INTRODUCTION Thi:. :.crvice manual describes the service procedures for the CU400F. every service proTl'\ls MO(Iel Spec1f1c ManuAl inr.l~1des cedure that is of a specific nature to this particular model. Basic service procedures that are common to other Honda Motorcycles/Motor Scooters Common Service Manual. This Model Specific Service Manual shoultl I.Je used together With the Common Service Manual in o rder to provide complete service information on all a:opec;ts of this motorcycle. Follow the Maintenance Schedule !Section 31 recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the U.S. Environmental Pr ~tecion Agency and the Califom ia Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. r-- Section 1 and 3 apply to t he whole motorcycle, section 2 illustrates procedures for removal/installation of components that may be required to perform service described in the followi ng sections. While section 4 through 1 8 describe parts of the motorto loc;ations. cyciP., grnupArl <~cording CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE z 1"1"'1 I .,..,.... ENGINE REMOVAL/INSTALLATION 7 CYLINDER HEAD/CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE REAR WHEEL/SUSPENSION BRAKES _, CHARGING SYSTEM/ALTERNATOR < u IGNITION SYSTEM ~ ELECTRIC STARTER/STARTER CLUTCH a: u Date of Issue: January, 1989 6 FRONT WHEEL/SUSPENSION/STEERING Most sections describe the serv1ce procedure through a :Jy:Jtem illustrotion . nefer to the neJll page for details on how to use thi6 manual. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATIOI\I AVAILABLE AT THE TIME OF APPROVAL FOR PRINT),NG. HONDA MOTOR CO .. LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIOATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL 16 WRIT· TEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES OR MOTOR SCOOTERS. FUEL SYSTEM CRANKSHAFT/TRANSMISSION Find the section you want on this page, then turn to the table of contents on the first page of the section. If you don't know the .source of the trouble, go to sP.r.tion 19, TROUBLESHOOTING. COOLING SYSTEM 4 5 LUBRICATION ~ > w _, w 1 2 3 LIGHTS/METERS/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX 8 9 10 11 12 13 14 15 16 17 18 19 20 HOW TO USE THIS MANUAL FINDING INFORMATION YOU NEED • Tl'lls manual Is divided Into sections wl'llch cover each of the major components of the motorcycle. To quickly find the section you are interested in, the first page of each section is marked with a black tab that lines up with one of the thumb index tabs before this page. The first page of each section lists the table of contents within the section. Read the service information and troubleshooting related to the section before you begin working. • An index of the entire book is provided in the lost chapter to directly locate the information you need. )) NOTE ON THE EXPLANATION METHOD OF THIS MANUAL • • ,r--. • • • • • The removal and installation of parts are for the most part illustrated by large and clear illustrations that should provide the reader with visual oid in understanding the major point for servicing. . The system ilustraom~ ure augmented by callouts whose numbers or letters indicate the order in which the parts should be removed or installed. The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately. For example, if the steps prior and up to camshaft removal are performed with the engine installed, but the subsequent steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders. The illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken. RM6r t6 the Mxt pag6 for the rnaaning of eaeh symbol mark. Also in the illustration is a chart that lists information such as the order in which the part is removed/installed, the name of the port, and oomo extra notes that may be needed. Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is necessary or illustrations alone would not suffice. Service procedures required before or after the procedure described on that particular page, or inspection/adjustment procedures required following the installation of parts, are described under the title Requisite Service. Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual. tl System illustration CAMIHAI'l IOU OIAIII CAII IHITAU.A'T'tOIH I""'' . .-.....__ . . ....... . . . . -_ . . . . . ......... ._. . . , __,___..... .....,-w ..,.,-..,, (u>~ .- j -oMIM t ...-11: - - C-OillfH ( ,..,.... Wl.a.-..ln$ ........ _ ..................... -...w...... . .., ~- ...._.. Mlllell . . . , . , ...... fWI t ........ _... .................._ _.., _ _ ......,. _ _ _ _ H'II!t f.,.... Step sequence (numerals or alphabets} __ _ __ ..,._ _..., o..-....--- fJ .,..._ tJ . ·--··---- - .. ... •J - - - - · '· __ ...... .,.. .,. .... ...... .... ...,_ _ , _., _,._ ,, .. ,.Hr .,.-. •"'"'' fJ 8·5 Part name Number of parts Extra notes or precaution related to the service procedure Symbols ., The symbols used throughout this manual show specific service procedures . If supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols . Replace the part(s) with new one(s) before assembly. IsT'ooa.. J Use special tool ('M ' ~Ol) Use optional tool. c , tools are obtained as you order parts . The~;a Torque specification. 10 N•m (1.0 kg-m, 7.2 ft-lb) 10 (1 .0, 7 .2) " U~1: ~ r~:cunmed engine oil, unless otherwise specif1ed. Use molybdenum oil solution (mixture of the engine oil and molybdenum grease with t he ratio 1 : 1). - c;;:_ Use 111ulli-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent) Use MOlybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent) E)(omplc: Molykote«> BA·Z plus msnufactured by Dow Coming, U.S.A. Multi-purpose M -2 manufactured by Mitsubishi Oil Japan ~ Use m olybdenulll uisuHilh:l paste (containing more than 40% molybdenum disulfide, NLGI #2 or equivalent) FY~mple : Molykotw® G-n Paste manufactured by Dow Corning, U.S.A. Honda Moly 45 (U.S.A. only) Rocol ASP manufactured by Rocol Limited. U .K . Rocol Paste manufactured by Sumico Lubricant, Japan ~ ~ Use silicone grease .t o,. llil Apply a locking agent. Use the agent of the middle strength, uniA!:S otherwise specified . ·~ Apply sealant I Use brake fluid, DOT 3 or DOT 4. Use the recomm ended brake fluid, unless otherwise - Use Fork or Suspension Fluid. specif~:d . 1. GENERAL INFORMATION GENERAL SAFETY 1-1 LUBRICATION AND SEAL POINTS 1-1 8 MODEL IDENTIFICATION 1-3 CABLE AND HARNESS ROUTING 1-19 SPECIFICATIONS 1-4 EMISSION CONTROL SYSTEMS 1-25 TORQUE VALUES 1-14 TOOLS 1-16 EMISSION CONTROL INFORMATION LABELS (U.S.A. Only) 1-28 GENERAL SAFETY Carbon Monoxide If the engine must be running to do some work. make sure the area is well ventilated. Never run the engine in an enc iOSI!U ~rt:a. Used Engine/Transmission Oil • • The exhaust contains poisonous carbon monoxide gao that oon cause lou of com;ciuusness and tnay lead to death. Run the engine in an open area or with an exhaust evacuation iYit&m in an enclosed area . Gasoline W ork in a well ventilated area . Keep c igarettes, flames or sparks away fro m the work area or where Qasoline is stored . • Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Hot Components Brake Dust Never use an air hose or dry brush to clean brake assemblies. Usc on OSHA-approved vacuum cleaner or alternate method approved by OSHA. designed to minimize the hazard caused by ~tirbone asbestos fibers. • Inhaled asbestos fibers have been found to cause respiratory disease and cancer . Brake Fluid CAUTION • • Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear Insulated gloves or walt until the engine and exhaust system have cooled before handling these Used engine oil (or transmission oil in two-strokes) may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis. It is still advisable to thoroughly w ash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. Spilling fluid on painted. plastic or rubber parts will damaR& them. Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN. GENERAL INfORMATION eoolant Under some conditions, the ethylene glycol in engine coolanl ill c.:umbustlble and Its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned . • • Avoid spilling engine coolant on the exhaust system or engine partR. They may be hot eno~gh to oauso the coolant to ignite and burn without a visible flame. Coolant (ethylene glycol) can cause some skin irritation and is poisonous If swallowed. KEEP OUT OF REACH OF CHILDREN . • • Do not remove the radiator cap when the engine is hot. The coolant is under prestiu~ and could scald you. Keep hands and clothing away from tho cooling fan, as it starts automatically. If it contacts your skin, wash the affected areas immediately with soap 11nrl wrial the crankcase. number is stamped on the right side of The Vehicle ldentifacation Number (VIN) is located on the safety certification label on the right side of the frame tube. (4) CARBURETOR IDENTIFICATION NUMBER The carburetor identification number is on the rear side of oach carburetor. The color code label is attached on the left frame tube under the seat. w:aen ordering a color coded part, always specify its designated color code. GENERAl INFORMATION SPECIFICATIONS General SPECIFICATIONS ITEM DIMENTIONS Overall length Overall width Overall height Wheel base Seat height Foot peg height Ground clearance Dry weight Curb weight Maximum weight capacity 2,035 705 1,025 1 ,370 FRAME Frame tYPe Front suspension • Front wheel travel Rear suspension Rear wheel travel Rear damper Front tire size Rear tire size Tire brand (Bridgestone) Front/Rear Tire brand IDunlopl Front/RAAr Tire brand (Yokohama) Front/Rear Tire brand (IRC) Front/ Rear Front brake Rear brake Caster angle Trail length Fuel tank capacity Fuel tank. reserve capacity Diamond Telescopic fork 130 mm (5.1 in) Swingarm 110 mm (4.3 in) Gas-filled damper 110/70-17 54H 140/70-17 66H G547/G54 8 K505F/K505 Bore and stroke Displacement CnmprA~io ratio Valve train Intake valve opens at 1 mm lift Intake valve close at 1 mm lift Exhaust valve opens at 1 mm lift Exhaust valve close at 1 mm lift Lubrication system Oil pump type Cooling system Air f iltratioll" Crankshaft type Engine weight (dry) Firing order Cylinder arrangement Front 55.0 x 42.0 mm (2.17 x 1.65 in) 399 cm3 (24.3 cu in) 11.6 : 1 Gear driven DOHC, 4 valves per cylinder 5 ° ATDC 33° ABDC 33° BBDC, 38° BBDC (California) 5° BTDC, 10° BTDC (California) Forced pressure and wet sump Trochoid-type Liquid cooling system with cooling fan Paper filter Unit-type, 6 main journals 57 kg 1126 lbs) 1 - 2 - 4-3 Vertical 30° in line four ENGINE mm (80. 1 in) mm (27.8 in) mm (40.4 in) mm (53.9 in) 775 mm (30.5 in) 335 mm (1 3 .2 in) 130 mm (5. 1 in) 170 kg (375 lbs) 183 kg (403 lbsl 157 kg (347 lbs) Hydraulic disc brake Hydraulic disc brake :l5°30' 99 mm (3.9 in) 11 .5 lit (3.04 US yal, 2.53 Imp gall 3.5 lit (0.92 US gal, 0.77 Imp gal) 'U ~eo ~ f 1-4 GENERAL INFORMATION r- General (Cont'd) ITEM SPECIFICATIONS CARBURETOR Carburetor type Throttle bore VG06 32.6 mm (1.28 in} DRIVE TRAIN Clutch system Clutch operation 3ystem Transmission Primary reduction Secondary reduction Third reduction Final reduction Gear ratio 1st Gear ratio 2nd Gear ratio 3rd Gear ratio -1th Gear ratio 5th Gear ratio 6th Gear ratio reverse Gearshift pattern Wet, multi-plate Mechanical type 6-speed constant-mesh ?. 181 (96/44) Ignition system Starting system Charging system Regulator/ rectifier type L1ghtmg system AC regulator type Full transistor ignition Starter motor Triple phase output alternator SCR shorted/triple phase full-wave rectification Battery . ELECTRICAL - - -2.733 3.307 2.352 1.875 1. 590 1 .434 1.333 - - (41/15) (43/13) (40/17) (30/1 6) (35/22) (33/231 (32/24 1 Left f oot operated return system 1 - N - 2 - 3 - 4 - 5-6 -- GENERAL INFORMATION Unit: mm (in) Lubrication Standard Item Service limit 2.9 t (3.06 US qt. 2.55 Imp qt) 3 .5 t (3. 70 US qt, 3.08 Imp qt) 3 . 1 t (3.28 US qt, 2. 73 Imp qt) HONDA 4-stroke oil or equivalent. API service classification SE or SF. Engine oil capacity at draining at disassembly at oil filter change RecommenriArl Anoine oil OIL VISCOSITIES The viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. 100 •F -20 - 10 o 10 10 JO Oil pressure at oil pressure switch Oil pump roter tip clearance CD body clearance @ end clearance (j) Fuel system Carburetor identification number (California) Main jet -.o •c 490 kPa (5 kg/cm 2 , 71 psi) 0 . 10 (0.004) 0.15-0.22 (0.006-0.009) 0.02 - 0 .07 (0.001-0.003) VG06B VG06C #105 0 . 15 (0.006) 0.35 (0.014) 0.10 (0.004) ( (High altitude) (2, 3) (1, 4) (Front) (Rear) Slow jet Jet needle crip position Pilot screw i11iliHI opening (California) Pilot screw adjustment final opening Pilot screw high altitude adjustment Air screw initial ooening (California) Air screw high altitude adjustment Float level Carburetor vacuum difference Base catbur~: (For carburetor synchronization) Idle speed (California) Throttle grip free play Accelerator pumo clearance Secondary air supply system Air injection control valve vacuum pressure 1-6 #35 2-1/4 turns out 2-1/2 turns out 1 turn out 1/ 2 turn in from initial opening t 8.0 (0.3 1) Within 30 mmHg (1 .2 inHg) No. 2 carburetor 1,300 ± 100 rpm 'I .400 ± 100 rpm 2-6 (0 .08-0.24) Reed valves are built into the ASV 360 mmHu ( 14.2 inHg) GENERAL INFORMATION - Unit: mm (in) Cylinder head Item Standard Cylinder compression Cylinder compression difference Valve clearance IN EX (cold ) Cylinder head warpage Cam lobe height G) IN IN (California model) EX EX (California model) Camshaft runout @ Camshaft oil clearance @ Service limit 1,280-1,320 kPa (12.8-13.2 kg/cm2, 182- 188 psi)/400 rpm W ithin 30 mmHg (1.2 inHg) of each other 0.12-0.18 (0.005-0.007) 0. 