled parts for wear or damage, replace the

parts if necessary.
Install the removed parts i n the reverse order of removal.
NOTE
* Use new O-ring and pin whenever the clutch lifter fever is
reassembled.
CLUTCH
REMOVAL
- right crankcase cover (Page 8-3).
- lifter rod and clutch lifter guide.
- lifter plate bolts, plate and clutch springs.
NOTE
-
Loosen the bolts in an X pattern in 2 - 3 steps.
Unstake the clutch lock nut with a drill or grinder. Be careful

not t o damage the shaft threads.
Using a clutch center holder as shown, remove the clutch lock

nut and washer.
TOOLS
Clutch center holder 07923- 9580000
Lock nut wrench, 20 x 24 mm 0771 6-00201 0 0
Extension 0771 6-0020500 - Equivalent commercially
available in U.S.A.
Remove the clutch center, judder seat, judder spring, discs,

plates, pressure plate and splined washer.
Remove the clutch outer, clutch outer guide and thrust wash-
er.
(71 SPLINED WASHER
/ \ 0 ) rncaaunc rLnI c
(4) PLATE
\ 'I VLV ' V
(3) JUDDERSPRING
(~)'JUDDERSEAT
INSPECTION
Check the slots of the clutch outer for nicks, cuts or indenta-
tions made by the clutch discs. Replace if necessary.
Measure the clutch outer 1.D.
Measure the O.D. and I.D. of the clutch outer guide.
SERVICE LIMITS:
O.D.:25.9 mm (1.02 in)
1.0.: 25.05 mm (0.986 in)
Measure the spring free length.
)I ) SERVICE LIMIT: 36.0 mm 11.42 in)
Replace the clutch discs if they show signs of damage or dis-

coloration.
Measure the disc thickness.
Check for plate and disc warpage on a surface plate using a

feeler gauge.
INSTALLATION
Install the thrust washer, clutch outer guide.

Install the clutch outer and splined washer.

1
NOTE
Note the direction of the splined washer.
Install the spring seat and judder spring onto the clutch outer
as shown.
Assemble the clutch pressure plate, discs, plates and clutch
center.
NOTE
Note the direction of the judder spring.
(1) CLUTCH CENTER

JUDDER SPRING
(3) SPR lNG SEAT
Stack the discs and plates alternately.

Coat new clutch discs with engine oil.
Install the lock washer with the word OUTSIDE facing out,
Attach the clutch center holder with the lifter plate bolts.
Install the new lock nut, then tighten it.
TORQUE: 50-56 N-m (5.0-5.6 kg-m,36-40 ft-lb)
TOOL
Clutch center holder 07923- 9580000
Lock nut wrench, 2 0 x 2 4 mm 07716-0010200
Extension 0771 6-0020500
Stake the end of the lock nut into the groove of the main shaft
with a punch.
lnstall the clutch springs and lifter plate.

Tighten the lifter plate bolts.
NOTE
Tighten the bolts in 2 - 3 steps and in cross pattern.
lnstall the bearing, clutch lifter guide and lifter rod.

lnstall the right crankcase cover (Page 8-10).
CLUTCH AND OIL PUMP DRIVE GEARS

REMOVAL
Remove the right crankcase cover (Page 8-31.

Remove the oil pass pipe and oil pump (Page 2-31.
Place the gear holder as shown.

Remove the lock nut and washer.
Remove the clutch assembly (Page 8-41.
Remove the oil pump drive gear and clutch drive gear.
INSTALLATION
Install the clutch drive gear and oil pump drive gear onto the
crankshaft.
lnstall the clutch assembly (Page 8-5).
lnstall the pin.
rnstall the lock washer with the word OUTSIDE facing out.
CLUTCHlGEARSHlFT LINKAGE
Attach the gear holder.

Tighten the lock nut.
TORQUE: 48-60 N-m (4.8-6.0 kg-rn, 35-43 ft-lb)
Install the oil pump (Page 2-51 and oil pass pipe with the
spring.
Install the right crankcase cover (Page 8-1 0).
GEARSHIFT LINKAGE
DISASSEMBLY

- oil pump (Page 2-3).
- clutch assembly (Page 8-4).
- gearshift pedal arm from the gearshift spindle.
Pull the gearshift spindle out of the crankcase.

- drum stopper bolt and stopper.
- drum stopper plate bolt and plate.
- drum pins.
CLUTCHlGEARSHIFT LINKAGE
I GEARSHIFT SPINDLE INSPECTION
I*) Check the gearshift spindle for wear or damage. .
ASSEMBLY
lnstall the drum pins into the gearshift drum.

lnstall the drum stopper plate by aligning the drum pins with
the drum stopper plate holes.
Tighten the drum stopper plate bolt.
TORQUE: 10-14 Nam (1 .O-1.4kg-m, 7- I0 ft-lb)
lnstall the drum stopper.
NOTE
Before tightening the bolt, make sure that the stopper is po-
sitioned properly.
DRUM STOPPER
lnstall the gearshift spindle into the crankcase.

Insert end of the spring into the shift return spring pin.
lnstall the gearshift pedal arm and check the operation of the
gearshift linkage.
lnstall the following:
- oil pump (Page 2-51.
- clutch assembly (Page 8-5).
I
RIGHT CRANKCASE COVER lNSTALLATION
Install the dowel pins and a new gasket.
Install the right crankcase cover.

Connect the clutch cable to the clutch lever.
Tighten the case bolts securely.
Adjust the clutch (Page 3-1 5).

Fill the engine with the recommended oil (Page 2-2).
Start the engine and check the clutch for smooth operation
Be sure there are no oil leaks.
MEMO
ALTERNATORISTARTER CLUTCH
9. ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION 9-1 STARTER CLUTCH 9-3
ALTERNATOR 9-2
SERVICE INFORMATION
) GENERAL
Refer to section 16 for troubleshooting and inspection of the alternator.
Refer to section 16 for service procedures and information of the starter motor.
The alternator and starter clutch can be serviced with the engine installed in the frame.
'I' ) SPECIFICATIONS
ITEM ~ A N D A R Dmm (in) SERVICE LIMIT mm (in1

1.D. 22.010-22.022 (0.8666-0.8670) 22.08 (0.8691
Starter driven sprocket
O.D. 36.975-37.000 (1.4557-1.45671 36.90 (1.453)
I
TORQUE VALUE
I
Flywheel bolt 55-65 N-m (5.5-6.5 kg-m, 40-47 ft-lb)
Starter clutch screws 8-12 N.m (0.8-1.2 kg-m, 6-9 ft-lb) Apply a locking agent.
TOOLS
Fli ) common
Flywheel puller 07733-0020001 or 07933-21 60000
Flywheel holder 07725-0040000 or Equivalent commercially
available in U.S.A.
I
ALTERNATOR
REMOVAL
Disconnect the alternator wires.
Remove the gearshift.peda1 arm.
Remove the drive sprocket cover.
Remove the left crankcase cover and alternator wire grommet
from the crankcase groove.
Hold the flywheel with the flywheel holder and remove the fly-
wheel bolt.
Remove the flywheel with the flywheel puller.

Remove the washer.
/
.a 07933-2160000
..n.~ 1 Equivalent commercially
STATOR REMOVAL/INSTALLATlON

- pulse generator attaching screws and the pulse generator.
- wire clamp attaching screw and the wire clamp.
- stator attaching screws and the stator.
Install the stator and pulse generator in the reverse order of re-
moval.
NOTE
lnstall the stator and pulse generator wire grommets se-
curely into the left crankcase cover.
INSTALLATION
NOTE
Check that there is no debris inside the flywheel before in-
stallation. The magnets tend t o attract steel filings and
other ferrous material.
* Clean the tapered hole in the rotor of any burrs and other
faults.
lnstall the washer, then install the flywheel aligning its groove
with the dowel pin on the crankshaft.
lnstall the flywheel bolt.

Hold the flywheel with the flywheel holder and tighten the
bolt.
TORQUE: 55-65 N.m (5.5-6.5 kg-m,40-47 ft-lbl
lnstall the left crankcase cover.
NOTE
lnstall the alternator grommet securely into the left crank-
case cover groove.
lnstall the drive sprocket cover and gearshift pedal arm

Connect the alternator wires.
lnstall the left side cover.
STARTER CLUTCH
REMOVAL
Remove the flywheel.

Remove the starter driven sprocket setting plate.
Remove the starter drive, driven sprockets and drive chain.
(3)SETTING PLATE BOLT
Remove the left side spacer and dowel pins.

Check the starter driven gear for abnormal wear or damage.

Check the starter drive and driven gear teeth for wear or dam-
age.
Check the oil seal for wear or damage.
gl-
Measure starter driven sprocket I.D. and O.D.
SERVICE LIMIT:
1.D.: 22.08 rnrn (0.869 in)
O.D.: 36.90 mrn (1.453 in)
Remove the rollers, spring caps and springs from the flywheel.
Check all parts for wear, damage or deformation.
Remove the clutch outer attaching screws with a impact driv-

er.
Remove the starter clutch and side plate.
Check the roller contacting area of the clutch outer for wear or
damage. (1) WEAR
ASSEMBLY 8- 12 ~ . r n(0.8-1.2 kg-rn, 6-9 ft-lb)
If the flywheel is to be replaced, insert the dowel pin into the

hole of the new flywheel.
Install the side plate, aligning its hole with the dowel pin.
PIN
Install the starter clutch outer using new screws with thread
locking agent.
Install the springs, spring caps and rollers into the clutch outer.
Check the starter clutch for smooth operation as shown.

INSTALLATION
Install the dowel pins and side spacer.
Install the starter driven, drive sprocket and drive chain.

lnstall the starter driven sprocket setting plate.
lnstall the flywheel (Page 9-3).
I SERVICE INFORMATION 10-1 CRANKSHAFT
TROUBLESHOOTING 10-2 BEARING REPLACEMENT 10-10
CRANKCASE SEPARATION 10-3 CRANKCASE ASSEMBLY 10-12
TRANSMISSION 10-4
' ' SERVICE INFORMATION

GENERAL ,
The crankcase halves must be separated to repair the transmission or crankshaft.
9 Remove the following parts before separating the crankcase.

Engine
Oil pump
(Section 5)
(Section 2)
CylinderIPistons
Clutch/Gearshift linkage
(Section 7)
(Section 8)
Cylinder head (Section 6) Alternatorlstarter clutch (Section 9)
SPECIFICATIONS
I ITEM STANDARD mm (in) I SERVICE LIMIT mm (in)

Shift fork pawl thickness 4.93-5.00 (0.194-0.1 97) 4.80 (0.189)
I.D. P
12.000- 12.018 (0.4724-0.4731) 12.05 (0.474)
Shift fork shaft O.D. 11.976- 11.994 (0.4715-0.4722) 1 1.93 (0.470)
- .
,1 Gear I.D.
C1 gear bushing
O.D. 19.979-20.000 (0.7866-0.7874) 19.93 (0.785)
Mainshaft O.D. M5, clutch outer 1 19.959- 19.980 (0.7858-0.7866) 19.91 (0.784)
Countershaft O.D.
Crankshaft big end side clearance 0.10-0.40 (0.004-0.01 6) 0.6 (0.024)

Crankshaft big end radial clearance 0.004-0.01 2 (0.0001 6-0.0005) 0.05 (0.002)
Crankshaft runout left and right - 0.1 (0.004)
bearing holder - 0.1 (0.004)
TORQUE VALUES
) Crankshaft mounting bolt 20-25 N'm (2.0-2.5 kg-m, 14- 18 ft-lb)
Crankshaft mounting nut 10- 14 N-m (1.0- 1.4 kg-m, 7- I 0 ft-lb)
Oil through plate attaching screw 8- 12 N-m (0.8-1.2 kg-m, 6-9 ft-lb) Apply a locking agent
TOOLS
Special
Bearing remover, 15 mm
Remover weight
Common
Pilot, 2 0 mm
Pilot, 25 mm
Pilot, 2 2 mm
Driver
Engine noise
-
* Worn crankshaft bearing
Worn connecting rod big end bearing
* Worn transmission bearing
Transmission jumps out of gear

Worn gear dogs and slots
Bent or damaged shift fork
Bent shift fork shaft
Damaged shift drum stopper
Hard t o shift
Clutch not adjusted properly
Bent shift fork
Bent shift fork shaft
Worn or damaged shift drum cam grooves
CRANKCASE SEPARATION
Remove the neutral switch set plate neutral switch.
Remove the t w o crankcase attaching bolts from the left crank-

case.
Remove the eight crankcase attaching bolt from the right

crankcase.
Separate the right and left crankcase halves
Remove the gasket and dowel pins.

