A Few Words About Safety Service information The service and repair information contained in this manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment ‘ud cause injury to yau or others. It could algo damage the vehicle oF ereate an unsafe condition. This manual describes the prover methods and procedures for performing service, maintenance, and repairs. Some procedures require the use of specially designed tools and decieated equipment. Any person who intends to use a replacement part, eervice procedure ora tool tha is not recommended by’ Honda, must detarmine the risks to their personal safety and the safe operation of the vehicle \Wyou need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recommended that you do not use replacement parts of inferior qual For Your Customer's Safety Proper service and maintenance are essential fo the customer’ safely and the Felabilty of the veniele. Any error or oversight while servicing a vehicle can result In faulty operation, damage to the Vehicle, oF injury to others. For Your Safety Bocause this manual is intended for the professional sorvice technician, we do not provide warnings about many basic shop safely practices (e. q.. Hot parts - wear loves). If you Nave not received shop Safely training or do not feel confident about your knowledge of safe servicng Practice, we recommended that you do Pot altompt to porform tho procaduras RULED seRIOUSLY HURT HF you dont folow instructions. You CAM bo KLLED or SERIOUSLY HURT If you dont olow PRUZNGININEH $23.52". * PCT AUE TONNE | You CaN be HURT if you don't follow instructions. + Instructions - on how to service this vehicle corectly and safely. ‘AS you read this manual, you wil find infomation hat is preceded by a [NOTICE symbol. The purpose: ofthis message is to help prevent damage to your vehicle, other property, or the environment ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON’ THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO.,LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN. PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA. MOTORCYCLES, MOTOR SCOOTERS OR ATVS,HONDA MOTOR CO.,LTD. SERVICE PUBLICATION OFFICEHOW TO USE THIS MANUAL et const it ag ary te ha ee mnaaute ‘sot t NGF ps" rea nena HONDA MOTOR CO.,LTD SERVICE PUBLICATIONS OFFICE (GENERAL INFORMATION CONTENTS |" FRAME/BODY PANELS/EXHAUST SYSTEM. | 2 [ /_twericarion sveTEM / ruetsverem L WIRING DIAGRAM. ‘TROUBLESHOOTING INDEX MAINTENANCE COOLING SYSTEM se ENGINE REMOVAL/INSTALLATION ELECTRIC STARTER LIGHTS/METERS/SWITCHES Date ofisoue Soper 2000‘SYMBOLS ‘The symbols used throughout this marusl shew specific service procedures. If supolemeniay information i required! pe taining to theca symbols, t would be explained sos In the net without he ue ofthe snbols Replace the pants with anew ones betoreaseembl. Use recommended engine it unless othonwive spectod, JJ Use melyodenim oll soliton (misture ofthe engin land malyndenum arse ina rato of 1. [seu range iim ed mt ren Wor anit ‘Use malvodenurs dingo area coriaining mare than 3% moWbdenurs deuide, NUGIBZ or | ‘equivalent Example: Molyote* BA? plus manufscsured by Dow Coming, USA | Mutt purpaee M2 manutactured by MlsubIGh Ol Japan | eae et es eis ean 8X ba FARE ‘equivalent Example Molo G-n paste, manufectured by Dow Coming, USA. Honda Moly 60(US.. ony) | Rocol ASP manfactured by Rocol Limited, UK. eco} Paste manufactured by Sumigo Lubiant. beak bah Use scone grease ‘Apply locking agent. Use mide stronath locking 2 | ‘Apoly sealant. Use DOT brake fui, Use the recommended bake uid unless otherwise specifi. Uso fork or suspension uid1. GENERAL INFORMATION LUBRICATION & SEAL POINTS. 6 CABLE & HARNESS ROUTING 118 Ei EMISSION CONTROL SYSTEMS. 128 EMISSION CONTROL INFORMATION. 14 LABEL (USA. only) 130 ‘SERVICE RULES 1. Use gentioe HONDA or HONDA-racommendad pers ard isbricants their aguvalents Pers thet dort mast HONDA'S design spestieaons may couse demage wo the motoryce 2. Une the apecal tole designed fr thie product te aveld damage and ineoroctassombiy. 2. Use only metric tools when servicing the motoryae. Matic belt, nuts and serous are net insrebangosble with English fosonare 4, natal now gokas,©inge, coor pine, and ook plates whan resetorbting 5 1, Route al leaticl wires an shown on pagas 118 rough 1-27, Cable & Harmose Routing. MODEL IDENTIFICATION 1-1(GENERAL INFORMATION ‘Venncue DenreicaTion NuMaee FRAME SERIAL NUMBER ‘Tha Venice Ideristion Number (Ne stached on the loft side ofthe steering head. steering heed. ENGINE SERIAL NUMBER [CARBURETOR IDENTIFICATION NUMBER “The engin serialnumber ie stamped on the right ide of {ha crenkoace below the rer cinder. Ity the designated color cove “The carburetor isatifeation numbers are stomped nthe Intate aide ofthe carburetor body ax show 1-2GENERAL INFORMATION SPECIFICATIONS /- GENERAL rent “SPECIFICATIONS: ‘DIMENSIONS | Overal tena Bama Overall with ‘B00 mm i315 0) vera eight Um mm (2.10) Wnsotoase {ist mm S48 in) ‘Seat elant 15 mm 268 0) ‘Ground clearance "20 rm (550 Drywolgnt [48 satConase 1p) 22454983 tbe) | | {catern pe) 2575914078 bs | | Curb wight [8 satsCanaco ype) | 295.449 (6180 bl | (Cater ype) 238349 8203 ba) | Maxim weight capac foeg 600 os | Fane Frome pe ‘Dove ere | Fron suspension ‘Tetseope fot | From ne mel {os mm 3m) foo svpensan Singer Rear sieved imma in in ‘howe-19508 Reartresizo som SMe 7s Fromtrebrend Dunlop ra Bridgonone | Cons Dino ras Bridgenore | Grea ysl sngl se rake imams xpancing so ieee {82 mm @0in) |i 348 US go 236mo ox | Fontan rear capaety {tet 08 ga 088 ps) ENGNE | Gyn erangerent Zoylnders PV vansvere Barend woe 180% 760 mm att 299) Dipacemant eens sa coi) Venu sin Stent muti ean ven and ONC wah rocker em io valve coors poe. att mnt. ie So So abe shaun vate ore Se-esoc eee oaroe Labiaton stm Foread prenute nd wet sump Spun aype “roe Goatna stom Taxi cote Kiciention Viscous papa sloment Cranks pe Untype, two man ourate Engines welt sets ico) Fine ous Front= 90" eat 412° Front Gyiner number Front 62 Root Bt(GENERAL INFORMATION, GENERAL (Cont'd) em ‘SPECIFICATIONS ‘CARBURETOR | Carburetor typ ‘Constant Vert Trott bore 3mm (1300) Drive TRAIN | Gluten svat Mun slo woe {Guth operation system Coble operating “Transmission Constant meth peed Primary reduction ‘696 635). Final reduction 2an uziaT, (oar ratio tx | Se6.sna znd | 2000 3017) sa | 300020) ain | aaa sm | to ws20) Goareit poten Let0ot opereted tum sytem, 1=N=2-3-4-5 ELECTRICAL | Ignition systom Ful ransisoied ignition Staring stem Elec starar motor {Grargng ster | Triple phase output aternstor Reguisrornectior SSCR ehortecpi phase Full wave retietion Lighting astern Battery 1-4[GENERAL INFORMATION ri nm i [> LUBRICATION SYSTEM TEM ‘STANDARD SERVICE LNT | Fogle i canary ‘aeiainng ‘a ers 232 US ae 1.9¢ima wo — after change 2 fers @54 US at 211 imo = - ‘at aleoseomaiy_ 2 re (3.56 US a. 255 imo at — Recommended engine all ond GN or HPa ¢-xrote ol or quivlart motor oil [serie clacton SF oF SG Viscosity: SAE 140 ‘i pressure a ol prose Bch SSDAPa (64g 77 pa a = 5.800 rb BO°CT76F) 7 zi ‘Oi pum ctor [Mis lonrance 0.15 (0.0061 2070.006) (0.18 -0.2 (006 0008) oasioow) | - (8020.67 (2003 — 0.0031 00.008) [- FUEL SYSTEM. Te ‘Carburetor derision number | a8 stteCavaci type Caloris ype sin jot Front Rest Siow et Pilot seraw inflanal apart roa ev Bese crbureto Wor synebvonzalion) [eis aces Carburetor vacuum dierence 20 mm fg (7 in “Tote ab ee play 2-6 me (12 Wein) [- COOLING system rem ‘SPecieaTioNs Coat emmy alto arava 7B hae SUS 15H mw een ae (042 US G35 Imp Taco cap at pesare T08= 19 Aa = ego 18=20 pa Thermostat [pane 0-246 (78-181 — Full en case Valve it am 3 in) minim ecorimended anc ons Fro Honda H colent ren equivelet high quay atylere yea! enrease containing este ree carosion iors 1-5(GENERAL INFORMATION, Unit: in [- CLUTCH/GEARSHIFT LINKAGE reM STANDARD SERVICE MIT Chih ver ea [fo 20 03750760 _— ‘hh speng es nah 550.78) OEE [Guach ise oes | = ae 2 00S [25000 2600.10) Git ple webege connor ‘hth outer ie ib. “Taa0a esr on. 3098 0.180 ‘i pump die aproskat 1B. ‘ans 90108 (9671-11 20160107 [Meine 0.0 suten oa ie 21a6)- 21990 09648-asse4| 7196 0860) [- ALTERNATOR/STARTER CLUTCH at eM STANDARD ‘SERVICE UNIT ‘Sar arven goer 1. abe (8748-176) HO TOUT STH 00. 57749-87709 22796-27163) | ST.7S B28 Siar coh outer Taare = T4400 (28267 -29007| | TAAB OSD oi eG) - CYLINDER HEAD/VALVE eM STANDARD seRvice UIT ‘inde compres aie: Gea 30> Loar —_ 15! ipa 40 pm Tyner heed wornege — ES Vave, | Vaweloarance iN [oe 002000 008) — ‘ave aul © | 020008 0008 09008) — vars aon 0D. ~~ fw [sans 5.490 02156-02767 sa070 [Be [eo 15 02508 -0.2606) 55,0258 Valve guide. [IN| Ss00= 5512 w2165-021701 5550210) [ex eto 5152508 0.26061 665,028) Sto. guide closance 70000), or10004) Valve guide projection above byline hese Tae Reo oae EO Taam ate i Heath aera) 38 18 ee eae asia cansatt | combo tio | ars sa B= ——srawtra [ek soe araes acon aee) [758 ta ara Fiaes= 98 Gass OMEN TTS fae = coor Cia eas oORH oreo | Identification marks PP: Front “RY: Rear — aa ant Teal omT Ta | Rocker arr shaft 0.D. INEX | 11.966 - 11.986 (0.4711 - 0.4718) [11.83 (0.466) Fest ar oT wa Te ate ons Gouee) | oar oar 1-6[GENERAL INFORMATION (CYLINDER/PISTON oem re STANDARD sevice Laat ‘bogs aoa. Fave aTe I ~ - [-e08(o0n2) I — [0:06 0.002) | — 0.100.004) Paonia | 2A ra eg over eiate Bae | — aa Tae faa 10) 7a 08 Paton 0.0. measurement point | 7-17@3-0,7itrombonomafeda | — Piston pin hole LD. ‘8.007 — 38.008 (0.7087 — 07090) Treo ery Te 18.00 (8,758 0.7087 1788 0,708) Fircnto-svon pi dnrence | 008-8814 00001-00008) | 0.040002) toning ong {1926 80550 0010- 00221 noon) | roove earanaa | o0%6- ants ioc o00%6) | cor oom Faton ing eos | o1s=025/0008- 0019 030(0012 —fasvianay “.0(00%) Raion ire a — See a ‘0 = 8045 (0 0054— DT) 7070804 ‘Comes rd eral ene. TB TOD 7058-07105 180 O70 Connecting odo-pston in lara 016-8040 (0.0008- core) 3.08 (0.0081 Unt mm Gp ~ CRANKSHAFT/TRANSMISSION rem STANDARD ‘sewice uM PoE Seine = 2.000.081 rnin cern a= oH wT = aDA 20710005 ‘an our earns 10000044 00012-0078 ‘3070 295.008 7802 {11024-15038 7504(1. 