17 - 0.23 (0.007 -0.009) 33.070-33.230 (1.3020- 1 .3083) 0.1 (0.004) 33.02 (1.300) 33.120-33.280 (1.3039- 1.3102) 33.07 (1.302) 0 .020-0.062 (0.0008-0.0024) 0.05 (0.002) 0.10 (0.004) 22.959-22.980 (0.9039-0.9047) 22.965 (0.9041 ) 3.775-3.790 3.755-3.770 3.800-3.812 3.800-3.812 3. 70 3.69 3.89 3.89 0.04 0.05 @ a..[] [IJ. u~ r n J [IJt~ E J-[]-.~ . .A Hold ~ t - 1 Hold Camshaft journal O.D. Camshaft holder I.D. Valve stem O.D. IN EX Valvu guide I.D. IN EX Stem-to-guide clearance IN EX Valve guide projectinn ~bove c;ylinder head (h) IN EX (0.1486-0. 1492) (0.1478-0.1484) (0.1 496 -0. 1253) (0.1496-0.1253) (0.146) (0.145) (0. 153) (0. 153) (0.002) (0.002) 13.37- 13.77 (0.526 - 0.542) 11.52-11.92 (0.454 - 0.469) Before guide installation: 1 . Chill the valve guides in the freezer section of a refrigerator for about an hour. 2. lleat lhl:l cylinder head to 1 uo1500C (212-300° F). Valve seat width Valve spring free length IN EX inner IN inner EX outer IN outee EX Rocker arm I.D. IN EX Rocker arm shaft 0 .0. IN EX Aocker arm-to-rocker arm shaft clearance Valve lifter O.D. Valve litter bOre I.LJ. Hydraulic lash adjuster assist spring free length Hydraulio la3h adjuster compnJssion stroKe with kerosene 0.9 - 1.1 (0.035- 0.043) 39.40 (1.661) 39.40 (1.551) - -- 1.5 (0.06) 38.6 (1.52) 38.6 (1.52) GENERAL iNFORMATION Unit: mm (in) r- Cylinder/piston Item Cylinder I.D. Cylinder out of round Cylinder taper Cvlinder warpage Piston mark direction Piston O.D. (D) Piston 0.0. measurement point (HI Piston pin hole 1.0. !dl Standard 55.000 - 55.010 (2.1654- 2.1657) Service limit 55.10 (2.169) 0.10 (0.004) 0.10 (0.004) 0.10 (0.004) , With "IN" mark facing to the intake side 54.960-54.990 (2.1638 - 2.1650) 10 (0.4) 14.002 - 14.008 (0.5513 - 0.5515) 54.90 (2.161) 14.05 (0.553) , Cylinder-to-piston clearance Piston pin 0.0. Piston-to-piston pin clearance Connecting rod-to-piston pin clearance Top ring-to-ring groove clearance Second ring-to-ring groove clearance Top ring ond gop Second ring end gap Oil rinQ (side raill end l}l'IP Top ring mark Second ring mark Crankahaft Connecting rod small end 1.0. ConnectinQ rod big end side clearanr:e radial clearance Crankshaft runout (j) 13.994-14.000 (0.5509-0.55 12) 0.002 - 0.014 (0.0001 - 0.0006) 0.016-0.040 (0.0006-0.0016) 0.015 - 0.050 (0.0006 -0.0020) 0.015 - 0.050 (0.0006-0.0020) 0.18-0.28 (0.00/-0.011) 0.18-0.33 (0.007-0.013) 0.2 0. 7 (0.01-0.03) Install with the marked side up Install with the mArked side up 14.016-14.034 (0.5518 - 0.5525) 0.05-0.20 (0.002 - 0.008) 0.10 (0.004) , 3.98 (0. 550) 0.04 (0.002) 0.06 (0.002) 0.08 (0.003) 0.08 (0.003) 0.5 (0.02) 0 .5 (0.02) , .1 (0.04) - - -14.07 (0.554) 0.30 (0.012) 0.05 (0.002) HOLD Crankpin oil clearance Crankpin bearing selection Main journal oil clearance Main journal bearing selection r- Kh:kstartor - Kickstarter pinion gear 1.0. Kickstarter spindle 0.0. Kickstarter idle gear 1.0. Countershaft 0 .0 . at kickstarter idle gear Kickstarter idle gear bushing O.D. 1.0. 1-8 0.020- 0.052 (0.0008 -0.0020) See page 10 7 0.022-0.046 (0.0009 - 0.0018) See page 1 0-6 0.06 (0.002) 0.05 (0.002) ·I GENERAL INFORMATION Unit: mm (in) ...- Transmission Standard Item 25.000 25.000 28.000 28.000 28.000- Transmission gear 1.0. M5 M6 C2 C3 C4 Tron:imission gear bushiny 0.0 . M5 M6 C2 C3 C4 Transmission gear busing 1.0. M5 C2 Gear-to-bushing clearance at M5 gear at M6 gear at C2 gear at C3 gear at C4 gear Mainshaft 0 .0 . at M5 gear bushing CD at clutch outer guide ® ® Ill § · ~ Il ~$ 25 .021 25 .021 28.021 28.021 28.021 Service limit (0.9843-0.9851) (0.9843-0.9851 ) (1 .1024-1.1032) (1. 1024 - 1 .1 032) (1.1024-1 .1 032) ~4 . 95 - 24.980 (0.9826 - 0 .9835) 24.959- 24.980 (0.9826-0.9835) 27 .959 - 27.980 (1.1 007-1 .1016) 27.959 - 27 .980 (1.1007-1.1016) 27.959 - 27 .980 (1.1007- 1.1016) 21.985 - 22.006 (0.8655-0.8664) 24.985 - 25.006 (0.9837 -0.9845) 0.020 - 0.062 (0.0008-0.0024) 0 .020- 0.062 (0.0008- 0.0024) 0 .020- 0.062 (0.0008 - 0.0024) 0.020- 0.062 (0.0008- 0.0024) 0 .020 - 0 .062 (0.0008 - 0.0024) 21.959-21.980 (0 .8645-0.8654) 21.967 - 21 .980 (0.8648-0.8654) 25 .05 (0.986) 25.05 (0.986) 28.05 (1 .104) 28.05 (1.1 04) 28.05 (1.1 04) 24.92 (0.981) 24.92 (0.981) 27.92 (1.099) 27.92 (1.099) 27.92 (1 .099) 22.07 (0.869) 25.07 (0.987) 0 .10 (0.004) 0 .10 (0.004) 0 . 1 0 (0.004) 0 .10 (0.004) 0.10 (0.004) 21.93 (0.863) 21 .93 (0.863) 24.967-24.980 (0.9830- 0 .9835) 24.93 (0.981 ) 0.020 - 0.062 (0.0008 - 0 .0024) 0 .005- 0 .039 (0.0002 - 0.0015) 5.93 - 6 .00 (0.233-0.236) 5.93- 6 .00 (0 .233-0.236) 5 .93 - 6.00 (0.233-0.236) 12.000- 12.018 (0.4724-0.4731 ) 12.000 - 12.018 (0.4 724-0.4 731) 12.000-12.018 (0.4724-0.4731 ) 11 .969- 11.980 (0.4712-0.4717) 0.10 (0.004) 0.06 (0.002) 5 .60 (0.220) 5.60 (0.220) 5 .60 (0. 220) 12.06 (0.475) 12.06 (0.475) 12.06 (0.4 75) 11.90 (0.469) CD · i:W Coutershaft 0 .0. at C2 gear bushing CD (1) •F = 10 Gear-to-shaft clearance Gear bushing-to-shaft clearance at M5 gear at C2 gear Sl'llft fork claw thickness L c r- Shift fork 1.0. L c R Shift fork shaft 0 .0 . GENERAL INFORMATION Unit: mm (in) .- Clutch system Item Clvtch lever free play Recommended clutch fluid Clutch master cylinder I.D. Clutch master piston O.D . Clutch outer I.D. Clutch outer guide O.D. I.D. Mainshoft O.D. at clutch outer guide Oil pump drive sprocket I.D. Clutch spring free height Clutch spring free length Clutch disc thickness A B c Clutch plate warpage Centrifugal clutch drum I.D. buGhing 0.0. Centrifugal clutch center guide I.D. O.D. Centrifugal clutch center guide collar height Centrifugal c lutch weight lining thickness Centrifugal clutch spring free length Clutch lining thickness Crantrocket nut Shock absorber mounting nut (upper) Shook ob:~rc mounting nut (lower) Shock absorber lower joint lock nut Swingarm pivot nut Brake: Front caliper pad pin plug pad pin bracket bolt pin bolt bracket pin bolt Front mo:Jtcr cylinder reservoir cover screw Front brake disc bolt Rear caliper pad pin plug pad pin mounting bolt pin bolt Rear master cylinder push rod joint lock nut Rear brake (liSe bolt Brake hose bolt O'ty Torque N•m kg-m 12 22 10 27 30 12 27 27 1.2 2.2 1.0 2.7 3.0 1.2 2.7 2.7 9 16 7 20 22 9 20 20 -16 10 18 1.0 1.8 7 13 3 22 4 23 3 2.3 0.3 17 2 2 1 1 1 1 4 6 10 10 10 20 20 10 10 40 50 50 15 65 45 40 4.0 5.0 5.0 1.5 6.5 4.5 4.0 29 36 36 11 47 33 29 2 2 1 4 2 2 2 2 1 8 6 14 8 7 10 37 6 24 26 8 27 10 60 22 20 50 23 20 105 25 25 2.7 1.0 6.0 2.2 1. 1 5.0 2.3 2.0 10.5 2.5 2.5 90 65 45 45 68 110 9.0 6.5 4 .5 4 .5 6.8 11 .0 H 6 2 1 1 8 10 10 1 1 1 4 . Thread dio (mm) , 1 1 1 2 6 6 8 8 1 5 1 1 1 1 16 10 10 10 14 1 10 10 8 1 2 1 1 2 6 1 1 1 1 1 4 4 1'1 --4 8 10 10 8 --8 10 11 2.5 18 27 23 13 6 30 2.5 18 23 23 17 40 35 0 .25 1.8 2.7 2.3 1.3 0.6 3.0 0 .25 1.8 2.3 2.3 1. 7 4.0 3.5 ft-lb 7 Remarks NOTE 1 NOTE 2 NOTE 2 NOTE 1 43 16 8 36 17 14 76 18 NOTE 1 18 NOTE 1 65 47 33 33 49 80 1.8 13 20 17 9 4 22 1.8 13 17 17 12 29 25 NOTE 1 NOTE 1, 4 NOTE 1, 4 NOTE 1, 4 GENERAL INFORMATION TOOLS • The tools for the boll beoring removal and install 1-16) REQUISITE SERVICE • • Engine oil draining (location: page 3·3, step: section 2 of the Common Service Manual) • Clutch disassembly (page 9-4)/ assembly (page 9-8) Exhaust system removal/installation (page 2-3) PROCEDURE (1) (2) (3) (4) (5) (G) (7) (8) (9) ReMOVAL ORDER Oil pan bolt Q'ty 12 Oil pan Gasket Relief valve 0 -ring Oil strainer 0 -ring Oil purnp driven sprocket bolt 1 1 1 1 1 1 1 Washer 1 (10) Oil pump driven sprocket 1 (11 I (12) (131 Oil pump mounting bolt Oil IJUIIlp Dowel pin 2 REMARKS • Installation is in the reverse order of removal. At installation. tighten the bolts in a gradual, crisscross pottern. Clean with the non-flammable solvent. NOTE: • Install the clutch outer onto the mainshaft temporarily (poge 9-81. hold the flywheel with the rotor holder and remove (or torque) the bolt. • Apply a locking agent to the tip of the threads (approx. 6 mm/0.2 in) At installation, install with the grooves facing inside. 1 2 4 -3 LUBRICATION SYSTEM OIL PUMP DISASSEMBLYIASSEMBLY PUNCH MARK GROOVE I I I I I I I NOTE • • Defore installing them, clean all removed parts thoroughly with clean engine oil. Refer to section 4 of the Common Service Manual for inspection information. • RefAr tn PJ:>QP. 1-R fnr !;pAr.if:~t i n . REQUISITE SERVICE Oil pump removal/installation !page 4 -31 • Q'ty PROCEDURE ( 11 (21 (31 (4 ) (5) (6) (7) 181 (9) Jl DISASSEMBLY ORDER Oil pump cover attaching screw Dowel oin Oil pump cover Outer rotor Inner rotor Drive pin PUIIIIJ shC:I rt Washer Oil pump body Jl . REMARKS 2 • Assembly is in the reverse order of disassembly. NOTE: • Install the dowel pins, then tighten the screws. 2 1 1 1 1 1 Install with its punch mark facing the cover. Install the rotor, aligning its groove with the drive pin. 1 1 Install with the tab side facing the cover (water pump side). 5. COOLING SYSTEM SERVICE INFORMATION 5 -1 TROUBLESHOOTING 5-1 5-2 5-3 SYSTEM FLOW PATTERN COOLANT DRAINING RESERVE TANK REMOVAL/ INSTALLATION 5-3 THERMOSTAT REMOVAL/ INSTALLATION RADIATOR DISASSEMBLYI ASSEMBLY 5-4 5-5 5-6 WATER PUMP DISASSEMBLY/ ASSEMBLY 5-7 RADIATOR REMOVAL/ INSTALLATION SERVICE INFORMATION • Walt until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the eoolant It under pressure may cause serious scalding. • Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. - If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. - If any coolant Is swallowed, induce vomiting, gargle and consult a physician Immediately. - If any coolant gets on your skin or clnth&$, rinse thoroughly with plenty of water. • KEEP OUT OF REACH OF CHILDREN Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. All cooling system service can be done with the engine in thP. fr;~me . Avoid spilling coolant on painted surfaces. For coolant replacement , refer to section 5 of the Common Service Manual; in this manual, only the coolant draining procedure is described. • After servicing the system, check for leaks with a cooling system tester. • l"or fan motor switch and thermo senMt inspections, refer to section 25 ot the Common Service Manual; for the sw itch and sensor locations, see page 17-2 of this manual. • • • • TROUBLESHOOTING Engine temperature too high • Faulty temperature gauge or thermo sensor • Thermostat stuck closed • Faulty radiator eap Insufficient coolant Paooagoa blocked in rodiotor. hoses or water jacket • Air in system • Faulty cooling fan motor • Faulty fan motor switch • Faulty water pump e: Engine temperature too low • Faulty temperature gauge or thermo sensor • Thermostat stuck open • Faulty ton motor switch Coolant leaks • Faulty oil pump mechanical seal • Deteriorated 0 -ring • Faulty radiator cap • Damaged cylinder gasket • Loose hose connection or clamp • Damaged or deteriorated hoses COOLING SYSTEM SYSTEM FLOW PATTERN • (3) RADIATOR CAP • • • (7) WATER PUMP ------------------------------------COOLING SYSTEM COOLANT DRAINING NOTE • For coolant replacument, refer t o section 5 of the Common Service M anual. CAUTION • Walt until the engine is cool before servic ing t he cool· lng system . Removing the radiator cap while the engine Is hot and the coolant Is under pressure m ay cause serio us scalding. To drain the coolant, remove the following: - fu~:l tank (page 2-4 ). - heat rubber and radiator cap. - water pump drain bo lt and sealing w asher. Remove the cylinder d rain bolts and sealing washers and drain the coolant completely from the syst em. - NOTE I •- C--al-if-o-rn_i_a_m_o_d_e_l_h_a_s_t_h_e_o_n_ly--le-ft-d-r_a_in__b_o-lt-.-------. ( 1) CYLINDER DRAIN BOLTS/ SEALING WASHERS Place a suitable tray under the siphon tube joint of the reserve tank and disconnect t he siphon tube from the reserve tank. Drain the coolant from the reserve tank. Install the water pump drain bolt and cylinder d rain bolts with new sealing wA~hrs, and connect t ho aiphon tu be to thereserve tank. RESERVE TANK REMOVAL/ INSTALLATION Drain the coolant from the reserve tank (see above). ReMove the following: - shock absorber (page 12-4) . - reserve tanlc muunting bolt . - collar and reserve tank. Install the reserve tank in the reverse order of removal. (3) RESERVE TANK COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION FRONT HOLE® r(7 )- - - - - (5) MARK -=~:; - (3) REQUISITE SERVICE • • Fuel tank removal/installation (page 2-4) Coolant dreti11i111:1 (page 5·3) PROCEOURE (,) (2) (3) (4) (5) (6) (7 ) (8 ) (9) REMOVAL ORDER I hermostat eover mountiny I.Joll Siphon tube nadiator h030 Thermo sensor connector ThArmostat cover 0 -ring Thermostat , Thermo sensor ThermostAt housing • Coolant refill (section 5 of the Common Service Manual) • A ir cleanAr c:ase removal/installation (PaRe 6 -3) O'ty REMARKS • Installation is in the reverse o rder of removal. 2 1 2 1 1 1 1 1 1 Install them with "0" marks facing up. Install the thermostat with its hole side forwards. At Installation, apply sealant to the threads. COOLING SYSTEM RADIATOR REMOVAL/INSTALLATION 131 REQUISITE SERVICE • Coolant draining (page 5-3) PROCEDURE (5) REMOVAL ORDER Radiator hose 1-an motor sw1tch connector Radiator lower mounting bolt Radiator upper mounting bolf/nut Fan motor connector (6) CollAr ( 1) (ll (3) (4) • Q'ty , 2 2 1/1 1 4 Coolant refill (section 5 of the Common Service Manual) REMARKS • Installation is in the reverse order of removal. Install them with "0" marks facing up. ........................