SERVICE MANUAL , H. ‘ ”mm-vaw-WW INTRODUCHON Thlj service manual describes the servroo procedures Ior the CMOOF. This Model Specilic Manual innludes every “mice pro 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 Manuel slluulu be used together with the Common Service Manual in order to provide complete service information on all aspects of this motorcycle Follow the Maintenance Schedule (Section 3! recent mendahonu to ensure that the vehicle is in peak operat- ing condition and the emission levels are within the standards set by the Us. Environmental Protection Agency and the California Air Resources Board. Performing the first scheduled ma' trauma is very im portant. It compensates for the initial wear that occurs during the breakrin parind Section 'I and 3 apply to the whole motorcycle, section 2 illustrates procedures Ior rsmovnl/instsllation of com. ponents that may be required to perform service deA scribed in the following sections. Whilc section 4 through 18 describe parts DI the motor- cycle, group-III according to locations. Find the section you went on this page, then turn to the table of contents on the first plgu of the section. M03! SECTIONS describe the service procedure through a ayatcm illustration neior to um nut papa rur details on how to use this manual. If you don‘t know the source of the trouble. go to sen tion 19, TROUBLESHOOTING. CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEMn MAINTENANCE l LUBRICATION COOLING SYSTEM CYLINDER HEAD/CYLINDERIPISTON CLUTCH/GEARSHIFT LINKAGE CRANKSHAFTITRANSMISSION CHASflS H ENmNEANDDMVETRMN FRONT WHEEL]SUSPENSION/STEERING :m REAR WHEEL/SUSPENSION BRAKES j CHARGING SYSTEM/ALTERNATOR IGNITION SYSTEM I E. ELECTRIC STARTER/STARTER CLUTCH ALL INFORMATION, ILLUSTRATIONS, DIREC- TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO” LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI~ GATION WHATEVER. NO PART OF THIS PUBLI» ‘ CATION MAY BE REPRODUCED WITHOUT i WRITTEN PERMISSION. THIS MANUAL I6 WRIT- TEN FOR PERSONS WHO HAVE ACOUIRED ‘ BASIC KNOWLEDGE 0F MAINTENANCE 0N l HONDA MOTORCYCLES OR MOTOR SCOOT- ‘ ens. _j .1 q 2 I p— U ui .i w LlGHTS/METERSISWITCHES ‘ WIRING DIAGRAM TROUBLESHOOTING INDEX . Date of Issue: January, 1989 HOW TO USE THIS MANUAL FINDING INFORMATION YOU NEED - This manual is divided Into sections which cover each or the molar 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 taps before this page. The lirst page of each section Iiats the table or contents within the section Read the servlce Information and troubleshooting related to the section before you begin working. i An index of the entire book is provided in the last chapter to directly locate the Inlormatlon you need. NOTE ON THE EXPLANATION METHOD OF THIS MANUAL The removal and Installation of parts are for the most part illustrated by large and clear Illustrations that should provide the reader with visual aid In understanding the major point for servicing. . Yhe system IIluatratlona are augmented by oallouls when number: or Iellere indicate the order in which the parts ohould be removed or installed. The sequence of steps rapraaantad numerically are differentiated from the ones represented alphabetically to notify the reader that they muet 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 raduire engine removal, the callouta are grouped in numerical and alphabetical orders, The illustrations may Contain symbol marks to indicate necessary "Nice procedur nd precautions that need to be taken. Refer to the next page for the meaning of each symbol mark. Also in the illustration la a chart that lists information such as the order in which the part is removed/installed. the name of the part, and porno extra notes that may be needed. Stan by step Instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces- sary or illustrations alone would not suffice. Service procedures required before or after the procedure described on that particular page, or inspection/adjustment pro- cedure: required lollowing the installation of parts. are described under the title Reouiaite Service, Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual. _ _ Detailed description Symbol mark Systlem illustration 9' m, procedure nw—I mm animal Im II: WAN-AM [ . Step sequence (numerals or alphabets) ' Number 0' Extra notes or precaution Port "am. parts related to the seryice procedure 3) )) 0] OJ Symbols The symbols uaed throughout this manual show specific service procedures. If supplementary Information is required pertain- ing to these symbols, it would be explained specifically in the text without the use of the symbols. Replace the pains) with new unele) ba'ora assembly. HQ Lise special teal Use optional [00L The-w tools ere obtained es you order parts, fl Torque specification. 