108 2.00 9.095 aoe Lz) ota) 21989-27300. 107 1.1018 F194. 100 9.950505 (5285-12185) sat 290 and. ome AH 4 mH 71 995= 280161 101 — 1.1009 E08 1108 ‘0.020 ~ 0.062 (0.0008 6.0024) 0.10 (0.004) | ‘025 0075 (0 070-0030) e19808) | Moa 00a 24572-24580 (09891-05840 24.95 (0.982 Courier 0. ot 2 busting | 27987 e980 071.101 7795000) | a007 0.049 (0003-801 0 9008) ‘8.015 — 0.048 (6.0006 - 0.0019) ‘0.08 (0.003) ‘sano 021 (OS118- 0126) Tan ost) ‘Si fork dw kre 90-600 0200-0236) (022) ‘Shitfork shat 0.0. "2966 12904 (15105-08772) 72900506) | Shit drvm 0.0. ar left side journal) 11.986 17.986 (0.4711 0.4778) [1194 (0.470) 1-7(GENERAL INFORMATION. [— FRONT WHEEL/SUSPENSION/STEERING — Sees re STANDARD SERVICE LNT nar owed aap — Pr) | Coss pressoe | Upto 90490 ood OAPs 2.00 glon, 29 ps) = Up ts maxi weight 2912 (2.0 hao, 29a) = cc 301008 Wheel sim raat [Radia — 201008 ‘Axial — 201008 | Wheel huibto-rim distance Page 1312 — ‘Whe balance weight = ‘eaten Fork Seog oe gt 2A 839) 2025 (18.01 Tube runout = ‘ez 0008) Recomended fr id ro Honda Siapesion Fuld $8 — Fork fluid tevel 124 (48) - — Fork ui pay 17326 on (180008 US ox 1882 — ims oo Tierng Food ean pala Ga 104 fa 220 = sa [- REAR WHEEL/BRAKE/ SUSPENSION rem ‘STANDARD ‘SERVICE LMT _ ll — 2.0 (0.08) ‘Celdte preseue | Up WO; UOT and we BOON, pa = {pio avin walg capacity | 250 (280 kt, 98 pal — Faerun 02010006 Wheel enone [Rash — 201008, ‘Axial — 2.01008 Whos balonce wait — ease Drive min ick 15-25 10800-0 08) fs swozsraa 7a [en ‘Shosk absorber ering pretend aus eting — | HYDRAULIC DISC BRAKE Soe met rem STANDARD. [service unarr ‘posted be id Dore — Brae ies kro 50-62)023-020 sai ~ Tesora Master yer i000 Tawa wamnt—o.aaMs) | 08 085 ‘Maser piston OD. 70.957 70.964 (0431 [084s (04008) [[calperevineerio.——~SSSSSS~S« 0 BERD 1.880} | 7.06.08 Capa ton OD. asia 26968 0868-10617) | aan (050) 1-8GENERAL INFORMATION — BATTERY/CHARGING SYSTEM TEM [SPECIFICATIONS ‘emery Capacity - iav- 12a ‘Curent ackage — mA max Vota Ful ergo 7a0- 1320 locos) [Needs charging Below 2.3 Charging auvent | Normal VAAKG-10h ‘lek SSAxi0 ‘Aerator | Gapaciy (0.355000 «pm — ‘Charging coil resistance (20°C)68°F oie [IGNITION sysTEM eM SPECIFICATIONS ‘Spark plug Standard DPRGEA 9 (NGK), X24EPR-US (DENSO) For cod inate below SANFL DPRTEA (NGK, X2ZEPA-UB (DENSO) For extonahiaheooed ring (DPROEA.S (NGG, XO7EPR-UD (OENSO} ‘Spal pon ae (09 mm 0.8 0.04in) | Tantion coil primary pe vonage anion pule generator pak voltogs 187 ¥ minimum Ignition timing FF" mar Br BTOCat ide nts in i p> EREGTRIG STARTER =m ‘STANDARD SERVICE UNIT ‘Sterer motor brush length as aw) 35/026 [> UGHTS/METERS/SWITCHES em ‘SPECIFICATIONS Bib Headlight (ighiow bear evens W Brakatailight av 718 W Front tum signalunaing Tht W2V- 205 Wed | Roar um aignal ihe V=nWa2 Instrument ight tp xs Tur signal inieaor i High bears indicator eo Neualinaieator Leo ‘Coolattempertureindiator Leo Oi proses indiestor fy Fase Main Fuse a08 Sub fuse WAx4 1SAXT Fan moter swich | Stato cosa ON ‘102°C (208-2167) ‘Stops (0 open (OFF) 98-97 (199 ~207"7 | Therosonsarrsi- | at aC 0767 5-000 | ae 127 (487) 30-200 ‘Cobureor haar oitanc a 20° (7) 13-150 Fuel pump flow capacity ‘Minimum 900 em 190.4 US 02, 31.7 imp o2) pee minute 1-9(GENERAL INFORMATION TORQUE VALUES STANDARD “TonauE ToouE FASTENERTVPE | yg ROUE y FASTENER TYPE ‘en Teg, ‘ba and mt 505.35 | Eamaiow 40825) mm tt and mt “atte. | Smmacrow 903.55) ‘Srom board nut 2122/16) | EmmTlange bot (-mm hens) and out Bia {orm belt and mit Higa 2e) | Smmtenge bit (tr Pen aed mt ena Vemm belts ut Stles io) | Smmnange vatsna nt 28127, {mm Reng tr ona not 38140.20 + Torq epectiatione ated boow afr iporant fasteners + there seule bo tahtned te standord frau value etd above, NOTES: 1 Aoply selena the teed 2 api ctig agent ote os 5 Ronly oraan othe trees an esting urea. 4 opt alto thethrends end seating sce. 5 Site {Lat hone roa. Une {8 ALOC bat reclce with anew oe, 9. Breet bole Pea ‘THREAD ‘TORQUE = TY iA tm) | Nem atm tatty | REMARKS ‘WAINTENANEE | Spare log ‘ 2 Mena 10 Crankshat hoe cap : x isasin | noves “ining hoe cap 1 z weasin | Nove Vote ding arm tock mut ‘ ? 37) | NOTES i dea bor : “ aieo2 Gi er arcoe 1 2 fone | noves Yoav aug 2 : 3103.22) LumaTION STEM: | (Ol prsrare ste |os | ere | zez9 | nores {i presture seh eral seen : ‘ 7024 ot puro cok 5 ° 139 FUEL S¥STEN ‘i eaer howsirg say bot 1 . 029) ccoOuNG Syste | ‘Water bum bok 5 ‘ Roa cuuTor GeARSHIFT LINKAGE: uth iter ate bot ‘ * none Guten comer loc et : ® TH U30.80 | NoTEA emery drive gee ot 1 2 eos) NOTES ‘Garant sping in bat 1 ® wea Di pup crwon socket ble : 6 150819) | nove? ALTERNATOR/STARTER CLUTCH: Fywheo! pot 1 2 wa7q3o.00 | NOTER Stir moving bolt 4 ® uae | NOTE? Stator isha ble 1 & eae) | Nove? Sarer doer noun bot ‘ & woz) NOTE? 1-10ENGINE (Conta) Tinea | __Tonaue tna © | oak nm) Non then ty | REMARES ‘CYUNDER HEABIVALVES ‘Cyinseenend cover bot “ 3 29119.) Seehond cover boi a 3 202.8) Camaposer ton ‘ 7 231m | Norez {Gam ehaintonaont mounting bot ‘ 3 jonan eat hoger mm bot . & 23,1 ‘mm aut ‘ a Basin vinder head sm bot t a Roam | sores Samm mit & 0 ies 39 | NOTES Cringe axa tn raurg bot 6 3 ona. ‘CRANKCASEICRANKSHAFT/TRANSMISSION: ‘Crankee mm Bot “ . 23,0 Sonnetng ad beating cp ut : & Beam | sores | Srkotthai guide ple St 2 6 wnaa Newest sutch i | 1203.81 1-11(GENERAL INFORMATION — FRAME = 7 - sem TV | otk om) | Monten ey | REMARES ‘FRAME/BODY PANELS/EXHAUST SYSTEM: Foote bracket bolt ‘ 0 3135.25) Exhont pipe jon nat | 3 8 25126, 18 Matfer mounting nt 2 5 7.20 Exhaust pipe jim pipe bal 4 8 20120.) Seat mounting dak 2 8 25(27.20) Reor fonder bat 2 0 465,47) Shock absorber sti bolt \4 | 108(79,00) et gear outing nat 1 | "eeiac.68) Fuel tank bot J} a 3 18143, 16) 1 | 2 34(35,26) bi) 8 051005 023) Let crankors fear cove bolt ca 6 2112.3) MAINTENANCE: | ‘Side stand assembly bolt 2 0 48(60,29 ‘Spoke nipple 108 # 408) (COOLING SYSTEM: | Recintor mounting bolt : 5 140.1,0.21 Fan motor sates + 6 7808.1 | ENGINE REMOVAL INSTALLATION: Front engine upporlower mounting nut 2 0 (35,40) Ree engine mounting mut 1 0 5855, <0) From engine bracket bit 2 a 25(22.20) Foor engine racket bor 2 3 28,23, 20) {Genes arm prah bo i 6 23.8) Drive sprociet xing plate bolt 2 6 ron0.7) ‘CLUTCH/GEARSHIFT LMKAGE: ‘Goarohit pada pot bolt ’ 0 24(95,25) [FRONT WHEEL/SUSPENSION/STEERING ‘Steotng ste nut 3 | 103,105, 76) ‘Steorng boring adjustment ru 1 2s ge 18.28 ‘Steoring Bseing oajusmane look nut 3 3 | gage 13.28 Top bricge iach bal 2 3 28122,20 Bottom bridge och bolt 2 10 3150.28 Hancledar upper Poder bolt ‘ 3 223, Hencletar lower holder nit 2 8 2303 Front axis bot 3 u 59 160,4) Frontal pinch bolt 4 8 2122.79) Front baka is bl ‘ 3 22(43,3) | NOTES Fork cap 2 a 2222.39 Fork socket ott 2 8 2012079 | Novez [REAR WHEEL/BRAKE/SUSPENSION: Rear axl at 1 93195,69) | NOTE7 Driven aprocet nut 5 2 (goes) | NOTET ‘Shock absorber upperilower mounting bolt 4 a 25 (27,20) Swingarm piv nut ; “ (80.6) | NOTE? Singetm pivat sdueting bot 3 ry 2059) Swringetm ptt ack nut 1 as Sates, 47) Drive chain ser seer 2 ° 303.22) Bear bata stopper em nut 2 8 206,79) Bear rake arm bot 3 & 238,29) ent brake midi roi belt 1 0 34105, 25) 1-12GENERAL INFORMATION — FRAME (Cont'd) THREAD TORQUE om QTY Arm) Nem gm. ney REMARKS. WVORAULIG BRAKE: Brate caliper mounting bolt 2 5 00,29 | noTES Brake caliper fin bot 3 5 "a(i3,9) | NOTE? Brake caliper bracket pin bot 1 a 2082 | NOTE? Peain 1 wo i881 Ped pin pig 1 we | 303,22 Bak clot bead valve 1 a Sis a3 Brake lover pivot bot 1 5 1169.07, pivot rut : 8 soean Brake master ylinder had bolt 2 5 12112,9) rate raster yin reset cap sew 2 20214 Front brake light serch aow i 4 ior0n nie howe ot ot 2 0 32(35,25) BATTERY CHARGING SVSTEM ‘Batary soto cove stew sis 9109,65) ELECTRIC STARTER: ‘Starter motor cable terminal aut 1 . 10(10,71 LUGHTSmeTeR/swnTcHES: ‘Side stang ewan muting bok 1 ° s0000,7) ‘hermonenscr 1 re 8108 Se) NOTED Ignition seh mounting bolt 2 6 122.9) NOTES Hom mounting bolt 1 8 22418) Speadometor seve! bot 2 é 40046, omens: Side stand pivot bot 1 0 won0.7) took ut 1 10 | a0z Too! box cove sztew 3 ¢ 20218) 1-13GENERAL INFORMATION TOOLS NOTES: 1, Alternativo oo, 2 Equivlont commorsinny avaible tn USA 3. Not avalible in USA. DESCRIPTION | TooLNUNBER | REMARKS: REF. SECTION Crburetor foe eval auge ‘07401 0070000 | is Oil pressure gauge ‘97506- 3uc0000 | NOTE2 « (07510- 3100200 | NOTE 1:o7LMU-o01000A(US.A.only) | 3 (o7s10-azz0t00 | NOTE2 ‘ Geor holder ‘772 onior00 | NOTE 3 8 Flywheet holder (07725 0040000 | NOTE 2 8 Rovor puller (077330720001 | NOTE 1:07") -2290001 U.S.A only | 8 Valve guide drver, 5 mm IN) ‘07742 - 0010100 0 Valve guide driver, 6mm (EX! 077420010200 | NOTE 1:c7B42~6570100 (U.S.A only) | 10 | Valve guide diver, agjosabie typs) 07243020000 | NOTES 10 ‘Atuchment, 32x38 m”™ | orzas—oororeo | 14 ‘Attachment. 37 «40 mm ‘07748 — 0070200 a ‘Attachment, 82x47 m-> ‘o77ag 0010900 12,13,14 ‘Aauchment 82x88 mmm (07788 — 0070400 1218 Driver 30 min 1. ‘orras — 0030300 43 Plot 15 mm ‘0774s — 0040300 14 Plot 20 mm (07746 -o040so0 rata t4 Plot 25 mm ‘o7ras —o040800 2 lot 30 mm (07746 - 0040700 8 Biot 28 mm 107746 0041100 cr Bearing temover shaft (07748 - 0050100 34 ‘Bearing remover head, 20 mm (07748 — 0060600 13,4 Driver (07349 0010000 Bi2 18.14 Valve spring compressor (07757 - 0010000 0 “seat cutar, 27.6 men ¢6"N} | 07780~0010200——; NOTE 2 seat cutter, 38mm (6"EX) | 077800010400 = fat eaten, 28 mis 32" IN) (077900012100 — fat cuter, 35 mn 32" EX) (07780 — 0012300 — interior eutar, 30 mm (60"IN) | 077800054000 — interior eter, 318men 60" EX) 97780—D0v8100 canter holder, 5 mm (IN) ‘o7rai — 0030101 — — cuntar holder 6.6 mm (EX) ‘ovmat ~o0t0202 ive aajusting wraneh (07808 —KEs0000 | NOTE 1; 07808-KEBOT00 (US.A. only) | 9 Shap rng piers (07914 SAs0001 415 Stooring sem socket ‘o7ai6—3710101 | NOTE 1: 070163710100 8 ‘Beating omovar set ‘79363710001 | NOTES @ — remover weight ‘o7ra\—0010201 | NOTE 1: 079363710708 (U.S.A. only or 07998 - 3710200 = remover hans ‘07936 —37 10100 | — remover head ‘07936 - 3710800 ‘Bearing race remover ‘oree 3710500 | NOTE 1: Me360-277-91774(US.A.oniy) | 19 ‘Bearing driver remover ‘07946 — KACO 4 Driver shaft 7046-Mu00100 | NOTE 3 a ‘oveas—Muco201 | NOTE 3 14 (7947 —KASO10O 13 (07987 ~KF0100 3 Boll ase romevor set 7053 -Mu10000 | NOTE 1:07852 ~M10008 or 13 (07958 = MJ1000A (U.S.A. only) = diver attachment 07953 ~ Mut0100 = detver handle 07953 ~ M10200 1-14GENERAL INFORMATION DESCRIPTION ‘Valve guide reamer. 