TRANSMISSION
REMOVAL
Remove the shift fork shaft, shift forks and shift drum.
Remove the mainshaft and countershaft assemblies as a set

from the left crankcase.
INSPECTION
Check that the shift forks are not bent, worn or damaged.
Measure the I.D. and shift pawl thickness.
SERVICE LIMIT:
Pawl thickness: 4.80 mm (0.189 in)
1.D.: 12.05 mm (0.474 in)
Check that thecshiftfork shaft are not bent, worn or damaged.

Measure the shift fork shaft O.D.

Inspect each gear for wear or damage and replace if neces-
sary.
Check the gear teeth for wear or damage.
Check the engagement dogs of the gears for wear or damage.
Measure the I.D. of each gear
SERVICE LIMIT:
M5, Cl. 64: 20.08 rnrn (0.791in)
Measure the C1 gear bushing I.D. and O.D.
SERVICE LIMIT:
I.D.: 16.58 rnrn (0.653 in)
O.D.: 19.93 rnrn (0.758 in)
Measure the O.D. of the mainshaft and countershaft.
SERVICE LIMIT:
M5. clutch outer: 19.91 rnrn (0.784 in)
C1: 16.41 rnrn (0.646 in)
C4: 19.91 rnrn (0.784 in1
Assemble the transmission gears and shafts.
Coat each gear with clean engine oil and check for smooth
movement.
( 1 COUNTERSHAFT
lnstall the mainshaft and countershaft assemblies together,

into the left crankcase.
Install the shift drum into the left crankcase.

Align the neutral switch rotor with the neutral switch hole on
the left crankcase.
Install the shift forks w i t h their marks facing down, into the
grooves of the shift drum.
Install the shift fork shaft.
After installing, check for smooth operation.
Assemble the crankcase (Page 10-12).
CRANKSHAFT
REMOVAL
Separate the crankcase (Page 10-3).

Remove the transmission (Page 10-4).
Remove the crankshaft mounting bolts and nut and remove
the crankshaft.
Remove the lock pin, plain washer and cam chain tensioner.
Set the crank weight balancer t o the position shown and

remove the cam chain.
INSPECTION
Measure the connecting rod big end side clearance.
Measure the connecting rod big end radial clearance.
Measure the crankshaft runout (left and right side).
Measure the drankshaft runout (bearing holder).
SERVICE LIMIT:
Check the cam chain guide and slipper for damage or exces-
sive wear.
Inspect the tensioner spring damage or weakeness."
1 INSTALLATION
lnstall the cam chain.

Set the crank weight balancer as shown.
I (1) CRANK WEIGHT
BALANCER
I Pass the cam chain between tensioner ,oin and- crank
~ - - - - - weioht
--
balancer.
lnstall while holding the chain between cam chain guide
insetion part and crank weight balancer.
(2) TENSIONER
PIN
lnstall the cam chain tensioner, plain washer and lock pin.
lnstall the crankshaft into the left crankcase.

Tighten the crankshaft mounting bolts and nut.
TORQUE: NUT 10- 14 N-m (1-0-1.4kg-m,7- I0 ft-Ib)

BOLT 20-25 N-m (2.0-2.5 kg-rn, 14-18 ft-lb)
lnstall the transmission (Page 10-61.

Assemble the crankcase (Page 10-1 2).
CRANKCASEITRANSMISSIONICRANKSHAFT
BEARING INSPECTION
Turn the inner race of each bearing with your finger. The bear-
ings should turn smoothly and quietly. The bearings must be
replaced if they do not turn smoothly or quietly.
BEARING REPLACEMENT
Separate the crankcase (Page 10-3).
Remove the transmission and crankshaft (Pages 10-4, 71.
RIGHT CRANKCASE
The bearings must be replaced if they are noisy or have exces-
sive play.
Drive out the mainshaft and crankshaft bearings.
Install the bearings into the right crankcase using the following
TOOLS:
Crankshaft bearing:
Driver 07749- 001 0 0 0 0
Attachment, 6 2 x 6 8 mm 07746-001 0500
Pilot, 25 mm 07746- 0040600
Countershaft bearing:
Driver 07749-001 0 0 0 0
Attachment, 52 x 58 mm 07746-001 0400
Pilot, 2 0 mm 07746-0040500
LEFT CRANKCASE
Remove the oil seals.

CRANKCASEITRARISMISSIORIICRANKSHAFT
Remove the oil through plate attaching screws and remove the
oil through plate.
Drive out the countershaft and crankshaft bearings.

Remove the mainshaft bearing with. the bearing remover.
TOOLS:
Bearing remover, 1 5 m m 0 7 4 3 6 - KC10 5 0 0
Remover weight 07936- 3 7 10200
Install the bearings into the left crankcase.
TOOLS:
Crankshaft bearing:
Driver
Attachment, 6 2 x 6 8 m m
Pilot, 2 5 m m
Mainshaft bearing:
Driver
Countershaft bearing:
Driver
Pilot, 2 2 m m
Install the O-ring as shown.

CRANKCASEITRANSMISSIONICRANKSHAFT
I
Apply a thread lock agent t o the oil through plate attaching
screws, then install the screws.
TORQUE: 8- 12 N.m (0.8-1.2 kg-m, 6-9 ft-lb)
Install the oil seals.
CAUTION
Do not drive the countershaft oil seal below the end of the
crankcase as this will block the oil passage in the shaft.
Install the crankshaft and transmission (Pages 10-9, 6).
CRANKCASE ASSEMBLY
Install a new gasket and dowel pins.
Assemble the crankcase halfs together using the eight attach-

ing bolts.
lnstall the t w o attaching crankcase bolts.
I
Install the neutral switch and neutral switch set plate.
Install the removed parts in the reverse order of removal

(Page 10-1I.
FRONT WHEEtlSUSPENSlONlSTEERlNG
I
4-5 N.m (0.4-0.5 kg-m, 2.9-36 ft-lb)
9-13 N.m (0.9-1.3 kg-m, 6.5-9.4 ft-lb)
27-33 N.? (2.7-3.3 kg-m, 2'0-24 ft-lb)
55-70 N-m
(5.5-7.0 kg-m,',
rn FRONT WHEEL/SUSPENSION/STEERlNG
SERVICE INFORMATION 1 1-1 FRONT WHEEL 11-5
) TROUBLESHOOTlNG 3 1-2 FRONT FORK 11-8
HANDLEBAR 1 1-3 STEERING STEM 11-14
I SERVICE INFORMATION
I GENERAL
I A jack or other support is required to support the front of the motorcycle when working on the front wheel br forks.
This section describes removal, installation and servicing of the front wheel, front fork, steering stem and handlebar.
SERVICE LIMIT
ITEM STANDARD mm (in)
mm (in)
Front axle runout - 0.2 (0.01 1
Front wheel rim runout Radial - 2.0 (0.08)
Axial - 2.0 (0.08)
Fork spring free length 546 (21.5) 535 (21 - 1 )
Fork tube runout - 0.2 (0.011
Fork fluid capacity 235.5-240.5 cc (7.96-8.13 US oz) -
Steering head bearing preload 0.9- 1.25 kg (1.98-2.756 Ib) -
Handlebar upper holder bolt 20-30 N-m (2.0-3.0 kg-m, 14-22 ft-lb)
Handlebar lower holder nut 27-33 N.m (2.7-3.3 kg-m, 20-24 ft-lb)
Axle holder nut 18-25 N-m (1.8-2.5 kg-m, 13-78 ft-lb)
Front axle 55-70 N-m (5.5-7.0 kg-m, 40-51 ft-lb)
Brake disc mounting bolt 37-43 N-m (3.7-4.3 kg-m, 27-31 ft-lb)
Fork top pinch bolt 9- 1 3 N.m (0.9- 1.3 kg-m, 6.5-9.4 ft-lb)
Fork bottom pinch bolt 30-40 N-m (3.0-4.0 kg-m, 22-29 ft-lb)
Steering stem nut 60-90 N-m (6.0-9.0 kg-m, 43-65 ft-lb)
Steering bearing adjustmint nut (First) 30-40 N.m (3.0-4.0 kg-m, 22-29 ft-lb)
(Final) 2.5-3.5 N*m (0.25-0.35 kg-m, 1.8-2.5 ft-lb)
Fork tube cap 15-30 N-m (1.5-3.0 kg-m, 11 -22 ft-lb)
) Fork socket bolt 15-25 N-m (1.5-2.5 kg-m, 11 -18 ft-lb) Apply a locking agent
Front turn signal mounting nut 4-5 N-m (0.4-0.5 kg-m, 2.9-3.6 ft-lb)
Headlight mounting nut 30-40 N-m (3.0-4.0 kg-m, 22-29 ft-lb)
FRONT WHEELISUSPENSIONISTEERING
TOOLS
Speciai
Steering stem socket 0791 6-3710100
Ball race driver 07944- 1150001- Not available in U.S.A.
Steering stem driver 07946- GC40000 -Steering stem driver 07946-MB00000
Attachment 07946-GC4000A (U.S.A. only)
Hex wrench, 6 mm 0791 7-3230000 Equivalent commercially
ava~lablein U.S.A.
Common
Lock nut wrench, 3 0 x 32 mm 077 16-0020400 Equivalent commercially
Extension 0771 6-0020500 available in U.S.A.
Driver 07749-001 0000
Attachment, 3 7 x 40 mm 07746-001 0200
Pilot, 15 mm 07746 - 0040300
Attachment, 42 x 47 mm 07746-001 0300
Bearing remover shaft 07746-00501 0 0 or Equivalent commercially
Bearing remover head, 15 mrn- 07746-0050400 available in U.S.A.
Fork seal driver 07747-0010100 Fork seal driver
Attachment 07747 -001 0500 07947-3330000 (U.S.A. only)
TROUBLESHOOTING
Hard steering
Steering bearing adjustment nut too tight
Faulty steering stem bearings
Damaged upper or lower cone and ball race
lnsufficient tire pressure
Steers to one side or does not track straight

Bent forks
Bent front axle
Wheel installed incorrectly
Front wheel wobbling

Bent rim '
Worn front wheel bearings
Faulty tire
* Axle and holder tightened improperly
Soft suspension
Weak fork springs
lnsufficient fluid in forks
Hard suspension
Incorrect fluid weight in forks
Bent fork tubes
Clogged fluid passage
Front suspension noise

Worn slider or guide bushings
lnsufficient fluid in forks
Loose front fork fasteners
Lack of grease in speedometer gearbox
FRONT WHEELISUSPENSIONISTEERiNG
HANDLEBAR
) REMOVAL
- wire bands from the handlebar.
- clutch and front brake lever brackets.
Remove the right and left handlebar switch mounting screws.

Disconnect the right and left handleber switch connectors.
Disconnect the choke and throttle cables.
Remove the grip end attaching screw, then remove the grip
end and throttle grip.
Remove the upper handlebar holder bolts and holders.
Remove the handlebar.
Remove the speedometer, ignition switch, and connection box
(pages 17-3,5).
Remove the front turn signal mounting nuts, then remove the
front turn signals.
Remove the lower handlebar holder nuts, holders and bush-
ings.
Inspect the rubber bushings for the damaged or deteriorated.
INSTALLATION
' Install the lower handlebar holders and bushings into the fork
) top bridge and attach then with the washers and nuts.
I
I
I 11-3
lnstall the right and left turn signals to the handlebar lower
holders.
Tighten the turn signal mounting nuts.
TORQUE: 4-5 N.m (0.4-0.5 kg-m, 2.9-3.6 ft-lb)
lnstall the ignition switch onto the top bridge.
Place the handlebar onto the handlebar lower holder.

Align the punch mark on the handlebar with the top of the
handlebar lower holder.
lnstall the handlebar upper holders on the handlebar with the

punch mark on the holder forward.
Tighten the forward bolts first, then the rear one.
TORQUE: 20-30 M.m (2.0-3.0 kg-m, 14-22 ft-lb)
Tighten the handlebar lower holder nuts t o the specified

torque.
TORQUE: 27-33 M-m (2.7-3.3 kg-rn, 20-24 ft-lb)
lnstall the speedometer and connection box.

lnstall the throttle grip and grip end onto the handlebar with
screw.
Connect the throttle cables and grease the throttle cable ends.
Align the right handlebar switch locating pin with the hole in
the hondlebar and install the right handlebar switch.
Tighten the forward screw first, then the rear screw.
Place the front brake master cylinder on the handlebar and in-
stall the attadhing bracket with the UP mark facing up.
Align the punch mark on the handlebar with the end of the
bracket, and tighten the upper bolt first, then the rear lower
bolt.
Connect the right handlebar switch connectors.
Connect thechoke cable t o the choke lever.