10 N-m l1.0 kg—m, 7.2 ft-lbl o I0 \l E Use recommended engine oil. unless otherwcae apecmed. Ute molybdenum oil aolutlnn (mixture at the cnulne oil and molybdenum grease with the ratio 1 : 1). Use multipurpose are-Ia (Lithium baaad mum-purpose grease NLGI 02 or equivalent) Uae molybdenum dlsulhde grease [containing more than 3% molybdenum disulflda, NLGI #2 or equivalent) Example: Molyltote" tin-2 plus manufactured by Dow Cunning, U.S.A. Multi»purpose M-Z menu'actured by Mitlubilhi Oil Japan Un molybdenum uisullluu pasta (contalnlng more than 40% molybdenum disulfide, NLGI #2 or equivalent) Fxsmplv: Molyltotodo G»n Paste manutaeturcd by Dow Corning, U.S.A. Honda Moly 45 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, U.K. Rocol Pena manufactured by Sumico Lubricant. Japan Use silicone grease Apply a locking agent. Use the agent ol the mlddle Hrength, unleu otherwiu Ipecifiod. Apply sealant Use brake lluid, DOT 3 or DOT 4. Use the recommended brake lluirl. unless otherwise specified. a-‘Hlx i Mel-l Use Fork or Suspension Fluid. 1. GENERAL INFORMATION GENERAL SAFETY 1-1 MODEL IDENTIFICATION 1 -3 SPECIFICATIONS 1-4 TORQUE VALUES 1-14 TOOLS 1 - 1 6 LUBRICATION AND SEAL POINTS 1 -1 B CABLE AND HARNESS ROUTING 1 -19 EMISSION CONTROL SYSTEMS 1 ~25 EMISSION CONTROL INFORMATION LABELS IU.S.A. Only) 1A28 GENERAL SAFETY Carbon Monoxide II (he engine must be running m do some work, make sure the area is well ventilaledl Never run the engine in en en- uluaeu urea. - The exhaust eonlelm poleoneue urban monoxlde sea lhe‘ Mn ceuu Ian at uunwluueneu Ind may lead to deem. Flun xhe englne In an open area or with an exhaust evecua» Ivan Bvltim In an enclosed evee. Geeullne Work in a well ventilaled 8'88. Keep cigarettes] flames or sparks away (mm the work even or where gasoline Is SIDl‘ed. - Guollne Ie exuemely flammable and is elpk‘lslve under cedun condhlmu. KEEP OUT OF REACH OF CHILDREN. Hm Component: Enema and exhuuu lynem pans become vuy but and vemlln ho! fer Iome tlme eher (he engi e II run. Wur lmullted glove: or well until the engl e end exhlust lyetem have cooled below. hendllnn men guru Used Enulm/Tnn-mlnlen Oil Used engine all [0' tr-mmlnlon all In lwo-nrokul may uuu Ikln cancer If reputedly left In com-c! wkh the ekln Io! prolonged pevlode. Although (MI II unlikely unleu you hendle uud oil on e dolly huh, I! is still edvIubIe (o ‘horoughlv wuh you! hand! wllh mp end wen: u soon I: noulble e or handllng used oil, KEEP OUT OF REACH OF CHI DREN. I'll“ Du" Never use an an hose or dry brush lo clean breke essemb» lies, Use an OSHA-approved vacuum cleaner or altemete method approved by OSHA. designed m minimize the hazard caused by airborne ”bones fibers. ‘ Inn-led ubum “In" have been mind to cnun "salutary dlueu and cancer. Brake Fluld CAUTION - Spllllng fluid on pelme plants 0! rubber pans will damage them. Place clean Ihop towel over the:- pane whenever the system a. "mum. KEEP OUT OF REACH OF CHILDREN. GENERAL INFORMATION Cool-m Under some conditions, the ethylene glycol In engine cool- ent in combustible and Its flame is not visible. If the ethyl ene glycol does ignite, you will not see any flame, but you can be burned. - Avoid spilling engine coolInt on the utmost IyItem or engine pun: they «my be hot enough to come the ancient to Ignite Ind burn without I visible flerrie. ~ CoolInt (ethylene glycol) con cause some skin Irrlte- tlon Ind II pollonouo It Iwellowed. KEEP OUT OF REACH OF CHILDREN. - Do not remove the dhtor cap when the engine '3 hot. The modem is under pressure end could mid you. . - Keep hand: Ind clothing Iwa lrorn the cooling fen. II It ItIrtI IutomItlcelly. II it contents your skin, wash the affected areas immedi- ately with sol-in and water. If it cont-ct: your eyes, flush them thoroughly with fresh water and get immediate medi» cal attention. II it I: swallowed. the victim must be towed to vomit then rinse mouth and throll with iresh water belore obtaining medical attention. Because oi these den- gere, always More coolant in l sale place, Iwey lrom the reach ol children. Nitrogen Pressure For shock absorbers with a gasAfillad reservoir: UIe only nitrogen to preuurlxI the shocli Ibsorber. the ii» of In unetIolI on our cause a fire or explo- sion limiting In eerious injury. The Ihock Mr cont-ins nitrogen under high pressure. Allowing fire or met nenr the Ihoclt