5.5m ON) ute eamer, 88mm (EX) Pak votage adactor Drive cain too set Spoke wrench Chih Sonor holdor Veeuur gauze sat Vecuuripresaure pure "Too NUMBER REMARKS: EF. SECTION ‘orgea z000003 70 Grand 2e200m | NOTE 1:0798«-ze20000 (U.S.A ony | 10 arana—KTra200 | NOTES nu O7HAA Pu70100 3 OMNGd —GG20100 | NOTE: Paak votage tester 7 (USA ony) o7umi-mmnoxos | NOTE v-o7HIMH-MAR7OI0B 3 (USA only) cruma-usgoico | NOTE? 2316 GrIM—MNSGQ0) NOTE T: 07480100 ® (USA only) o7xma-—masa0101 \s (TUM 0010008 | NOTE 1: MaS7B— 221 - 0000 3 (USA. only) [ASST 081 900K | NOTET: ST-AH=20-MCT USA ony | 5 STAN 255-MCT (USA ont! 1-15(GENERAL INFORMATION LUBRICATION & SEAL POINTS LOCATION ENGINE MATERIAL [ REMARKS ‘Camanat iobeejeumai Valve stom valve guide ising surtaos) Rocker arm sippar surface Recker arm shat outer surlace CConnoeting roa bearing curace Crankshaft jourels Clute outer guide outer surface ‘Tranamiclon gar eh fork groove ‘Transmission eoleinor an eutorouroea ‘Transmission spline cll outer surface Prston cute euros Piston ring outer surtoce Piston pinout suroce Primary drive gear bolt treads and seating sface Fynheel bot treoee and soa ng artace Stet’ eluteh spre slicing lock surface Starter le gear and reduction gee abet exter surace ‘hatch canto lock nu throade {teh tar or 1 ight erankoses cover aiding surface itch iter rdtoright cross cove scingeuroce {lsteh sine out: surtece (Glndorstus bot hreses (ylinder ee am bol treads Valen adjonsng sew tienda nd Seating surface Cytnder need mounting bot, nut eouing erfoce {Gyn heed cover mounting rubber sal whol surtca (Connecting od blut threads and seating surfoco ‘Tranomiscon ger toth Citta earicgo treace and Ong Bearings roling area ung ennecting ro small nd nee ura 7 Matanum ot soiaion Mmocre of Terao a | Teewohyedenum dsutide | resee) Fine a Air cleaner outing te-chember band nae surface Crankahatt ole cap treads “Timing Mole cap treads tins te purpose arose ‘pressure switch threads ‘Thermonenor treads Lat end ight cranicase mating srfoce ot and right erankease cover mating euface ‘Sealant Seo page 43. See page 18-8. am procket pot three Starter cuten Rousing bok treads ‘if pump driven sprocket bot reeds ‘Stator wire holt bol Seeds oor cam plats bot read Transmission boring et plate bolt threads CCourtnrshat seal et plate ol threads ‘Gam shaintansione et plate bl threads Stator mounting bok reeds Oi iter bose thrends lean tease sd) Ignition pulse generator bolt treads Lert crantcave cover bok threads “TLeeking ogone | coating with: 68.1 mm (02520019) Seo page 84 1-16(GENERAL INFORMATION FRAME LOCATION MATERIAL REMARKS. ‘Side stand pvt aang surface ‘Wult-purpoesgresee Spreading 103 ‘Staorng heed baring siting surface ‘Staering heed Gusts lipe {Guten ever pivot boeing cures ‘Feats grip tnnersriace Spreading 19-209 ‘Tat pipe roll-up parson thratleeable end Speeding 02-039 Rear wha ane siding suttace Rese whe steve aiingauace Bear brake car ling sures Rear brake showto-cam siding surface oor brake anche ain elcing surace Beer brake pace anc rod pivot ing erie [eor brake pedal mide od joint bt sing surace ‘Swingact vot dust ea Ips ‘Swingarm svat rood bearing roling ares Footpeg and pillon tep pivot Sing area Duet sea ip Ol sect ipe ‘Steering bearing adjustment nat heads Engnael Rear bree fet ea ‘take master endo ison Supe DOT arate id Brake master ender ston Brake caliper pston rake calipr piston saa Brake vor pot ‘Siicone geste ‘Spreading 09 in ‘Brake lever corteting eurtace of master piston Sprosding 2.49 min Brake salpr brackat pin sng surface Spreading 24g min Brake caliper dust zee Final driven flange etd bot hres Brake caper bracket retainer bo hroeds rake oaliper bractt pinball threads | Broke caliper pin bot threads ‘Swingerm pivot bolt and distance collar whe oirace | Gear ll Dive cain aan -20 ero E Front ek rebaund ang Fore fuis Front er spn Frente sa st a pe [cabins [bie bree Han gr ide | Hendsbond Ao Handa gripcomont LWA only 1-17GENERAL INFORMATION CABLE & HARNESS ROUTING cuTcH caste AIGHT HANDLEBAR SwrTcn Wie renornue tases LEFT HANDLEBAR srcen seXsor wine AIGHT HANDLEBAR swrTCH {5° CONNECTOR (Green! TURN SIGNAL WIRE CONNECTORS LEFT HANDLcBAR swiTa SP CONNECTOR isle) HEADLIGHT CONNECTOR cum iit ape portion) 1-18GENERAL INFORMATION 1-19(GENERAL INFORMATION ue Tune 1-20(GENERAL INFORMATION ALTERNATOR WR STARTER MOTOR CABLE ‘SUB.WIRE HARNESS {OW PRESSURE SwWiTCH Vane, (NEUTRAL SWITCH WIRE) 1-21(GENERAL INFORMATION FUEL TANK BREATHER TUBE FUEL TUBE (ofl tank) BATTERY NEGATIVE () CABLE ike Bano: ALTERNATOR Wine + Sie Srane SwrTcH YHRE 1 SUB-WiRe HARNESS {Ol pressure swircx wine, NEUTRAL swerct! + STARTER MOTOR CABLE & ‘Grounn caste + T@NmnoN SwWiTeH WIRE 1-22(GENERAL INFORMATION IGNITION PULSE GENERATOR: ZPCONNECTOR (wn) FAN MoTOR SWITCH BP CONNECTOR (Bloc) \WiRe Bano: NTQMITION PULSE GENERATOR Wife TAN MOTOR swTe WIRE REAR BRAKE LIGHT SwTTCH vane lure caste ‘REAR oRAKE LIGHT SwToH BP CONNECTOR (lack) \GNTION Puts [GENERATOR WIRE REAR BRAKE LIGHT swtc FAN MOTOR SwITCH RESERVE TANK OVERFLOW TUBE 1-23(GENERAL INFORMATION, AIR TEMPERATURE SWITCH SPARK PLUG WHRES. Cconwectoa poor: "REGULATORIRECTIFIER 5°, 2° CONNECTOR (Whit) IGNITION CONTROL MODULE ‘tea -ONNECTOR aCoT: SGRAKETTAILUGHT & REAR TURN SIGNAL WIRE CONNECTOR STARTER RELAY SWITCH Uinelugina mai fuse 0) (OL PRESSURE SYMTCH Fuse 26x, (nating odo + SIDE STAND SWITCH 2° eee ‘CONNECTOR (Green) + FUEL PUMP 2? CONNECTOR (white) i FUEL TANK REATHER TUBE 1-24[GENERAL INFORMATION(GENERAL INFORMATION CALIFORNIA TYPE: /APORATIVE EMISSION CARBURETOR Ala VENT (EVAP CAN) CONTROL VALVE No. # TUBE (From EVAP conieor) No 11 TUBE No. 6TUBE EVAPORATIVE EMISSION (EvAM PURGE CONTROL VANE 1-26(GENERAL INFORMATION io. 4 TUBE No. 47UBe. (TEVA purge contol valve) [To EVAP CAV conto vals) No.2 TUBE (To open at EVAPORATIVE EMISSION: (VAP) CANISTER No. TUBE Mrofuetterk “Thi abot eeatod ante revere sea othe i edo cover. 1-27GENERAL INFORMATION EMISSION CONTROL SYSTEMS The US. Environmental Protection Agency 8nd Caltomia Alt Rasoursoe Boerd (CARB) roqulre manufacturer to carly that {hair motorcycles comply with apolable exhaust emisions stonderés Goring tel Uae Ife, whan opsrated rad al {alnad aesorsing tothe inswuctons proved, and that motoroyetes bull fer Junuary 1, 188 comely with applicable nae ‘omission standards for one year or 8000 kr (9,730 rie) arth time of sale te the ulimete purchase, when operted and ‘rantanad according to the instructions previged. Complisnce withthe torme of the Distbutor® Limited Warranty for Hends Motoreyl Erssion Contol Systems Is nacessary inorder Kaep the emissions system warn nee SOURCE OF EMISSIONS “The combustion process produces carbon monoxide and hycracarbons. Corto! of hydroserbone s very imponant beesuse Under carta sendtione- hey reat to form photochemiel smog when midjecied to nunlght Carbon monoxide does not Feact inthe same way, buts tx Honds Motor Co, Lid, vue len carburetor eetngs ax wal as other systems, to reduce carbon monoxide and hyo EXHAUST EMISSION CONTROL SYSTEM sssion control eyetem ie cornzosed of @ lean carburetor setng, and no adjusts should be made except rt withthe thro stop are. Te exhaust ericson sone eyetom fe aperse from te erankraseois- (CRANKCASE EMISSION CONTROL SYSTEM “Tho engine ie cuippad with» dosed crankcase system which routes crankcase omissions through the sr cleaner into the Condensed cranicase vapors ae accumulated in # dein tube it must be emptied perocisly (page 39). The drain tube ‘neo fo be shocked for of aseumuleton more frequen ifthe machine has been eonsstry rin at high speeds or in AIR CLEANER CHAMBER [AR CLEANER HOUSING: (CRANKCASE BREATHER CASE =: FRESH AI = alewavcas 1-28(GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) ‘his mada! complies with Caiforis Air Resourns Board (CARB) evaporative emission requirements Fuel vapor from the fo! tak nd carburetor = Grecia ita the veporative smiswon (EVAR) canter whe it x adsorbed ‘nd sored wile the engine is stooges. Wien de engine i running an the evaporative emission (EVAP) purge conrl valve ‘open, fo! vapor in the EVAP canisters drawn into the engine through the earburetor VAP PURGE CONTROL VALVE DRAIN VAP CANISTER EVAPCAY EVAPCAY ‘CONTROL VaLvE ENGINE STOP), TOOPEN AR FRESH AIR ‘S:FUEL VAPOR NOISE EMISSION CONTROL SYSTEM ‘TAMPERING WITH THE NOISE CONTROL SYSTEM'S PROHIBITED: Federal in prohibits the following acts or the easing ‘hordo (1) The ramoval or ranting inoperative by any pean, other than fr purposes of maintonane, ropa of replace ‘ant of any davies or elaman: of dabign incorporeted Into ery Naw vehi othe purpose ot nals coil ror toe Sr delivery tothe ultmateputenaser or while isin use: oF 2 the se ofthe vehiele ater ach device or eiement Of Seon hasbeen remove or rendered inoperative by any person ‘AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal oF puncturing ofthe mute bafies der pipes or any other component which conduct exhaust gases. 