Align the left handlebar switch locating pin with the hole in the
handlebar and install the left handlebar switch.
Tighten the upper screw first, then the rear screw.
FRONT WHEELlSUSPENSlONlSTEERlMG
Place the clutch lever on the handlebar and install the bracket
with the UP mark facing up.
Align the punch mark on the handlebar with the end of the
bracket and tighten the upper bolt first, then the lower bolt.
Install the wire bands,
FRONT WHEEL
REMOVAL
Raise the front wheel off the ground by placing a block or work
stand under the engine.
Disconnect the speedometer cable from the gear box.
Loosen the axle holder nuts and remove the axle.

Remove the front wheel.
Remove the spacer from the right side and speedometer gear
box from the left side.
INSPECTION
\ Set the axle in V blocks and measure the runout.

ings should turn smoothly and quietly. Also check that the
bearing outer race fits tightly in the hub.
Remove and discard the bearings if they do not turn smoothly,

quietly, or if they fit loosely in the hub.
NOTE
Replace hub bearinns in oairs.
Pack new bearings with grease and install them into the hub
with the special tools (page 1 7-71.
Check the rim runout by placing the wheel in a truing stand.

Spin the wheel by hand, and read the runout using a dial indi-
cator.
SERVICE LIMITS:
Radial: 2.0 mm (0.08 in)
Axial: 2.0 mrn (0.08 in)
DISASSEMBLY

- dust seal and speedometer gear retainer from the left side
hub.
- brake disc mounting bolts and disc.
- dust seal from the right side hub.
Insert the beabing remover head into the bearing.

From the'opposite side install the bearing remover shaft and
drive the bearing out of the wheel.
Remove the distance collar and drive out the other bearing.
ASSEMBLY (2) RIGHT BEARING
(3) DISTANCE COLLAR
(1) BRAKE DISC
-
EDOMETER GEAR BOX
SPEEDOMETER GEAR RETAINER

I
(7) LEFT BEARING
Pack all bearing cavities w i t h grease. CHMENT, 42 x 47 mm
NOTE
Do not allow the bearings t o tilt while driving them in.
CAUTION
-
-
Never install the old bearing, once the bearings has been re-
moved, the bearing must be replaced with new ones.
Drive the right bearing first, sealed side facing out, then press
the distance collar into the place.
~\.-*%-, ~ ~~-\-**
.~~%,
NOTE
Be certain the distance collar is in position before installing
the left bearing.
Drive in the left bearing squarely w i t h it sealed side toward out

until i t seats.
Install the brake disc and tighten the bolt.
TORQUE: 37-43 Nsm (3.7-4.3 kg-m,27-31 ft-lb)
Install the dust seal.
- -grease o f f the brake disc or stopping power will be re-

Keep
duced.
lnstall the speedometer gear retainer in the left side of the hub,
alining its tangs w i t h the slots in the hub, and install the dust
seal.
Fill the speedometer gear box with grease.

lnstall the speedometer gear box in the wheel hub, alining its
slots with the retainers tangs.
lnstall the spacer onto the wheel right side.
INSTALLATION
Position the wheel between the fork legs.

Position the tang of the speedometer gear box against back
the of the lug on the left fork.
lnstall the axle holder with the arrow pointing forward.
lnstall the axle and tighten the axle.
Tighten the axle holder nuts.
Connect the speedometer cable.
FRONT FORK
REMOVAL
- front wheel (Page 11-5).
- brake caliper from the right fork.
- front brake hose from the front fender.
- front fender.
i
FRONT WHEELiSUSPENSlONiSTEERlNG
I
Loosen the fork top and bottom pinch bolts and pull the fork
tubes out.
DISASSEMBLY
Hold the fork tube in a vise, with soft jaws or a shop towel, and
remove the fork tube cap.
CAUTION
Do not damage the sliding surface.
The cap is also under spring pressure.
Use care when removing and wear eye and face protection.
Remove the fork spring and drain the fork fluid by pumping the
fork tube back and forth several times.
r-9, '
Hold the fork slider in a vise with the soft jaws or use a shop - . (1
1
HEX WRENCH. 6 rnm 07917-3230000
towel. (COMMERCIALLY AVAILABLE I N U.S.A.)
Remove the socket bolt with a hex wrench.
NOTE
Temporarily install the spring and fork tube cap if difficulty
is encountered in removing the socket bolt.
Remove the dust seal and pry the set ring with a screwdriver.
Separate the tube from the slider by sliding the t o w parts away
from each other, using the force of the impact t o remove the
seal from the slider.
Remove the lock piece, circlip and the piston from the fork
tube.
Remove the oil seal, back up ring and slider bushing from the
fork tube.
Remove the piston ring and rebound spring from the piston.
NOTE
Do not remove the fork tube bushing unless it is necessary
to replace it with a new one.
INSPECTION
Measure the fork spring free length.
SERVICE LIMIT: 535 mm (21. I in)
Check the fork tube, fork slider and piston for score marks, (1) PISTON RING
scratches, or excessive or abnormal.wear. Replace any com-
ponents which are worn or damaged.
Check the fork piston ring for wear or damage.
Check the rebound spring for damage.
SPRING TUBE
Set the fork tube in V blocks and check the runout.
Visually inspect the slider and fork tube bushing. (1) BUSHING
Replace the bushing if there is excessive scoring or scratching,
or if the teflon is worn so that the copper surface appears on
more than 314 of the entire surface.
Check the back-up ring; replace it if there is any distortion at (3) BACK-UP RING
the points shown.
POlNTS
ASSEMBLY
Before assembly, wash all parts with a high flash point or non-
flammable solvent and wipe them off completely.
(2) REBOUND SPRING

0
(16) OIL SEAL (1) DUSTSEAL
SET RING -4 fl
/
(9)SOCKET BOLT
1 '\ (8)LO?K PIECE
PISTON
Insert the rebound spring and piston into the fork tube.
Install the circlip and oil lock piece onto the piston end.
lnsert the slider bushing, back-up ring and oil seal onto the fork
tube.
lnsert the fork tube into the slider.

Place the fork slider in a vise with soft jaws or use a shop
towel.
CAUTION '
Do not damage the sliding surface.
Apply a locking agent to the socket bolt and thread it into the
piston.
Tighten the socket bolt.
TORQUE: 15-25 N*m (1.5-2.5 kg-m, 1 1- 18 ft-lb)
NOTE
Temporarily install the spring and fork tube cap if difficulty
is encountered in installing the socket bolt.
lnstall a new oil seal using the fork seal driver and attachment.
lnstall the set ring and dust seal.
Pour the specified amount of ATF into the fork tube.
CAPACITY:
235.5-240.5 cc (7.96-8.13 US 02)
Install the fork spring into the fork tube.
NOTE
Note the spring direction, the tightly wound end must face
toward the bottom.
Hold the fork tube in a vice with soft jaws or a shop towel.
CAUTION
* Do not damage the sliding surface.
Install the fork tube cap a new O-ring and tighten the cap.
TORQUE: 15-30 N.m (1.5-3.0 kg-m, 11 -22 ft-lb)
INSTALLATION
Install the fork legs into the steering stem and fork bridge.
Align the fork top end with top surface of the bridge.
Tighten the top and bottom fork pinch bolts.
TORQUE:
TOP: 9- 13 N.m (0.9- 1.3 kg-m. 6.5-9.4 ft-lb)
BOTTOM: 30-40 N-m (3.0-4.0 kg-m, 22-29 ft-lb)
Install the following:

- front fender.
- brake caliper and connect the brake hose to the clamp
(Page 13-7).
- front wheel (Page 1 1-81.
STEERING STEM
REMOVAL

- handlebar (Page 1 1-31.
- front wheel (Page 13-51.
- headlight (Page 17-2).
- right and left turn signals.
- speedometer and connection box. -
- ignition switch.
Remove the steering stem nut. (After '86: steering stem nut
and washer).
Remove the front forks (Page 11-8).
Remove the fork bridge.
v
BEARING RACE REPLACEMENT
NOTE
Always replace the balls and bearing races as set.
Remove the bottom cone race from the steering stem.
Drive the top and bottom ball races out of the steering head
using a ball race remover.
(2) BEARING ADJUSTMENT NUT
(1) STEERING STEM G ( 3 )TOP CONE RACE

L(41 BALLS (21)
(5)TOP BALL RACE
(6) BOTTOM BALL RACE

b(7) BALLS (21
8) BOTTOM CONE RACE
9) DUST SEAL
10)WASHER
FRONT WHEELfSUSPENSlONlSTEERlNG
Drive the top and bottom ball races into the steering head.
-
Install the washer and dust seal onto the steerina stem and (1) STEERING STEM D R ~ E 07946-GC40000
R or - 1 1
press the bottom cone race over the stem using the special 07946-MB00000 and 07946-GC4000A (U.S.A. o n ~ v d
tool.
INSTALLATION
Apply grease to the top ball race, and install the 21 balls as
shown.
Apply grease t o the bottom cone race and install the 21 balls.
Insert the steering stem into the steering head pipe being care-
ful not to drop the balls and install the top cone race.
Install the steering bearing adjustment nut. d z ^STEER ING STEM SOCKET-07916-3710100
Check the steering stem rotates freely and that there in no ver-
tical play.
Tighten the steering bearing adjustment nut t o the first torque.
TORQUE: 30-40 N.m (3.0-4.0kg-m, 22-29 ft-lb)

Rotate the steering stem lock t o lock five times t o seat the
bearings, then loosen the steering bearing adjustment nut.
(1 STEERING
Retighten the steering bearing adjustment nut t o the final STEM
torque. SOCKET
07916-3710100 1(
TORQUE: 2.5-3.5 M-m (0.25-0.35 kg-m, 1.8-2.5 ft-lb)
Install the fork bridge, steering stem nut (After '86: steering'
stem nut and washer) and front forks (page 1 1-1 4).
Tighten the steering stem nut.
TORQUE: 60-90 N.m (6.0-9.0 kg-m, 43-65 ft-lbl
TOOLS:
Lock n u t wrench, 30 x 32 m m 07716-0020400
Extension 07716-0020500
STEERING HEAD PRELOAD

Install the front wheel (Page 11-81.
Raise the front wheel o f f the ground and place a qtand under
the engine.
Position the steering stem straight ahead.
Hook a spring scale t o the fork tube and measure the amount
of steering head bearing preload.
NOTE
Make sure there is no cable or wire harness interference.
The oreload should be within 0.9-1.25 k g (1.98-2.756 Ib).

If thk readings do not fall within the limits, lower the front
wheel of the ground and adjust the bearing adjustment nut.
After making sure of the bearing preload, install all removed
parts in the reverse order of removal.
REAR WHEELIBRAKEISUSPENSION
" 38-48 N-m

(3.8-4.8 kg-m,
27-35 ft-lb)
12. REAR WHEEL/BRAKE/SUSPENSlON
SERVICE INFORMATION 12-1 SHOCK ABSORBER
TROUBLESHOOTING .I2-2 SWINGARM
REAR WHEEL 12-3 REAR FENDER
REAR BRAKE 12-8
I 1
-lSERVICE INFORMATION
GENERAL
8 A jack or other support is required to support the motorcycle.