___________________ COOLING SYSTEM RADIATOR DISASSEMBLVIASSEMBLV (3) FAN MOTOR GROUND TERMINAL • (9) Ill ~ (8) ~ 18 (1.8, 13) REQUISITE SERVICE • Radiator removal/installation (page 5-5) PROCEDURE • Q'ty • Assembly is in the reverse order of disassembly. (2) DISASSEMBLY ORDER Radiator shroud attaching screw Left and right radiator shroud (3) Radiator grille (4) Fan motor shroud mounting bolt/nut (6) (6) Fan motor mounting nut Fan motor 3 1 (7) (8) Cooling fan Fan motor switr.h 1 1 (9) 0 -ring 1 111 . REMARKS 4 2 , 1/2 At installation, align the grille tabs with the shroud grooves . At installation, align four grille grooves with the radiator lugs. At installation, install the fan motor ground wire terminal properly as shown. Install the fan motor, with the motor wireharne ss facing down. At installation, align the fan groove with the motor shaft. At installation, apply sealant to the threads. CAUTION: • Do not ov er-tighten the fan motor sw itch, or the radiator may be domoged. • -·------------------------.............. COOLING SYSTEM WATER PUMP DISASSEMBLY/ASSEMBLY NOTE • If the mechanical seal is damaged, the water pump must be replaced as an assembly. REQUISITE SERVICE • • • Coolant ara1n1ng !page 5-3) Engine oil draining (drain bolt location: page 3-3, step: Manual) 5eotion 2 of the Common Servic~; Coolant refill (section 5 of the Common Service Manual) PROCEDURE ( 1) (2) (3) DISASSEMBLY ORDER Radiator hose Water pump mounting bolt (7) Water Water Water 0 -ring Water (8) 0 -ring (4) (5) (6) pump cover bolt pump side cover stay pump cover pump body O'ty • • Gearshift spindle joint removal/installation (page 9-6) Water pump side cover removal/installation (page 7-2) REMARKS • Assembly is in the reverse order of disassembly. . 2 2 NOTE: • Before removing bolts, loosen the pump cover bolts(3) . 2 1 1 1 1 1 At installation, align the pump shaft slot with the oil pump shaft. 6. FUEL SYSTEM SERVICE INFORMATION 6-1 TROUBLESHOOTING 6-2 CARBURETOR DISASSEMBLYI ASSEMBLY AIR CLEANER CASE REMOVAL/ INSTALLATION 6-3 FUEL PUMP/FILTER 6-8 6-10 6-13 CARBURETOR REMOVAL/ INSTALLATION 6·4 EMISSION CONTROL SYSTEMS (California Model Only) 6-13 CARBURETOR SEPARATION 6-6 CARBURETOR COMBINATION SERVICE INFORMATION • • A ., ~- Gasoline I• extremely flammable and is explosiv e under certain conditions. W ork in a well ventilated area. Smoking orallowing flames or sparks in the work area or where gasoline is stored can cause fire or explosion. Bending or twisting the control cables will impair smooth operation tnd could cause the cables to stick or bind, resultJng In loss of vehicle control . - ~ CAUTION • To prevent domogo. be sure to remove the diaphragms before cleaning ait and fuel passages with compressed air. The diaphragms might be damaged. NOTE • It vehicle is to be stored for more than one month, drain the float chambers. Fuel left in the float chambers may cause c logged jets resulting in hard starting or poor driveability. • When di~tasemblng fuel system ports, note the locations of the 0-rings. Replace them with new ones on reassembly. • I::Jetore removing the carburetors, place a suitable container under the carburetor drain tube, loosen the drain bolts and drain the carburetors. • After removing th~ c;nlJunnors, cover the Intake port of the engine with a shop towel or cover it with pieces of tape to prevent any foreign material from dropping into the engine. • The vacuum chamber and float ohambcr con be serviced with the ca r bur~tos assembled. • For fuel tank removal/installation, see page 2-4. • California Model Onlv: All hoses used in the secondary air supply and evaporative emission control systems are numbered for identification. When connecting one of these hoses, cQmpare the hose number with the Vacuum Hose Routing Diagram Label, page 1-29, and carburetor tubes, page 6 -12. -. FUEL SYSTEM TROUBLESHOOTING Engine won't start • No fuel to carburetors - fuel strainer clogged - fuel tube clogged - float valve stuck • • • - float level misadjusted - fuel tank cap breather hole clogged - fuel pump malfunction Too much fuel getting to the engine - air cleaner clogged - flooded carburetors Intake air leak Fuel contaminated/deteriorated • Slow circuit or bystarter circuit cloggea • Ignition malfunction Engine stalls. hard to start. rough idling • Fuel line restricted • Ignition malfunction • Fuel mixture too lean/rich • Fuel contaminated/deteriorated • Intake air leak • Idle speed misadjusted • Fuel pump malfunction • Pilot screw misodjusted • Slow circuit or bystarter circuit clogged • Float level misadjusted • Fuel tank breather tube clogged • Emission control system malfunction (California Model Only) - air vent control valve (AVCV) faulty - purge control valve (PCV) faulty - loose, disconnected or deteriorated hoses of the emission control system Afterburn on deceleration • • lean mixture in slow circuit Emission control system malfunction (California Model Only) - secondary air supply system faulty - loose. disconnected or deteriorated hoses of the emission control system Backfiring or misfiring during acceleration • Ignition system faulty • Fuel mixture too lean Poor performance (driveability) and poor fuel economy • Fuel system clogged • Ignition malfunction • Emission control system malfunction (California Model Only) - air vent control valve (AVCV) faulty - loose, disconnected or deteriorated hoses of the emission control system Lean mixture • Fuel jets clogged • Float valve faulty • Float level too low • Fuel line restricted • Carburetor air vent hole (or tube) clogged • California Model Only: air vent control valve (AVCV) faulty • Intake air leak • Fuel pump malfunction • Vacuum piston faulty • Throttle valve faulty Rich mixture Bystarter valve in ON position Float valve faulty Float level too high Air jets clogged Air cleaner element contaminated Flooded carburetors • • • FUEL SYSTEM AIR CLEANER CASE REMOVAL/INSTALLATION (3) SPARK PLUG W IRES SPARK PLUG WIRES REQUISITE SERVICE t • 1-uel tank removal/ installation (page 2-4) PROCEDURE (1) (2) (3) (4) (5) 16) (7) (8) (9) AIR CLEANER CASE REMOVAL ORDER Main wire harness Heat guard plate Air eleaMr case cover Air cleaner element Air cleaner case bolt/collar Crankcase breathP.r tunA Air hose Air injection tube (No. 15) Air cleaner case U'ty 1 1 • Installation is in the reverse order of removal. Install it into the wire harness clamp of the case cover. 1 1 Install it with the i}' mark forwards and with the TOP rnark racing up. 2/2 2 1 1 1 (12) SUB AIR CLEANER CASE REMOVAL ORDER (Except California Model) Attaching screw Sub air cleamu ca~1: cover Sub air cleaner element 1 (13) Sub air cleaner case 1 (10) ( 11) REMARKS Except California Model California Model Only • Align the holes of the connecting tubes with the air jets. • Install the spark plug wires as shown. • Installation is in the reverse order of removal. 1 1 NOTE : 2 (AIR CLEANER: • For element cleaning, refer to s~;ction Oiled Urethane Foam Element) of the Common Service Manual. FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION (7) California Model Only AVCV FUEL SYSTEM • Gasoline Is axtrAmtly flammable and ia oxploslvo under certain conditions. Work In a well ventilated area. Smoking orallowing flames or sparks In the work area or where gasoline Is stored can cause a fire or explosion. REQUISITE SERVICE • • Fuel tank removal/ installation (page 2-4) Air cleaner case removal/installation (paQe 6-3) PROCEDURE ( 1) (2) (3) (4) (5) (6) (7) (8) REMOVAL ORDER Insulator band Choke cable Throttle cable ~uel tube No. 10 vacuum tube (from the AVCV) ' No.4 Lui.Je (from the AVCV and PCV) Carburetors Insulator • Carburetors draining O'ty 4 REMARKS • Installation is in the reverse order of removal. Only loosen the screws. 1 2 1 1 2 1 4 California Model Only California Model Only Each insulator has the identification number as shown. At installation, align the insulator groove with the engine lug, with the fr UP mark facing upwards (carbretor side). FUEL SYSTEM CARBURETOR SEPARATION (19) ··--------------.................................. FUEL SYSTEM REQUISITE SERVICE • • Fuel tank removal (page 2-4) Air cleaner case removal lpage 6 -3) • • Separate No. 3 /No . 4 carb. from No. 1/ No. 2 carb .. (1 ) Bystarter arm shaft (2) Spring (3) Bystarter arm (4) ChOke cable holder (5) Rear bracket (6) Front bracket (7) No. 3 carb. synchronization spring (8) Air joint pipe (3-way)/0-ring (9) Fuel joint pipe (3-way) /0-ring 1 1/2 1/ 2 Separate No. 3 corb. from No. 4 carb.. No. 4 carb. synchronization spring Thrust spring Air joint pipe (rubber) Air vent pipe/0-ring Fuel joint pipe (2-way) /0-ring 1 1 1 1/2 1/2 . 114) (15) (16) (1 7) (18) (19) (20) Separate No. 1 carb. from No. 2 carb .. A VCV and PCV as an assembly No. 1 carb. synchronization spring Thrust spring Air joint pipe (rubber) Air vent pipe/0-• iuy Fuel joint pipe (2-way)/0-ring REMARKS Q'ty PROCEDURE (10) (11) (12) (13) Carburetor removal (page 6 -4) California Model Only: AVCV and PCV tubes removal from carburetors 1 1 3 1 1 , 1 1 1 1 1/2 1/ 2 California Model Only FUEL SYSTEM CARBURETOR DISASSEMBLYIASSEMBLY ,---(1) • DOWEL.o:-~ PIN SIDE 8~ .l -·-----(20) (3) (211 1--(221 I (26) ( 2 5 ) - - -.... I R-R • FUEL SYSTEM NOTE • • The vacuum chamber and floAt ch amber can be serviced with the carburetors assembled. The pilot screws are factory pre-set and should not be removed unless the carburetors are overhauled. Turn each pilot screw in and carefully count the number of turns before it seats lightly. Make a note of this to use as a reference when reinstalling the pilot screws. If new pilot screws are installed, turn pilot screw s out to the initial opening (page 1-6). REQUISITE SERVICE Fuel tank removal/installation (page 2-41 Air c leaner case removal/installation (page 6-31 Carburutor removal/Installation (page 6-4) • • • O' ty PROCEDURE (1 ) • • DISASSEMBLY ORDER Vacuum Chamber Vacuum chamber cover screws . 4 Vacuum chamber cover 1 (~I Sprlno 1 (41 Diaphragm/vacuum piston Jet needle holder 1 1 Spring Spring holder Jet needle Washer 1 1 1 , (10) Float Chamber Float c hamber eover screws 4 (11 I Float pin 1 (12) Float 1 (131 Float valve Valvu !;l:lat Sealing washer Fuel filer Main jet Needle jet Slow jet 1 1 1 1 (61 (7) (8) (0) (14) (15) (16) (17) ( 18) (19) (201 !21 I (221 Bystartar Valve Valve nut Spring Bystarter valve (23) Pilot Screw Pilot screw (24) (25) (20) Spring Washer 0 -ring REMARKS • Assembly is in the reverse o rder of disassembly. (2) (5) Carburetor separation (page 6-61/combination (page 6-101 Carburetor synchronization (page 3-81 At installation, first tighten the two screws on the dowel pin side. T urn the holder 90° counterclockwise while pushing it in and remove it. At installation, align holder claws with piston grooves. At installation, first tighten the two screws on the dowel pin side. NOTE: • For removal of the No. 1 (or No. 3) carburetor f loat pin with the carburetors assembled, first remove the No. 2 (or No. 41 carburetor float chamber. For f loat level inspection, refer to the section 8 of the Common Service Manual. 1 1 1 , 1 1 1 1 Canada model : No. 1 and No . 4 carburetor pilot screws are shorter than th ose for No . 2 and No . 3. 1 1 1 e:.o FUEL SYSTEM CARBURETOR COMBINATION • (14) (10) ( 11) • f ;(7) (19) 6-10 FUEL SYSTEM REQUISITE SERVICE • Carburetor assembly (page 6-8) PROCEDURE Assemble No. 1 carb. with No. 2 carb •. Fuel joint pipe (2-way)/ 0 -ring Air vent pipe (3-way)/0-ring (3) Air joint p1pe (rubber) (4) Thrust spring (5) No. 1 c erb. synchronization ~p r ing (6) Front bracket (71 Front bracket screw (8) Fuel joint pipe (3-wayl/0-ring (9) Air joint pipe (3-way)/0 -rina I 1l (2) (10) ( 11) (12) (13) (14) 11 6) 116) (17) (181 (19) (20) (21 ) (22) (23) (24) 126) Assemble No. 3 carb. with No. 4 carb .. . Fuel joint pipe 12-way)/0-ring Air vent pipe 13-way)/0 -ring Air joint pipe (rubber) Thrust spring No. 4 carb. synchronization spring Front bracket screw A<mble No. 1/No. 2 carb . with No.3/ No. 4 carb .. No. 3 corb. 5ynchronization liiJriuy Rear bracket Rear bracket $:r.rew Front bracket screw Choke cable holder Bystarter arm Spring Bystarter arm shaft A VCV and PCV as an assembly AVCV and rev tube Q'ty REMARKS No. ? carburetor is the base carburetor. 1/ 2 1/2 1 1 1 1 4 1/2 1/ 2 The shorter. Do not tighten screws yet. Onto the No. 2 carburetor. Onto the No. 2 carburetor. 1/2 1/ 2 1 1 1 2 The shorter. Do not tighten screws yet. Do not install two screws of the front bracket/choke ·c able holder yet. 1 1 a 6 1 3 1 1 1 - T ighten them. Tighten them. U!