2. Removal of, puncturing oF any par ofthe intake eyo. 3. Lack of proper maintenance 4 Replacing any moving pars ofthe voice, or pare ef the wshaust or isk eystim, with pare other than those peeled bythe manutecturr 1-29(GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL ‘An Emission Convo! Information Label is located on the reveras ele of telah side cover es shown. The [oh side cover mst be romoved 9 read I got asi tune-up specications VEHICLE EMISSION CONTROL INFOR- MATION UPDATE LABEL Aner making a high atitude carburetor edlstment, ‘Stach an update lata onthe reverse side of te let ‘Side cover 9 ain [pose 823), Instructions for obtaining the updote label oe ahve In Servic Lear No. 132 ‘wan readjsting the serourtors back to the low Stade specications, be sre to remove tis update ‘aoa VACUUM HOSE ROUTING DIAGRAM LABEL (California type only) ‘The Veouum Hose Routing Diagram Label ison the ‘verve si ofthe ated dover ay shown (pape 2 Mission conTROL INFORMATION LABEL VACUUM Hose ROUTING Diacwane {Cattormta ype ont 1-302. FRAME/BODY PANELS/EXHAUST SYSTEM ‘SERVICE INFORMATION 24 LEFT CRANKCASE REAR COVER 23 RCL emo a1 (NEAAEEIER x | som at unr. a FEL TANK ee paar Sieh = SIDE COVER 23 SERVICE INFORMATION GENERAL + This eaton covers removal and installation ofthe fara body panels, ft tank ad exhoust sym. {Werk ina well vontlted area, Smoting or sllowing ares or spars in the working aaa where gasoline Is sore can cote a fie of explosion. + ‘Away replace the exhaust pipe gasket when removing the exhaust pi rom the engine. {Aware Inspoct the exhaust eystm fr leaks offer istoltin. ‘TORQUE VALUES Footpag bree bolt Sano (35kghn, 25 et) Exhast pps oie nut 25m i2ekgton, een) Mutter meurting nt 25m (27 kot, 20 Exhaust pipe oi ppe bolt 2aNm @okghm Yee) Seat mounsng bot 26 Nm 27 kgm, 20 RS Rent tender bot GEN seam, 47 i Shock absorber stud bolt 08 Ren (1.0 gf, 30) Latta rll mounting nut 8.0 kgf, 88 bt Fel tank mcunting bolt TaN (ng eg, 140 Fal valve S4Nm 5 Rahm, 25 Be Fuel valve crow Bienen (Odo ighin, 240 eM) of ernkesee roar gover bot 12 Nom (1.2 kg, bet ‘Shock absorber upoariower mounting bolt 26Nm 2.7 kat, 2016100 TROUBLESHOOTING Excosiveonhaust noise "Broken aehauet oyster + Exhoust gos leaks, Poor performance + Detormod oxhauet eystom Exhaust gs es 1 clogged mutterFRAME/BODY PANELS/EXHAUST SYSTEM SEAT cours REMOVAL SEAT BELT Remove the svat mounting bolts, coles, and sest ‘Shido and remove the seat resraards to avoid dam ‘ging the rear fer surface INSTALLATION Install the seat by Inserting the hook of the reat Lndar the raised ip of tha frame and posh he vot 12 the forwars. Alig the Dott holes and instal the seat bot calls land mounting bolts, then tighion the Bole to the specie toraue, ‘TORQUE: 26 Nr (27 ken, 20 ot) FUEL TANK Tae Remove the seat (soe above) Remove the speedometer (page 1:4, sour waster Turn th fal vatv tthe ot poo. Disconnsetthe fal tbe and breather tube Remove te ual tak mounting ol, washer and co- ‘Stee and rere the el nk rw, Inctalason i inthe rovers order of removal, ‘TORQUE: Fuel tank mounting bat ‘8Nm (13g, 4 SREATHER TUBE.SIDE COVER Relesee the side cover bosses end tab from the ‘rommere and eid cover Installation sin the reverse onder of removal LEFT CRANKCASE REAR COVER Remove the clip and washer from the boss ofthe ‘Remove the cover bolt, wacher and colar. ‘Relesee he bosses from the grommets and eemove ‘he ot exanhoses rar cove Anstalntin is inthe avert order of romov ‘Torque: ‘eft renkcase rear cover bot ‘2m (1.2 kof. 3 tt) FRAME/BODY PANELS/EXHAUST SYSTEMFRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER ‘CONNECTORS | ASSEMBLY REMOVAL/INSTALLATION | "TAR FENOFRASSEMBLY Remove the saat page 2.2 Disconnect th brokanalight, ear turn signal wite ‘Connectors located in th connector Bock. Remove the four bolts, washers and rear fendor ‘avamaly fom tha frame to avo ertering tha rear tender ‘roraue: oer fendor bot 64 Nen (65 kam, 47 te) DISASSEMBLY /ASSEMBLY Ps SEAT BRACKET ore Remove the two bot and cost racket. Remove the sezing bolt. Remove the sctew ard ell, then remove the rear ‘ender rm the subteme seTmNa 80.7 ‘Assembly ie inthe reverse order of easesembly REAR FENDER scnev "coutAr 2-4FRAME /BODY PANELS/EXHAUST SYSTEM GRAB RAIL MOUNTING NUT Remove the rear tender sssembly jnee previous age. ‘Loosen theif rab all mounting ut then ranave ‘hegre a FIGHT GRAB RAIL Remave he right shock absorber (pe 1418 Remove th hog ra hock absorber std bol, then cemove Installation isin the overs order of rows ‘Tonave: ‘Shock sbsorber upper/lower mounting bt: 26 Nm (27 kat, 2016) Let ora rail mounting nat 88 Wen (9.0 eg, 6 IE) Shock sbeorbor sud ble 108 thm (72.0 kgm, BOE srloeour FIGHT SHOCK ABSORGER EXHAUST SYSTEM REMOVAL Remove te bots, washers and righ footpe9 asemn- Diy rom te ram, RIGHT FOOTE: 2-5FRAME/BODY PANELS/EXHAUST SYSTEM Remove he extouet pipe Joint nara Remove the muir mounting nuts and & Pipetmuter ame Remove the exhaust pia joint cellars. Remove he frontend rear eskets MOUNTING NUTS: INSTALLATION lesa ie exhaust pipe jin ols, Mata eure new gesiate are inezaled tn tw proper postion. Align the rear exhaust pipe Mange wit the cylinder ead tu bot, Loosely instal the exhaust pipe joint nuts ond ‘Tiahtan the mounting mutate the speded tore. ‘TORQUE: 26 Nm 2.7 kam, 201A) ‘Tlahan the join ute othe sped orqus TORQUE: 26 Nem 28 kfm, 18 ‘ole othe speed toraue. ‘TORQUE: 34 Nom (3.5 kgf. 25 tt) Bours Fick Forres 26FRAME /BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY MUFFLER PROTECTORS REAR EXHAUST PIPE OVER REAR MUFFLER Protector REAREXHAUST PIPE PROTECTOR —\ rermmeceneast fs Sean £i 2. Y FRONT MUFFLER "EXHAUST PIPE BANDS. FRONT EXHAUST PPE JOINT PRE [MUFFLER PROTECTOR rrr] ria the rar end ofthe protector using the place Ihammer and brek the ttt tab rovers sido of the ‘rower and remove it (a netsewe the remaved potato Insta the now proctor by allgning the holders with the tabs on ho muti peMEMO3. MAINTENANCE SERVICE INFORMATION 3: EVAPORATIVE EMISSION CONTROL MAINTENANCE SCHEDULE £3 SYSTEM ICaforia type only) a avin 33 ORIVE GHAIN 216 THROTTLE OPERATION a4 BRAKE FLUID 318 eet Gone Se BRAKE SHOES/PADS WEAR “| Rees ge BRAKE SYSTEM 319 (CRANKCASE BREATHER 36 BRAKE eR eWIFOHE bod camertue 3 HEADLIGHT AIM 320 ‘VALVE CLEARANCE ee ba ENGINE OIL 319 SIDESTAND sar ENGINE OIL FILTER aio SUSPENSION mat (CARBURETOR SYNCHRONIZATION Ai! (NUISIBOLTS- FASTENERS nae ENGINE IDLE SPEED arg REELS ai TAbUTOR OBOEANT gg STEERING HEAD BEARINGS 324 COOLING SYSTEM 28 SERVICE INFORMATION SPECIFICATIONS + ae he mtr onal ground bore tang any wt Te SrGREATIONS | vc ie — Fenn iam | Spt lug sana DenieAs wo atch Ur WENO) | For cold climate/beiow DPRTEAS (NGK) | mea xciEPn OS DENS) Foret ch aed OPRIEAS WOR fang arom 0s ENS) 4 Spork soa oe aa 09mm n8-oa0 Tale soernce [1 5i5 a2 mm eRe aoaHia———] ex a0 = 009 mm (8608 = 80 Engine oli capeclty | at draining __ 22 irs 12:32 US at, 7.94 imp ath stl ior ora 2.4 Ree (254 US @. 211 np ct at cisssombiy 29 tara 206 US at 258 Imo at Fecommended raion a ond GN or Pa tstecke llr equivalent motor ol | {Pl sorce caesfeation SF oF SC Viscosity: SAE TOW.A0 ‘Caburetar vacuum aference Witin 20 maf (087 Ha) Das carborator No.1 rat) Engine ile speed 0 00 rp 3-1MAINTENANCE Trew ‘SPECIFICATIONS | Drive chai laa 16-25 mm (0600-11 ‘Dive chain stain KD $525 SMOZ5/I24 L Recommends brake fla ore Brake pedsl free pay 20-50 mm (0750-1250 ‘Gtch ever tree oley 30=20 nym (0575-0760 in) Cold iw pressure | Up ro 90 ke oo tbe) | Front 200 Pa 2.00 ken, 28 ph tons Rear | 200K [2.00 kation, 29 el). Uptomaximum | Font 200.Pa 200 kglem, 28 pal) | weiantespecny Roar 200 4Pa 280 kone, 38 ini tr ad depth Front 1.5 mm (0.06 aac 20 mm 008i) Trasiee Frost —rraeo-10 505 Treer Jens. MCS Tietiaed antop Frost Fes eer Kas ————$_ at ‘Bgasione Front iw \ Rear ‘e702 ‘TORQUE VALUES: Spark lua ation (14 gt, 10 Erarsht hole cap 15th (18 kat, 11 BER Apoly arse tothe treads and seating surface. Timing hale ap {13thm (15 kgem, 11 BED Apply grease tothe tends and seating auracs. Valve adueting ecrow ose nut 23Nm(23kgtm, 17M) Apply alta the threads ae seating suMece Oi grain bot 29m (aokatm, 22 be Gite earridge TONm (1.0 kgtm, 7 oe Apply oto tho threads and coating surtace. ‘Vacuum pg BNan(OSkghi, 22 (eh) Fear axe nat 93nbm (Gughm, eB bem Lent ‘Side stand assembly bot 491m (eoagem, 30 bn) Side sand pivot bolt SON (10 Kgt, 7 oe Side and locket 28 tm (2D Aghe, 22) Gvornacd cover bolt H2Nim (12 kon, SIGE TooLs Valve aciusing wonen 107908 -KE90000 0+ 07908 KE80100 (U.S.A. only) Oil fter wrench OrHAA- PsTOIO0 Spoke wrench ‘o7sMa~Meor00 or aquivstent commercialy avasbie in USA. ‘Vacuum gauge asehmane ‘70 2000200, ‘OTL COTOO0A (U 5A. oni) ‘ewum gauge aot ‘7s 0010008 - MB578 ~ 021-3600 (USA, ony) Dive chan too at ‘7nd aaR0108 ‘OrDTHMA-MTDIOB (U.S.A ony)MAINTENANCE SCHEDULE Perform the PRE-AIDE INSPECTION in the Owners Manual at eoch scheduled meintanence period. [enspect and Clen, Adjust, Lbviate or Rapince necessary. Chen Fe Replace AAs L Lubricate ‘The following tome require sore rmachanical tnowiedge. Cerin heme (paiclalythove marked® and **) may require ‘More echeieel information and ols. Consult your HONDA desler. FREQUENCY | WRICEVER ‘ODOMETER READING (NOTE 1) ue nesen 0) ximomi [oe] + | 8 [|v] 20] a) PAGE wore eramien [10 [eae zoe FORLUNE TL “THROTTLE OPERATION ‘CARBURETOR CHOKE TAR CLEANER CRANKCASE BREATHER SPARK PLUG VALVE CLEARANCE ENGINE OL ENGINE O1 ALTER CARBURETOR SYNCHRONZATIN ENGINE OLE SPEED RADIATOR COOLANT oouNG SYSTEM EVAPORATIVE EMISSION CONTROL ‘i SYSTEM RIVE CHAIN ‘BRAKE FLUID ‘BRAKE SHOES/PADS WEAR ‘BRAKE SYSTEM 38 7 | BRAKE UGHT SWITCH 320 = | HEADUGHT Aw 320 [-cwure# sysTem 30 [SIDE STAND 3a | SUSPENSION 32 © NUTS, 6OLTS, FASTENERS 32 =) WHEELSiTinES 32 77 STEERING HEAD BEARINGS 4 EMISSION RELATED TEMS t t z ie ® t ® ® r ® r SERRE +, Should be coricod by your destr, unless ho owner ha proper tool and serco data and mechanically qualified. * Inte interest of stey, we recomend these items be serviced only by your HONDA coaer NOTES: 1. At higher odometer reading, repeat a he Frequency Interval established here. {2 Seric more roquonty wr ing unvevaly wat oF dusty 7906 ‘Service moro requanty wren ing in rin ora ful rote altri type ony. |5. Raplce evary 2 youre ra indleted odometer tana, whichover comes frst Replecamentrqulr mechanics! oa 3-3(MAINTENANCE FUEL LINE eave the lt side cover (page 23 (Chek the felines for detriraion, dam Pepiace the ual linas if recossay. For the tube routing, 0 ction 1. THROTTLE OPERATION (Chock for ny datecoratin or damage to the theatle ables ‘Check th hte tip for smoot aperation. ‘Check tac he trate opens and autornatealy closes inal storing pootons. 