) Note the direction of installation on all of the bolts.
8 Never try to straighten a bent wheel.
Brake dust majJcontain asbestos which can be harmful to your health. Do not use compressed air to clean brake drums or brake
panels. Use a vacuum cleaner with a sealed dust collector. Wear a protective face mask and thoroughly wash hands when finished.
SPECIFICATIONS
1 ITEM 1 STANDARD rnrn (in) / SERVICE LIMIT rnrn (in) I

/ Axle runout 1 - 1 0.2 (0.008) 1
1
Rear wheel rim runout Radial - 2.0 (0.08)
Axial - 2.0 (0.08)
Rear brake drum I.D. 130 (5.12) 131 (5.161
1 Rear brake lining thickness 1 4.0 (0.161 1 2.0 (0.081 I
I Rear shock absorber spring free length i 187 (7.361 1 183 (7.21 1 I
TORQUE VALUES
Driven sprocket nut 6 0 - 7 0 N.rn (6.0-7.0 kg-rn, 43-51 ft-lb)

Brake torque link arm nut 18-25 Nsrn (I .8-2.5 kg-rn, 13- 18 ft-lb)
Rear axle nut 8 0 - 1 0 0 N-rn (8.0- 10.0 kg-rn, 58-72 ft-lb)
Brake arm bolt 8 - 1 2 N-rn (0.8- 1.2 kg-rn, 6 - 9 ft-lb)
Brake pedal bolt 18-25 N-rn (1.8-2.5 kg-rn, 13-18 ft-lb)
Rear shock absorber lock nut 3 0 - 4 5 Nsrn (3.0-4.5 kg-rn, 22-33 ft-lb)
Rear shock absorber mounting bolt (Upper) 2 4 - 3 0 N-rn (2.4-3.0 kg-rn. 17-22 it-lb)
) (Lower) 3 8 - 4 8 Nsrn (3.8-4.8 kg-rn, 27-35 ft-lb)
Swingarrn pivot bolt 80- 100 N-m (8.0- 10.0 kg-rn, 58-72 ft-lb)
Rear fender attaching bolt 80- 1 0 0 N-rn (8.0- 10.0 kg-rn, 58-72 ft-lb)
REAR WHEELfBRAKEISUSPENSlON
TOOLS
Special
Shock absorber compressor attachment 07959-MB10000
Needle bearing remover 07946-KA50000
Bearing remover weight 07936-3710200
Bearing remover handle 07936-3710100
Bearing remover, 20 m m 07936-371 0600
Common
Attachment, 4 2 x 4 7 m m 07746-001 0300
Pilot, 1 5 m m 07746-0040300
Attachment, 32 x 3 5 m m 0 7 7 4 6 - 0 0 1 0 10 0
Bearing remover shaft 07746-00501 0 0
Bearing remover head, 1 5 rnrn 07746-0050400
Shock absorber compressor 07959-3290001
Driver 07749-001 0000
TROUBLESHOOTING
Oscillation
Bent rim
Loose wheel bear~ngs
* Faulty tire
Loose axle
Trre pressure rncorrect
- Incorrect tlre pressure
* Worn swrngarm bushrngs
Soft suspension
Weak spring
Hard suspension
Bent shock absorber
Suspension noise
Shock case binding
Loose fasteners
REAR WHEEL/BRAKE/SUSPENSlON
REAR WHEEL
REMOVAL
Raise the rear wheel off the ground with a jack or workstand
under the engine.
Remove the brake torque link arm.
Remove the brake adjusting nut and brake rod from the brake
arm.
Loosen the drive chain then remove the axle and rear wheel.
Remove the brake panel from the wheel hub.
I ( 4 ) REAR AXLE k,W K -

E TORQUE LINK A R M b
INSPECTION
Place the rear axle in V-blocks and measure the runout.
SERVICE LIMIT: 0.20 mrn (0.008 in)
Check the rim runout by placing the wheel on a truing stand.

Turn the wheel by hand and measure the runout using a dial in-
dicator.
SERVICE LIMIT:
Radial: 2.0 mrn (0.08 in)
Axial: 2.0 rnrn (0.08 in)
BEARINGS
ings should turn smoothly and quietly. Also check that the
) bearing outer race fits tightly in the hub.
Remove and discard the bearings if the races do not turn

smoothly, quietly, or if they fit loosely in the hub. (Page 12-6).
NOTE
) Replace hub bearings in pairs.
Pack new bearings with grease and install them into the hub
with the special tools. (Page 12-6).
Check the condition of the final driven sprocket teeth.

Replace the sprocket if worn or broken. ( 1 ) GOOD (2) REPLACE
NOTE
If the final driven sprocket requires replacement,inspect the
drive chain and drive sprocket.
DISASSEMBLY
Remove the side collar from the final driven flange.

Remove the final driven sprocket and flange together.
NOTE
Do not separate the driven sprocket and flange, unless re-
placement of the driven sprocket or flange is necessary.
Replace the damper rubbers if they are damaged or worn.
Remove the damper rubbers and O-ring.
Insert the bearing remover head into the bearing.

From the opposite side install the bearing remover shaft and
drive the bearing out of the wheel.
Remove the distance collar and drive out the other bearing.
(2) BEARING REMOVER

a
v-wisaa-m
HEAD, 15a>
<n
mm
%
--say--
07746-0050400
* srar
n *--x
REAR WHEELlBRAKElSUSPENSlON
Remove the oil seal from the final driven flange.
Remove the center collar and drive out the bearing.
ASSEMBLY
(1) CENTER
1OLLAR
(2) FINAL DRIVEN
60-70 N-m
(4) SIDE
COLLAR
(7) O-RING (8) DISTANCE

COLLAR
REAR WHEELiBRAKEiSUSPENSION
Install the center collar and oil seal.
Pack the new bearing cavities with grease.
NOTE
Do not allow the bearings t o tilt while driving them in.
CAUTION
Never install the old bearing, once the bearing has been re-
moved, the bearings must be replaced with new ones.
Drive a new left bearing into the wheel hub first with the
sealed side facing out.
Install the distance collar into place.
NOTE
Be certain the distance collar is in position before installing
the right bearing.
Drive a new right bearing in squarly with the sealed side facing
out.
TOOLS
DRIVER 07749-001 0000
ATTACHMENT, 42 x 47 mm 07246-001 0300
(Bracket side)
ATTACHMENT, 32 x 35 mm 07746-0010100
(Driven sprocket side)
Pilot, 15 mm 07746-0040300
REAR WNEEtlBRAKEISUSPENSlON
If the driven sprocket has been removed from the final driven
flange, tighten four driven sprocket nuts in a criss-cross pat-
tern in 2-3 steps.
TORQUE: 60-70 N.m (6.0-7.0 kg-rn, 43-51 ft-lb)
Install the side collar into the final driven flange.
lnstall the brake panel into the rear wheel.
INSTALLATION
lnstall the chain adjusters in the swingarm ends.

lnstall the drive chain onto the driven sprocket.
Place the rear wheel assembly between the swingarm legs,
and insert the rear axle from the right side.
Loosely install the rear axle nut.

lnstall the brake torque link arm onto the brake panel.
lnstall the rubber spacer, washer and nut.
TORQUE: 18-25 N-rn (1.8-2.5 kg-m, 13-18 ft-lb)
lnstall a new cotter pin.

Connect the brake rod with the brake arm and adjust the rear
brake (Page 3-14).
Adjust the drive chain (Page 3-1 1).
Tighten the rear axle nut.
1) TOROUE: 80-100 N*m 18.0-10.0 kg-m, 58-72 ft-lbl

REAR BRAKE
REMOVAL
Remove the rear wheel (Page 12-31.
Remove the brake panel from the rear wheel.
INSPECTION
Measure the rear brake drum I.D.
SERVICE LIMIT: 131 mm (5.16 in!
Measure the rear brake lining thickness.
DISASSEMBLY

- brake arm and wear indicator.
- cotter pin and washer.
- brake shoes and springs.
- brake cam.
(4)BRAKE
@@
(6) BRAKE
SHOES
ASSEMBLY
Apply grease t o the anchor pin and brake cam.

lnstall the brake cam.
Apply oil t o the felt seal and install it on the brake panel. -.
lnstall the wear indicator plate on the cam aligning its wide
tooth with the cams wide groove.
lnstall the brake arm, aligning the punch marks on the cam and
the brake arm and tighten the brake arm bolt.
TORQUE: 8- 12 N-m (0.8- 1.2 kg-m, 6-9 ft-lb)
lnstall the brake shoes and spring.

lnstall the washer and new cotter pin.
Contaminated brake linings reduce stopping power.

Keep grease off the brake linings. Wipe any excess grease off
the cam.
lnstall the brake panel onto the rear wheel.

lnstall the rear wheel (Page 12-7).
REAR WHEELIBRAKEISUSPENStON
REAR BRAKE PEDAL REMOVAL/INSTALLATION
Remove the brake rod from the brake arm.

Remove the rear brake pedal.
Unhook the brake light switch and return springs.
Pull the pedal pivot shaft out of the frame.
Apply grease t o the pedal pivot shaft and insert the shaft.
lnstall the brake pedal aligning the punch marks on the shaft
and pedal, and tighten the brake pedal bolt.
TORQUE: 18-25 Ngm (1.8-2.5 kg-m,13- 18 ft-lb)
Install the removed parts reverse order of removal.

Adjust the rear brake (Page 3-14).
SHOCK ABSORBER
REMOVAL
Raise the rear wheel off the ground with a jack or workstand
under the engine.
Adjust the shock absorber to the softest position.
Remove the rear shock absorber upper and lower mounting
bolts.
DISASSEMBLY
Set the shock absorber in the shock absorber compressor and

compress the spring.
Place the upber joint in a vise and pull the shock rod out.
Loosen the lock nut and remove the upper joint.
Loosen the compressor and remove the shock absorber from
the compressor.
I
REAR WHEEL/BRAKE/SUSPENSION
INSPECTION
Check the following:

- damper rod for damage.
- damper unit for oil leaks.
- damper rubber for damage.
Measure the rear shock absorber spring free length.
SERVICE LIMIT: 183 mm (7.21 in)
ASSEMBLY
(1 LOCK N U T
Place the spring adjuster, lower spring seat, spring,
spring seat and damper rubber on the damper.
upper (6) UPPER JOINT
Install the spring with the tightly wound coil facing up.
%(2) DAMPER
RUBBER
UPPER
(3) LOWER
SPRING SPRING
SEAT SEAT
SPRING ADJUSTER
CAUTION
Be sure the base is adjusted correctly for the shock spring seat
and the clevis pin is all rhe way in.
Apply a locking agent t o the rod threads and install the lock
nut. Place the shock absorber into the compressor.
Apply a tocking agent t o the damper rod threads and screw the
upper joint on. Hold the upper joint in a vise and tighten the
lock nut securely.
NOTE
* Check that the lock nut is seated against the rod's bottom
thread.
Align the spring seat with the upper joint while releasing the
compressor.
INSTALLATION
Install the shock absorber and tighten the upper and lower
mounting bolts.
TORQUE:
UPPER MOUNTING BOLT
24-30 Nam (2.4-3.0 kg-m, 17-22 ft-lb)
LOWER MOUNTING BOLT
38-48 N.m (3.8-4.8 kg-m, 27-35 ft-lb)
SWING ARM
REMOVAL
Remove the following parts:

- rear wheel
- chain cover
- rear shock absorber lower mounting bolt
Remove the swingarm pivot bolt and swingarm.
DISASSEMBLY
Remove the t w o screws, then remove the chain slider.

Remove the cotter pin, nut, washer, spring washer and pivot
bolt then remove the brake torque link arm.
INSPECTION
Remove the dust seals and collars.

Check the pivot bushing and collars for wear or damage.
Check the swingarm for cracks or damage.
PIVOT BUSHING REPLACEMENT
Remove the outside pivot bushing using the special tools

shown.
Drive out the inside pivot bushings.
Apply grease to the inside of the pivot bushings.

Drive a new pivot bushings into the swingarm using the special
tool shown.
ASSEMBLY
Apply grease to the inside of the collars and lip of the dust
seals.
lnstall the brake torque link arm, pivot bolt, spring washer,
washer and nut.
Tighten the nut.
TORQUE: 18-25 N-m (1.8- -2.5 kg-m, 13-18 ft-lb)
lnstall a new cotter pin.

lnstall the chain slider.
lnstall the swingarm and tighten the pivot bolt.
TORQUE: 80-100 N-m (8.0- 10.0 kg-m, 58-72 ft-lb)
lnstati the following parts:

- chain cover.
- rear shock absorber lower mounting bolt (Page 12-12).
- rear wheel (Page 72-71.
Lubricate the swingarm pivot through the grease fittings.