ab- sorber could lead to In explosion that could result In IerlouI injury. Failure to releue the pronure train I rhoclt absorber before disposing of it me leId to a possible explo- elon Ind Ierioua iniury M It ll heated or pierced. To prevent the possibility of an explosion, release the ni~ trogen by pressing the valve core. Then remove the valve stem lrorn the shock absorber reservoir. Diapose oi the oil in a manner acceptable to the Environmental Protection Agency (EPA), Belore diepos-I ol‘ the shock absorber, lull-ruse the nitrogen by pressing the valve core. Then remove the valve stem lrom the shock absorber. Bettery Hydrogen Gee Ir Electrolyte The battery ulvee o" exploelve glue; keep sputter flame: and clgerettel Iwey. Provide Adequate venti- letlon when charging. The battery contIlnl lullurlc Icld (electrolyte). Con- toet with oitin or eyes mey cqu uvere huml. Wear protective clotting and I he lhlold. ll electrolyte gets on your akin. 1|th with water. — It electrolyte get: In your eyu, flush with wIter for It leeet 1 5 mlhutII Ind cell l phynicien. Electrolyte II poleonous. 7 ll Iwellowed. drlnlt large quentltleI 0' water or milk and follow with milk or megneIlI or vegetI— ble oll Ind cell I phyllclen. KEEP OUT OF REACH OF CHILDREN. 1-9 MODEL IDENTIFICATION GENERAL INFORMATION The films sarial number is stamped on the right slda of (he naming held, (3) VEHICLE IDENTIFICATION NUMBER The angina nevlal number is stamped on the right side I)! the clunkcue. The Vshlcle Identification Number (VIN) is locatcd on the safaty canilica‘iun label on the light side of the frame tube. I4) CARBURETOH IDENTIFICATION NUMBER Wflfififil/ V N ,, / a3) I (5) COLOR CODE LABEL The carbuvatm identllicalion number is an the rear side of cash carburatur. The cqur code label is attached an the left Irame tube under the sen. When ordering a calm coded part, always specily ns dasignaxed cola! node. I GENERAL INFORMATION SPECIFICATIONS Displacement Cnmpnuuinn ratio Velve train Intake velve opens at 1 mm lift Intake valve close at 1 mm lilt Exhaust valve open: at 1 mm Iih Exhaust velve close at 1 mm Illt Lubrication system Oil pump tvpd Cooling system Air filtration Crankshaft type Engine weight ldrv) Firing order Cylinder arrangement Front Gmrll ITEM SPECIFICATIONS DIMENTIONS Overall length 2,035 mm (80.1 In) Overall width 705 mm (27.3 in) Overall height 1,025 mm (40.4 in) Wheel base l,370 mm (53.5 in) Seat height 775 mm l30.5 In) Foo! peg height 335 mm (13.2 in) Ground clearance 130 mm (5.1 inl Dry weight 170 kg (375 lbs) Curb weight 133 kg (403 lbs) Mexrmum weight capacity 157 kg (347 Ibll FRAME Frame type Diamond Front suspension Telescopic lurk Front wheel travel 130 mm (5.1 in) Rear suspension Swinqarm Rear wheel (revel ”0 mm (4.3 in) Rear damper Gus-filled damper Front tire size 110/70— 1 7 54H Rear tire :Ilrc 140/70— 1 7 65H Tire brand (Bridgentonel Front/Rear G547/6548 Tire brand (Dunlap) FrantlFlMIr KSOSF/KSOS Tire brand (Yokohama) Front/Rear ._. Tire brand (lRCl Front/Rear Front brake Hydraulic disc brake Hear breke Hydraulic disc brake Custer angle 25”30' Trail length 99 mm (3.9 in) Fuel tank capacity 115 lit (3.04 US uni, 2.53 Imp null Fuel tank reserve capacity 3.5 lit (0.92 US gel, 077 Imp yell ENGINE Bore and ctruke 55.0 x 42.0 mm (2.17 x 1.65 In) 399 cm1 (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, l0° ETDC (California) Forced pressure and wet sump Trocliold~type Liquid cooling system with cooling fan Paper tiltcr Unit-type, 6 main journals 57 kg (126 lbs) 1 —27473 VBlIlCII 30w in line four 1—4 ~ General (Cont‘dl GENERAL INFORMATION Starting system Charging system Regulator/rectifier type Lighting system AC regulator type ITEM SPECIFICATIONS CARBURETOR Carburetor type V606 Throttle bore 32.6 mm (1.28 in) DRIVE TRAIN Clutch system Wet, muIti-plate Clutch operation aystem Mechanical type Transmission 6-speed constant-mean Primary reduction 7.l8| (96/44) Secondary reduction *- Third reduction — Final reduction 2.733 “1/15! Gear ratio 1st .1307 (43/13) Gui ratio 2nd 2.352 (co/i7) Gear ratio 3rd 1.875 (30/16) Gear ratio 4th L590 (35/22) Gear ratio 51h 1.434 (33/23) Gear ratio 6th 1.33? (32/24) Gear ratio reverse v Gearshift pattern Left loot operated return system 1 4N—2—3—4-5—6 ELECTRICAL Ignition system Full transistor ignition Starter motor Triple pheee output alternator SCR shorted/triple phlse (UH-wave rectification Battery GENERAL INFORMATION ®®j @E Unit: mm (in) — Lubrication llom Slandlrd Sorvlcl lirrlll Ennlne oll capaclxv at draining 2.9 l (3.06 US ql, 2.55 Imp q!) — at dlaassembly 3,5 I (3.70 US at, 308 Imp qr) — at oil filter change 3.1 l (3.28 US qt. 2.73 Imp u!) —- Racommendnd nnuine oil OlL VISCOSITIES HONDA 4-stroke all or equivalent — API service classification SE or SE The viacaeities shown in the chart may be used when the average temperature in your riding are. is within the indicated range. a n no to en roc w «a -ro n n to w w n: Oil pressure It oil pressure switch 490 kPa (5 kg/cm’, 7| psi) 7 Oil pump rotor Xip clanrlnce (D 0.10 (0.004) 0.15 (0.006) body clonrlnce ® 0.15—0.22 (0006—0009) 0.35 (0014) and clearance Q) 0.027007 (0001—0003) 0.10 (0.004) — Fuel IV em Carburetor Idemilicelion number (Celilurnie) Main jet (High altitudi) l2, 3) (1, 4) (From) (Rear) Slow ,ar Jer naldla crip posirion r'ilm screw iniliul opanlng (Calirornial Punt screw adjunrmam final opening Pilor screw high nlrimde ediusrmenr Air screw initial opening - (Calilornll) Air screw high altiiuda adjusimem Hall level Carburetor vacuum difference Base carburetor (For carburetor synchronizarloni Idle speed (California) Throttle grip free play Acceleraxor pump clearance Se pndary air supply system ' njection conirol valve vacuum pressure 2-l/4 turns out 2-1/2 [urns our I turn out 1/2 turn in from initial opening 3.0 (0.31) Within 30 mmHg (1.2 ian) No. 2 carburetor 1,300 x 100 rpm 1,400 g 100 rpm 276 (0.08—0.24) Reed valves are built into the ASV 360 mmHg (14.2 ian) illlHlHlllHllllll'lilll 1-6 ___‘_— GENERAL INFORMATION Unit: mm (in) — cwmm-d Iii-m Standard Sendai Hm“ Cylinder compraaainn 1280—1320 kPa (12.87131 kglcmz, — 182—188 run/400 rpm Cylinder compression difference Within 30 mmHg (1.2 ian) of each other —- Valve clearance lN 0.12—0.18 (ODDS—0.007) —- (cold) EX 017—023 (0007—0909) —- Cvllnder head warpage — 0.1 (0.004) Cam lobe height ® IN 33070—33230 (1 .3020— I 13083) 33.02 (1.300) IN (Cllflornia madel) — — EX 33.120731280 (1.3039~1.3102) 33.07 (1.301) EX (Calilmnia model) # H Camshaft runoul ® — 0.05 (0.002) Camshaft oil clearance 0.020—0032 (00008—00024) 0.10 (0.004) (D o Camshaft journal 0,0. 22359—22380 10.9039—015047) 22365109041) Camahah holder LD. —— — Valve Ila") 0.0. IN 3.775—3.790 (01486—01492) 3.7010‘146) EX 3.765—3.770 (0.147B—OJ4B4) 3.6910145) Vulvu guide |.D, W 1800— .81210.1496-—0,1253) 3.89 (0153) Ex 3300—3312(01496—01253) 3.8910153) Stom~tnrguidc clearance IN — 0.04 (0.002) EX — 0.05 (0.002) Valve uuide prnjemlnn above cylinder head (h) IN 13137—1177 [0526405421 — EX 11.52—11.92 10.45.470.469) — Bernie guide installation: 1. Chill the valve guides in the freez- er section 0' a rerrlgarator for about an hour. 2. Heat the cylinder head to 1007 150°C (212—300“F). Valve seat width 0371.1 (003570.043) 1.5 (0.05) Valve apring free length IN 39.4011.561) 38.6 [152) EX 39.40 (1.551) 35 611.52) inner lN — i innar EX — — outer IN — 7 outs! EX ‘ 7 Rocker arm 1.0. IN ; # EX — — Rocker arm aha" OD. IN — 7 EX ‘ — Hacker arm-ta-rocker arm shah clearance — — Valve lifter DD. V — Valve llrrar bore LU. — — Hydraulic lash adjuster assist spring free length —— # Hydraulic lash adjuster compression stroke wnh kerosene — — GENERAL INFORMATION Unit: mm (In) Piston mark direction Piston 0.0, (D) Pislon 0.0, measurement point (H) Piston pin hole LB. [0) With "IN” mark racing tn the intake tide 54.960— 54.990 (2.1 638—11650) 10 (0,.) 14.002~14.008 (05513705515) — Gym/Pinon Item Standard Service Ilmn Cylinder LD. 55000—55010(21654—11657) 55.10 (2.189) ’ Cylinder 001 of round ‘ 0.10 (0.004) Cylinder taper ¥ 0.10 (0.004) Cvllnder warpaqe -— 0.10 (0.004) 54.90 (2.161) 14.05 (0.553) , Cylinder-to-piston clearance — 0.10 (0,004) Piston pin 0.0, 11994—14 000 (0.5509—0.5512) 13.98 (0.550) Piston-to-plflon pin clearance 000270.014 (00001—00006) 0.04 (0.002) Connecting radar-piston pin clearance 0016—0040 (GOODS—0.00161 0.06 (0.002) Top ri g-lo-rlng groove clearance 0.015~0.050 (00006—00020) 0.08 (0.003) Second rinq»to-ring groove clenrnnce 0.01570.050 (noose—0.0020) 0.08 (0.003) Tan ring and gap 0.18—0.23 (DAMN—0.011) 0.5 (0.02) Second ring end gap 0.18—0.33 (0007—0013) 0.5 (0.02) on ring mac rail) and gap 0.2 0.7 (0.01—0.03) 1.1 (0.04) Top ring merk Install wlth the marked side up — Second ring mark Install with the marked side up — -— emu-run ' Connecting rod smell end LD. 14016—14334 (05518—05525) 14.07 (0.554) Ccnnectlna rod big and side clearance 0.05—0.20 (0.002 0.005) 0.30 (0.012) radial clearance —— — Crankshaft runout (1‘) — 0.06 (0.002) Crenkpin oil clearance 0.020—0.052 (00008—00020) 0.06 [0.002) Crankcin bearing selection . See page 10 7 7 Main journal oil clearance 0022—0046 (00009700018) 0.05 (0.002) .1 Main journ-l hearing selection See page 1045 i — chlmlnur — Kickstaner pinion gear LD, Kickstartar soindle 0.0. Kickstarler idle gear I.D. Countersheh on, at kickstarter idle gear Kickstaner idle gear bushing O.D. I.D. (HIM llllll ,/_—__—— Shift fork shah 0.D. 11.969 11.950 (04712—04717) GENERAL INFORMATION ~ Trommhuon mm. mm "m hum Sand-rd Sonic. Ilmit Transmission gear I.D. M5 26.000 25.021 (0.9843~0.9851) 25.05 (0.986) M6 250007251121 (0.9843~0.9851) 25.05 (0988) C2 28000—23021 (l.1(124—1.1032) 23.05 (1.104) C3 18000—20021 (1.1024—1.1032) 28.05 (1.104) C4 28.000v28.021 (1.1024—1JO3Z) 28.05 (1.104) Trunamiuion gear bushing 0.D. M5 24359—24380 (0.9826 *0.9835) 24.92 (0981) M6 24359—24380 (03826—03835) 24.92 (0.981) 02 27359727380 (1.100771.1016) 27.92 (1.099) C3 27359—27380 (l.100771.1018) 27.92 (1099) C4 27.958 27.980 (1 .100771.1018) 27.92 (1.099) Transmiuion gear busing ”3. M5 21 .985v22.006 (03655—03684) 2207 (0869) C2 24335—25006 (0.9337~0.9945) 25.07 (0.987) Gaer-tmbushing char-nee It M6 gear 0020—0062 (00008—00024) 0.10 (0.004) 3! M6 gear 0.020—0062 (0.0008400024) 0.10 (0.004) a! C2 gear 0020—01162 (00008—00024) 0.10 (0.004) at C3 gear 0.020~0.062 (00008—00024) 0.10 (0.004) a( C4 gear (1020—01382 (00003-03024) 0.10 (0.004) Mainshah CD. at M5 gear bushing G) 21359—21380 (08645—03654) 21.93 (0.863) a! clutch omcr guide ® 21.967 21.900 (03648—03654) 21.93 (0.863) 24367-24380 (03830—03335) 24.93 (0.981) Sauna-shah claarance — fl Gear bushing-to-shah clearance at M5 gear 0.020v0.062 (0.0003~0.0024) 0.10 (0.004) a! C2 gear 0005-0039 (00002—00015) 0.06 (0.002) Shlft (ark claw thickness L 5.93—8.00 (0133—0236) 5.60 (0.220) C 5.93—6.00 (0.233~0.236) 5.60 (0.220) R 5.93—6.00 (0233—0235) 5.60 (0.220) Shift (ark (.0. L 12000—11018(04724—04731) 12.06 (0.475) C ‘ 12000—11018(01724—04731) 12.06 (0.475) R 12000712018 (0.4724#0.4731) 12.06 (0.475) 11.90 (0.469) GENERAL INFORMATION Unit: mm (in) — clutch lvmm Item Standard Service limit cimcn lever free play Recommended clutch fluid Clutch muter cylinder I.D. Clutch matter plston 0.0. Clutch outer I.D. Clutch outer guide 0.0. I.D. Meinehnft 0.0. at clutch outer guide Oil pump drive sprocket LD. Clutch spring lrno height Clutch spring has length Clutch disc thickness A B C Clutch plate warpege Centrilugal clutch drum LD. huehing O.D. Centrifugal clutch centar guide LD. O.D. Centrifugal clutch center guide collar height Centrifugal clutch weight llnlng thickness Centrifugal clutch spring free length Clutch lining thicknaas Cf‘nklhdfl 0-D. I! CiUICH GOING? 10—20 (0.4—0.8) 37005—37030 (I .4569~1.457Si 29394—30007 HANDS—1.1814) 21380—22007 (03654—03664) 21367—21380 (03648—03654) 30025—30075 (1.1821 —1.1841) illlllllll' 37.08 (1.460) 29.96 (1.179) 22.05 (0.868) 21.93 (0.863) 30.13 (1,156) 36.0 [1.42) 2.9 (0.11) 2.9 (0.11) (0.12) (001) or.) “A ilillilll — Cooling "mm Coplant capacity (Radiator and engine] (Reserve tank) Radiator cap reliel pressure Thermostat bealnn to open Thermostat Gully open Thermoetet valve lift 15 l (0.40 US gal. 0,33 Imp gal) 03! (0.08 US gel, 007 Imp gall 93—123 kPa (0.95—1.25 kg/cm', 14—18 psi) 80—84%? ll76—153°F) 95°C (203°F) 8.0 (0.315) min llllll - Drive train Recommended final drive oil Final drivu uuul uil uupauily al disassembly at draining Finli drive gear backluh Ring geerAmvetop pin clearance (A) Step pin shlm , Ring gear spacer Pinion spacer Output gear backlash Output gear LD. Oulpul uuul Dunning OD. I.D. Output drive shaft 0.0. Output gear damper spring free length Output shaft adluetrnent shim Counterehalt drive shaft adjustment ehim llllllllllllli illlllllllllllll GENERAL INFORMATION Unit: mm (in) Fork spring fraa Iangtn A B Fork spring dircction Fork tube runout Recommended fork oil Fork Oil level Fork oil Ieval (R) (L) Fork oil capacity Fork oil capacity (R) (L) Fork air preuura With tightly wound coil and facing down Fork Fluid 95 (3.7) 510 C: (17.2 US 02.17.5lmp ox) — Winds/that Itlm Sllndlird Sonic. limit Minimum tira tread depth (FR) —— 1 5 (0106) (HR) — 2 0 (0.08) Cold tire pressure Up to 90kg (2001b) lold (FR) 225 kPa (2.25 kglcml, 33 Pli) — Up to 90kg (zoom) lurid (RR) 225 kPa (2.25 kg/cml, 33 pai) — Up to maximum weight capacity (FR) 225 kPa (2.25 kglcm’, 33 psi) — Up to maximum weight capauity (an) 250 kPa (2‘50 ku/cm'. 36 psi) — Front and rear axla runout a 0.2 (0.01) From and mm wheel rim runout (Radial) — 2 0 (0.08) (Axial) — 2.0 (008) Front wheal hub-to-rim distance —~ ——- Fiunl whoa) hub atandurd aurlace — — Rear whwl hulrto-rim distance — -— Rnr whnol hub stand-rd sullauu — — Whaal balanc- wpight Front/Hear —— 60 p (2.1 0:) Drive chain Ilack 15! 