1 he that grip dons nat rturn property, brieate the throttle cable and Qverhiul snd lubricate the ‘hvott grip housing. Forlubsemton: Disconreat ho thot cable a thir Upper ends (page 13-3). Thoroughly lubricats the tables and their pivet pols with e cormecioly valle cable woriant om ontweieh Ie the throttle grip el ds replace te thr cable. Fusing dam With he engine ing. ur the handlebar alt way Tpoderainar totholettond ight to oneure tha th isle speed owe ‘raly bower not change. Inked nrete File spre! increases, check the trate grip free catiecaprwet play end the Oot cab connection Etc operion Manaure the tote ip 00 pay atthe trator axineyiasioe tango tos cate Smreteele FREE PLAY: 2 5 mm (Ut vam n) “Tate gr few play can be ated at either end ‘of tho trate cable: Minor edjusorens ere made ‘withthe upper ecster. Loosen the Sock ut ad tutn the adjuster t obtain there lay ‘Tightn te lock nt and reposition the edster boot propery ater the aantment has baer made 3-4MAINTENANCE remade with the lower adjster, (ROGUBTERIS Too NOT] Mejor est Looten the lack nuts an urn the aster to obtain the tee pay Tight the ick nuts ater the edhstment has been Recheck the thot gro tae pay CARBURETOR CHOKE “This motoreyele's choke system uses a fel erching Stel controled by «starting enlehment 1S valve ‘Tha SE valve opone tha onrching eet via cbl shen the oe knob on the left ide of the carure tor's pulled up. Cheek tor smooth choke knob operation and lubricate the choke I requited Check the choke cable for frayed, inksd or other ‘damage ‘STARTING ENRICHMENT (SE) VALVE Starting enrichment system operation can be checked bythe way te engine tarts and runs + ict in starting bafore the engin ie warmed Up obey once ie warmed ups SE valvels not employ opanes + ole speed i erotic ave aftr warmup finpefset combustion) SE vale isnot complealy Sona’ Yen the above symptoms occur, inspact the SE ‘valve using tha folowing prococure SE VALVENUTS: Remove the carburetor age 8, Re Chosen the SE valve nuts and remove carburetor ova the choke sable boots rom the SE valve 3-5MAINTENANCE AIR CLEANER {re moore ‘csadin wa ot mors eas Inept are required CRANKCASE BREATHER Pull the SE valve knob sl bo way out 10 fully open positon and recheck for emoath operation ofthe SE Yelenab. “Thate should be no fre play ‘Chac vve seat onthe SE valve for damage. Note: ihe viscous paper alemant ype at clasnor cannot beclened because he lament conainsa dust ‘snes Remove the four bolts from the sir leaner housing cover and remove the cover. FRamove te ai loaner sloment. Replace the ar lane olemant in aceordanee with the maintenance schedule o” any tre Ie 5 exces ‘val diny or samogod. AIR CLEANER HOUSING coven Irstal the air claw lament rovers order of Nove: Service more traquentiy when fi {ull vata er after the motoryee ‘Overturned. Service I the deposit Remove ti sr cls housing breather ube plug tam tne tube ond an ran dapost nto a sultabie ontniner, then instal the tue sug cura. BREATHER TUBE PLUGSPARK PLUG Fromevinder yndor gh oe pe fpetoine oi tren napa ‘bg eto sped rrgu Remove the two bolts and eyinder head overhead Disconnect the sparkplug cape end clsan around the spark log bocce. NTE: ‘Clean around the sparkplug bases with com pressed air before removing, and be sure tht no {bras allowed to ener the combustion chamber Remove the spark plugs and Inspoet or ropioee ac Ganzribed in he mointanonce schedule. (Check the ineuletor for eracke or dermaga, and the slocrodos for wear, fouling oF diacoloraton Replace the plug if necoseary. Ife aleevoda fs contaminatod wi carbon deposte, Clean the electrode using the sparkplug eeaner. Clan the spark pg electrodes wth a wite brush or special plug cleaner Chek ne gop betwoan tha corr ans sido eiozreces swith» wie type footer gauge. H necnsary, adjust the {ep by bending the side lotro eae ‘SPARK PLUG GAP: 0.80 - 0.90 mm (0031 0.035 in) Reinstall the perk plug in the cylinder head and hand ttten thon toraue te specfestion. ‘TORQUE: 16 Nn (1.4 kon, 10 EH) Instone sparkplug caps ‘TORQUE: ‘Overhead cover bolt: 12 Nm |1.2kghm, 8 fot [OVERHEAD COVER) X d 3-7MAINTENANCE VALVE CLEARANCE 3-8 INSPECTION note Spsbect and act the valve elesrance who ths tani e cls (below 35°C, 05 + Rajat he ont alin Road vives i. Remove the front and ear eylinder head covers (ap8 10-4, Remove the timing hole cap nd erankshat hole ca. FRONT CYLINDER HEAD Rotate the erenkanaf counteeicocules and align se Spe srk onthe Hywhel ty the index mack om lof oranecate oo Mats sure the piston is at TOC (Top Dead Centen on omprssion ke {This position can be obtalnad by confirming that ‘here's slack nthe recker arm theres no wack ie bocaue the piston mowing tough the exhoast Fre to TOG, Rotate the crankshaft one fl turn and ‘atch up the “FT mark again. lr gauge Botwoen te valve alusting ‘VALVE CLEARANCES: 1: 0.15 + 02 mm (0.006 + 0.008 in) 12X:0.20 +062 mm (0.008 + 0.0008 in) REAR CYLINDER HEAD Fora the eranianat eountarlockwice and RT" markon the flywheel withthe index mark on the lot rankssee cover, ‘Maka sure the piton le at TDC (Top Deas Contr) on the compression stoke, ‘his postion can be obtained by confirming that {hore lc in the rockar arm, thot sack, ie because tv pston' moving though the exhaust ftroke to TDC, Rotate the erantshat one fl ur and ‘atch tha “RT” ark apaMAINTENANCE ure the rar evinder head valve claarance by ingering Toler gauge between the valve acting ‘VALVE CLEARANCES, IM 0.5 £ 002 mm (0.006 + 0.0008 n) EX: 0:20 + 0.02 mm 1.008 # 0.008 nb ADJUSTMENT Pai VALE Raver WRENCH) Adjust by loosening the lock nut. and tucning the Sajusting serew unl there ix = ight deg on the {eater gauge. ‘Appi cl tthe valve esi ook nut trae ‘Hale aaucting sre ard Ughten the eck rut ‘TORQUE: 23 Nm (23 kgf, 7 ee oot: ‘Valve aajusting wreneb ‘oro ~Ke0000 ‘o7s08—Kes0100 (USA onh) Aner ignoring the lock nt recheck the valve lee Insta the fron end rer eylinger head cover (nage oe). Asply groac tothe timing hola exp end eranehatt hole cp treed, Coat the new Oings with oil and instal her onto ‘he ining hole cep and erantahat hae ep. Tiphton tho timing hola cap an erankhatt hole eo TORQUE: 15 en (15 kgfn, 11)MAINTENANCE MAINTENANCE ENGINE OIL Sarthe engine ane at tie fra fow minutes. Stop the engine, remove the oiler eapipstck and swine theo rom the api witha oan clot Woit 2 or 3 minute ster stopping the engine. With the motoroyle in an upright postin, Ineo: Sve dip sit int the pats hole without eereing Ki Whe ot evel is below oF nthe lowe level mark fon the cipatas 8d the recommended ol up to the ‘Shp level mark [RECOMMENDED ENGINE OM: Honda GN4 or HPA 4-2bcke oll oF equivalent motor ‘tered to mest [APteorvice eaiestion:SF or SG ‘Vscoaey: SAE 10¥-40 Note: e Otervizostes shown in the chart may be used ‘when the average ‘emporsture in your ding ties ls wtrin the incest an eines the ol er capiipetice Forangine cil change, sae bolow. ENGINE OIL FILTER Note: Change te engine oll wth the wagine wars anc the motoreete on it ede sand to assure com plete and apis dining. Engin and axhaust system parts become very hot fnd romain hot for em Ee ar the engine i run. ‘Weer inuloted gloves or wat unt the engine and {aust system have cooled before hansing these Remav= the engin oil rain bot nd tar eapiae ‘tick and drain the Remove and decor he ol or corde Too: Ot ar rene o7HAA-Ps70100 ‘Aker draining the oil completly, Install and ihn the engine ait arin bolt with a now soling washer. TORQUE: 28 Nem (3.0 kgf, 21 ‘OEALTER WRENCH] 3-10MAINTENANCE ‘Apply oil to ¢ new ol titar O-ing and the of tor ‘threads an instal the i ter cori. “TOROUE: 10 Nm (1.0 ken, 71 Filth erankense wit the recommended ol (20a pro viour pagel Insta he ol flor appa ‘Start thn engine and let tile for20r3 minutes Stop the engine end chock thatthe cil leva sat the Uppor love mare te ips (eve previous pegs. Moke ure thore oe no leak. CARBURETOR SYNCHRONIZATION Ferneve the ar claener housing nage 63). omove the epar plug cap from the at se of the Fear ayindar head then remove the four Woke, choke fable holder and ren le evi Nea Reinstall the spe plug ea (CHOKE CABLE HOLDER Remove the pluge and washers from the cylinder hedintoe pare puuas AND WASHERS Insel ne vecuun gauge attachment. VACUUM GAUGE ATTACHIENT ‘Connect the vacuum gauge the gauge attachment ‘Toots: ‘Vacuum gouge attachment 07510 3000200 ‘Vaeuum gauge eat ‘ona 0010008 (USA ony! sae ~ 021 ~ 20000 (USA oni)(MAINTENANCE Remove the ful tank (page 2.2) and connect sue fbi tube Derwean the fl tank an fel ine 1, Star the engine and aust the idle sped with the ‘oul stop soem to the speciation below. IDLE SPEED:1,00 + 100.pm 2. Cheek the eitrence in vacuum betwoon eat ca. Binet ‘CARBURETOR VACUUM DIFFERENCE: 20 mm Hg (08 in Hs) To ho cart 8, Turn the synchronization assting ceow 20 that smtristicho. + the dferance between each carburetor is below owleaturew, — theeptcfeation. 