REAR FENDER
Raise the rear wheel off the ground with a jack or wbrkstand
under the engine.
Disconnect the taillight and turn signal connectors and remove
the turn signals.
Remove the six rear fender attaching bolts and remove the rear
fender from its bracket.
Remove the rear shock absorbers.
Remove the rear fender bracket attaching bolts and remove
the rear fender bracket.
TORQUE:
REAR FENDER ATTACHING BOLT
80- 100 N-m (8.0-10.0kg-m, 58-72 ft-lb)
REAR SHOCK ABSORBER MOUNTING BOLT
Upper: 24-30 N-m (2.4-3.0 kg-m, 17-22 ft-lb)
Lower: 38-48 N-m (3.8-4.8kg-m, 27-35 ft-lb)
REAR FENDER
BRACKET
(2.4-3.0 kg-m,
' lP-7 17-22 ft-lb)
HYDRAULIC BRAKE
25-35 N.m
(2.5-3.5 kg-m,
I
15-20 N.m
(1.5-2.0 kg-rn,
10-14 ft-lb)
\ 24-30 N-m (2.4-3.0 kg-m, 17-22 ft-lb)
13. HYDRAULIC BRAKE
SERVICE INFORMATION 13-1 BRAKE DISC 13-4
TROUBLESHOOTING 13-1 BRAKE CALIPER 13-5
BRAKE FLUID REPLACEMENTIBLEEDING 13-2 BRAKE MASTER CYLINDER 13-7
BRAKE PAD REPLACEMENT 13-3
D SERVICE INFORMATION
I GENERAL
The front wheel can be removed without disconnecting the hydraulic system.
Once the hydraulic systems have been opened, or if the brake feel spongy, the system must be bleed.
Do not allow foreign material to enter the system when filling the reservoir.
Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic, and
rubber parts by covering them with a rag. If fluid does get on these parts, wipe it off with a clean cloth.
Always check brake operation before riding the motorcycle.
SPECIFICATIONS
ITEM STANDARD mm (in) SERVICE LIMI? mm (in)
Disc thickness 4.0 (0.16) 3.5 (0.14)

runout - 0.3 (0.012)
Caliper piston O.D. 25.368 (0.9987) 25.300 (0.9961 1
cylinder I.D. 25.4 (1) 25.450 (1.002)
Master cylinder piston O.D. 12.7 (0.5) 12.64 (0.498)
cylinder I.D. 12.7 (0.5) 12.755 (0.5022)
I TORQUE VALUES
Bleed valve 4-7 N-m (0.4-0.7 kg-m, 2.9-5.1 ft-lb)

Caliper mounting bolt 24-30 N-m (2.4-3.0 kg-m, 17-22 ft-lb)
Pad pin bolt 15-20 N.m (1.5-2.0 kg-m, 10- 1 4 ft-lb)
Oil bolt 25-35 N*m (2.5-3.5 kg-m, 18-25 ft-lb)
Master cylinder holder bolt 10-14N.m (1.0-1.4 kg-m, 7 - l o f t - l b )
TOOLS
Special
) Snap ring pliers
TROUBLESHOOTING
Brake lever soft or spongy Brakes grab
Air bubbles in hydraulic system Pads contaminated
) Low fluid level Disc or wheel misaligned
* Hydraulic system leaking
Brake chatter or squeal
Brake lever too hard Pads contaminated
Sticking piston(s) Excessive disc runout
Clogged hydraulic system Caliper installed incorrectly
! ) Pads glazed or worn excessively Disc or wheel misaligned
Brake drag
Hydraulic system sticking
Sticking piston(s1
I
HYDRAULIC BRAKE
I
BRAKE FLUID REPMCEMENT/BLEEDING
BRAKE FLUID DRAINING
A contaminated brake disc or pad reduces stopping power.

Discard contaminated pads and clean a contaminated disc with
a high quality brake degreasing agent.
CAUTION
-
Do not allow foreign material to enter the system when filling

the reservoir.
* Avoid apilling fluid on painted, plastic, or rubber parts.
Place a ran over these parts whenever the system is serviced.
With the fluid reservoir parallel t o the ground, remove the

reservoir cover.
Connect a hose to the bleed valve.
Loosen the caliper bleed valve and pump the brake lever until
no more fluid f l o w s out of the bleed valve.
Close the bleed valve.
BRAKE FLUID FILLING/BLEEDING
Fill the reservoir w i t h DOT-3 or 4 brake fluid from a sealed con-

tainer.
CAUTION
Do not mix different types of fluid. They are not compatible.
Connect a commercially available bake bleeder t o the bleed

valve.
Pump the brake bleeder and loosen the bleed valve.

Add fluid when the fluid level in the master cylinder reservoir is
low.
NOTE
Check the fluid level often while bleeding the brakes t o pre-
vent air from being pumped into the system.
When using a brake bleeding tool, follow the manufactur-
-
er's o ~ e r a t i n ninstructions.
If air is entering the bleeder from around the bleed valve
threads, seal the threads w i t h teflon tape.
Repeat the above prodedures until air bubbles do not appear i n

the plastic hose.
Close the bleed valve and operate the brake lever. If it feels
apongy, bleed the system by performing the BLEEDING proce-
dure.
If a brake bleeder is n o t available, perform the following proce-

dure: Pump up the system pressure w i t h the lever until there
are no air bubbles in the fluid flowing out of the reservoir small
hole and lever resistance is felt.
I HYDRAULIC BRAKE
1. Squeeze the brake lever and hold it down, then open the
bleed valve 1/2 turn and then close the vafve.
NOTE
Do not release the brake lever until the bleed valve has been
closed.
2. Release the brake lever slowly and wait several seconds

after it reaches the end of its travel.
Repeat steps 1 and 2 until bubbles cease to appear in the fluid

coming out of the bleeder valve.
Tighten the bleed valve.
TORQUE: 4-7 N*m (0.4-0.7kg-rn, 2.9-5.1 ft-lb)
Fill the fluid reservoir t o the upper level mark.
Reinstall the diaphragm and master cylinder cover.
A contaminated brake disc or pad reduces stopping power.

Discard contaminated pads and clean a contaminated disc with
a hiah oualitv brake deareasinz aaent.
BRAKE PAD REPLACEMENT

NOTE
Always replace the brake pads in pairs t o assure even disc
pressure.
Remove the pad pin bolt plugs from the caliper.

Loosen the pad pin bolts.
Remove the caliper mounting bolts and caliper.
Remove the pad pin bolts and brake pads.

HYDRAULIC BRAKE
Make sure that the pad spring is installed in the position

shown.
Install new brake pads and pad pins.

Push the caliper pistons into the caliper housing completely.
CAUTION
Be careful that the master cylinder does not overflow when the
caliper pistons are compressed.
Brake fluid can cause damage to painted, plastic, or rubber sur-
faces.
Install the caliper to the front fork so the disc is positioned be-
tween the pads, being careful not to damage the pads.
Tighten the caliper mounting bolts.
TORQUE: 24-30 N-m (2.4-3.0 kg-m. 17-22 ft-lb)
Tighten the pad pin bolts.
TORQUE: 15-20 Nam (1.5-2.0 kg-m, 10- 14 ft-lb)
lnstall the pad pin bolt plugs and tighten them securely.
BRAKE DISC
INSPECTION
Measure the brake disc thickness with a micrometer.
SERVJCE LIMIT: 3.5 mm (0.14 in)

HYDRAULIC BRAKE
Measure the brake disc for warpage.
SERVICE LIMIT: 0.3 mm (0.012 in!
BRAKE CALIPER
REMOVAL
Drain the brake system (Page 13-21.

Remove the oil bolt and brake hose from the caliper.
Remove the brake pads (Page 13-31.
CAUTION
Avoid spilling f/uid on painted, plastic, or rubber parts.
Place a rag over these parts whenever the system is serviced.
DISASSEMBLY
Remove the caliper bracket from the caliper
Remove the pad spring and caliper pivot boots from the cali-
per.
HYDRAULIC BRAKE
Position the caliper with the pistons down and apply small
squirts of air pressure t o the fluid inlet t o remove the pistons.
Do not use the high pressure air or bring the nozzle too close to
the inlet. Place a shop towel over the piston to prevent the
piston becoming a projectile.
Push the dust and piston seals in and lift them out.
Clean the seal groove with clean brake fluid.
CAUTION
Be careful not to damage the piston sliding surfaces.
INSPECTION
Check the caliper cylinders for scratches, scoring or other

damage.
Measure the caliper cylinder I.D.
Check the pistons for scratches, scoring or other damage.

Measure the piston O.D.

HYDRAULIC BRAKE
ASSEMBLY
) Coat new dust and piston seals with clean t,rake fluu4 and in-
stall them in the seal grooves in the caliper.
Lubricate the caliper cylinders and pistons with clean brake
fluid and install the pistons into the caliper cylinders with the
dished end of the piston facing the pad side.
Apply silicone grease to the pivot boots and install the boots
making sure that the boots are seated in the caliper grooves
properly.
Install the pad spring.
Coat the caliper pins with silicone grease and install the calipei'
bracket t o the caliper.
Install the brake pads and caliper (Page 13-3).
-
Connect the brake hose t o the caliper with the oil bolt and t w o
sealing washers, and tighten the oil bolt.
TORQUE: 25-35 N-m (2.5-3.5 kg-rn. 18-25 ft-lbt
Fill the brake reservoir and bleed the brake system (Page
13-21.
1 BRAKE MASTER CYLINDER

REMOVAL
Disconnect the front brake switch wires.
Remove the rear view mirror.
Drain the brake system (Page 13-21.
Remove the brake lever and disconnect the brake hose from
the master cylinder.
CAUTION
- Avoid spilling fluid on the paint&, ytumrr, or rubber ports.
Place a rag over these parts whenever the system is serviced.
When removing the oil bolt, ocver the end of the hose to pre-
vent conlamination,
Remove the brake master cylinder holder and master cylinder.

HYDRAULIC BRAKE
DISASSEMBLY
Remove the piston boot and snap ring from the master cylinder
body.
Remove the brake light switch.
Remove the master piston and spring from the master cylin-
der.
Clean the master cylinder, reservoir and master piston in clean
brake fluid.
INSPECTION
Check the primary and secondary cups for wear or damage.
Check the piston for scratches, scoring or other damage.
Measure the piston 0.1).
NOTE
The piston, piston cups and spring-must be replaced as a
set.
Check the master cylinder for scratches, scoring or other dam-

age.
Measure the master cylinder 1.0.
SERVICE LIMIT: 12.755 mm (0.5022 in1

HYDRAULIC BRAKE
ASSEMBLY
Coat the piston, and secondary cups w i t h clean brake fluid,

then install the piston spring and piston.
Install the snap ring.
CAUTION
Do not allow the lips of the cups to turn inside out and be cer-
tain the snap ring is firmly seated in the groove.
Install the boots.

Install the brake light switch.
I
i
-
INSTALLATION
Place the brake master cylinder o n the handlebar and install

the holder w i t h the "UP" mark facing up.
Align the end of the holder w i t h punch mark on the handlebar
R
and tighten the upper bolt first, then tighten the lower bolt.
!
TORQUE: 10- 14 N.m (1.O- 1.4 kg-B,I 7 - I 0 ft-lb)
Connect the brake hose t o the master cylinder w i t h the oil bolt
and t w o n e w sealing washers.
Tighten the oil bolt.
TORQUE: 25-35 Nam 12.5-3.5 kg-m, 18-22 ft-lb)

)
Connect the brake switch wires and install the brake lever.
iI - Install the rear view mirror.
Fill and bleed the master cylinder (Page 73-21.
I
BATTERYICHARGING SYSTEM
( 1 ) IGNITION SWITCH
(2)MAIN FUSE ( 1 5A)
TTERY
-
(5)ALTERNATOR
R : Red
BI : Black
Y : Yellow
Br : Brown
Bu: Blue
14. BATTERY/CHARGING SYSTEM
SERVfCE INFORMATION 14- I REGULATORiRECTlFlER 14-4
) TROUBLESHOOTlNG a14-1 CHARGING COIL 14-4
I BATTERY 14-2 REGULATED VOLTAGE INSPECTION 14-4 1
CHARGING SYSTEM 14-3
I h SERVICE INFORMATION
,
GENERAL
Battery acid level should be checked regularly and filled with distilled water, when necessary.
Remove the battery from the motorcycle for cha~gingwhenever possible. If the battery must be charged on the keep
flames and sparks away from a charging battery because it produces hydrogen gas which is explosive.
All charging system components can be tested on the motorcycle.
@ For alternator removal, see page 9-2.
0 Quick-charging should only be done in an emergency; slow-charging is preferred.
SPECIFICATIONS
ITEM STANDARD
I
Capacity 12V 9AH

Battery Specific gravity 20°C (68OF) 1.270- 1 .290/20°C (68OF)
Charging current 0.9 amperers maximum
TYpe I Transistorized non-adjustable regulator
- -.-- -
Vnitanc?
J
/
I
14- 15 VJ5000 r ~ m .
Charging coil resistance at 2Q°C (68OF) 0.3-0.6 D (KOWA or SANWA TESTER)
No power-key turned on Intermittent power

Dead battery Loose battery connection
- Low fluid level Loose charging system connection
- Low specific gravity Loose starting system connection
- Charging system failure Loose connection or short circuit in
Disconnected battery cable ignition system
Main fuse burned out
) Faulty ignition switch Charging system failure
Loose, broken, or shorted wire or connection
Low power-key turned on Faulty voltage regulatorlrectifier
Weak battery Faulty alternator
- Low fluid level
- Low specific gravity
- Charging system failure
I ) Loose battery connection
I Low power-engine running