<:e two longer front bracket screws. • Callifornia Model Only California Model Only: page 6-1 2 c: 1 "' FUEL SYSTEM CALIFORNIA MODEL ONLY: AVCV AND PCV TUBES ROUTING ' (3) No. 2 CARBURETOR (5) No. 4 CARBURETOR • (4) No.3 (1) No.5 CARBURETOR TUBE t • (11) AVCV ( 14) AVC'.V · (15) No. 6 TUBtS (19) AVCV 6-12 (10) PCV (181 PCV ( 16) No. 5 TUBES (171 No. 10TUBE ~ (8) No.5 TUBES FUEL SYSTEM FUEL PUMP/FILTER Turn the fuel valve OFF. Remove the rear-left side cover (page 2-3). Remo ve lhH fuel pump and fuel filter to the left. Install the fuel filter and pump in the reverse order of removal. NOTE I • Fuel fille• uliHIIlatiun us shown. (4) TO ~ EMISSION CONTROL SYSTEMS (California Model Only) CARBURETOR (2) '/ (3) FUEL PUMP (1) AVCV (2) PCV EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE (PCV) AND AIR VENT CONTROL VALVE(AVCVIRtMOVAL Remove the followina : fuel tank (page 2-41 air cleaner case (page 6-3) - carburetors (page 6-4) A W - - (4) SET PLATE Dlseonneet the tubes trom Pl;v and A VCV, and remove the set plate from the No. 1 carburetor float chamber cover. Remove the PCV end A VCV. Inspect the PCV Anti AVCV (refer to 5ection 7 of the Common Service Manual) . Install the PCV and AVCV in the reverse order of removal. NOTE • For PCV and AVCV tubes routing, see previous paQe. (3) TUBES UEL CUT-OFF RELAY FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM NOTE I • The ASV has reed valves built into t he A ICV. Remove the fuel tank (page 2-4). Disconnect the air injection tube (No. 1 5 tube) from the air ease. ~IMner Disconnect the vacuum tube (No. 10 tube) from the ASV. Install the plug onto the No. 10 vacuum tube and connect the vacuum pump to the ASV. Perform the secondary air supply system (ref er to section 7 of the Common Service Manual). SPECIFIED VACUUM: 3 60 m mHg (14.2 lnHg) AIR SUCTION VALVE (ASV) REMOVAL Remove two bolts and air suction valve as an assembly. Disconnect the following from t he ASV. - No. 10 vacuum tube. - No. 1 5 air injection tube. - air supply hoses. (5) VACUUM PUMP Remove bolts, air injection pipes and gaskets. Remove t l'le reed valve covers Hntl reetl valves. Install tho air ouotion valve in the reverse order of removal. (2) GASKET ~ (91 REED VALVE 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7·1 ENGINE REMOVAL/ INSTALLATION 7 -2 SERVICE INFORMATION t • A floor jack or other adjustable support is required to support and maneuver the engine. CAUTION • Do not jack up the motorcycle using the oil filter. • The following components can be serviced with the engine installed in the frame: - alternator (Section 14) • - camshaft (Section 8) - carburetors (Section 6) - clutch (Secliun Sl - gearshift linkage (Section 9 ) - oil pump (Section 4) - pulse generator (Section 1 5) - starter clutch (Section 16) - starter motor (Section 16) - water pump (Section 5) • The following components require engine removal for service: - connecting rod (Section 10) - crankshaft (Section 1 0) - r.ylint1er (Section 8) - cylinder head (Section 8 ) - piston (Section 8) - transmission (Section 1 0) .., .. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL/INSTALLATION c (27) 40 (4.0, 291 (26) c 65 (6.5, 47) • 1201 0 • 15(1 .5 , 11) (21) • c 40 (4.0, 29) ENGINE REMOVAL/INSTALLATION NOTE • Turn the ignition switch orr and dis~.:Ul! l hl:! l>attery ground (-) eable. CA UTION • Do not jack up t he m otorc ycle using the oil filter. REQUISITE SERVICE • • • • • Exhaust system removal/installation (page 2-3) Fuel tank removal/ installation {page 2-4) Air cleaner case removal/installation (page 6-3) Carburetor remuval/im:tullat lon (page 6-4) Coolant draining (page 5-3) • • • PROCEDURE (1) (2) (3) (4) (5) (6) (7) (8) (9) REMOVAL ORDER 6pork plug cap Pulse generator 2P mini (blue) connector A ltP.rn(ltor 3P (black) connect or Neutral switch/oil pressure switch 2P mini (black) connector Starter motor cable Engine ground cable Water hose JOint/U-nng Clutch cable Gcorshift spindle joint • Installation is in the reverse order of removal . 4 1 1 1 1 1 1 1 1 1 1 ("13) Unve cham guide Dowel pin Water hose Drive sprocket bolt 1 2 (16) (17) (18) (1 9) (20) (21) (22) (n) (24) (25) (26) (27) (28) (29) Washer Drive sprocket l::ngme mount bolt (rear/lower) Adjusting bolt lock nut Adjusting bo lt Special washer Fnainlil mount bolt (Frontl/washer Engine sub frame bolt Engine sub frame Engine brac ket bolt Bolt cap l::ngine mount bolt (rear/upper)/collar Engine assembly On the starter motor 212 Water pump !;inA r:nvAr Speedometer cable Drive sprocket cover (151 REMARKS Q'ty (101 ( 11) (12) (14) Engine oil draining (location: page 3-3 , step: section 2 of the Common Service Manual) Remove the radiator lower mounting bolts and loosen the upper mount ing bolt/nut (page 5-5) . Swing the radiator forward. Coolant refill (section 5 of the Common Service Manual) At Installation, align the punch marks on the joint and spindle. CAUTION: • Make sure the drive sprocket bolt is aligned w ith t he speedometer gear box joint securely as shown. 1 1 1 1 1 1 I 1 2/2 4 1 2 2 111 1 NOTE: • Hold the motorcycle on its side stand and shift the transmission in 6th gear. With the brake pedal applied, remove (or install) the drive sprocket bolt. loosen the drive chain. With its tab facing down. Only remove the left/ lower and right/ lower bolts. Install the collar on the left side. Move the engine out of the frame to the left. CAU TION : • Carefully align mounting points w ith t he jack to prevent d amage to mounting bolt threads, wire harness and cables. 8. CYLINDER HEAD/CYLINDER/PISTON SERVICE INFORMATION 8-1 TROUBLESHOOTING 8 -1 CAMSHAFT REMOVAL/INSTALLATION 8 -2 CYLINDER HEAD REMOVAL/ INSTALLATION 8 -4 CYLINDER HEAD DISASSEMBLYI ASSEMBLY 8-6 CYLINDER/PISTON REMOVAL/ INSTALLATION 8-8 SERVICE INFORMATION • Camshaft service can be done with the engine in the frame. • Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling the cylinder head. Fill the cylinder head oil pockets with the clean engine oil of the proper type and viscosity. • Clean all disassembled parts with cleaning solvent and d ry them by blowing them off with compressed air before inspection. • He tore reassembly, lubricate the camshaft journals and cam lobes with a molybdenum oil solution. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their proper locations. • Be careful not to damage the mating surfaces by using a screwdriver when removing the cylinder. Do not strike the cylinder too hard during disassembly, even with a rubber or plastic mallet, to prevent the possibility of damage to the cylinder fins . • Take care not to damage the cylinder walls and pistons. • Store the valve and piston components in the same order they were installed so they can be reinstalled in the original positions. TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by a compression or leak down test, or by tracing noises in the top-end with a sounding rod or stethoscope. If performance is poor at low speeds, check for white smoke in the crankcase breather tube. If the tube is smokey, check for seized piston rings. NOTE • For cylinder compression and leak-down test procedures, refer to section 3 of the Common Service Manual. Rough idle • Low cylinder compression Low compression • Incorrect valve shim adjustment' (page 3-5) • Burned or bent valves • lncottecl valvtt timi11y • Broken valve spring • Uneven valve &eating • Leaking or damaged head gasket • Warped or cracked cylinder head • Loose spark plug • Worn, stuck or broken piston rings • Worn or damaged cylinder and piston Compnnn>iun too high • Excessive carbon build-up on piston top or combustion <:hamber Excessive smoke • Worn valve stem or valve guide • Damaged stem seal • Worn cylinder, piston or piston rings • Improper installation of piston rings • Scored or scratched piston or cylinder wall Excessive noise • Incorrect valve shim adjustment (page 3-5) • Sticking valve or broken valve spring • Damaged or worn camshaft • Damaged camshaft drive gear Abnormal noise (piston) • Worn cylinder and piston • Worn piston pin or piston pin hole • Worn connecting rod big end bearing 8-1 CYLINDER HEAD/CYLINDER/PISTON CAMSHAFT REMOVAL/INSTALLATION I c 12( 1. 2,9) (6) REQUISITE SERVICE • • Fuel tank removal/installation (page 2-4) Air cleaner case removal/ installation (paQe 6-31 PROCEDURE ( 1) (2) (3) REMOVAL ORDFR Heat guard plate Cylinder head cover bolt (5) Washer Cylinder head cover Gasket (6) Camshaft holder bolt (7) Camshaft holder Dowel pin ExhAust (EX I camshaft Intake (IN) camshaft (4 ) (8) (~) (10) Q _? • Q'ty Remove the radiator lower mounting bolts and loosen the upper mounting bolt/nut (page 5-5). Swing the radiator forwa rd. REMARKS • Installation is in the reverse order of removal. 1 8 8 1 1 16 4- 811- At installation, tighten the bolts in a gradual. crisscross pattern . Install them with the " UP" mark facing up. Install with the "¢::>" mark forward. NOTE: • Apply Three Bond 1 521 or equivalent to the head cover and install the gasket onto the cover with tabs facing forward. NOTE: • Before removing bolts, turn the flywheel clockwise and insert suitable pins into the cam gear holes to ease the installation of camshaft serrated gears. Take care not to d rop pins into the crankcase and that the pins do not interfere with the cylinder head. 1- Camshaft installation (page 8-3 ) CYLINDER HEAD/CYLINDER/PISTON CAMSHAFT INSTALLATION Remove the following: - c rankshaft hole cap cover (page 9-2) . - c rankshaft hole cap (page 9-2). - timing mark hole cap (page 9 -2). Rotate the crankshaft clockwise and align the flywheel " T " mark (Yellow colored line) with lh~ cover Index mark. Lubricate the camshaft journals and cam lobes with a molybdenum oil solution . Lay the EX marked (Exhaust) camshaft onto the cylinder head with EX mark line as shown and lay the IN marked (Intake) camshaft with IN mark line as shown. In this posit ion, the No. 4 piston is at TDC on the compres~iOn stroke. (2) EXHAUST CAMSHAFT \ (4) " IN" MARK LINE (3) " EX" ( I I (6) INDEX MARK Install the dowel pins onto the camshaft holders and install the camshaft holders in their original positions. ( 1 l DOWEL PINS NOTE • •t Each holder has identification marks. EXR: Exhaust camshaftEXL: Exhaust camshaftL~:h H•ght INA: Intake camshaftINL: Intake camshaftLeft n ight Tighten the camshctH huh.hH bolts fn a gradual, cnsscross pattern. TORQUE: 12 N·m (1 .2 kg-m, 9 ft-lb) Turn the crankshaft counterclockwise so as not to interfere the camshaft serrated gear holder pins with the cylinder head. Remove the holder pins from each c amshl:lllli.Jiy - guide plate - ratchet pawl -plunger - spring - drum shifter Collar Dowel pin (161 (171 (181 (191 (201 Stopper arm spring Spring collar Stopper arm Clutch removal/installation (page 9 -4 , 9 -8) REMARKS • Installation Is In the reverse order of removal. REMOVAL ORDER ( 11 Gearshift spindle joint bolt (2) Gearshift spindle joint (3) (41 (51 • 1 1 , At installation, align the punch marks on the joint and spindle. 1 . 1 1 2 - 1 2 2 2 1 1 1 Assembly! as Illustrated Install onto dowel pins properly, or shift to hard. Pawl orientation as shown. 1 1 1 wasner , Shift drum center bolt 1 (211 Shift drum center 1 (221 Dowel pin 1 At installation, torque after applying a locking agent to bolt lhreaus. At installation, align the drum center groove with the dowel pin. CLUTCH/GEARSHIFT LINKAGE CLUTCH INSTALLATION c (22) '~ ~23) 15 (1.5, 11 ) (5) ..................... ____________________ • CLUTCH/GEARSHIFT LINKAGE REQUISITE SERVICE • Gearshift linkage installation (page 9-6) • PROCEDURE (1) (2) (5) (6) (7) Needle bearing Clutch outer 1 1 - (12) (13) (14) (15) (16) (17) Clutch assembly - pressure plate - clutch friction disc A - clutch plate A - clutch friction disc B - clutch plate B - clutch friction disc C - judder spring - spring seat - clutch center (18) { 19) (20) (21) (22) (23) lock washer Clutch center lor.k n••t Clutch spring Clutch lifter plate Clutch lifter plate bearing Clutch lifter plate bolt (4) (8) (9) (10) (, 1) • O'ty Clutch out er guide Oil pump drive sprocket/drive chain Oil pump driven 3procket Washer Oil pump drive sprockAt bolt (3) Right crankcase cover installation (page 9-21 REMARKS 1 1/ 1 1 , At installation, install with the grooves facing inside. 1 . 1 1 4 4 1 1 1 1 1 1 1 Apply a locking agent to the threads. Installation (page 4 -3). Installation (see below) Smaller 1.0. disc/Color: black Color: silver Smaller 1.0. disc Color: gray Larger I.D. disc/Color: black Face the dished side of the judder spring to the outside. With the OUTSIDE mark facing up. Installation (payt~ 9 - 1 0) 4 1 1 4 Install it with the marked side facing out. Install them in a Qradual. crisscross pattern. CLUTCH OUTER INSTALLATION ~ Turn the crankshaft clockwise and face the flywheel " T " mark up so that the primary rlriven gear does not interfere witft Llt~ crank weight. • (1) CLUTCH OUTER Align the serrated tooth of the primary driven y1:11H with the drive gear teeth, as shown, and temporarily install the clutch outer onto the mainshaft. While holding the clutch outer and pushing in on it lightly, rotate the oil pump driven sprocket bolt. Install the clutch outer properly, aligning the clutch outer holes with the oil pump drive sproc ket busses. ( 1 l CLUTCH OUTER HOLE CLUTCH/GEARSHIFT LINKAGE CLUTCH CENTER LOCK NUT INSTALLATION If you have the universal type of the clutch center holder, you will be able to use it. Position the tools as shown and use at least two clutch lifter plate bolts to secure the tool to the clutc h . CLUTCH CENTER HOLDER 07HGB- 001000A (U.S.A. only) Hold the clutch center holder and torque the clutch center lock nut as shown. TORQUE: 85 N·m (8.5 kg-m, 61 ft-lb) Stake the lock nut onto the mainshaft. If you do not have the above holder, use the below holder. Hold the clutch center as shown and torque the clutch center IO~k nut. (s~ l CLUTCH CENTER HOLDER e 07GMB- KT80100 (Not eveileble in U .S.A .) TORQUE: 85 N·m (8.5 kg-m, 61 ft-lbl Stake the lock nut onto the mainshaft. (11 CLUTCH CENTER HOLDER / v 10. CRANKSHAFT/TRANSMISSION SERVICE INFORMATION 10-1 TROUBLESHOOTING 10-1 CRANKCASE SEPARATION 10-2 CRANKSHAFT/CONNECTING REMOVALJINSTALLATION ROD 10-4 CRANKSHAFT BEARING REPLACEMENT TRANSMISSION REMOVAL/ INSTALLATION 10-8 TRANSMISSION DISASSEMBLYI ASSEMBLY 10-10 CRANKCASE INSTALLATION 10-12 10-6 SERVICE INFORMATION • Remove the engine and separate the crankcase to inspect the crankshaft, connecting rod and transmission. • Servic9 9in1~P Service Item Connecting rod . . ... • Cumk.shaft Transmission Removed Components Cylinder head (page 8-41 Cylinder/Piston (page 8-81 Crankcase separation (page 10-21 . Starter clutch (page 16-8) Flywheel (page 14- 71 Crankcase separation (page 10- 21 Connecting rod bearing cap (page 10 -41 .