4. Be sire the synehvonizatin is stale by snapoing the tote grip several mes 5. Snap the trot grip several ime and recheck ‘he tle spoed and ciference In vacium Dotwoan ‘seh eaburator Disconnect the vacuum gauge snd Install the removed pars. oRaUE: ‘Vaca plug 2 Nm (0.3 kof, 22 bt) (ylnder ed Hr ol: 10 Nam 1.0 kg 7 It) ENGINE IDLE SPEED NOTE: + Inept and aust ile speed ator al ater engine tsclusmente or nthin apectfentione. + The engine must bo warm for acourata auetment. ‘Tan minutes of kop-and-go ring i ufient ‘Warm up the engine. Suppor the moteryele on a Ieee! aria ar shit the ronsmiaion ino noua ‘Chock te le rove ap act By tutring she tot tle eop euro I cesta IDLE SPEED: 1.000 £ 100rpm syvcurONgaTioN ADJUSTING scnEW. ‘THROTTLE stoP scREW 3-12RADIATOR COOLANT LEVEL CHECK [Shack the eaolant oval n he reserve tok wth the {engine uoning at ccrmal cpereing temperature ‘Te fovol should ba betwoen the "UPPER" ang LOWER” ive ines withthe motrsyle ina vsti positon ona lat evel sutace, It nooeosary,rameve the reserva tank cap and the “UPPER* ive ine with $050 elution of ce tlle water and recommended antiasse feo ‘itu preparation page 88) SLOWER” LEVEL UNE RECOMMENDED ANTIFREEZE: Pro Honda HP coolant or an equivalent high quality ‘thylone glycol antfoeze containing seat fo {ovrosion inhibitors NOTICE) sing coolant with elicte corrosion inhibitors may {2ause promatire wear of water pump sala sr bck 1298 of rater passages Using tap wate may cous ‘engine dmege, {Check to Ge if hare are any coolant lak hon the coolant lve catenses vary opi Ie toserv tune bocomes completly empty, the ise possiblity a geting Ite the cating system. Be sre to remove all alo te cooling oytom seecrbed on pag 64 ‘COOLING SYSTEM (Choc the ractator ai passage for eogging or dam crichton bent fins wih smal ar lade rw A. Vor and remove ingets, mus of other obatrutons \witrcomorossea ait a low preasure water Replace the raat the sir low i rested over 20% ofthe radiating suave 4 Forradiotor placement relerto page 68 Remove the fuel tank (ps9e 22) and check for any coolant leakage from the water pump, water hors “oat fhe hose ot ‘Make sure the hoses are in goed condition: thay Should nat snow any sign of deterioration, yA Replace ary hose that shows sry sign of deteriora ‘lon. Cheek na al hose camps a= Bah 3-13MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) ‘Ghee the tubes betwoen the fuel nk, EVAP canis: ter, EVAP purge contol valve, EVAP CAV contol valve and Carburetors for deterioration, camago oF lose connections (Gheck the EVAP canister fr er or other damage, ofr to tna Vacuum Hose Routing Diagram bel and (Cable Be Hermess Routing Ipage 1-18) Tor tube corDRIVE CHAIN CHAIN SLACK INSPECTION Turn he ignition sitch t the off postion. place tne ‘rotoroyle an is sie wand and shi th Sion inte nour ‘Check th alec nthe erive chain low run midway betwoon te sproctae ‘CHAIN SLACK: 15 ~25 mes (0.800 1} ADJUSTMENT Loosen the ros al nu ‘Turn both adjusting bots an equal number of ts Untl te comect dive cbr slacks obttne’. te sure the Index marke on both njstar tihaned withthe rearend of he singer. ‘Fgiten the rear axe rut the speed toraue TORQUE: 25 Non (8.8 kam, 68 st) o~ L\\\ anivenn bouts echch he i chain sand wl ton, TEAR ROERTOR TAREE as in a wa ind l w ok ‘nthe ef ive chain adueter PSE a If the red zone of the indicator label reaches the end ~ =a ofthe svingar replace the eve chan with & fre see nast page). CLEANING AND INSPECTION Clean the chin with @ of brush using 8 noon ‘abi or high Mesh pein soWvant and wipe it dry. Be sure the Sha has ed vorpletely before ubr- Inapoct the de chain for posible damoge or wear Replace any chain tot hee araged toll, ose ft- ting irks, or oterwise appears unearcesbe. Instaling # new chain on bly worn sprockots wil {buse the now chain to wear guehy. Inspect and ‘loce toe sprocket a neooaay.(MAINTENANCE. Drive chin tot sat LUBRICATION Lubricate the drive chain with #60-80 ger ol oF scuivalont coin lbreant designed speetealy for to win O-ring crane Wipe off the excess chan ube ‘SPROCKET INSPECTION Inapoct the drive and dren sprocket testh for dam- ‘a6 or weer. Replace Hf necessary. Never isa 3 worn chai on ew sprockets: Both chain land eproctts must bein good sonditon, or the new replacement part wll wee epi. Check the attachment bol and note on the deve and ‘riven sproates any era cose torque thom REPLACEMENT This motoreycla uses a drive chain with a staked roster line Loosen the ve chain -Assomble the special oo Too: rs. rave tan70108 (USA oni ‘NOW FLAMMABLE OR HIGH FLASH PONT soyvENT DRIVE CHAIN TOOL SET an el 3-16MAINTENANCE ‘erie wn crwmotainines Ineo he master Ine she pte ‘ngousge Locate th erimpad pin ends of the master ink from ‘he outlseof the enon an remove he link fhe (ive chain oo et Remove te drive chain, Remove the excoee drive chain ine fom the new (Hive chet wth the dive Chin fal st [SPECIFIED LINKS: 124 rks ‘REPLACEMENT CHAIN: RK: 525 SMOZS. Remove thea renkcase ror cove page 2 natal the new ceva chan over the ceive and avon [Assemble the new master lok; O-rings ans master Aeature the mater ink pin length projected rom the pate. “SPECIFIED LENGTH. 120140 mm [0047-065 n) State the master ink prs with the dive chain toot Make sute the master nk pins ar staked propery by ‘measuring the diomoter aft sees sre DIAMETER OF THE STAKED AREA: '550~5:80 mm (0217-02289) DRIVE CHAN TOOL SET 1 omnesMAINTENANCE ‘A.aive onan Ahar staking, check he staked are ofthe master nk wena cipyee tor erack. maser inka thar i ony ereking replace the master link, 0: ‘ot wed rings ond plate Intl tafe rear cover oa 23) BRAKE FLUID Note: + Wn the uid level is ow, check he brake pads {or wear (se blow). low fu level moy be ave torwor brake pods If the broke pads are warn, {he eliporplatons pushed cua this causes low reeorailova, ‘Avoid sping fu on pints, pasic or rubber parts Poe a rag over ue parte whandver tha sya Is tana, Donocrak kt orion the handlabart the sight shea position featevzes af oo atthe aarti al anc eck he fom brake (ios thy ore reservoir evel through the sight gles. I the level Toscomattia (fost edge! i ner the lower level mark remove the seen sen othr cover, aot plate end dlaphragm anf the tsar Bootatow or With DOT 4 brake faa rom 8 ssa container othe ‘onmateia casting inde ster tees ti Teron iag tne Reter to page 182 for bake fui veplacemenioed Teen ing procesures. BRAKE SHOES/PADS WEAR FRONT BRAKE PAD (Chock the baka pad for woo Repce the brake pace f ther ped Is worm to the Dttorof de wear init groove, eter to page 16-8 for brake pas aplacemant Wear umiT GROVES 3-18REAR BRAKE SHOE Replee tne brake shooe if the strow mark on the Drake arm aligns win the rfeonce mark "A" when the ear Drake sapped BRAKE SYSTEM FRONT BRAKE Firmly apply tho broke lovar, and chesk that no air has entered the system. ithe lever feta soft of pongy wien operated, bed iam the syst, Inapect the brake hose and fing for deterioration, racks and leetage. Tighten any loose ftings. Replace hoses an tings as rela Refer to poge 15.3 fr brake booding rocoduros REAR BRAKE PEDAL FREE PLAY ‘Mature tha rer brako peda tos pla. FREE PLAY: 20~30 mn [0.750 1250) ‘dst mts vate a one ‘Adjust the brake pedal fee play by turning the ‘sting na tho brake arm, 3-19MAINTENANCE BRAKE LIGHT SWITCH ‘efron trate Adjust the roar brake lit etch ghrowinhdons comes an Just prior to the Brak ratrguce sgnged cfustmart the lght fale to come on, adjust the witch so the Tight comes on st the proper timo. Hold the switch body and tum the adjusting not. D9 net turn the swan body. HEADLIGHT AIM Adjust thas Adjust varieally by turning the vertical adjusting “ont bsom 25 sor. “oscedby Adjust hovizomly by turing the horaort adust- (ecalisaod Ing soem CLUTCH SYSTEM Mossure the elute lever fee play atthe end of the chit ever FREE PLAY: 10-20 mm (0375 -0.750in) ‘Adjust a toiows Minor adjustments are mace th eater near ho leva. Loser the lack nut and ten the adster: Tighten the iy cannot be ot roy ine back out ano Tur. Tighton fhe lock nut'end make a mojor edjustment at ‘escbed onthe nent page. 3-20MAINTENANCE jor adutments ate pecormed et the atch lttar [LOCK NUT ‘ADUUSTING NUT Loosen the lock nut ang tun the adjusting nut to acjoat play, Hold the adjusting nut socursly while Semening the lock rut it propar fe play eanvot be obtained othe cuter {i during the test rice, claeaembie ed Inopect ‘he cut coe socson 7 SIDE STAND ‘Suppor the motoreyele ona vel surtce (Check the edo etand spring Yor damage or los of tension. ‘Chacko stand assembly for feedom of movement Spa breast alco atand pivot necessary. Mae sore tne ude stone i ot Bont ‘Chuck the sid stand ignition cutoff system Mot stride to metorejeo ans ales Ne de stand, = Star the engine with nowral, thon shit te transmission into gear, with the ‘lath over equaarod. = Move the side stand down, The engine should stop mx the ide stand is toe Wt here fs 9 prob withthe syst, check the side sand suit (page 1816 3-21(MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the fark by parting the font Sls oneoomaresing the rom suepeeion svat {Soaks ce sbsebly or igs of ek cee Replove comoged components whlch cannot be Tena nue and bot Referto section 1 for ork eaves REAR SUSPENSION INSPECTION hock absorber assembly for sans ‘emage oF fos esteners ged companents which cannot be ‘ohtan all nits nabs. Reterte section 1 for shook absoria seve alee the rear whe! off the ground ard support the motoreyte securely ‘Grock for worn ewingsrm Senrings by grabbing the reorshee! and atterping to move the whee! si 10 oe Replace the boarnge if any loceonses Ie noted (ese Sesion 18 NUTS, BOLTS, FASTENERS that al ehasia nus and ols are tightened to correct torgue values (page 1-12 that all cote" pins, safety lips, hose clamps ‘nd cable stave are in plac and propery abeured. 