I Battery undercharged
- Low fluid level
- One or more dead cells
Charging system failure
-
REMOVAL
Remove the bolt and open the battery cover.
Remove the battery terminal cover.
Disconnect the battery breather tube and both cables from the
battery, then remove the battery.
NOTE
Disconnect the negative cable first, then the positive cable
from the battery.
TESTING SPECIFIC GRAVITY
Test each cell with a hydrometer.
SPECIFIC GRAVITY: ( 2 0 ° C , 68OF) 1.304 (1) ELECTROLYTE TEMPERATURE VS.
/ 1.270- 1.290 / Fully charged 1 .SPECIFIC GRAVITY
NOTE
The battery must be recharged if the specific gravity is
below 1.230.
* The specific gravity varies with the temperature as shown
in the accompanying table.
Replace the battery if sulfation i s evident or if the spake i7" 5O '01 I!? 20' 25' 30" 35' 4oe
below the cell plates if filled with sediment. 32O 41' 50' 51' 68O 77" ma 95' 104"
(3) ELECTROLYTE TEMPERATURE "C (OF) -+
CHARGING
Remove the battery cell cap and fill the battery cell with dis-
tilled water to the upper level, if necessary.
Connect the charger positive ($1 cable t o the battery positive

(+I terminal and charger negative I-) cable to the battery nega-
tive (-1 terminal.
Charging current: 0-9 Amperes rnax.
Charging:
Charge the battery until specific gravity is 1.270- 1.290 at
20°C ( 6 8 O F ) .
II BATTERYlCHARGlNG SYSTEM
f 3
3- Before charging a battery, remove the cap from each cell.
Keep flames and sparks away from a charging battery.
CAUTION
PIPING AS SHOWING BELOW
Turn power ON/OFF at the charger, not at the battery termi-

nals.
Discontinue charging if the electrolyte temperature exceeds
45 O C (113OF).
CAUTION
-
Quick-charging should only be done in an emergency;
- -.
slow-
charging is preferred. BREATHER TUBE
Route the breather tube as shown on the battery caution label. SECURELY
t
b After installing the battery, coat the terminals with clean
grease.
LEAK TEST
If undercherged, disconnect the negative cable from the bat-

tery.
Connect the voltmeter t o the battery nagative terminal and
negative (ground) cable.
There should be no voltage with the ignition switch turned

OFF.
If there is voltage, check the wire harnesses, couplers and con-
nectors for short circuit and the main switch for function.
i
i
1 REeULATOR INSPECTION
NOTE
Be sure the battery is in good condition before performing
this test.
Warm up the engine.
!1 b. Connect a voltmeter across the battery terminals.
Start the engine, gradually increase engine speed, and mea-

sure the voltage.
I
I
1 NOTE
I
Avoid short circuiting t o the tester during the test.
VOLTAGE: 14- 15 V15000 rpm 20°C (6S°F)

Disconnect the regulatorlrectifier couplers.

Inspect the items listed in the chart below by measuring resis-
tance or voltage at each of the wire harness terminals speci-
fied.
Item Measure at: Standard

Battery wire Red (+)-Green (-) Battery voltage
Charging coil Between the yellow 0.3-0.6 Q
wire terminals (KOWA or
SANWA TESTER)
Ignition switch Battery voltage
Black (+)-Green (-)
(Ignition switch ON)
If abnormal, check part of abnormal line.

If normal, wire harness is faulty.
Replace the regulatorlrectifier if the above components check
out OK.
CHARGING COIL
Disconnect the 3P coupler from the regulatorlrectifier.
Measure the resistance between the yellow wire terminals.
RESISTANCE:
0.3-0.8 Q (KoWA or SARIWA TESTER)
REGUMTED VOLTAGE INSPECION

Remove the hgadlight and connect a voltmeter.
Switch the dimmer t o "HI" position.
Start the engine and check the meter readings while increasing
engine speed slowly.
NOTE
Measure in A.C range.
VOLTAGE: 14- 15 Vl5000 rpm

MEMO
IGNITION SYSTEM
(5) ALTERNATOR (4) PULSE

GENERATOR
(7) PULSE
( 1 ) IGNITION COIL GENERATOR
(5) SPARK PLUGS (3) IGNITION (4) ENGINE (6) ALTERNA-

SWITCH STOP SWITCH TOR
R: Red
BI: Black
Y: Yellow
G: Green
W: White
Bu: Blue
1% IGNITION SYSTEM
-
SERVICE INFORMATION 5 1 IGN~TIONCOIL 15-2
TROUBLESHOOTlNG * 15-1 EXCITER COIL 15-3
CDI UNIT INSPEC1 15-2 PULSE GENERATOR 15-3
SERVICE INFORMATION
GENERAL
0 A CDI (Capacitive Discharge Ignition) is used and it can not be adjusted. If the ignition timing is incorrect, inspect the CDI
unit and pulse generator and reptace any faulty parts.
0 For spark plug inspection, refer t o page 3-8.
0 For alternator and pulse generator removal, refer t o section 9.
0 A continuity check can usually be made without removing the parts from the motorcycle by simply disconnecting the wires
and using a continuity tester or ohmmeter at the terminals.
SPECIFICATIONS
-
-
ITEM STANDA*RD
1 Initial 5O BTDC at 1300 rpm
I Ignition timing
Full advance
I
30° BTDC at 3500 rpm 1

Primary coil 0.1 -0.2 0
lgnition coil resistance
With plug cap 7.4- 11 kQ
20°C (68OF) Secondary coil
Without plun cap 3.7-4.5 k0
/ Pulse clenerator resistance at 20°C (68OF)
Exciter coil resistance at 20°C (68OF) 270-340 D
Engine cranks but will not start Engine starts but rune po
* Engine stop switch OFF lgnition primary circui'
No spark at plugs - Faulty ignition coil
Faulty CDI unit - Loose or bare wire
* Faulty pulse generator - Intermittent short c
Secondaw circuit
No spark at plug Faulty pluQ
Engine stop switch OFF raulty spz~ r plug
k wire
Poorly connected, broken or shorted wires
- Between ignition switch and CDI unit Timing advance incorrect
- Between ignition coil and spark plug - Faulty CDI unit
- Between engine stop switch and CDI unit
- Between CDI unit and ignition coil
- Between CDI unit and alternator
- Between CDI unit and pulse generator
Faulty ignition coil
Faulty ignition or engine stop switch
* Faulty CDI unit
* Faulty pulse generator
Faulty exciter coil
IGNITION SYSTEM
CDI UNIT
INSPECTION
Disconnect the CDI unit wire connectors from the CDI unit.
Inspect the items listed in the chart below by measuring the re-
sistance or voltage at each of the wire harness connector ter-
minals specified.
Replace the GDI unit if the above components check out OK.
IGNITION COIL
REMOVAL

Disconnect the ignition coil leads, then remove the ignition
coil.
NlTlON SYSTEM
Measure the resistance between the primary wire terminals. PRIMARY
RESISTANCE: 0. I-0.2 n L
Measure the resistance between the secondary terminal end

spark plug cap.
RESISTANCE: 7.4- 1 1 kQ
If the result does not satisfide the specification, disconnect the

spark plug cap from the spark plug wire and measure the resis-
tance between the secondary terminal and spark plug wire.
RESISTANCE: 3.7 -4.5 kQ
EXCITER COIL
NOTE
* This test can be performed with the alternator installed in
the engine.
Disconnect the exciter coil wire connector and measure the re-
sistance between the blacklred wire terminal and ground.
RESISTANCE: 270-340 R 20°6 (68'F)

Refer t o section 9 for exciter coil replacement.
PULSE GENERATOR
NOTE
This test can be performed with the pulse generator in-
stalled in the engine.
Disconnect the pulse generator wire coupler and measure the

resistance between the terminals.
RESISTANCE: 90-100 Q 20°C 168'F)
Refer to page 9-2 for pulse generator replacement.

ELECTRIC STARTER SYSTEM
(2) M A I N FUSE
-
-
15A
-R/W
G/R
-
(6) DIODE (9) NEUTRAL SWITCH
STARTER RELAY 4,
' SWITCH SWITCH (7) CLUTCH SWITCH
I
16. ELECTRIC STARTER SYSTT"
:"
I
I SERVICE INFORMATION 16-1 STARTER RELAY
I # TROlJBLESHOOTlNG 16-1 CLUTCH DIODE
STARTER MOTOR 16-2
8 SERVICE INFORMATION
I GENERAL
The starter motor can be removed with the engine installed in the frame.
TROUBLESHOOTING
Starter motor will not rotates
* Dead battery
Loose or disconnected wire or cable
Burned out fuse
Faulty:
- ignition switch
- starter relay
- starter switch
- neutral switch
- clutch switch
- clutch diode
- starter niotor
Starter motor 'turn

, ,
W e a ~oarrery
* Excessive resistance in circuit
Binding in starter motor
Starter motor rotates, but engine does not.

* Faulty:
- starter clutch
- starter drive chain
- starter drive and/or driven sprocket
Starter rotates, engine rotates, but does not start
STARTER MOTOR
REMOVAL
Disconnect the battery negative cable at the battery and
remove the starter motor cable from the starter motor.
Remove the starter drive and driven sprockets, chain and side
spacer (Page 9-31.
Remove the four starter motor mounting bolts and the starter
motor.
DISASSEMBLY
Remove the t w o starter motor case screws and front and rear
covers.
Remove the thrust washers and pull the armature out of the (1) THRUST WASHERS
starter motor case. 4% II\
NOTE
Note the number and location of the thrust washers for re-
assemblv.
Remove the screws attaching the brushs and remove the

brush holder and O-ring from the case.
SCREWS
Measure th'e length of each brush.
SERVICE LlMlT: 6.0 mm (0.24 in)

ELECTRIC STARTER SYSTT-
Measure the each brush spring tension with a spring scale.
SERVlCE LIMIT: 4009 (0.9 Ibl B
COMMUTATOR INSPECTfON
Check the commutator bars for discoloration and other visual
faults. Bars discolored in pairs indicates shorted coils.
NOTE
Do not use emery or sand paper on the commutator.
Check for continuity between pairs of commutator bars.

There should be continuity.
Also, make a continuity check between individual comrnutator

bars and the armature shaft.
There should be no continuity.
CASE INSPECTION
Check for continuity between the cable terminal and the motor
case.
-.
Also, make a continuity check between the cable terminal and

the brush terminal.
There should be continuity.
ASSEMBLY
STARTER SYSTEM
Install a new 0 - r t n y unru the case.

Insert the commutator into the starter motor case.
Install the brushes into the brush holder and connect the field
coil wire t o the positive brush and tighten the screws.
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 previously noted, have been placed on the shaft.
Install the front, then the rear cover while aligning the slot on
t the rear cover with the pin on the brush holder.
1 Install a new O-ring onto the case.
INSTALLATION
Install the starter motor with four bolts and tighten the bolts.
Connect the starter motor cable t o the motor terminal and

place the rubber cap onto the terminal.
Install the left side spacer, starter drive and driven sprockets
and chain (Page 9-3).
Install the flywheel and left crankcase cover (Page 9-6).
STARTER RELAY
Depress the starter switch button with the ignition switch OM.
The coil is normal if the starter relay clicks.
Disconnect the starter relay connectors and cables from the

starter relay.
Connect an ohmmeter to the starter cable terminals.
Connect the' yellow/red wire to a 12 V battery positive termi-

nal and greenired wire to the negative terminal.
The relay switch is normal if there is continuity with the bat-

tery connected and no continuity with the battery disconnect-
ed.
CLUTCH DIODE
REMOVAL
Remove the fuel tank and clutch diode from the wire harness.
-
LECTRIC STARTER SYSTEM
INSPECTION
$ Connect t h e n?ster posiltive wire t o the diode positive terminal

and tester ne! lative wir.e t o the diode negative terminal and
I
check for con1tincrity.
There should tl e contini
Connect the tester in the reverse order of above connection

and check for continuity of the diode.

I
I
1
' 1
NOTE
* Use a Sanwa Electric Tester 07308-0020000or Kowa
Electric Tester TH-SH, or Digital rnuitirneter, KS-AHM-32-
003 (U.S.A. only)
MEMO
17. LIGHTS/SWITCHFn 'HORN
SERVICE INFORMATION 17-1 NEUTRAL SWITCH
HEADLIGHT -17-2 REAR BRAKE LIGHT SWITCH
INSTRUMENT 17-2 BULBS
IGNITION SWITCH 17-5 HORN 17-8
HANDLEBAR SWlTCH 17-5
SERVICE INFORMATION
GENERAL
3 * Some wires will have diffenmcolored bands around them year the connector. T h ~ s eare connected t o other wires which
correspond with the band color.
All plastic plugs have locking tabs that must be released before disconnecting and must be aligned when reconnecting.
e The following color codes used are indicated throughout this section and on the wiring diagram.
Bl = Black G = Green Lg = Light green R = Red

Bu = Blue Fr = Gray 0 = Orange W = White
@ To isolate an electrical failure, check the continuity of the circuit or part. A continuity check can usually be made without
removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or volt-ohmmeter t o
the terminal or connector.
@ A continuity tester is useful when checking t o find out whether or not there is an electrical connection between t w o
points. Ah ohmmeter is needed t o measure the resistance of a circuit, such as when there is a specific coil resistance in-
valved, or when checking for high resistance caused by corroded connections.
?
HEADLIGHT
HEADLIGHT REPLACEMENT
Remove the screws and connection box cover.
Loosen the headlight rim screw and remove the headlight rim.
Pull the headlight out of the headlight case and disconnect the
coupler.
Replace the headlight as required.
REMOVAL
Remove the screws and connection box cover.