• Crankease separation (page 10-2) Gearshift linkage (page 9-61 • Prior to assembling the crankcase halves, apply a sealant to their mating surface. Wipe off excess sealant thoroughly. • Mark and store tho bearing inserts to be sure of their conectlucations for reassembly. If the inserts are improperly installed they will block the oil holes, causing insufficient lubrication and eventual engine seizure. • If it is no longer clear which bolt bP.InnoR in which hole, insert all bolts in the holes and check the exposed lengths; each should be exposed the same amount. TROUBLESHOOTING • Excessive noise • Worn oonneoting rod beorings • Bent connecting rod • Worn crankshaft main bearing Hard to shift • Improper clutch operation • incorrect engine oil viscosity • incorrect elutel'l adjustment • Bent shift forks • Bent ohift fork 3hoft • Bent shift fork claw • Damaged shift drum cam groovP.!': • Bent shift spindle Transmission jumps out of gear • Worn gear engagement dogs or slots • Sent shift fork shaft • Oamaged shift drum stopper arm • Damaged o r bent shift fork • Broken shift linkage return spring • Damaged shift drum cam grooves CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION CRANKSHAFT/TRANSMISSION REQUISITE SERVICE • • • • Starter motor (page 16-5) • Oil pan (page 4 -3) Engine (page 7 -2 ) Clutch/oil pump drive chain (page 9-4) Left crankcase cover (page 16-8) PROCEDURl: O'ty ( 1) Upper crankcase bolt (6 mm) 6 (2) Lower crankcase bolt (6 mml 13 (3) Lower crankcase bolt (8 mm) Lower crankcase Dowel pin Oil nrifir.A 13 1 3 (4) (5) 16) REMARKS Bolts (2 psc/marked .t:.. on the crankcase) have sealing washers. Bolts (2 psc/marked .t:.. on the crankcase) have sealing washers. Bolts ( 1 2 psc) have sealing washers. 2 CRANKCASE BOLTS LOCATION (1 l BOLTS: 26 psc Loosen all bolts in l:l yr~:nJ ual , c risscross pattern. Bolts location: as shown .A : bolt with a sealing washer Clean any liquid sealant off the crankcase mating surface. •t (2) LOWER CRANKCASE (1 l BOLTS : 6 psc CRANKSHAfT/TRANSMISSION CRANKSHAFT/CONNECTING ROD REMOVAL/INSTALLATION • )c 24 (2.4 . 1 7 ) , • OIL HOLE FACING TO INTAKE SIDE 10 -4 CRANKSHAFT/TRANSMISSION NOTE • Determine the replacem.:u•liJuaring color code according to the main bearing selection table (page 10-6) or the connecting rod bearing selection table (page 10-7). Merk and store the bearing inserts to be sure of their correct locations for reassembly. At installation, apply molybdenum solution to the main journal bearing and connecting rod bearing surface. Refer to page 1-8 for crankshaft and rod specification. Refer to section 14 of the Common Service Manual for bearing inspection. • • • • REQUISITE SERVICE • Refer to Service Information (page 10 -1) PROCEDURE Q'ty REMARKS 8 Do not remove them without necessary . Wipe all oil from the bearing seating areas. (7) REMOVAL ORDER Connecting rod bearing cap nut Bearing cap Connecting rod Connecting rod bolt Conneetlng rod beanng Crankshaft Crankshaft main journal bearing 1 12 Wipe all oil from t he bearing seating areas. (7 ) INSTALLATION ORDER Crankshaft main journal bearing 12 (6) Crankshaft 1 (5) Connecting rod beanng 8 141 Connecting rod bolt Connecting rod 8 (3) ( 2) (1) Bearing cap Connecting rod bearing oop nut 4 (1) (2) (3) (4) (6) 8 4 4 8 4 0 The bearing tabs should be aligned with the grooves in the crankcases. Install it onto the upper crankcase with t he flywheel side facing to the clutch side. NOTE: • The bearing oil hole should be aligned with the oil hole in the connecting rod. NOTE: • Face the oil holes to the intake side. Install them with the code letters read properly. Apply oil lu tl n:1 nut t hreads and torque them in gradual, crisscross pattern. CRANKSHAFT/TRANSMISSION CRANKSHAFT BEARING REPLACEMENT MAIN JOURNAL BEARING SELECTION Record the crankcase I.D. code letters from the pad on the left RirlA nf the crankcase. NOTE • Letters (A, B or C) on the upper crankcase are the codes for the main journal I.D.s f rom the left. (1) CRANKCASE I.D. CODE Record the corresponding main journal O.D. code numbers from the crank weight. NOTE • Numbers ( 1 or 2) on the crank weight are the codes for the main journal O.D.s from the left. (1) MAIN JOURNAL O.D.CODE Cross reference the case and journal codes to determine the r~:IJiaumlent bearing eolor code. A ll c 33.000 33.008 mm (1.2992 1.2995 inl 33.00933.016 mm (1.29961.2998 in) 33.017 33.024 mm 1 29.992 - 30.000 mm (1 . 1808 1.1811 IM Pink Yollow Green 2 29.984 - 29.992 mm (1. 1805-1. 180 8 in) Yellow Green Brown '-......., Crankcase ~.c ode Main jQIIrntl 0 .0. code e -~ Bearing thickness Brown: Thick t Green: Yellow : Thin Pink: 10-6 (1.2999- 1.3002 in) (1) MAIN JOURNAL BEARINGS CRANKSHAFT/TRANSMISSION CONNECTING ROD BEARING SELECTION Record the connecting rod I.D. code numbers on the rod. NOTE • Numbers ( 1 or 2) on the connecting rod are the codes for the connecting rod I.D.s. l (1) CONNECTING ROD I.O .CODE t Record the crankpin O.D. code letters from the crank weight. NOTE • Letters (A or B) on the upper crankcase are the codes J for the crankpin O.D .s from the ________________ left. Cro~ (1) CHANKPIN 0.0. CODE reference the cr Clrtk.pin and rod replacement bearing color code. ~ e n e A 1!1 29.992 - 30.000 mm (1.1808 - 1.1811 in) 29.984 - 29.991 mm (1.1805- 1. 1807 in} Bearing thickness Brown: Thin Blae<~ Blue: t Thick eod~ to determine the 1 32.992- 2 33.001 - 33.000 mm :J:J.008 mm (1.29891.2992 in) (1.29921.2995 in) Yellow Green llreen Brown (1) CONNECTING ROD BEARINGS (2) COLOR CODE CRANKSHAFT/TRANSMISSION TRANSMISSION REMOVAL/INSTALLATION (6 BEND THE ~~ \ (3) cw 10-8 CRANKSHAFT/TRANSMISSION REQUISITE SERVICE • Ref er t o Service Information (page 10 -1 ) O' ty PROCEDURE ( 1) l:ll REMOVAL ORDER Countershaft assembly ( 5) l.:ountershatt bearing set ring Mainshaft bearing set plate bolt Mainshaft bearing set plate Needle bearing (6) w~sher (3) (4) 1 1 1 1 1 Mainshaft M2 gear/ spline washer/M6 gear - (8) Mainshaft assembly Center shift fork bolt 1 1 I (10) ( 11 ) lock washer Shifl furk shaft 1 1 (12) (13) (14) (15) (16) Right shift fork Center shift fork l eft shift fork Shift drum bearing set plate bolt Dowel pin Shift drum bearing set plate Shift drum bearing Shift urum ~j 117) (18) (19) • Installation is in the reverse order of removal. At installation, align the bearing groove with the set ring and align the oil seal with the case groove. 2 17) (9) REMARKS 1 1 1 1 1 At installation, face the M6 gear engagement dogs forward the M4 gear. Remove after bending down the lock washer tab. Install and bend new lock washer tabs as shown. Install a new lock washer. At installation, face the shaft flatted surface side forward the drive sprocket. Install them with the identification marks (R: Right, C : Center, l: left) fac ing forward the cl~th side. Install with the bearing stopper near the outside. 1n_a CRANKSHAFT/TRANSMISSION TRANSMISSION DISASSEMBLY/ASSEMBLY • MAINSHAFT (2) 1~@J. ALIGN OIL HOLES (3) (6) ~- t~cq (14) () (A (1) ~ ~(15) --:7l : SHIFTER GEAR I GROOVE _..,. : GEAR SLIDING . .• SURFACE (4) NOTE • • • Apply molybdenum solution to the shifter gear grooves. Apply oil to all sliding surface of the mainshaft, countershaft and bushings. Install the thrust WA!':hAr!': And snap ring$ with the chamfered edge facing to the thrust load side. Refer to section 13 of the Common Service Manual for inspection information. -~ REQUISITE SERVICE • Transmission removal/installation (page 1 0-8) PROCEDURE (1) (2 ) (3) (4) (5) (6) (7) (8) (9) (10) ( 11) (12) (13) (14) (15) ( 16) MAIN SHAFT OISASSEMBLY ORDER Needle bearing , Thrust washer M2 gear (17T) Spline washer M6 gear (24T) M6 spline bushing SJ,1Iin1:1 wash1:1r Snap ring M3 (1 eT)/M4 (22Tl shifter gear Snap ring Spline washer M5 gear (23Tl M5 bushing Thrust washer Mainshaft bearing Mainshaft IM 1 gear/ 13Tl Q'ty REMARKS • Assembly is in the reverse order of disassembly. 1 1 1 1 1 1 , Align the oil holes of the bushing and mainshaft. 1 1 1 1 1 1 1 1 1 Install it with the bearing stopper near the outside. c CRANKSHAFT/TRANSMISSION (24) ,;; ~ - - ..., ALIGN OIL HOLES (3) J':f~ (1) : SHIFTER GEAR GROOVE : GEAR SLIDING SURFACE rnOCEDURE (1) (2) (3) (4) (5) (6) (7) (8) (9) (1U) • ( 11) (12) (13) (1.4) (15) (16) (17) (18) 11 !:J) (20) (21) (22) (2~) (24) (25) Q'ty COUNTERSHAFT DISASSEMBLY ORDER Bearing Thrust washer C1 gea• (43Tl Needle bearing Thrust washer C5 shifter gear (33Tl Snap ring Spline washer C3 gear (30Tl (.;~ splint~ bushing Lock washer Spline washe1 C4 gear (35Tl C4 spline bushing Spline washer Snap ring C6 shifter gear (32T) Snap ring Spline washer C2 bushing C2 gear (40Tl Thrust washer Oil seal Bearing Countershaft . 1 1 I REMARKS • Assembly is in the reverse order of disassembly. Install with the sealed side facing outside. 1 1 1 1 1 1 1 1 Align the oil holes of the bushing and countershaft. 1 1 1 1 1 Align the oil holes of the bushing and countershaft. . 1 1 1 1 I 1 1 1 1 Install with the bearing stopper near the outside. CRANKSHAFT/TRANSMISSION CRANKCASE INSTALLATION (5) c:?1 24 (2 .4 , 171 (41 - --;---___.a c 12 (1 .2. (4 ) c 12 11 .2, 9 1 • 10-1? ...................... ·-~ CRANKSHAFT/TRANSMISSION REQUISITE SERVICE • • Transmission installation (page 10-8) Crankshaft/connecting rod installation (page 10-4 1 PROCEDURE (1) (2) (3) (41 (5) (6) (7) Oil orif1ce Dowel pin Lower crankcase Lower crankcase bolt (6 Lower crankcl\!1;6 holt {8 Lower crankcase bolt (8 Upper crankcase bolt (6 Q'ty REMARKS 2 3 1mml mml mm x 651 mml 1312 - Crankcase installation (see below) 1- 6- CRANKCASE INSTALLATION Apply a light but thorough coating of sealant to the upper crankcase mating surface except to the main bearing journal I)Oit Mating areas and the o1l passage area as shown. (1) SEALANT AREAS Set the mainshaft and countershaft into neutral position first, then shde the (;6 shitter gear onto the C2 gear (2nd gear position) as shown, to ease upper crankcase installation. ( 11 C6 SHIFTER GEAR CRANKSHAFT/TRANSMISSION Set the shift drum in the 2nd gear position as shown. NOTE • The shifter-pin of the left shift fork (marked "L") should be located as shown. Align the left shift fork (marked "L") with the C6 shifter gear, and the right shift fork (marked "R") with the C5 shifter gear first, then lowering the lower crankcase, align the center shift fork (marked "C"I with the M3/M4 shifter gear. Assemble the crankcases. Make sure each crankcase is assembled securely. Install tho Gronkcase bolt~ and sealing washers as shown. (1 I BOLTS: 26 psc NOTE • Four 6 mm bolts (marked !::. on the crankcase) have sealing waGhors . • Twelve 8 mm bolts (for the crankshaft main journals) have sealing washAr~. • Four 8 mm bolts (marked !::. on the crankcase, ®. @ . ® and @ I is black in color. (2) LOWER CRANKCASE 3) SEALING WASHERS Tighten all crankcase bolts in 11 or~dual, crisscross pattern. beginning with larger diameter bolts first as shown. TORQUE: 8 mm crankcase bolt: 24 N·m (2.4 kg-m. 17 ft-lb) 8 mm x !S!S crant........- cr··./r-- • '====--== SHORTER T/\BS: Bend down LONG.ER TABS: • aend up 11 - 1 7 (10) FRONT WHEEL/SUSPENSION/STEERING NOTE • • • 811arinys should always be replaced as a set- inner and outer raees. Remove the fork, after loosening the steering stem nut. Check the steering head bearing preload (page 1-11) after torquing the stem nut. REQUISITE SERVICE • Front wheel removal/installation (page 11 -4) PROCEDURE Q'ty (5) REMOVAL ORDER Steering stem nut Washer Ignition !;Witr.h r.onnector Top bridge Headlight/Stay assembly (6) lock nut 1 (7) 1 1 1 1 1 1 1 1- (17) lock washer Steering head bearing adjustment nut Dust seal StP.P.rino !;tP.m Upper inner race Upper bearing lower bearing lower inner ra ce Dust seal Upper outer race lower outer race (17) (16) (15) (14) (13) (12) ( 11) INSTALLATION ORDER lower outer race Upper outer race Dust seal Lower inner race lower bearing Uppl:n bearing Upper inner race (1) (2) (3) (4) (0) (9) (10) ( 11) (12) (13) (14) (1 b) (16) e t • (10) . 111- 1- , Steering stem Dust seal (8) Steering head bearing adjustment nut (7) Lock washer (6) lock nut (~) Headlight Stay assembly (4) Top bridge (3) Ignition switoh oonneotor (2) Washer ( 1) Steering stem nut (9) 1 1 2 1 1 111111- Fork removal/installation (page 11-6) REMARKS After removing, remove the fork. Disconnect inside the headlight case (page 1-19). Support with a piece of wire so that they do not hang from the cables or wire h arnesses. NOTE: • Remove, after straightening the lock washer tabs. Replace if they were removed. ·Use race remover attachment (07953-MJ1000Al with driver (07949 - 371 0001) ·and attachment, 37 x 40 mm (07746 - 0010200) for upper outer race removal. • Use race remover (07946 - 3710500) with driver (07949-3710001 I and attachment, 37 x 40 mm (07746-001 0200) for lower outer race removal. Replace as a set, if necessary. • Use attachment, 52 x 55 mm (07746-0010400) and driver (07749-001 0000) for lower outer race installation. • Use attachment, 42 x 47 mm (07746-0010300) and driver (07749 - 001 00001 for upper outer race install ation. • U:>c :>tccring stem driver (07946-MBOOOOOI for lower inner race installation. 1 1 Installation: refer to section 18 of the Common Service Manual (Retainer-Type Ball Bearings). ~j 1 1 2 Connect them (page 1·19). 