25 (5/8— 1) — Drive chain sin/link (DID) DID525V8I104 — (HK) RK5255M4I104 —~ — Front aulp-nlion Fork npring ire: langth 324.5 (12.78) 318 (12 5) Shock absorber spring (roe length (A) (B) Damper gas pressure Damper compresud gas ' Danlpul iuu compressed force at 10 mm (0.4 in) compressed Dampar drilling point E 20 mm (0.8 in) Shock absorber spring installed length (Standard) (Adjustable range) Sliuuk absorber spring direct-on Recommended shock absorber oil Shock absorber oil capacity air pressure Steering puring praload I.O—1.6 kg —- Bur Imp-union Shock absorbar spring in... lung"! 170.0 (701) Ill)! Adjuster position Ill Position IVVII With the taper and facing to adjuster Hill; llllillliglll GENERAL INFORMATION — Erik" Unit: mm (in) Item Standard Service llnih Front brake fluid brake lever lree play brake pad wear indicator Li) brake disc thickness brake elee runcui master cylinder I.D. mamor pinion 0.0. caliper cylinder |.D. caliper cylinder |.D.(Uppar) (Lower) caliper platen O.D. caliper plaron O.D.(Upper) (Lower) brake drum I.D. brake lining ihickneea Fleer brake fluid hrake pea-i height brake pedal free play brake pad wear indicator r5) brake disc mlcknass 5.8— 6.0 (0.22 —0.24) 1|.0007l (.0‘3 (04331—04343) 10.957 10.984 (0.4314 04324) 21000—21050 (1.0630—1.0650) 26318—26368 (10598—10617) to the groove ® 5.0 (0.20) 0.4 (0.02) 11.055 (0.4352) 10.945 (0.4309) 27.06 (1.065) 26.91 (1.059) ||H||| to the step ® 4.8—5.2 (0.19—0.20) 40 (0.16) runoui — 0.4 (0.02) mailer cylinder LD. 14000—14043 (0.5512—0.5529) 14.08 (0.554) manor piatnn 0.0. 13357—13384 (05495—05506) 13.95 (0.549) caliper cylinder LL). 38,1BO~38,230 (15031715051) 3814(1506) caliper piston 0.0. 38.098? 38.143 (1.4999715019) 38.09 (1.500) brake drum LD. — — brake lining thickness — _ — Battery/charging- ' Allernalor charging cail resisience (At 20"CI68°F) 0.1—0.5 11 — Regulator/rectifier regulated voltage/amperage 14.0—16.0 VIC—8 A at 5,000 rpm — Battery capacity i2 v—a AH — Battery specific gravity (Fully charging) —— _ (Neath nhnroing) — 7 Battery charging rate (Normal) 0.8 A (5— 10 hours) — (Quick) 4 A (1 hour) 7 Battery voliege (Fully charged ZONE/68°F) Over 12.8 V 7 (Need: charging 20°C/BE"F) Below 12.5 V 7 Alternator lighting coil reaiaiance (At 20"C168“F) — — AC reguleior regulated voliege (with analogue iypa) ¥ 7 lWith digit-i type) — — Starter driven gear 0.13. 41175—42100 (156047113614) 42.12 [1.655] Siariei cluich oulor |.U. # _ Starter motor brush spring tension 920 : 140 g (32.4 2 4.9 oz) — bruah length l2.5 (0.49) 8.5 (0.33) 1-19 I°Cl41'fi NGK] 5‘6/41 'E MD) “2v4n ‘ :1s—v7la 1‘ enema ‘ ‘ j uusgns ; ‘ ‘cnsema ‘ Mums H 0.3—9.9! av— . mama kn- ‘ 1,70dvpm 11 23—27 m ‘ ado—H20 n‘ 1 33m; mmmfl) } 860 0: (22.3 us at am: (1 75m ‘ ‘ ‘ mm: mm ; 30A 10AII4 ‘12vmlssgw Izvamqr 12vazemz 12v 32c”: 11v 1.7mm ‘12vl.7w11 12v1.7w]‘ H uvqu 12vmw 12V1JW‘ ”—510 14—180 ‘ SIB—102°C 1m- um u.- human—w. m aim 10m 93-91% (“139.2 ‘ i GENERAL INFORMATION TORQUE VALUES STANDARD TORQUE VALUES Torque Torque mm N-m (kg-m. ft-lh) "'m N-m (kg-m, ft-lbl 5 mm bolt end nut 5 (0.5, 3.5) 5 mm screw 4 (0.4. 3) 6 mm bolt end nut 1011.0, 7) 6 mm screw 910.9, 7) 3 mm bolt and nut 22 (2.2, 16) 6 mm Henge bolt (3 mm head) 910.9, 7) )0 mm bait and nut 35 (3.5, 25) 3 mm clung. bolt no mm hand) and nut 12 (1.2, 9) ’ 12 mm bolt and nut 55 15.5, 40) 3 mm Henge bolt and nut 27 (1,7. 10) 10 mm flange bolt and nut 40 (4.0, 29) Tureua specification: listed below are tor imponnnt fasteners. Others should be tightened to standard torque values listed above. NOTES: ‘ ’ 1. Apply I locking eqent to the threads. 2. Apply sellent to the threads. 3. Stakn. 4. Apply silicone grease to the sliding surtuce. ENGINE Item O'ty The“ Torque Remarks 11-6 (mm) N-m kg m ft-Ib Lubrication: Oil pump driven sprocket bolt 1 8 15 1.5 I I NOTE 1 Oil pressure switch 1 — 12 1.2 9 NOTE 2 oil drain bolt 1 12 35 3.5 25 Oil filter base 1 20 18 1.8 13 . Oil filter 1 20 10 1.0 7 Cylinder Medleyllnderlpleton: Cyllndar heed cover bolt B 6 10 1.0 7 Clflllhefl holder bolt 18 8 12 1.2 9 Cylinder heed cover breather plate bolt 2 8 12 1.2 9 NOTE 1 Cylinder hand spacial nut 12 8 30 3.0 11 Cylinder heed mounting bolt 2 6 12 1.2 9 Cylinder mounting bolt 1 8 10 1.0 7 Cylinder stud bolt 12 8 26 2.6 19 Spark plug 4 10 11 1.1 8 clutch/menrtm linkage: Crankshaft hole cap 1 30 7 0 7 5 Tlrrllng hole cap ‘ 1 14 10 1 o 7 Clutch center lock nut 1 20 85 8.5 51 NOTE 3 Gearshift spindle return spring pin 1 B 23 2.3 17 Crankceulwkuuflltrenunlulon: Connecting rod nut 8 7 24 2.4 17 