Disconnect the headlight wire connectors and remove the
headiight mounting n u t ,
Remove the headlight.
INSTALLATION
Install the headlight in the reverse order of removal.
TORQUE: 30-40 N+m(3.0-4.0 kg-m, 22-29 ft-lb)
NOTE
After installing the headlight, adjust the headlight aim (Page
3-15).
INSTRUMENT
INDICATOR LIGHT BULB REPLACEMENT
Remove the indicator light lens.

Pull the bulb from the socket and replace it as required.
SPEEDOMETER BULB REPLACEMENT
Disconnect the speedometer cable and remove the t w o cap

nuts and remove the rear cover.
Remove the bulb socket from the back of the speedometer and
replace the bulb as required.
REMOVAL
Remove the t w o screws attaching the connection box cover

and the cover.
Disconnect the indicator lights and illumination light wire con-

nectors.
Remove the speedometer cable.
Remove the speedometer mounting bolts and speedometer.
INSTALLATION
Install the speedometer in the reverse order of removal.

I LIGHTSISWITCHESIHORN
1 IGNITION SWITCH
1i ) INSPECTION
1 Remove the connection box cover and disconnect the ignition
I switch wire coupler and connectors.
Check for continuity between the color coded wires in the
1)
I
chart below.
I
! REMOVAL
(1 ) SCREWS
I Remove the speedometer.
Disconnect the ignition switch wire coupler and connectors.

Remove the ignition switch mounting screws and ignition
I switch.
INSTALLATION
i
i Install the ianition switch in the reverse order of removal
HANDLEBAR SWITCH
Remove the connection box cover and disconnect the handle-
bar sw:+ch connectors.
Conti~nuity sholdd exist between ttl e color cc~ d e d

wires on each
cart.
.- - - A - - . ~ .
ENGINE STOP SWITCH
Terminal IG E
OFF 0 0
RUN
- Color BI/W G
STARTER SWITCH
FRONT BRAKE SWITCH

TURN SIGNAL SWITCH
DIMMER SWITCH
I Terminal HL / Hi I Lo /
I I
Lo 0 4
Color BuIW Bu W
HORN SWITCH
I Terminal / HO / BAT
I Free 1 1 I
I *+ Cotor
CLUTCH SWITCH
1 Depressed / 0
+0 1
NEUTRAL SWITCH
Remove the left side cover and disconnect the neutral switch
wire connector.
Place the transmission in neutral and check for continuity be-

tween the LgiR and ground.
There should continuity with the transmission in neutral and

no continuity when other gear position.
REAR BRAKE LIGHT SWITCH

Disconnect the rear brake light switch coupler and check for
continuity between the terminals.
Continuity should exist with the brake pedal depressed there

and should be no continuity with the pedal released.
I
'9
1
I
BULBS
TURN SfGNAL
Remove the three screws and the lens.
I d
Replace the bulb as required and install the lens with

screws.
After installing, check the operation of the turn signal.
b- TAlLlBRAKE LIGHT
i- Remove the t w o screws and lens.
Replace the bulb as required and install the lens with two
screws.
After ir check the brake and tail light operation.
9
I
LICENCE PLATE LIGHT
Remove the t w o nuts and fight cover, and replace the bulb as
required.
Install the license plate light in the reverse order of removal.
HORN
If the horn does not operate, connect 12 V DC directly t o its
terminals; if it works, check the button and its circuits.
If the direct connection does not blow the horn, replace the
horn.
-
19. TROUBLESHOOTING
ENGINE DOES NOT START OR IS POOR HANDLING 19-1"1
HARD TO START
'*I STARTER MOTOR 19-!
'-'
*
ENGINE LACKS POWER
UNDER CHARGEDIOVER CHARGED
POOR PERFORMA ' LOW BATTERY 19-6
AND IDLE SPEEDS
9-3 NO SPARK AT PLUG 19-7
POOR PERFORMANCEAT HIGH SPEEDS 19-4
ENGINE WES NOT START OR IS HARD TO START

Probable Cause
1. Check if fuel is getting t o NO FUEL TO ,I%) No fuel in fuel tank

carburetor CARBURETOR (2) Clogged fuel tube or fuel filter
(3) Clogged float valve
FUEL TO CARBURETOR (4) Clogget fuel tank cap breather
I
$
hole
2 . Try spark test WEAK OR NO SPARK *(I ) Faulty spark plug

( 2 ) Fouled spark plug
GOOD SPARK (3) Faulty CDI unit
(4) Broken or shorted spark plug wire
(5) Faulty alternator
( 6 ) Broken or shorted ignition coil
( 7 ) Faulty pulse generator
(8)Poorly connected, broken or short-
ed wires
(9) Faulty ignition switch
3. Test cylinder compression LOW COMPRESSION ,(I 1 Slow starter cranking speed
(2) Valve clearance too small
COMPRESSION NORMAL (3) Valve stuck open
(4) Worn cylinder and piston rings
(5) Damaged cylinder head gasket
(61 Seized valve
(7) lmproper valve timing
4. Start by following normal ENGINE STARTS BUT + ( I 1 Starter valve stuck close or
starting procedure SOON STOPS damaged
(2) Incorrect choke cable free play
ENGINE DOES NOT START (3) Air leaking past carburetor
insulator
(4) Improper ignition timing (CDI unit
or pulse generator faulty)
(5) Fuellair mixture too lean
5. Remove spark plug WET PLUG ,(I 1 Carburetor flooded

(2) Starter valve stuck open or
damaged
DRY (3) Fueliair mixture too rich
1
6. Start with choke applied
(41 Air cleaner dirty
TROUBLESHOOTING
ENGINE LACKS POWER

Probable Cause
1. Raise wheels off ground and WHEEL DOES NOT SPIN -(I J Brake dragging
spin by hand FREELY (21 Worn or damaged wheel bearing
(3) Wheel bearing needs lubrication
+
WHEEL SPINS FREELY
2. Check tire pressure with the gauge PRESSURE TO0 LOW b ( 11Punctured tire
(2) Faulty tire valve
PRESSURE NORMAL
t
3. Check clutch slipping CLUTCH SLIPS +(1 Weak clutch spring
(2) Worn clutch disclplate
+
NORMAL
4. Lightly accelerate engine ENGINE SPEED NOT

INCREASED SUFFICIENTLY
(31 Warped clutch disclplate
@ ( I J Fuellair mixture too rich or lean

(2) Clogged air cleaner
ENGINE SPEED INCREASED 13) Restricted fuel flow vent
(4) Clogged fuel tank cap breather
hole
(51 Clogged muffler
5. Check ignition timing INCORRECT * (1J Faulty CDI unit

(2) Faulty pulse generator
CORRECT (31 Improper flywheel installation
i
6.Test cylinder compression TOO LOW * ( I J Valve stuck open
using a compression gauge (21 Worn cylinder and piston rings
(3)Leaking head gasket
NORMAL (4) lmproper valve timing
(5) Incorrect valve seat contact
7. check valve clearance INCORRECT + ( 1J Improper valve adjustment

12) Worn valve seat
+
CORRECT
'
8. Check carburetor for clogging CLOGGED * Craburetor not serviced frequently
enough
NOT CLOGGED
+
9. Remove spark plug FOULED OR DISCOLORED -----.-,IT ) Plug not serviced frequently
enough
NOT FOULED OR (2) Use of plug with improper heat
DISCOLORED range
10. Remove oil filler cap/dipstick gauge OIL LEVEL INCORRECT -(I 8 ..,.
Oil level toa hinh
and check oil level (2) Oil level too low
1 (3) Contaminated oil
+
CORRECT
1 1. Remove cylinder head cover

and inspect lubrication
VALVE TRAIN NOT
LUBRICATED PROPERLY
,
(1 Clogged oil passage
(2) Clogged oil strainer
'n VALVE TRAIN LUBRICATED

PROPERLY
1
t
"
12. Check if engine overheats OVERHEATED +( 1I Excessive carbon build-up in
combustion chamber
1
NOT OVERHEATED
13.Accelerate or run at high speed ENGINE KNOCKS ,

-
(I
(2) Use of improper quality of fuel
(3) Clutch slipping
(4) Fuel-air mixture too lean
) Worn piston and cylinder

(21 Fuel-air mixture too lean
ENGINE DOES NOT KNOCK (3) Use of improper grade of fuel
(4) Excessive carbon build-up in
combustion chamber
(5) Ignition timing too advanced
(Faulty CDf unit or pulse
generator)
POOR PERFORMAMCE A N O W AND IDLE SPEEDS

Probable Cause
I 1. Check ignition timing and INCORRECT at- ( 1) Improper valve clearance

valve clearance (2) Improper ignition timing (Faulty
1
,- CDI unit or pulse generator)
CORRECT
1f
2. Check carburetor adjustment INCORRECT .- Fuellair mixture to rich or t o lean.
I +
CORRECT
3. Check for air leaking past LEAKING rc (11 Deteriorated insulator O-ring
carburetor insulator (2) Loose carburetor
NOT LEAKING
i
4. Try spark test WEAK OR INTERMITTENT -11 1 Faulty, carbon or wet fouled
SPARK spark plug
1 GOOD SPARK 42) Faulty CDI unit
43) Alternator faulty
(4) Faulty ignition coil
( 6 ) Faulty pulse generator
TROUBLESHOOTING
POOR PERFORMANCE AT HIGH SPEEDS

Probable Cause
1. Check ignition timing and INCORRECT 1 ) Improper valve clearance

valve clearance (2) Faulty CDI unit
131 Faulty pulse generator
+
CORRECT
2. Disconnect fuel tube at

carburetor
FUEL FLOW RESTRICTED -(I
141 Improper flywheel installation
1 Lack of fuel i n tank

12) Clogged fuel fine
(3)Clogged fuel tank cap
breather hole
+
FUEL FLOWS FREELY
3. Remove carburetor and

check for clogged jet
CLOGGED
(4) Clogged fuel valve
+ Cban
+-
+
NOT CLOGGED
4. Check valve timing INCORRECT ,Cam sprocket not installed properly
+
CORRECT
5. Check valve spring tension WEAK * Faulty spring

NOT WEAKENED
POOR HANDLING Check tire pressure
Probable Cause
1. If steering is heavy c- (1I Steering head adjuster too

tight
(21 Damaged steering stem bearing
2. If either wheel is wobbling rc ( I ) Excessive wheel bearing play

(2) Bent rim
(3)Improperly installed wheel hub
(4) Swingarm bushings
excessively worn
15) Bent frame
(6)Loose swingarm pivot bolt
3 If the motorcycle pulls to one side b (1 1 Front and rear wheels not
aligned
, (2) Bent front fork
(31 Bent swingarm or frame
TROUBLESHOOTING
STARTER MOTOR
STARTER MOTOR DOES NOT TURN Q
Probable cause
1. Check operation of brake stop light DID NOT GO ON ,(I1 Blown fuse
by operation brakes (2)Weak or dead battery
(3) Faulty stop light switch
WENT ON (4) Disconnected terminal
(5) Broken or shorted ignition
2. ~ h e d battery
k
turn signals
circuit by operating SIGNALS DIM, REMAIN-
ON, OR DO NOT OPERATE AT ALL
- switch
Dead battery
i
SIGNALS OPERATE PROPERLY
+
(60- 120 flasheslminl
3. Check starter relay operation ABNORMAL 1 Bad starter switch contacts

E=- (1
by depressing starter switch 12) Broken or shorted starter relay
(3) Loose connector or terminal
+
NORMAL
4. Test starter by connecting it to

battery
DID NOT TURN ~ ( 1 Worn
) brushes
(2) Broken or shorted rotor windings
(3) Broken starter motor sub wire
TURNS (4) Loose terminal
STARTER MOTOR TURNS SLUGGISHLY OR FAILS TO CRANK ENGINE
Probable cause
1. Check battery circuit by operating SIGNALS DIM, REMAIN *Dead bartery

turn signals ON, OR DO NOT OPERATE AT ALL
+
SIGNALS OPERATED PROPERLY
2. Connect starter motor sub wires

across battery terminals
TURNS PROPERLY * c-( 1)
Loose connectorlterminal
(2) Poorly contacted starter relay
TURNS SLOWLY (SPEED DOES