3-22NHEELS/TIRES Wile making sure the fork isnot allowed 19 move, faisa tho front whos! and check for play. Turn the ‘hoot and eneck tha lt rotates smoothly with 90 ‘ru noises tout re found nepectthe whee! bangs Support the motoreyele soeutaly and false the oar whest fhe grou. ‘Check for py ln ethar the who! or the swingarm pivot. Turn the whos! and check that fr rotates ‘Smoothly with no urususi nolees. Wt sonormel conditions are suzpected, check the ear wioal osrngs (eto saetion 18). Inspect the spokes for looseness by tapping ther ‘tho eerowsrver if spoke does not sound clearly, orf k sounds di {ent irom the other spokes tighten Rte We epee: ‘ied torque, ‘TORQUE: 4 Nn 04 kgm, 29 tte Toot: Speke wrench o7sma-Rso100 ‘Chack the tre pressure wit the tre pressure gauge, when the tree ars eal RECOMMENDED TRE PRESSURE- ‘Upto 90g 200 be: "ont 200 KPa 00 kato? 29 al) Rear, 200 Pe 200 kgt/en 29 sl) Upto maximum weight eapeciy: Front: 200 kPa (2.0 ter, 28 pl) Fear 250 KPa (2.50 kptlem 36) (Chock tho tes for euts, embeded nals, or other emoge ‘Shnc the fant and rear wheels for trveneas eer to ‘scion and 18, Monture the 00d dapsh et tha contr of he thes. Replace the tires when the trees depth reaches the following limite [MINIMUM TREAD DEPTH: Front 15m (00 nd Reo: 2.0 mm {08 in) 3-23MAINTENANCE ‘STEERING HEAD BEARINGS 3-24. Asia the front wheel of the ground and support the rmotereete sacuroy. Chose thot the handlober moves froely fer sido to So ana the contol cables donot intrtrs wth Pan votation. Ifthe nandlobar moves unevenly, binds, ot hae vert= tal movernent, Inspect the stoering heac bearing {tee esction 13LUBRICATION SYSTEM ROCKER ARN caMgHAET PISTON cou.ser ‘CRANKSHAFT MANYSHAF CCOUNTERSHAET ‘iL PRESSURE SwiTCH Gl cal” ENGINE of ALTER PRESSURE RELIEF VALVE Ou stRANER 4-04, LUBRICATION SYSTEM SERVICE INFORMATION 4-1 OIL PRESSURE CHECK 43 ‘TROUBLESHOOTING 42 OlLPUMP +4 SERVICE INFORMATION GENERAL ia Wl es BY Used engine ol may cms skin cancer Hf repeatedly left in contact withthe akin for prolonged priogs Although this Js ual unis you tance used of on dalty bac, fs sil éviablato thoroughly wash your hends wih wep {nd water aa oon ae pots ater handing vee oi “The service procedures inthis section cam be performed with he engine nthe eam {When removing and fsaling the ol pump ure care nat llow dust ar ditto enter the engine any person af na 0| pus i worn bayond ta epoctiodeorice limit, rplace ine ol pump a3 an aeeorbly. 5 ita the sit pump nes Sean installed ebock that here ae noo leaks anf hat presse nore. * Forollpreaure incest nepecion, refer to section 18 ofthis menue. earICA Unit: mm din) a od Engine oicapecty —[serahing Tas 932 0S at 194m exit eh 2amere 254 US at 21 Impay | — eta 28 ers 8.00US at 255 mp) = Rocormendederaine al onda GNG or WP ote io sNaericn cetioaion Forse | | — ‘Oil pressure at ol prossure Batch "E80 KPa (6.4 katie’, 7 pal at Exot e787) _ Oiipampraior [Tieden 0.95 10.006) am 10008) Side csrnce a2-aor(a0n1-aoea1 | ex9@a00) | ‘TORQUE VALUES ot preestlowtch 1212 ghey 81H) Aly saan othe tds Ol preesresutcn terminal sxow BN 102 kgm 14 FR) Si pom pk Enmasigen aterm) Too.s pen os 506-an0000 cammeciaty aviation USA. Si penta gage etchment ——BYS10— 2010 41LUBRICATION SYSTEM TROUBLESHOOTING ‘it leve! to tow — gh al consumption PN extemal ook {Worn piston singe or incomes ison ring instalation Worn einer {Wor vaive guide or stem seals (it contamination white sppearance| oNCooiant mining wth —nuty head gasket, Weer lek in crantones Low oil pressure 2 "Oi era low 1 Oli preseure ret valve tt open logges ol stain’ or ter + Sitpump worm or domoges 5 neoeact ol being eed Nol pressure es DI level oo ow {Oli pump dive shaln or divatdeiven sprocket broken * 01 pump camages High ol pressure Di pressure rele valve suckclored + Plugoos aller, or metering erie Ineorreet a bang ui 42LUBRICATION SYSTEM OIL PRESSURE CHECK ftncrmally i, Warm up the engine to normal operating tempers: {Ure Before somina thi toe, St0p the enaine. Remove te sich cover an lecannect he ol pre: re ewan wie by removing the terminal eorew é oo. ress Svan Remove the oll preeture suitch and connect an oi (lL PRESSURE GAUGE Brovaure gouge aachment and gouge t0 the proc ore ewnck nl. roots. (OF pressure gauge attachment 07510 — 4220100 sreuiaent smmereayaaianein USA. (on preceure gauge, ‘orto = se0000 Sregulvaentcommorcialy avaiable USA. (Check the ci eval and ad the recommended oi i necessary ipge #10, ‘Stat the engine and check the oll pressure at 8 500 pmo en, (lL PRESSURE: 520 Pa 54 katlon?, 77 pei). ‘Stop the engine 1 rot apply othe fhrans head ‘Apaly sealant to the ol pressure switch threecs 6b ‘how and neal aot TORQUE: 12m (12kgtm, 91th) CConnaet the ol presse sitch wire and tight the ‘weminal Sor tothe spectfed toraue ‘TORQUE: 2 Nm (02 bat. 14 6¢A) Install the ewitch cover. ™ Sor the engine ‘Check thatthe ol pressure Indicator goes out afer 1 or 2 seconds. tho ol posture Incest says on ‘stop tho engine immedistaly and gtormine th nuse (page 19). 4-3LUBRICATION SYSTEM Ol PUMP REMOVAL ‘Senarte the crankcase (page12-4 femovethe bolt sr ral rps Remove the pressutereliel valve and Oving ‘whan the cil pump le raady to bo dieassemblog, Toosen the the of pump cover bats Remove tho two olf pump mounting bolts and ot pune. Remove the calls and O-ringsDISASSEMBLY Remove he ol pipe cl pipe sel and O-rings. the oll strsiner and packing from the oit Remove the bolts and pump sover. Remove the dowel pine Remove th specer rotor shat dive pin inner anc LUBRICATION SYSTEM DRIVE PN ‘On IE PACKING DOWEL PINS: ‘SPACER 45LUBRICATION SYSTEM [PRESSURE RELIEF VALVE SNAP RING rove the snap rng ane! deassemble the prsure oe ralot vals, ae 3) Checkthe spring ad piston for wear o megs. | PRESSURE RELEF VALVE Cheecte vive for cogging or garage. ae TE ro (oY . nN ™ we INSPECTION “Teporsy insta te foliwing — rotor ahat drive pin Measure the rotor tp elaarance, ‘SERVICE UNIT 0:20 mr (0.008) Mesure the pump boy ea’once ‘SERVICE LIMIT: 0.25 mm (0.014 in) 4-6LUBRICATION SYSTEM Rernave the drive pin and rotor shat Measure tho pump side clesranca, [SERVICE UNM 0.1 mr (0.008) MBLY aie INNER ROTOR SNAP RING ourenroron aeyer Pe onive pe wasn noToR SHAFT &. gq. N | spacer #8, So | SPAN oitruwe goov TON oondtons Ohne pressure RELIEF VALVE Ohare ‘ “Nou pune cover CANS Olt STRAINER Inetal tha ower rotor and nner roto. Insert the rotor shaft and install the drive pin by tligning the sot then tar o DAVE PN 4-7LUBRICATION SYSTEM Pie the apace nt the inna ator groove {natal the dowel nent the pump body ‘nz the ot pump cover onto the pump Body withthe over bois, (Coat s new packing with engin oi and instal nto the {g1aove ofthe oll pump, aa rsa te ol strainer Ino tho pump. Coat s new ol pipe esa wth engine ol shon neal itt Coat the new O-ings wth engine ol and instal them to thal pipe with ther epared ade Folng out tnsal the ol pipe tothe oii pump secur INSTALLATION Ieaal he calls ond dow! pin, Coat te new O-rings with Snglne oll and instal them ‘ont the colar BOWEL PINE PACKING. 274 DOWEL PIN 48LUBRICATION SYSTEM natal the ol pump with he mounting bo. f ; ost 9 raw O-ring wit engine ol nd inet i int tho ‘100¥e ofthe pressura rele! valve. Insta the pressure rei valve othe ol pump securely Insta hel li pipe with batt ‘Tighton be oll purp mounting bots “iahton tool flit poe Bot an cl um cover bots ‘TORQUE: 13 Nim (13 kof, 916M) Aeserbe the crankcase (page 12-18 49FUEL SYSTEM 5-05. FUEL SYSTEM SERVICE INFORMATION 5-1 CARBURETOR ASSEMBLY ‘TROUBLESHOOTING 5-2 CARBURETOR CLEANING AIR CLEANER HOUSING 53 CARBURETOR COMBINATION SUB-AIR CLEANER 5-4 CARBURETOR INSTALLATION CARBURETOR REMOVEL 55 PILOT SCREW ADJUSTMENT ‘VACUUM CHAMBER 58 HIGH ALTITUDE ADJUSTMENT 523 FLOAT CHAMBER/PILOT SCREW © 5-11. FUEL PUMP REMOVAL/INSTALLATION 5-24 AIR CUT-OFF VALVE 5-14 EVAPORATIVE EMISSION CONTROL | 5] (CARBURETOR SEPARATION G10, SYSTEM [California type oniy} e SERVICE INFORMATION GENERAL + Workin a wel ventieted area, Smating o alawing femes or sparks in tne work {ues fra or axcloton. + Bening or twigang te conrol cabo wil imgelr recth operation ane en couse the ble to mick oF bind, result ing n tees of vanes coro + Before removing the carburetor, place an sppreved fuel sontainer uncer the cin tuba, loosen the drain arow end Srantnecorsuonor + After rornoving the carburetor, cover the Intake port of she evlndot head win shop towel to prevent any foreign ‘patra from dropping ino te ena + When arent ft eee par + Ft waite st be store for more than one mont, eran the fost emamber, Fuel aft in the oat enamber may ‘ue clogged ots reuting in tard starting or poor ervey. + Forfuel tank removal and italian soo secon 2, 5 Reterta suction 18 forearbretor heater espa 1 Allhones use in the evaporative eesion cot! system (California typ ony) are num {When connecting one of eas hose, compare th Howe number with Weouuny Hose Rl V2, forts propa outing. or whore gesoline is stored ean note the Iccations of he O-rings. Roplace them with new ones on for isenstioston, ‘Diogram Lsbal on page NOTICE] Be sure the to remove laphragms before cleaning sir fuel passages with compressa slr The claphvagms might be damaged. ‘SPECIFICATIONS Carre Renita | aataaneda pe i a California type Sowiee screw lina opening Sos pope 22 [Poatove 0mm (28nd [ eae crburtor for yprroriatont - 5) idle speed ee Cs Carburetor vaca dference mm Hg (0 in Ho) Tote ip res iay ink 5-1FUEL SYSTEM. ‘TORQUE VALVES \Vecwum plug Air lanor housing stay bolt Choke cable noir bolt Toois Ccarmuretor font evel couse Poe scm wrench ‘Yacuumipeessure pup Nassim pump — Pressure pum ‘TROUBLESHOOTING Engine ranks but won't start Sho fl Intank 1 Noel fo enrburetor hil fiter clogged Ful ine clogged Ful ever msadhuced ual tank brother ube reeled (49 satelCaneda ype — Evaporative Emiaion (EVAP) tbe Not restrited (altars y=) + Too much fuel gating the engine “Tin conor elooged —Foded sroureoF + intake arent {Fuel eontaminateddetrorated “ies legge + enproper String Enrichmont (5) valve opertion 1 SBvaive creat oped Improper thrate operation Fouty fel pump fever inapection, see age 18-14) "No apork at lug anion eyetom aut Lin ee Fuss clogoed Floetvawatauity Foal