Crenkclse bolt (8 mm) 12 B 24 2.4 17 18 mm x 65) 1 B 27 2.7 20 (6 mm) 19 6 12 1.2 9 Seallng bolt (lower nranlrmkn) 1 20 30 3.0 22 )l Spuulul bolt (lower crankcase) 1 14 25 2.5 18 NOTE 2 Neutral switch 1 10 13 1.8 1 3 NOTE 2 Drive sprocket bolt 1 10 55 5.5 40 Altern-tor: Flywheel bolt 1 10 85 8.5 61 Starter clutch: Start.) Elulull bolt 1 10 as 8.5 61 1’ 1-14 GENERAL INFORMATION FRAME Thread Toroua l ' . turn 0 ty ma mm) N-m kfl-m ft-Ih Remarks Frumoloxhnun syn-m: Eaiiauut pipe lolnt nut 3 6 12 1.2 9 Muffler mounting bolt 2 8 22 2.2 16 Side Itand Divot bolt 1 10 10 1.0 7 Side stand pivot lock nut 1 10 27 2.7 20 Side stand switch mounting bolt 1 6 30 3.0 22 Gearshift pedal ioint bolt 1 6 12 I .2 8 Gearshift pedal mounting bolt I 8 27 2.7 20 NOTE 1 Footing stnv non 4 e 27 2.7 20 Cooling Int-m: Tmnpuraturu sensor 1 — 10 1.0 7 NOTE 2 Fun motor switch 1 18 18 1.8 13 NOTE 2 Fuel system: Fuel valve nut 1 22 23 2.3 17 Fuel tank can mounting bolt 3 4 3 0.3 2 Englm mount: Engine mount nut (front) 2 10 40 4.0 29 Engint mount nut (rear/upper) 1 10 50 5.0 36 Engine mount nut (rear/lower) 1 10 50 5.0 36 Adlunlng bolt 1 2O 15 1.5 1 1 Adjusting bolt lock nut 1 20 85 6.5 47 Engine nub frnrnc nut 4 10 45 4.5 33 Engine bracket bolt 6 10 40 4.0 29 From: Handlebar pinch bolt 2 B 27 2.7 20 Handlebar weight screw 2 6 10 1.0 7 NOTE 1 Axle bolt 1 14 50 6.0 43 Axle pinch bolt 4 8 22 2.2 16 Fork plncn bolt (upper) 2 7 1 1 1 1 B Fork pinch bolt (lower) 2 10 50 5 O 36 Fork nap bolt 2 37 23 2.3 17 Fork sockat bolt 2 6 20 2.0 14 NOTE 1 Steering stem nut 1 2'1 105 10.5 76 Steering head bearing adjustment nut 1 26 25 2.5 15 ignition switch mounting bolt 2 B 25 2.5 Is NOTE 1 Rear: Axle nut 1 16 90 9.0 65 Drlven sprocket not 5 10 65 5.5 47 Shock absorber mounting nut (upper) 1 10 45 4.5 33 Shook absorber mounting nut (lower) 1 10 45 if: 33 Shock absorber lower Iomt lock nut 1 14 68 6.5 49 NOTE 1 Swinglrm pivot nut 1 14 110 11.0 80 Broke: Front caliper pad pin plug 1 10 2.5 0.25 (.8 pad pin 1 10 18 1 .5 1 3 bracket bolt 2 8 27 2.7 20 pin bolt 1 i 23 2.3 17 NOTE 1, 4 bracket pin bolt 1 i 13 1.3 9 NOTE 1, 4 Front mnatcr cylinder reservoir cover icrew 2 4 5 0.6 4 Front brake disc bolt 6 B 30 3.0 22 Rear caliper pad pin plug 1 10 2.5 0.25 1.3 pad pin 1 10 18 1.3 13 mounting bolt 1 8 23 2.3 17 pin bolt 1 ¥ 23 2.3 17 NOTE 1. 4 Rear master cylinder push rod ioint lock nut 1 '— 17 1.7 12 Rear brake disc bolt 4 8 40 4.0 29 Brake hose bolt 4 10 35 3.5 25 GENERAL INFORMATION TOOLS - The tools for the ball bearing removal and installation or: not contained in this list, Refer to section 1. Bell Beering Replacement, at the Common Service Manual, - The newly designed tools are indicated with ' mark in the list. Description Tool number Alternative tool Rel. section“) Oil filter wrench Vacuum gauge Oil preaeure gauge on pressure gnuga attachment Rotor holder Antifreeze teeter Coollng system teeter Float level gauge Vacuum pump Preeaure pump 'Valve guide driver (guide removal! inetelltionl 'Velve bucket hole protector Valve Ipring compreucr ‘Velve spring compressor attachment ’Velve guide reemer, 18 mm VINO l!!! CUflBl, 22 mm [45' IN, EX) Valve llet cutter, 22 mm (32' IN) Volvo llet outtor, 21.6 mm (32“ EX) Valve interior cutter. 22 mm (60" W, EX) ' Cutter holder Piston rinw compressor Piston beee Compression gauge 'Compraaalen gauge attachment ‘ Glutoh oentor holder 07HAA—PJ70100 07404A0030000 07506—3000000 07510—4220100 07725—0040000 Commercially evaileb|e Commercially available 07401 — 0010000 ST—AH—IGO—MC7 ST—AH—ZSS—MC7 07JMD—KV20100 07JMG — KY20100 07757 — 0010000 07JME — KV20100 O7JMH — KV20100 07780—001070) 07780—0012601 07750 — 0012800 07780 70014202 07JMH—KV20200 07954—2500000 07958—4130000 07305— 0010000 O7JMJ , KV‘20100 076MB _ KTEO'I 00 ciallv available in Jar equivalent commer- U.51Ar AU.S.A. only —U.S.At only —O7JMH-KV2010A (U.S.A. only) or equivalent commer- cielly available in U.S.A. 707954-2350000 —07958—2500001 lU.5.A. only) jar equivalent commer- lly avillible in U.S.Ar 07HGB—001000A (USA only) —Not Iveilable in U.S.A. .14,16 mommmbhemw marinate ummwmmm cum 1-16 (Cont'di GENERAL INFORMATION Description Tool number Alternative tool Rafi section“) Bearing remover head. 20 mm Bearing remover shah Driver Attachment, ‘2 x 47 mm Attachment, 52 x 55 mm Pilot. 