1 1 TAmpnr;uily install fork and torque the nut. 11 1 ~ 12. REAR WHEEL/SUSPENSION SERVICE INFORMATION 12-1 TROUBLESHOOTING 12-1 REAR WHEEL REMOVAL/ INSTALLATION t 12-2 REAR WHEEL DISASSEMBLYI ASSEMBLY 12-3 SHOCK ABSORBER REMOVAL/ INSTALLATION 12-4 SHOCK ABSORBER DISASSEMBLYI ASSEMBLY 12-5 SWINGARM REMOVAL/ INSTALLATION 12-7 SWINGARM DISASSEMBLYI ASSEMBLY 12-8 SERVICE INFORMATION • The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. • Before disposal of the shock absorber, release the nitrogen (Step: section 19 of the Common Service Manual; Drilling point: page 1-1 1) • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. • Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to eleal'l brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers. • Riding on damaged rims impair5 5afe operation uf the vehicle. .-.:1 L---------------------' .a • Refer to the Motion 13 for brake system information. • Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service Manual. TROUBLESHOOTING • t Rear wheel wobbling • Bent rim • Worn rear wheel bearings • FaultY tire • Unbalanced tire and wheel • low tiro prcaaurc • Faulty swingarm pivot bearing(s) Wheel tums hard • Faulty wheel bearing(s) • Brake drag (page 1 3-1 l • Bent rear axle Soft suspension - W cok spring • Incorrect suspension adjustment • Oil leakage from (!(lmper unit • l ow tire pressure Hard suspension • Damaged shock absorber upper or lower bearings • Incorrect suspension adjustment • Bent damper rod • Damaged swingarm pivot bearing pressure • High tin~ Rear suspension noisy • Loose fasteners REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL/INSTALLATION (3) (4 ) t ( • • c ( 1) • • 90 .(9.0, 65) A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers. NOTE • • • • • Put the motorcycle on its center stand. Do not depress the brake pedal when the caliper is removed, or it w ill hP. difficult to refit the disc between the brake pads. Support the removed caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake hose . Adjust the drive chain free play adjustment after installing the wheel. PROCEDURE Q'ty REMOVAL ORDER (1 ) RARr RXI~?. (2) Drive chain adjusting nut Drive chain (3) (4 ) (b) (6) (7) nllt Rear axle Hear wheel assembly Left side collar Right side collar REMARKS • Installation is in the reverse order of removal. 1 2 1 1 1 Loosen the lock nuts and loosen the adjusting nut fully. M ove the rear wheel forward. and disengage the drive chain f rom the driven sprocket. REAR WHEEL/SUSPENSION REAR WHEEL DISASSEMBLY/ASSEMBLY @J et (11) (2) ~-M, e;;,. c t I • {91 161 65 (6.5, 47) A contaminated brake disc or pad redu~A Atnpping power. Di1card contaminated pods and clean a contaminated disc with a high quality brake degreasing agent. NOTE • • • ror driven SIJ ru uk.~:t r1:1rnoval. loosen the sprocket nuts wrth the driven flange installed into the wheel hub. Replace wheel bearings as a set. For wheel bearing replacement, refer to the section 1 of the Common Service Manual. REQUISITE SERVICE • Rear wheel removal/installation (page 12-2) PROCEDURE ( 1) (2) (3) (4) DISASSEMBLY ORDER Right side collar Left side collar Right dust s1:1al Left dust seal . (5) Driven flange assemiJiy (6) (7) (8) (9) (10) ( 11) - driven driven driven driven dr ive11 flange collar flanQe bearing !6204 U) sprocket nut sprocket fla11g11 (13) (14) (15) (16) (17) 0 -ring near wheel damper Brake disc bolt Brake disc Left wheel bearing (6303 UU) Distance collar Right wh1:11:1l IJ!laring (6303 UU) (18) Rear wheel/tire (12) Q'ty ASSEMBLY REMARKS • Assembly is in the reverse order of disassembly . 1 1 ~ =r 1 1 1 5 1 1 Apply grease to the dust seal lips and install them with the lip side facing inside. Install with the sealed side facing out. 1 4 4 1 1 , 1 NOTE: • Drive in the right side bearing first, then the left side bearing. 1/1 .......... --------------------------------------------------------------REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION ( c 45 (4.5, 33) t NOTE • • Put the motorcycle on it center stand_ Before removing the shock absorber for disassembly, adjust the shock absorber to position I (for lightest loads) before removing the shock absorber from the frame. REQUISITE SERVICE • Fuel tank removal/installation (page 2-4) PROCEDURE ( 1) (2) (3) REMOVAL ORDER Shock absorber mountinQ bolt (upper) Shock absorber mounting bolt (lower) Shock absorber assembly, Q'ty ~T 1 REMARKS • Installation is in the reverse order of removal. f-At installation, install them from the left side. NOTE: • Remove it upwards from the frame. • Install with the drain tube forward. REAR WHEEL/SUSPENSION SHOCK ABSORBER DISASSEMBLY/ASSEMBLY • • The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Before disposal of the shock absorber, release the nitrogen (Step: section 19 of the Common Service M anual; Drilling point: page 1-11) NOTE • • Adjust the shock absorber to position I (for lightest loads) before removing the shock absorber from the frame. For lower jnint needle bearing replacement, see next pege. REQUISITE SERVICE • • Shock absorber r emnv o:~l /i nstalio PROCEDURE (1) (2) (~) (4} (5) (6) (7) (8) DISASSEMBLY ORDER Lower joint Seat stopper Spring seat Spring Adjustee Lower joint lock nut Damper r~obe Damper (page 12-'1} . Q'ty 1 REMARKS • Assembly is in t he reverse order of disassembly. NOTE: • Removal/Installation (page 1 2-6} • At installation , align the lower joint with the seat stopper pin. 1 1 1 1 Install with the taper end facing to the adjuster. 1 1 1 ... -- REAR WHEEL/SUSPENSION LOWER JOINT REMOVAL/INSTALLATION (1 l ATTACHMENT Install the shock absorber compressor and attachment on the rear shock absorber as shown. t SHOCK ABSORBER COMPRESSOR 070ME-0010000 (Not available in U.S.A.) or 07959-3290001 07GME-0010100 - screw assembly 07959-MB10000 ATTACHMENT Turn the compressor handle and slowly compress the spring. t (2) COMPRESSOR Hold the lower joint and loosen the lock 'nut (turn the nut clockwise). Remove the lower joint and clean off any locking agent from the threads. (1) LOCK NUT (2) LOWER Installation: Apply a locking agent to the damper threads. Install the lower joint securely onto the damper rod. Hole the lower joint and torque the lock nut. TORQUE: 68 N•m (6.8 kg-m, 4~ JOINT ft-lb) Make sure the Lower joint Is aligned with the seat stopper pin and remove the compressor . LOWER JOINTS NEEDLE BEARING REPLACEMENT Remove the dust seals. Hold the joint with a s~1itable tool, Press the needle bearing out of the joint. ...-(2) NEEDLE "' {s ~OL) DRIVER PIN ur PILOT, 22 mm DRIVER 07GMD- KT80100 (Not available In U.S.A.) 07746-0041000 07749-0010000 Pack a new bearing with grease. Preii the bearing into ttw joint until the bearino surface flushes with the joint surface as shown. cs:TOOL I DRIVER ATTACHMENT, 24 x 26 mm PILOT, 17 mm BEARING 07749-0010000 07746-0010700 07746-0040400 (1 l DRIVER (2) NEEDLE BEARING tW I(3) ATTACHMENT (4) PILOT REAR WHEEL/SUSPENSION SWINGARM REMOVAL/INSTALLATION 0 1 10(11.0.80) (2) (4) c 45 (4.5, 33) NOTE • • Put the motorcycle on its center stand. Do not depress the brake pedal when the caliper is removed, or it will be difficult to refit the disc between the brake pads. Support the removed caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake hose. If necessary, loosen the rear engine mounting nut near the swingarm pivot to ease the swingarm removal/installation . • • REQUISITE SERVICE • e t nesr wheel removsl/instsllstion (psge 12·2) PROCEOURE ( 1) (2) (3) (4) (5) (6) REMOVAL ORDER , Rear brake caliper Brake hose clamp Shook abGorber lower mounting bolt Swingarm pivot nut Swingarm pivot shaft Swingarm assembly Q'ty REMARKS • Installation is in the reverse order of removal. 1 1 1 1 1 1 REAR WHEELJSUSPENSION SWINGARM DISASSEMBLY/ASSEMBLY • NOTE • For pivot bearing replacement, see next page. ( REQUISITE SERVICE • PROCEDURE (1) • • Rear wheel removal/installation (page 1 2-2) (2) (3) (4) (5) (6) {7) {8) (91 (10) { 11) DISASSEMBLY ORDER Drive chain adjuster . Right pivot collar Left pivot collar Drive chain cover Drive eMin slider Right dust seal Loft duot oeal Distance collar Snap rin~ Ball bearing Needle bearing Q'ty 2 , Swingarm removal/installation (page 1 2-7) ASSEMBLY REMARKS • Assembly is in the reverse order of disassembly. Install them with the UP mark facing up and the index mark facing out. 1 1 1 1 1 1 1 1 2 1 Apply grease to the lip. Install it into the groove securely. Replacement {page 1 2-9) REAR WHEEL/SUSPENSION SWINGARM PIVOT BEARING REPLACEMENT Press the right pivot bearings (ball bearings) out of the swingarm . (s Tc;ot.. l 07946-MJ00100 (Not available in U.S.A.) DRIVER SHAFT or DRIVER 07949-3710001 Set the needle bearing remover onto the left •pivot bearing (needle bearing) as shown. Press the bearing out of the swingarm. (s ;;;oL J NEEDLE BEARING REMOVER ATTACHMENT 07GMD-KT70200-,_(Not available 07946-MJ00100__r-in U.S.A.) DRIVER SHAFT or BUSHING REMOVER M967X - 038- XXXXX DRIV!R 07949 - 3710001 PraGc the needle bearing into the swingarm with the marked side facing out. NOTE • The bearing lil.lrface surface as shown. liho ~old [ s Tc;oLJ DRIVER ATTACHMENT, 28 x 30 mm PILOT, 22 mm fl1.11ih with the pivot inliide (1) DRIVER (2) ATTACHMENT \\ I 07749-0010000 07946-1870100 077 46-0041 000 Press one ball bearing (inner bearing) into the swingarm first, then press in another on top of it (outer bearing). (s~L I UHIVEH ATTACHMENT, 32 x 35 mm PILOT. 15 mm 07749 - 0010000 07746-0010100 07746-0040300 (4) BALL BEARINGS,, 13. BRAKES SERVICE INFORMATION 13-1 TROUBLESHOOTING 13-1 FRONT BRAKE PAD REPLACEMENT 13-2 REAR BRAKE PAD REPLACEMENT 13-3 FRONT BRAKE CALIPER REMOVAL/ INSTAllATION 13-4 REAR BRAKE CALIPER REMOVAL/ INSTAllATION 13-5 FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY 13-6 REAR BRAKE CALIPER DISASSEMBLYI ASSEMBLY 13-7 FRONT MASTER CYLINDER REMOVAL/INSTALLATION 13-8 REAR MASTER CYLINDER REMOVAL/INSTALLATION 13-9 FRONT MASTER CYLINDER DISASSEMBLY/ASSEMBLY 13-10 REAR MASTER CYLINDER DISASSEMBLY/ASSEMBLY 13-11 BRAKE PEDAL REMOVAL/ INSTALLATION 13-12 e SERVICE INFORMATION • A contAminAttt e (4) BATTERY I (3) REGULATOR/ RECTIFIER - .... ( 1 l ALTERN A TOR 14-? CHARGING SYSTEM/AlTERNATOR TROUBLESHOOTING Battery overch arging • Faulty regulator/rectifier Battery undercharging Measure the battery current leakage (Leak test) (oa~:e 14-41 regulator/rectifier unit inspection INCORRECT INCORRECT L: CORRECT Inspect the charging voltage (page 14-4) • CORRECT Shorted Jire harness Faulty ignition switch Faulty regulator/rectifier Check the battery using a Honda Battery Tester CORRECT I INCORRECT • Electric NOT CHARGING Check the voltages of the regulator/rectifier battery charging line and ground line (page 14-5) CORRECT ABNORMAL _........ • 1 • s~tem overloading Faulty battery Open circuit in wire harness Poorly connected connectors NORMAL CM~k tfle alternator (charg1ng coil) resistance at the regulator/rectifier connector (page 14- 5) ABNORMAL ABNORMAL L: NORMAL t Poorly connected alternator connector NORMAL Faulty alternator Check tl'le regulator/rectifier umt Inspection (page 14-61 ABNORMAL - • Faulty regulator/rectifier NORMAL e t ' - - - - - - - - - - - - - - - -- - - - - · Faulty battery CHARGING SYSTEM/ALTERNATOR CHARGING SYSTEM INSPECTION LEAK TEST Turn off the ignition switch, and disconnect the ground (-) cable from the battery. Connect the ammeter (+) probe to the ground cable and the ammeter (-) probe to the battery (-) terminal. With the ignition switch off, measure the leakage current. NOT[ • • When measuring current using a tester, set it to a high range, and then brmg the range down to an appropriate level. Current flow larger than the range selected may blow out the fuse in the tester. While measuring current, do not turn the ignition on. A !U •rlriAn !luroA nf r.urrAnt may hlow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 0.01 mA max. If current leakage exceeds the specified value, a shorted circ uit is likely. Locate the short by disconnecting connections one by one and measuring the current. CHARGING VOLTAGE INSPECTION NOTE • Before performing this test, be sure that the battery is fully charged whose voltage between its terminals is greater than 12.8 V. St art the engine and warm it up to operating temperature, then turn the ignition switch OFF. Connect a multitester between the battery terminals. DIGITAL MULTITESTER 07411-0020000 or KS - AHM - ~2 !U.S.A. only) - 03 .&............................................ CHARGING SYSTEM/AlTERNATOR Disconnect the starter relay switch connector and remove the main fuse (~0 A). Reconnect the connector onto the relay switch. (1) MAIN FUSE Connect the ammeter as shown. CAUTION • Be careful nut tu short any tester probes. • Although the current could be measured when the ammeter is connected between the battery positive terminal and the positive cable, a sudden surge of current to the starter motor could damage the ammeter. • Always turn the ignition off when conducting the test. Disconnecting the ammeter or wires when current is #lowing may damage the ammeter. Start the engine and increase the engine speed gradually. • REGULATED VOLTAGE: 14.0-16.0 V/5,000 rpm CHARGING CURRENT: 0-8 A/5,000 rpm REGULATOR/RECTIFIER WIRE HARNESS INSPECTION • Remove the rear fairing (page 2-2). Disconnect the regulator/rectifier connector and measure the following between connector terminals of the wire harness side . Item Terminals Specification Battery charging line Red/White (+) and ground(-) ~ Uround line Ureen and ground Continuity exist. Charging coil line Yellow and Yellow 0.1-0.5 n (20°C/68°F) Battery voltage should resister. (4) AMMETER CHARGING SYSTEM/ALTERNATOR UNIT INSPECTION Remove the regulator/rectifier. Inspect the regulator/rectifier unit by measuring the resistance between the terminals. NOTE • There are two types of the regulator/rectifier as shown. Select the proper resistance chart. • Resistance value will not be accurate if the probes touch your finger. • Us~ thY following recommended multltester. Using another manufacturer's equipment may not allow you to obtain the specified voluc3. This is due to the characteristic of semiconductors,, which have different resistance value depending on the applied voltage. Unit: kO ~ abnormal. Install the regulator/rectifier in the reverse order of removal. NOTE • Install the ground wire onto thA rAgul;:~to lower mounting bolt properly as shown. / rectif Unit: kO ~" 1 Jl 1:! .yeen power input line (Black/White) and ground (Green) at the spark unit connector with the ignition switch ON and the engine stop switch at RUN (page 15-6). ~N O I VOLTAGE_. Faulty ignition switch or engine stop switch • Open circuit in wire harness o Loose or poor contact of related circuit connectors BATTERY VOLT AGE MEASURED Measure the pulse generator resistance at the unit connector (page 1 5 -61. ABNORML ~ LI_ c _ h _ e _ c _ k _ t rhe ~ p _ u _ ls _ e ~ g ~ e _ n _ e _ ra _ t_o,r~(p _ a ~ g ~ e _ 1 _ 5 _ - _ 8 _ l. I I NORMAL NORMAL • • Check the neutral switch for continuity at the spark unit connector (page 1 5-6). ABNORMAL ! j ABNORMAL - - L I_c_h_c_c_k_trh_e_n_e_u_t _ ra_l_s_w_i_ t c_h....,.. - - - - -- - - - - - ' I I NORMAL • • Ch~:cl. Lh1:1 sil.le slaml swilt.:h Ill l111:1 spark unit connector (page 15-6). ABNORML~ L ~C_heckt ABNORMAL ! t. Faulty neutral switch Open circuit between the unit and neutral switch Loose or poor contact of the neutral switch connectors I ~ e ~si d ~es NORMAL t ~an ~ d ~ s~w.,itrc_h(page I ' Faulty spark unil 1 • __ 1_5_ - 8_l_. ____~ ABNORMAL f GOOD o Faulty pulse generator Open circuit between the unit and pulse generator Loose or poor contact of the pulse generator connector NORMAL ,• ______~ Faulty side stand switch Open circuit between the unit and side st8nd switch Loose or poor contact of the side stand switch connectors IGNITION SYSTEM No spark at either Ignition group o If there is no spark at either group, the problem is suspected in the primary coil side of the ignition system (ignition coil, or unit and ignition coil circuit) . " No Spark" Switch the Ignition coil primary terminal condition connection between the faulty pair and good -remains with pair. Try spark test ayain. faulty pair Remove the faulty pair ignition coil and check the ignition coil resistance (page 15-7) . I ABNORMAL ! " No Spark" condition shifts to other pair Measure res1stance of the ignition primary coil at spark unit connector (page 15-6). o OUT OF STANDARD_. VALUE o GOOD Faulty ignition coil Faulty spark plug wire Poor or loose contact of ignition coil 4P mini ~.:onectr Open circuit between the unit and ignition coil t Faulty spark unit o No spark at one plug (Trouble In secondary coil sldel o Faulty spark plug is most likely. Replace (suspected bad spark plug) with known I----SPARK--good spark plug and conduct spark test. r Original spark plug no good. NO SPARK Put the spark plug wire on and measure resistance of ignition secondary coil (page 15-7). NORMAL OUT OF STANDARD VALUE Remove the spark plug wire, and measure the resistance of the ignition secondary coil (page 15-7). GOOD o o 15-4 ~or contact of spark plug wire Faulty spark plug wire Conduct spark test on good ignition coil. SPARK OUT OF STANDARD_. VALUE ! Faulty ignition coil IGNITION SYSTEM Engine starts, but side stand switch does not function at all. NOTE The side stand switch should function as follows: • When the transmission is shifted into a gear from neutral with the side stand down, the ignition shuts off and the engine will stop. • When in neutral, the neutral switch line (a) of the spark unit is connected to ground via the side stand switch . When tho 3ide stond is up, the side stand switch line (b) of the spark unit passes to ground via the side stand switch. The spark unit monitors lines (a) and (b). and provides spark only when one or both of those lines is connected to ground ' via the neutral switch or the $Ide stand switch. Check the side stand indicator for function. NORMAL - · Open circuit in Green/White wire NORMAL - · • • Loose or poor contact of related connectors Open circuit in Green/White wire Burnt indicator bulb ABNORMAL Check the side stand switch (page 15-8). ABNORMAL • Fatlty side stand switch IGNITION SYSTEM IGNITION SYSTEM INSPECTION CIRCUIT INSPECTION NOTE • Follow the steps in the troubleshooting flow chart for servicing. Remove the seat. Disconnect the connector from the spark unit and conduct these tests at the connector. Terminals Item Specification Power source input line Black/White (+) and ground (- ) Battery voltage should resister with the ignition switch ON and the engine stop switch at RUN . PulsP. g enerator coil Yellow and White/Yellow 340 - 420 0 (20°C/ 68°F) Ignition primary coil No. 1- 4: Black/White and Yellow/Blue No . 2 - 3: Black/White and Blu~:/Yeow 2 - 4 0 (20°C/68°F) Neutral switch line Light Green/Red and g round Continuity into neutral No continuity in any gear except neutral Side stand switch line Green/ White and ground Continuity with the side stand up No continuity with the side stand down Ground line Green and ground Continuity IGNITION COIL INSPECTION U•sconnect the ignition coil 4P mini connector under the fuel tank and measure the primary coil resistance between the terminalt> beluw. • No. 1 - 4 primary coil: Black/White end Yellow/ Blue • No. 2 - 3 primary coil: Black/ White and Blue/Yellow STANDARD: 2 - 4 0 (20 ° C/68°F) 15-6 I 1 ) IGNITION COIL CONNECTOR IGNITION SYSTEM Disconnect the spark plug caps from the spark plugs and with the spark plug mco3ure the secondary coil 1esitam:~ wire at each ignition pair: No. 1 - 4 secondary coil: between ENG 1 and ENG 4 wire No. 2 - 3 secondary coil: between ENG 2 and ENG 3 wire STANDARD: 23 - 27 kO (20° C/68° F) Remove t he ignition coil, d isconnect the spark plug wires and measure the primary and secondary coil resistances as shown. ( 1) SECONDARY COIL STANDARDS: Primary coil: 2- 4 0 (20 ° C/68°F) Secondary coil: 13- 17 kO (20° C/68° F) (2) PRIMA RY COIL REMOVAL/ INSTALLATION (2) IGNITION COIL Disconnect the ignition coil 4P mini connector under the fuel tank. Remuve lln:l !Jolts and collars. ASSEMBLY ( (3) Y/Bu D i&~:onect the ignition primary terminals from the coils and remove the ignition coil as an assembly. Remove holts and No. 2-3 ignition coil first, then remove bOltS aM NO. 1-4 ignition COli. lnotoll the ignition coils in the reverse order of remov~ l. (1) No. 2-3 IGNITION COIL NOTE • Connect the spark plug wire properly as shown (right). • Connect the ignition coil primary terminals properly as shown above. J f osan:- IGNITION SYSTEM PULSE GENERATOR INSPECTION NOTE • It is not necessary to remove the pulse generator from the engine. Disconnect the pulse generator 2P mini blue connector under the fuel tank and measure the resistance between White/ Yellow and Yellow terminals. STANDARD: 340 - 4 20 0 (20° C/68°FI REMOVAL/INSTALLATION • R~rnove Remove the left crankcase cover (page 16-8). the bolts and pulse generator. Install the pulse generator and wire clamp, and tighten the bolts securely. Set the wire harness Qrommet into the cover groove. Install the left crankcase cover (page 16-8). SIDE STAND SWITCH INSPECTION Disconnect the side stand 3P mini green r.onnector ~mder the fuel tank and check for continuity between each terminals as below. There should be continuity between the positions on the continuity chart. o--o Green/White Side stand down Side stand up 0 Yellow/Black Green 0 {) --.- (1 l SIDE STAND SWITCH {) (3) DOWN IGNITION SYSTEM REMOVAU INSTAl lATION Disconnect the side stand connector. Remove the water pump side cover. With the side stand up, remove the side stand switch mounting bolt and side stand switch. Install the switch in the reverse order of removal. TORQUE: Side at•nd sw itch mounting bolt: 3 0 N •m (3.0 kQ-m. 22 h-lb) 3) SIDE STAND SWITCH NOTE • e Align the switch pin with the side stand hole end align the switch groove with the side stand return spring holding pin. Route the side stand switch wire harness properly as shown. (1) SIDE STAND SWITCH WIRE HARNESS IGNITION TIMING Warm up the engine. Stop the engine and connect a timing light to the No. 3 cylinder 3pork plug wire. NOTE • , Read the instructions for timing light for operating. Remove the following: - crankshaft hole eal) Mver (page 9-2). - crankshaft hole cap (page 9 -2). - timing mark hole cop (page 9-2). Start the engine and let it idle. The timing is correct if the F mark aligns With the crankcase cover index mark. (1) F MARK NOTE • ~ If the correct timing could not be ulJserved, connect a t iming light to the No. 2 cylinder spark plug wire and rer.heck the ignition timing. lnorooGo the engine speed by rotating the thrullle stop screw on the carburetor, make sure the F mark begins to move counterclockwise at Apprnxim8tely 1, 700 rpm. --- (3) ADVANCE START " 121 INDEX MARK ~ ~ ""' 16. ELECTRIC STARTER/STARTER CLUTCH ' SERVICE INFORMATION 16-1 SYSTEM LOCATION 16-2 CIRCUIT DIAGRAM 16-2 TROUBLESHOOTING 16-3 STARTER MOTOR REMOVAL/ INSTALLATION 16 -5 STARTER MOTOR DISASSEMBLYI ASSEMBLY 16-6 STARTER CLUTCH REMOVAL/ INSTALLATION 16-8 SERVICE INFORMATION t • Alw ays t urn the ig nition sw itch OFF befo re servicing the starter motor. The mot or could suddenly start, causing serious lnj\lry. • A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. • If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. • For the following component inspections, refer to the following pages; for the parts locations, see page 16-2 of this manual (SYSTEM LOCATION). Clutch switch diode Section 24 of the Common Service Manual. Starter motor Section 24 of the Common Service Manual. Starter relay switch SAction 24 of the Common Service Manual ("A" circuit type). Clutch switch Section 25 of the Common Service ManuaL Neutral swlten St!ction 25 of the Common Service ManuaL Ignition switch Check for continuity on the continuity chart of the WIRING DIAGRAM , page 18-1 . Disconnect the switch connector inside the headlight case (page 1- 19) and check it. Side stand switch - (page 15-81 m ... ~ ... ELECT RIC STARTER/STARTER CLUTCH SYSTEM LOCATION (4) STARTER RELAY SWITCH/ N FUSE 30 A (5) FUSE 10 A ' NEUTRAL SWITCH (8) SIDE STAND SWITCH (9) CIRCUIT DIAGRAM • ( 11 ) IGNITION SWITCH fr R/BI (5) FUSE 10 A 121 NEUTRAL INDICATOR ( 1) SIDE STAND SWITCH INDICATOR R ( 10) STARTER MOTOR (5) USE 10 A Bl BI/Br ~TRA:¥ ~o- Y/R - - - - (3) STARTER SWITCH c~ L 112) CLUTCH f SWITCH DIODE down Y/BI (8) SIDE STAND SWITCH ~ 16 -2 up G - • ELECTRIC ST ARTER/STARTER CLUTCH TROUBLESHOOTING Starter motor w ill not tum • Check for a blown out main or sub fuses before servicing. • Make sure the battery is fully charged and In good condition. ChAr.k for lnose or poorly connected battery terminals, and opened or shorted battery cable. ABNORMAL-· Poorly connected battery terminals • Open or short circuit in battery cable NORMAL Check fOr loose or poorly connected starter relay switch terminals and 4P connector. ABNORMAL_. Poorly connected terminals or 4P connector NORMAL Check for loose or poorly connected start,er motor cable, and opened cable. ABNORMAL-· Poorly connected motor cable • Open circuit in motor cable NORMAL ., A ' With the ignition switch "ON", push the starter switch and check tor a "click" sound from the r----- CLIKS ~ s ~ ta ~ rt~e_lay ~ s ~ w ~ it ~ c _h _ . _ _ _ _ _ _ _ _ __ _ _ J - Connect the starter motor terminal to the battery positive terminal directly. (Because a large amount of current flows, do not use thin wires) _,~o I Starter motor turns NO CLICK • • Disconnect starter relay switch connector, and chec._ the r~:lay cuil yruund wire lines as below for continuity: 1. Green/Red terminal-clutch Gwitoh diodeneutral switch line (with transmission into t- NO CONTINUITY._. neutral and c lutch lever released.) • 2. Green/Red terminal-clutch switch-side stand • switch line (in any gear except neutral, and • with the clutch lever pulled in and the side • stand up.) • I ! I Starter motor does not turn t• Faulty starter motor loose or disconnected starter motor cable Faulty starter relay switch Faulty neutral switch Faulty clutch switch diode Faulty clutch switch Faulty side stand switch loose or poor contact of connector Open circuit in wire harness CONTINUITY Connect the starter relay switch connector. With the ignition switch ON and the starter switch pushed, measure the starter relay voltage at the starter switch connector (between Yellow/Red (+) and ground (-)). VOLT AGE APPEARED Check the starter relay switch opArRtinn. NO VOLT AGE-· • • • • NORMAL.--· .__---- -- - - - - - --ABNORMAL-· Faulty ignition switch Faulty starter switch Blown out main or sub fuses loose or poor contact of connector Open circuit in wire harness loose or poor contact of the starter relay switch connector Faulty starter relay switch ELECTRIC STARTER/STARTER CLUTCH The starter motor turn~ when the transmission is in neutral, but does not turn with the transmission in any position except neutral, with the side stand up and the clutch lever pulled in. Check the side stand indicator is properly operated with the ignition switch ON. NORMAL Check the c lutch switch operation. ABNORMAL - · • • Faulty side atand switch Burnt bulb Open circuit in wire harness ABNORMAL - Faulty clutch switch • NORMAL Check the side stand switch (page 15-8). ABNORMAL- • Faulty side stand switch NORMAL L - - - - - - - - - -- - -- -- - - - - • • Starter motor turns slowly • low specific gravity in battery (or Dead battery) • Poorly connected battery terminal cable • Poorly connected starter motor cable • Faulty storter motor • Poorly connected battery ground cable Starter motor turns, but engine does not turn • Starter motor is running backwards - Case assembled improperly - Terminals connected improperly • fiaulty starter eluteh • Damaged or faulty starter pinion • Damaged reduction gears Starter relay switch "clir.k", but engine doea not turn ovor • Crankshaft does not turn due to engine problems • Excessive reduction gear friction 16-4 Open circuit in wire harness loose or poor contact of connector '· \ ELECTRIC STARTER/STARTER CLUTCH STARTER MOTOR REMOVAL/INSTALLATION ' • Turn the ignition switch OFF. REQUISITE SERVICE • , e Fuel tank removal/installation (page 2-4) PROCEDURE ( 11 (2) (3) (4) (5) REMOVAL ORDER Starter motor cable ' Starter motor mounting bolt Ground cable on engine Starter motor 0-ring O'ty REMARKS • Installation is in the reverse order of removal. 