tina rested (Carburtor iver tube logged Intake alent "Yaoutm pitn futy Need valve uty Eminsion contol stom fet (California type) “Evaporative Emasion Carburetor ir Vert VAP ‘CAV cone valve fauty — Foes ofthe omision contol systom fait ich mitre PSE vale open 1 lst vaive fey 1 isatlavares high * Airitselogged + ir cleene logged Vacuum piston fauty 1 Emission cont systam faut (Calor ype only) =TEVA® purge corral ve uly —Hioae att eminson eontol sytem felty ‘7401 - 710000 IRMA = Mmseo%0) DERI 04 = KOO of ‘ST-AH-260-MCT (USA only) ST_AK_255-MC7 USA oni) Ne asgte, 22 1) 12 en (1.2 eg, 8 HEA) 1ONen (1.0m, 7 Be Engle als, hard stato ising Fuel tne retcte 1 Fual minture tooleanich { Fusl contaminstesidetorcrated lets logged intake ita lala speed misasustes Fost ove misesustes Fat tak beater tbe restate (49 stte/Coned ‘ype EEVAP tube No.1 reer (Califia type) Pit screw misealustes Starting evchmert vole rc clogged Ignition eytam matfunetion Emission contol aystors fut (altoria type) ATEVAP CAV contrlvelve auty SEVAP purge contel valve faulty — Hose ofthe omission cont syetam fuy Afi wba engine baking wed {loan mre in slow eet 1 vector valve matfuncion + Igntion Control Module (CM) stops ignition intorit- tantly to prevent ever ravoltion[warking over fev Timtaefoneon! Poor performance drvebity and fel esonomy Fost eyetom clogged + Igntion eystem malfunction ‘Emission contol ayster fut (aoria type ony) STEVAP CAV cont valve faulty Hse of he emission contr Systm faulty 5-2FUEL SYSTEM AIR CLEANER HOUSING REMOVAL MOUNTING BOLTS Remove the fuel tank (ge 22, Remove the two mounting bos ooren the Land sew and tomove the ar leaner housing INSTALLATION ‘Apply greets tothe ai? cesner housing bend nse 12 ir cleaner housing ond tighten the band Insal and Ughten the mourting bok Inst the fuel tank poe 22). AIR CLEANER CHAMBER. REMOVAL/INSTALLATION Removs the sircleaner housing (se #bove [AIR CLEANER CHAMBER Loosen the band sre, Disconneat the erane ‘i cleaner shar chamber roster exes ube from he \dremove the avrcleaner | sREATHER CASE TUBE Inatatinion is inthe revares orc of removal. BAND SCREWS 5-3FUEL SYSTEM ‘SUB-AIR CLEANER Remove te ful tank pogo 2:2. Remove the fort eyinder let overhesd cover (one et Dloconnest the oub ar leaner tubes: Remove the subral leaner cage cover from the case Remove the sub sir clearer case and remove the ele ‘mont irom the coe. point solvent queers out {nd allow the element to cy. (NOTICE) ‘Never use gesoine or ow flash point solvents for ‘leaning the steer fhe or beplosion cou rsut font in gear oll (SAE ¥80-90) and Instalton inthe revere oar of romaval 5-4FUEL SYSTEM SARBURETOR REMOVAL Famovethe airlesner chamber page 5) Fug, Tus tube fram the tbe carp, Loon the carburetor drain servis and ain the car Remove the tllowing: Loosen the theo cable oak nt Disconnect the thats sates rom the trate eum. Remove the bol nd choke cae hoi Dioconnoc the carburetor hastarcannactor from theFUEL SYSTEM. Disconnect the srt leaner ube fom the rear ear Logs the band srew a the ineultor side Diesonnse the carouretor nese connectors tam tha Disconnect the sub-alt cleaner tube from the front Looten ine bend sare athe insulatorsFUEL SYSTEM Catia type Te tube numberof he evaporative emission corto onic sytem are pred one ubes. Refer othe tubing diagram forthe tube connections Disconnect the No, S tube and No. 10 tube fram the | fen carburetor. Diaconnecs the No. 5 tube and No. 11 tube fom the front carouetor. Disconnect the No 6 tube 49 sttetCanado type: ar onc tue) ftom the Evaperatve Emission Carourtar [ir Vent @VAP CA) coral vale. (CARBURETORS. No, 10 TUBE Noe TUBE No.6 TUBE Releasa the carburetor with the Inslatrs from the fyunder head Inks pore wile coeflly raising the fnrurtor acer Remove the eaburator assembly by rotating and ‘than disconnecting the ue! We fom he earburat. Loosen the bong eerow and remove the insulators INSULATORS {om each eorburetor 5-7FUEL SYSTEM. Remove the choke cable hocts from the Starting Enrichment (SE] valve nut. Loosen the SE valve nus nd remove them from the ‘VALVE NUTS Disconnect the carburetor sie ven tubes (Calor: AIR VENT TUBE! [No.6 tube| from the carouretors and raleagn the {bes rom the camps. Disconnse te fue tuba trom ane carburetors and CLAMS, feteese the tubo fom te camps FUEL TUBE 5-8FUEL SYSTEM ASSEMBLY /DISASSEMBLY NOTE: eer tothe following pages for service of each + Vacuum chambers, lost chambers, pilot screws ‘nd ar eutof valves can be sestced without Sep ig he earburtars. + Keop tach carburetors parts saperate from the tthe’ 20 you can natal he prt a tai gine AETAINER AIR CUT-OFF VALVE COVER 0 HOSE JON NEEDLE HOLDER FLGAT CHAMBER. Loar ‘SEALNG WASHER paraacw FLOAT VALVE VALVE SEATPFILTER, VACUUM CHAMBER acToa uoneN Boer REMOVAL amovethe four serews and vacuum chamber cove.FUEL SYSTEM ‘Remove the compression spring end eiopheagmwac- swum peter (Check the piston for smacth operation up snd down Inthe carburetor boy, “Turn the needle elder countarcockaiee wile press Ing tin ana remove the hale flangoe trom tho pit Remove the needle holder spring and jot neae from the vacuum piston. INSPECTION Crack the jt needle or stepped wear. \Ghack the vacuum piston for wear oF damage. ‘Chace daphragm fr damage ln holes wines orbend Feplace theca part If nocessay. ‘Ale wl leak out of te vacuum chamber the a- ‘phragm e damaged in ony way evan pin Hoe INSTALLATION Instat neo into the vacuum sion Insal the sping orta tha noose older ard aot the [at nea holder into th piston, ‘Turn the needle holdar clocknise while pressing Ln locke. Holder flanges end pleton groaves ‘ould te ttes eter suming ‘NEEDLE HOLDER JET NEEDLE SPRING DiAPHRace YACUUM PISTON DIAPHRAGMWACUUM PISTON NezoiE WOLDER 5-10FUEL SYSTEM nat te vacuum sistowslapheagr ito the carb reter boy by aligning the tab of te iaphragn wh thecavhy. Lit the Bottom ofthe piston with your Finger to set the diaphragm rin the groove Inthe carburetor boty. Note: + Be careful nt t pinch he diaphragm net ke the spring straight when intalling the eharber over by compressing the spring. Insta the spring ad chamber cover while the pieton ‘omens hats n place. Align the concave ofthe cover ‘rth the eat in the carrer and eecure the over ‘hat let two eee Boor lssing the vee isto, Tighten the four chamber cover scraws, FLOAT CHAMBER/PILOT SCREW REMOVAL ‘Remove te four sreus, clamp and Yost chamber Remove ine Cxing tom he fet chamber grave ‘io? sere) Remove the rt sto ere ‘pilceieron,FUEL SYSTEM er prosr pet row adosirene "bt pet ace The ple sons seit rot ‘hecerauetre lovato sat lets phan aoa the aoa Remove the fat pi, Flat and foe valve ‘Remove the following main ot needle der Som et fot valve seater and sting washor Coverall openings with tape to koon articles out ‘hen the lugs are cle. Use sxrome care than ging nto the pilot serow lg fo avoid demoging the ct screw, Center punch the pilot sero pg to cantor the dl point. Brit through the plug with e& mn (23) det ‘rach sl stop to thet 3mm (178 In from the fond te provant dling into tho plot ere Force the sftepping 4 mm screw (NIC 009988, PN 53503.35¢10) imo the oiled plug and eomcinue ttn- Ing the serew cor unt the lug rotates withthe Pullouthe raw head with piers removetha lus. Use compressed arto clean the plot ser eee and remavs mets shavings “Tum esen pilot serew in an careful coun the num ‘er of tums unt seats Kgl. Make a ote ofthis 1 Gee a3 teference hen renwaling the pis eorae, Too: Plt seraw vranch orkma —masso101 Remove th following: Sorina ester Oring (poar VALVE VALVE SEATIITER ‘SCREW DRIVER PLERS 5-12FLOAT VALVE INSPECTION Check he lost for damage, deterioration or tut in the font Check the flont valve and valve aoet for scoring. ‘scrtches clogging or damage, Cece te up of eet vale, where it cones the ‘Salve sat for stopsed wes or contamination ‘Awom or eanteminatd valve dovs not seat propery ‘nd wl vertually flood he carburetor. JETS/RLTER/PHLOT SCREW ‘Ghackosen at for woar or carano. {een the ets with nomflammeble or high flash point solvent and Bow open wih cornpassed ai ‘chock the fiter for damage or clogsing, an be sure titre socal installed onto he valve se {isan te iter with low pressure compress ar. (Chock the pilot screw or wear or damage Replace its worn or damages FLOAT LeveL Chock the float love! ar checking the float valve, Valve set ar oat ‘Set the carburetor eo tht the float valve end just contacts the loam i. Se sure the let valves ‘Securely in contac withthe vas set Msesure the oat ovl wth the Hoot vel sauge oo: Flot level gauge ‘7401 - 0010000 FLOAT LEVEL: 70 mm (028 in} the fvel i ou of speciation and the lata ip ‘an bo bon, asset feat lovel by sartuly bend ina thei INSTALLATION Intel he flowing row Oring shee sping Instn he pt seru one return t erga poo {on as noted ving remove Perform the plot screw adjustment if « new lot ‘rem i inetd (page 2 Insta the following Thm sealing washer anos valve seater Tlwjet —Peealajet holder on 7 VALVE SEATD FILTER FLOAT LEVEL GAUGE ai ‘SEALING WASHER 5! joeFUEL SYSTEM. No tira pehenironye AIR CUT-OFF VALVE serra ro Hang the lot waive ont the fos arm ip. Ear] FLOAT VALVE! Install the fos valve withthe foot Io the earbutetor ” body, then intl the Fest pln through the Body an fest Inet a now Ong nto te harbor cova graows. Install the charsber cover with the lam end tghton nine {ha for screws Inet th trot top serow. REMOVAL Remove the wo screws and retainer while holding ‘th er cut of valvo cover then remove he cover and song Remove the claphragm and Oring. Remove the aub-or lsaner hse joint I nocoesay INSPECTION Visually check te olowing: the daptragm or deterioration or pin Roles ine spring fr deterioration ine neadle ofthe apagm for excessive wear st 27 thetip ine oils of heat vert for logging or estrition ine Crng for damage ‘ORNS Pea Slow open ar passage inthe cover wit ccmpronsed : a i. Pee | our 5-14