NOT CHANGE)
STARTER WON'T STOP

Probable cause
1. Turn ignition switch OFF STOPS + Starter clutch stuck out

in the engaged position
DOES NOT STOP E=- Starter relay shorted or
stuck closed
TROUBLESHOOTING
UNDER CHARGED/OVER CHARGED BATTERY

NOTE: Make sure that the battery is in good condition, use a known-good battery if necessary. C
Possible Case
1. Test bartery for leaks (See page LEAK * ( 11Shorted wire harness
14-2) (2) Faulty ignition switch
NO LEAK C
4
2. Start the engine and check the STANDARD !w(11 Faulty regulatorlrectifier
regulated voltage at the battery
terminals (See page 14-3).
VOLTAGE DOES NOT RISE FROM

THE BATTERY VOLTAGE
71 HlGHER THAN STANDARD-(1 Faulty battery
Battery beyond service life
(2) Faulty reguratorlrectifier
C
1
(3) Short or open circuit in (Black)
(4) Loose or poor contact at
regulatorlrectifier connector.
3. Check the regulatortrectifier ABNORMAL * (1 1 Poor contact

connector for loose connection.
NORMAL
I
f
4. Check the regulatortrectifier NORMAL *( 11 Faulty regulatorlrectifier
(See page 14-4).
i
I
ABNORMAL
i
5. Inspect the faulty items ABNORMAL +(I Open or short circuit in (Red,
C
Black or Green wires) of wire har-
ness
(2) Loose or poor contact at alterna-
tor connector.
(3) Faulty charging coil.
NORMAL @(ILoose or poor contact of alterna-

tor connector.
(2)Open circuit of wire harness.
WEAK OR NO SPARK
GOOD SPARK w (1f Faulty spark plug
spark plug
I
+
WEA-K OR NQ SPARK
12. Check spark forlooseal3 SPARK ,(TI Loose or poor contact of spark
poor contact at the spark plug cap, plug wire
then try spark test again.
I
WE~K OR NO SPARK
I
3. Check CDI unit coupler for loose or
poor contact.
NORMAL
ABNORMAL (1j Loose or poor contact of CDI unit
coupler
14. Check the resistances or continuity at the CDI unit coupler of the wire harness side (See page 15-2). 1
,
I I
ABN~RMAL NORMAL
+
Faulty ignition coil
+
Faulty CDI unit
NORMAL ABNORMAL
B- (1) Faulty part
6. Check the wire harness for open or ABNORMAL B- (1) Faulty wire harness
short circuit between the CDI unit
and each part.
I
NORMAL (1 Loose or poor contact of connec-

tors on ignition related parts
20. INDEX
Accelerator Pump ............................................. 4-3 Fuel Line ........................................................ 3-5
) Air Cleaner ................................................ 3-7 Strainer ................................................. 3-5
Case ....................................................4-1 2 System ..................., ......................... 4-t
AlternatorIStarter Clutch .................................. 9-1 Gearshift Linkage ............................................. 8-8
Alternator .................................................... 9-2 General Information ......................................... 1-1
BatteryICharging System .................................. 14-1 Safety ................................................... 1-1
Battery ....................................................
3-1 2. 14-2 Handlebar ....................................................... 11-3
Bearing Replacement ........................................
10-10 Switch .................................................. 17-5
Brake Caliper ...................................................
13-5 Headlight ........................................................ 17-2
Disc ..................................................... 13-4 Headlight Aim ................................................. 3-14
Brake Fluid .................................................... 3-13 High Altitude Adjustment .................................. 4-10
Replacement/Bleeding .............................13-2 Horn .................................................. . . . . . . 17-8
Brake Light Switch .......................................... 3-15 Hydraulic Brake ............................................... 13-1
Master Cylinder ......................................13-7 Ignition System ............................................... 15-1
w Pad Replacement .................................... 13-3

ShoeIPad Wear ...................................... 3-12
System ................................................ 3-14
Coil ......................................................
Switch .....;................... .....................
Timing ................................................ 3-10
15-2
17-5
Bulbs ........................................................... 17-7 instrument ................................................... 17-2

Cable & Harness Routing .................................. 1-8 LightslSwitcheslHorn ....................................... 17-1
Camshaft and Rocker Arm Installation ................ 6-13 Limiter Cap Installation ..................................... 4-9
Carburetor Removal ......................................... 4-3 Lubrication ................................................... 2-1
Choke ................................................ 3-6 Points ........................ .
..... . ............ 2-6
Installation ............................................. 4-8 Maintenance ....................................... ': ........... 3-1
Carburetor-Idle Speed ....................................... 3-9 Schedule ............................................... 3-3
CDI Unit Inspection .................................. .
.... 15-2 Model Identification ......................................... 1-2
Charging Coil .................................................. 14-4 Neutral Switch ................................................ 17-6
System ................................................. 14-3 Nuts. Bolts. Fasteners ...................................... 3-17
ClutchIGearshift Linkage .................................. 8-1 Oil Filter Screen Cleaning .................................. 2-2
Clutch ...................................................... 3-15. 8-4 Pump .................................................... 2-3
Diode .................................................... 16-6 Pilot Screw Adjustment ................................... 4-9
Oil Pump Drive Gears .............................. 8-7 Piston ............................................................ 7-3
CrankcaselTransmissionICrankshaft ................... 10-1 PistonlCylinder Installation ................................ 7-5
Crankcase Assembly ........................................ 10-1 2 Pulse Generator ............................................... 15-3
Breather ........................................ 3.8. 4-14 Purge Control Valve lnspection
Separation ................. ..................
. 10-3 [California Model) ........................................... 4-15
Crankshaft ...................................................... 10-7 Rear Wheel/Brake/Suspension ........................... 12-1
Cylinder HeadlValves ....................................... 6-1 Rear Brake ...................................................... 12-8
CyIinderlPistons ............................................. 7-1 Brake Light Switch ................................. ' 1 7-6
Cylinder ........................................................ 7-2 Fender ..................................................12-15
Compression ........................................ 3-10 Rear Wheel ..................................................... 12-3
Cylinder Head Assembly ................................... 6-1 2 Regulated Voltage Inspection ............................ 14-4
Disassembly ....................................... .
6-7 Regulator/Rectifier ................................... ..... 14-4
fnstatlation ............................................. 6-1 3 Right Crankcase Cover Installation ..................... 8-10
Removal ................................................ 6-6 Removal ................................................ 8-3
Drive Chain ..................................................... 3-11 Rocker ArmlCamshaft Removal ......................... 6-3
Electric Starter System ...................................... 16-1 Service lnformation
Emission Control lnformation Label AtternatorlStarter Clutch ......................... 9-1
( U S A . only) ................................................... 1-14 BatterylCharging System ......................... 14-1
System (U.S.A. only) ..............................1-12 Clutch/Gearshift Linkage .......................... 8-1
Engine Removalllnstallation .............................. CrankcaseTTransrnissionlCrankshaft .......... 10-1
Engine lnstallation ............................................ Cylinder HeadlValves .............................. 6-1
. Oil ........................................................ CylinderlPistons ..................................... 7-1
Removal ................................................ Electric Starter System ............................ 16-1
Evaporative Emission Control System Engine Removalllnstallation ...................... 5-1
(California model only) ...................................... Front WheellSuspensionlSteering .............. 11-1
Exciter Coil ..................................................... Fuel System .......................................... 4-1
Float Level lnspection ....................................... Hydraulic Brake ...................................... 13-1
FloatlFloat ValvelJets ....................................... Ignition System ...................................... 15-1
Front WheelISuspensionlSteering ....................... LightlSwitcheslHorn ............................... 17-1
Front Fork ....................................................... Lubrication ............................................. 2-1
Wheel ................................................... Maintenance .......................................... 3-7
Fuel Tank .......................... . ........................... Rear Wheel/BrakelSuspension .................. 12-1
INDEX
Service Rules .................................................. 1.1

Shock Absorber ...............................................
12-10
Side Stand .....................................................3-16
Spark Plugs .................................................... 3-8
Specifications ................................................. 1-3
Starter Clutch ................................................. 9-3
Motor .................................................... 16-2
...
Relay .................. ............................
Steering Head Bearings .................................... 3-18
Stem ........................
... .....................
16-6
11-14
Suspension ..................................................... 3-17
{a
Swingarrn .......................................................
12-12
Throttle Operation ........................................... 3-5
TOOIS ............................................................. 1-7
Torque Values .................................................
Transmission ................................................... 10-4
Troubleshooting
Batterylcharging System ......................... 14-1
1-5
{a
ClutchlGearshift Linkage .......................... 8-2
CrankcaselTransmissionlCrankshaft .......... 10-2
Cylinder HeadlValves .............................. 6-2
CylinderlPistons ..................................... 7-1
Electric Starter System ............................ 16-1
Front WheellSuspensionlSteering.............. 11-2
Fuel System ........................................... 4-2
Hydraulic Brake ...................................... 13-1
Ignition System ...................................... 15-1
Lubrication ............................................. 2-1
Rear Wheel/Brake/Suspension .................. 12-2
Vacuum Chamber ............................................ 4-4
Valve Clearance .............................................. 3-9
Guide Replacement ................................. 6-9
<.a
Seat InspectioniRefacing ......................... 6-9
WheelsiSpokes ................................................ 3-18
Wiring Diagram ............................................... 1 8-1 -
M O E FROM 5096 RECYCLED PAPl
MINIMUM 11Wb POSTCONSUMER COh
IPC @ @ 500.2001.11
PRINTED IN USA

Honda Rebel Cmx250 Manual 85-87

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Honda Rebel Cmx250 Manual 85-87

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HONDA

Sections 1 through 3 apply to the whole CYLINDER HEADIVALVES

Find the section you want on this page, then

Most sections start with an assembly or

All information, illustrations, directions and speci- BATTERYICHARGING SYSTEM

HONDA MOTOR CO., LTD. WIRING DIAGRAM

Date of Issue: Dec., 1986

The battery gerierateshydrogen gas which can be highly explo-

The carburetor serial number is stamped on the left side of

(4) VEHICLE IDENTIFICATION NUMBER

DIMENSIONS Overall length 2,115 mm (83.3 in)

Up to 9 0 kg Front 2 0 0 kPa (2.00 kglcm2, 2 8 psi)

Revised: August 1987

Engine oil drain bolt

Drive sprocket bdlt

Exhaust muffler mounting nut

Brake disc mounting bolt

Apply a locking agent.

Brake arm bolt

Swingarm pivot bolt

Caliper mounting bolt

Master cylinder holder bolt

STANDARD TORQUE VALUES

DESCRIPTION NUMBER ALTERNATIVE NUMBER

I Valve adjusting wrench, 8 x 9 mm

Float level gauge

Valve spring compressor

CABLE & HARNESS ROUTING

A loose wire, harness or cable can be a safety hazard.

Do not squeeze a wire against the weld or end of its clamp

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

Protect wires and harnesses with electrical tape or tubes if

Do not use wire or harness with a broken insulator.

Route wire harnesses to avoid sharp edges or corners. Also

Be sure grommets are seated in their grooves properly.

After clamping, check each harness t o be certain that it is

Wire harnesses routed along the handlebars should not be

Do not bend or twist control cables. 0:CORRECT

CARBURETOR OVERFLOW TUBE MOTOR CABLE

,(I) CLUTCH CABLE

(2) CHOKE CABLE

CABLES (3) MAIN WIRE HARNESS

(5) BRAKE OIL (41 SPEEDOMETER

(7) CONNECTION BOX

(1) MAIN WIRE

(2) STARTER MOTOR CABLE

EM ISSlON CONTROL SYSTEM (U.S.A. only)

CRANKCASE EMISSION CONTROL SYSTEM

0( 6 ) FRESH AIR )5(' DRAIN PLUG

EVAPORATIVE EMISSION CONTROL SYSTEM (California model only)

@ (5) FRESH AIR

4 NOISE EMISSION CONTROL SYSTEM

2. Removal of, or puncturing of any part of the intake system.

4 3. Lack of proper maintenance.

EMISSION CONTROL INFORMATION LABEL (U.S.A. only)

(1) EMISSION CONTROL INFORMATION LABEL

EMISSION CONTROL INFORMATION UPDATE LABEL

VACUUM?WSEROUTING DIAGRAM LABEL (California model only)

1.5 liter (1.6 US qt, 1.3 Imp qt) at change a

Use Honda 4-Stroke Oil or equivalent.

ITEM STANDARD mm (in) SERVICE LIMIT mm (in)

,tor tip clearance 0.1 5 (0.0006) 0.20 10.008)

Oil level too l o w Low oil pressure

Place the oil pan under the engine.