1 2 1 1 1 1 ELECTRIC STARTER/STARTER CLUTCH STARTER MOTOR DISASSEMBLY/ASSEMBLY (11) (19) ., (5) (6) ELECTRIC STARTER/STARTER CLUTCH REQUISITE SERVICE • Starter motor removal/installation (page 16-5) Q'ty PROCEDURE ( 1) ' ' (?) s~t (3) 0-ring Front cover/0-ring 0 -ring Motor case (4) (5) (6) (9) (10) ( 11) (12) (16) (17) (18) ( 19) • A~;rnbly Lock washer Insulated washer Washer Armature Shims Brush terminal holding nut Waslt~r Insulated washer - bigger - smaller -smaller 0 -ring Brush holder assembly Brush and terminal Rear cover i~; in the reverse order of disassembly. 2 pl<~t (7) O•ring (8) (13) (14) (15) ' DISASSEMBLY ORDER Set screw ASSEMBLY REMARKS 2 2 1/1 1 1 . Align the index marks on the cover and case. NOTE: • lntall with the groove side facing to the brushes. • Align the index marks on the rear cover and case. 1 1 1 1 1 - Record and store the shims in the seme order they were installed so they can be reinstalled in the original positions. 1 1 3 ( 1) ( 1) (1) 1 1 1 1 Align the holder tab w ith the rear cover groove. ELECTRIC STARTER/STARTER CLUTCH STARTER CLUTCH REMOVAL/INSTALLATION • • • Is ~o ALIGN THE WIDE GROOVE AMONG THE CRANKSHAFT SPLINES AS SHOWN ... l (page 16-9) c 85 (8.5, 61) • ELECTRIC STARTER/STARTER CLUTCH REQUISITE SERVICE ' ' ' • Right crankcase cover removal/installation (page 9-2) Q'ty PROCEDURE ( 1) (2) (3) ( -1) (5) (61 (7) REMOVAL ORDER Left crankcase cover bolt Left crankcase cover Gasket Dowel pin Starter clutch bolt Washer Pulse rotor (10) (1 1) Starter clutch assembly - starter driven gear - needle bearing - starter clutch (12) 113) (14) Spline washer Starter drive gear shaft Starter drive gear (8) (9) 7 1 1 1 1 1 1 . REMARKS • Installation is in the reverse order of removal. Install the pulse generator wire clamp properly as shown. Removal and installation (page 16-9). Install it with the marked side facing out. 1 1 1 At installation, make sure the starter clutch roller is installed properly into the clutch housing. 1 1 1 STARTER CLUTCH BOLT REMOVAL/ INSTALLATION CAUTION I• Do not hold the pulse rotor. Set the rotor holder onto the flywheel. ROTOR HOLDER 07725-0040000 or equivalent commercially available in U.S.A . ( 2) HOLDER Hold the rotor holder and remove the starter clutch bolt with a helper. t Set the rotor holder and hold it onto the engine bracket as shown. Tlgl'lt&l'l tM starter clutch bolt to the specified torque. TORQUE: 85 N •m (8.5 kg-m. 61 ft-lb) 17. LIGHTS/METERS/SWITCHES SERVICE INFORMATION 17-1 METER REMOVAL/INSTALLATION 17-5 SYSTEM LOCATION 17-2 METER DISASSEMBLY/ASSEMBLY 17-6 HEADLIGHT REMOVAL/ INSTALLATION TACHOMETER INSPECTION 17-7 17-3 TURN SIGNAL LIGHT 17-4 IGNITION SWITCH REMOVAL/ INSTALLATION 17-7 TAILLIGHT 17-4 SERVICE INFORMATION • • ) Halogen headlight bulb becomes very hot while the headlight is ON. and remain hot for a while after It is turned OFF. Be sure t o let it cool down before servicing. • Use a flam e and heated w at er/ coolant mixture for the thermo sensor Inspection. Keep all flammable materials away from the burner . Wear prot ective clothing, gloves and eye protection . • Note the followings when replacing the halogen headlight bulb. - Wear clean gloves while replacing the bulb. Do not put fi nger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break. - If you touel'\ tM bulb wltl'\ your bare M Ms, clean It with a cloth moistened with alcohol to prevent its early failure. - Be sure to install the dust cover after replacing the bulb. • Chock tho bottory condition before performing any inspection that requires proper battery voltage. • A continuity test can be made with the switches installed on the motorcycle. For the following component locations. see page 17-2 of this manual (SYSTEM LOCATION); fo r inspect ions. refer to the applicable pages. Component Inspection method 2~ Remarks Clutch switch Section Coolant temperature gauge/ Thermo sensor Section 25 of the Common Service M anual Temperature gauge removal (page 17-6) . Thermo sensor removal (page 5-4). Fan motor switch Section 25 of the Common Service Manual Removal (page 5-6). Front brakelight switch Section 25 of the Common Service Manual Fuel pump/ Fuel cut-off relay Section 25 of the Common Service Manual Horn Section 25 of the Common Service Manual Handlebar switc hes Check for continuity on the continuity c hart of the WIRING DIAGRAM, page 18-1. Switch connectors are located inside the headlight case (page 1-19). Neutral switc h Section 25 of the Common Service Manual TORQUE: 18 N·m (1.8 kg-m, 13 ft-lbl Apply sealant to the threads. Oil pressure switc h/ warning light Section 25 of the Common Service Manual Oil pressure check: Section 4 of the Common Service Manual Oil pressure switch torque: 12 N·m (1.2 kg-m , 9 ft-lb) Rear brakelight sw it ch Section 25 of the Common Service Manual Tu rn Section 25 of the Common Service Manual Ignition switch s i ~ mal liQhts of t he Common Service Manual Removal (page 6-13). 3 terminals relay. LIGHTS/METERS/SWITCHES SYSTEM LOCATION (2) COOLANT TEMPERATURE GAUGE (3) FRONT BRAKELIGHT SWITCH (5) FUSE BOX • (11 I NEU RAL SWITCH (101 FUE;L PUMP (7) REAR • BRAKFLIGHT SWITCH (8) TURN SIGNAL RELAY f LIGHTS/METERS/SWITCHES , , HEADLIGHT REMOVAL/INSTALLATION • Halogen headlight bulb becomes very hot while the headlight Is ON. and remain hot for a while after It is turned OFF. Be sure to let It cool down before servicing. CAUTION • • • WAt'r c l~ ft n olv ~$ wvhil~ r•placing th• bulb. Do not put finger prints on the headlight bulb, as they may create hot spots o n the bulb and cause it t o break. If you t o uch the bulb with your bare hands. clean it with a cloth moistened with alcohol to prevent its early failure. Be sure t o install the d ust cover after replacing the bulb. Q'ty PROCEDURE ( 1) (2) (3) (4 ) (5) (6) (7) REMOVAL ORDER Screw Hoadlight bulb Gookot Dust cover Headlight bulb Headlight assembly Connectors Headlight case REM ARKS • Installation is in t he reverse order of removal. . 3 1 1 1 1 1 Install it with the TOP mark fa cing up. Connection (page 1- 19) A lign the index marks on the case and bracket. LIGHTS/METERS/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT ReMove the screw and lens from the wrn signal ease. Turn the bulb socket counterclockwise and remove it. Turn the bulb oounterolookwiGe and remove it. Install a new bulb in the reverse order of removal. TAILLIGHT (1) BULB BULB REPLACEMENT Remove the screws and lens from the taillight case. Turn the bulb counterclockwise and remove it. Install a new bulb in the reverse order of removal. s • LIGHTS/METERS/SWITCHES METER REMOVAL/INSTALLATION 6P-RED CONNECTOR ' • ' ~ :;r- 1) REQUISITE SERVICE • Headlight assembly removal (page 1 7-3) PROCEDURE e ) ( 1) (2) (3) (4 ) REMOVAL ORDER Meter mounting bolt Speedometer cable Meter connector Meter ossembley O'ty REMARKS • Installation is in the reverse order of removal. , 2 1 2 6P mini White connector and 6P mini Red connector 1 Ill.., - LIGHTS/ METERS/SWITCHES METER DISASSEMBLY/ASSEMBLY Remove the five screws and the meter rear cover. Pull all indicator bulbs out of the meter housing. Remove the wire harness clamps, and remove the nuts, washers and meter stay. Disconnect the meter terminals, and remove the wire harness. Remove the screw and meter front cover. Remove the following: - two strews and tachometer. - trip meter reset knob. four 3crcw3, 3peedometer gear joint and 0 -ring. - speedometer. Assemble the meter in the reverse order of disassembly. NOTE • Connect the proper color wire to the meter terminals. Y/G: Yellow/Green B/BR: Black/Brown G/L: Green/Blue G: Green G/B: Green/Black ( 1) FRONT COVER (2) 0 -RING 3) GEAR JOINT LIGHTS/METERS/SWITCHES TACHOMETER INSPECTION ' Remove the headlight assembly (page 17-3), and disconnect the 6P mini Red connector and 6P mini White connector. l.nnnAr.t A vnltmAtAr the Blaclc;/ Rrown (+) And GrP.P.n Ar.n~:$ (-) terminals of the main wire harness side. Turn the ignition switch ON and battery voltage should resister. It there is not O .K., the electric tachometer do not catch power from the battery . Trace and repair the related wiring, sub fuse and/or connectors. Disconnect the spark unit connector (page 15-6). Check for continuity between the Yellow/Green wire terminals of the 6P mini White connector and spark unit connector. Continuity exists at all times. If there is no continuity, replace the main wire harness. If all checks are O.K., replace the tachometer. ( 1) SPARK UNIT CONNECTOR ) IGNITION SWITCH REMOVAL/ INSTALLATION fii:HTIUVI:l thl:l rnl:ltl:lr a!> an a!>st:~mbly (pagl:l 17-5). Disconnect the 3P Black connector and 2P mini connector inside the headlight case, Remove the bolts using the torx bit (T40) (07703 001 01 00) and iQnition switch. Remove the screws and separate the contact base from the cylinder. NOH • You can separate the switch in all key position. --- Apply a locking agent to the threads and install the ignition switch in the reverse order of removal. TORQUE: Switch mounting bolt: 25 N·m (2. 5 kg·'"!"'· 18 ft-lbl 1\/ (3) CONNECTORS (2) BOLT (s ;oo._l (page 1-17) cw 18. WIRING DIAGRAM Cl Cl ,._ CQ i ·-~ ll I~ ~ It. ·~: f ; • & 5uy~· t ~ J ~ ir.:l_ j lft. ~! I ' I I I -,[}I~ I · "N! '- I w ~ ~ «;tr-• 1 i I 8 :t= ! ..I _{;:;r- £ It ~ I .. ( ~ - ~ _'I ~ •:t;l ..: - - - --, ~ ~ I 6 I ~fY I I ~ I I I I I ~ 'f - tl ll .., ;.~ ~ E:-j-.- =r L 1~ n I 1 i ijU i It "----/ ~ h dl stiJ ~ 1 ;, .~ J f I ~ ~ 5\: l~ ·-~ . "~ ; ~l - ! ~ 4'1 ~ .... ~ ... . ,_ -~ .o·~ I i~ ....-~ ~ J, ! e·~ ¥¥! ~ 'Iii- ' •I ! 0 ::;:;r, CI(A (1 r ~k rr) i i ~. ~ 'J- - ~. I I l .,. _ -~ =-·"' . . - ~ u-· - I!! "' I " I• 1· 1 --'::-I ~" I xi. r -~ ....._ ~· ~ (o) ~! - J ·- I ...... o ~ 0 ',-G?..£I ~ Cl Cl I 1lfY .... ~o. .-~.: ~ 0? • _J"l.., I I I I .,~ ~ ~ I •~ u: ~ '--- !~ i I • ; ! Cl 0 I a ' N ~ Jfll ~ :ar:: . .... :~ ~ I "' H •f l [~ ; I t ¥'i ~ ,, ~ . $ I ~I _, I ... ... cI I i I I· ~f- l!llrir- L.!~ tn . 1f-;~ " ~ ...2.L.L.!. ' 'D ~I H~ • 1v l!l f . v i ~ :i v Q .\...) I ~ s: ~ § v "I 18-1 19. TROUBLESHOOTING EN G I N~ DOES NOT START OR IS HARD TO ST ART 19- 1 POOR PERFORMANCE AT HIGH SPEED 19-4 ENGINE LACKS POWER 19-2 POOR HANDLING 19-4 POOR PERFORMANCE AT LOW AND IDLE SPEEDS 19-3 ENGINE DOES NOT START OR IS HARD TO START POSSIBLE CAUSE 1 . Check fuel flow to carburetor REACHING CARBURETOR 2. Perform spark test NOT REACHING CARBURETOR - - -..• • • • • • WEAK OR NO SPARK - - - - - - - • Faulty following (page 1 5-3): - ignition coil - pulse generator - neutral switch - spark unit - side stand switch - engine stop switch WET PLUG - - - - - - - - - - - • • • Mixture too rich Carburetor flooded Carburetor choke excessively closed Cylinder f looded Air cleaner dirty Faulty Purge Control Valve (California model only) GOOD SPARK 1 3. Remove and inspect spark plug SPARKS e l l • • • 4 . TUpm~iun pressure POSSIBLE CAUSE 1 . If steering is heavy - - - - - - - - - - - - - - - - - - - - - - • • Steering head bearing adjustment • • 2 . If either wheel is wobbling ---------------------- • • • • • nut too tight Damaged steering head bearings Bent steering stem Excessive wheel bearing play Bent rim Improperly installed wheel hub Swingarm pivot bearing excessively worn Bent frame 3 . If tM motorcycle pulls to one s1de - - - - - - - - - - - - - - - -..... • Incorrect drive chain adjustment • Front and rear wheels not aligned • Bent fork legs • Bent swingarm • Bent frame 19-4 T • • • e • • • 20.1NDEX Air Cleaner .................................................... . 3-5 6-3 Case Removal/Installation ....................... . Alternator ...................................................... . 14-7 Brake Pedal Removal/Installation ....................... . 13-12 Brakes ........................................................... . 13-1 Cable and Harness Routing ............................. .. 1-19 8-2 CamsMft R61'1'16v&I/1Mt&llation ......................... . Carburetor Combination ................................... . 6-10 Disassembly/assembly ............................ . 68 Removal/Installation ............................... . 6-4 6-6 Separation ........................................... .. 3-8 Synchronization .................................... .. Charging System/ Alternator ............................ .. 14-1 Circuit Diagram ..................................... . 14-2 Inspection ................................... ~ ......... . 14-4 Location ............................................... . 14-2 9-8 Clutch Installation ........................................... . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Clutch/Gearshift Linkage . .. . .. .. .. . .... .. .. .. .. .. . .. . .. .. .. 9-1 Conl