20 mm Fork eeel driver Fork anal driver attachment Lock nu! wrench, 30 x 32 mm Steering stem sucker Bell race remover A anechmenr — drlver Bearing rec. remover Driver Attachment, 37 x 40 mm Steering stem driver Bearing remover need, 17 mm Attachment, 24 x 26 mm Punt, 17 mm Pilul, 22 llllll Shock absorber compressor iscraw assembly Shock absorber compressor attachment " Driver pin Diivsi slislt 'Naedle bearing remover enachmenl Attachment, 28 x 30 mm Anachmenk, 32 x 35 mm Fiiul, 15 mm Snap ring pliers Rslor puller Christie battery charger Dalleiv leeks! Digital multitester (KOWAD Analogue tester Torx bit (T40) 07746—0050600 07746—0050100 077119—001 0000 07746—0010300 07746—0010400 07746—0040500 07947— KA50100 07947 7 KFOOI 00 07716—0020400 07916—3710100 07953 — MJ10000 07953—MJ10100 07953 — MJ10200 07946— 3710500 07949 — 3710001 07746 —0010700 07948va 07746 —0050500 07746— 0010700 07746— 0060400 07 7464 0041000 07GME-0010000 07GME—0010100 07959 ~ M31 0000 076MB — K180100 U /948— MJOO1OO O7GMD7 KT70200 0794671570100 07748—0010100 07746—0040300 0791473230001 07733—0020001 MCIOIZIZ EM—21U 07411—0020000 07305—0020001 (SANWA) or TH—5H (KOWA) . 0770370010100 MJ1000A), Driver (07949—3710001) and Attachment, 37 x 40 mm (07746— 00102001 JAttachmonr (07953 — —Not available in U.S.A. 07969-3290001 —Not available in USA Pilor‘ 22 mm (07746— 0041000) and Driver lO7749v0010000) —Not available In USA. Driver (07949— 3710001) —Not tvlilnble in USA Buehing remover (M967X7038 — XXXXX) 707933 7 2160000 (USA. only) —KS—AHM—32—003 (USA. only) for equivalent commerr clslly available In U.S.A. 11 11 “.12 11,12 11 11,12 11 11 11 11 11 (11) I11) 12 12 14,15,115. 17 17 GENERAL INFORMATION LUBRICATION AND SEAL POINTS ENGINE Point Material Remarks - Camshaft iournal - Transmission gear shifter groove - Connectlng rad bearing sliding surface - Intake and Exhaust valve stem sliding surface - Connecting rod small and-piston pin sliding surface - Crankshaft main journal bearing sliding wrtaca Molybdenum solution (mixture at the engine all and molybde- num disulfida grease with the ratio I : ll - Upper crankcase mating eurtaca Liquid sealant Do not apply sealant to the oll passages and near the main iournal bearings - Shaft ioumlll - Sliding surface ‘ 0" pressure switch Sealant Do not apply sealant to the - Fen motor switch oil pressure switch thread - Thermo sensor head as shown. - Neutral switch ‘ Gear teeth Engine oil FRAME Pull“ Material Remarks ‘ Center stand pivot - Side stand pivot - Brake pedal pivot - Gearshift pedal plvut - Steering head bearings - Dusr seal lips: - Clutch lever pivot - Throttle cable ends ~ Swingarm pivot bearings ' Seat locking tab - Rear wheel driven Mange bearing - Wheel bearings - Speedometer gear Multipurpose oraasa - Brake caliper seals - Caliperrplaton sliding surlaca - Master cylinder piston cups - Master aylindcr piston sliding sdrl‘auu DOT 4 Brake fluid - Brake caliper pivots - Brake caliper pivul bums - Rear brake master cylinder push rod head Silicone grease - Speedometer cable - Throttle cable - Choke cable - Clutch cable Light weight oil - Handlebar grip inside surface Honda Bond A or Honda Hand Grip Cement (U.s.A. only) GENERAL INFORMATION CABLE AND HARNESS ROUTING [1) SP-WHITE CONNECTOR (2) BPVRED CONNECTOR (METER) (METER) (3) 6P»SLACK CONNECTOR (TURN SIGNAL SWITCH) (6) ZIP-BLACK CONNECTOR (IGNITION SWITCH) (4) 6P»GREEN CONNECTOR (TURN SIGNAL SWITCH) (5) BP-REO CONNECTOR (STARTER SWITCH, ENGINE STOP SWITCH) (7) BRAKE NOSE (3) CLUTCH CABLE (15] THROTT LE (9) LEFT L‘AHLE HANDLEEAR SWITCH WIRE (14] RIGHT HANnLEBAR SWITCH WIRE (10] CHOKE CABLE (11) IGNITION SWITCH WIRE (13) MAIN WIRE (12) TURN SIGNAL HARNESS WIRES GENERAL INFORMATION (2) CHOKE m WEI: CA” 5 3: SET THE wme HARNESS SECURELY WI HARNFSS a) THROTTLE CABLES 5) BRAKE HOSE (8) No. 2 a. No‘ 3 SPARK 6] SET THE No, 2 L No. 3 SPARK PLUG wags WIRES SECUHELY [7) CI IITCH CABLE HO) THROTTLE CABLES ,4 7% \\ C «VIE :1” g‘mw.’ 3/) //;:,i (u) SET THE No, 1 1. kn; £17 m / mew/:2: \ 19) (52(3):: ’ §r\w"l \k‘ / SECURELV / s’r\ 1?”? 115) CLUTCH (12) SIPHON CABLE was \\ (14)\N 1&N 47 0. 0‘ ‘ \ SPARK PLUG Ha) SPEEDOMETFR WIRES CABLE 1 ~20 GENERAL INFORMATION (2) DIODE (3) BATTERY POSITIVE TERMINAL . (1 ) SPARK I5) WIRE GUIDE - IGNITION COIL WIRE - NEUTRAL SWITCH a. OIL PRESSURE SWITCH WIRE - PULSE GENERATOR WIRE / - SIDE STAND SWITCH WIRE (7) CLAMP - ALTERNATOR WIRE - MAIN WIRE HARNESS - REAR BRAKE LIGHT SWITCH (9) No. ‘l 81 No, 4 SPARK PLUG WIRES HOSE (8| :gkiiAYOR (I I) SIDE STAND SWITCH I3?) CONNECTOR (12) CRANKCASE BREATHER TUBE (131N0.2 51 Nov 3 SPARK PLUG WIRES I14) ALTERNATOR (18) REAR val» CONNECTOR BRAKE . HOP-F (1 7) RESERVE TANK (16) FUEL TANK (l5) IGNITION COIL OVERFLOW TUBE DRAIN TUBE I4PI CONNECTOR GENERAL INFORMETION (4) REGULATOR/ RECTIFIER I I FUEL CUT-OFF (2) FUEL FILTER I1) WIRE GUIDE ' IGNITION COIL WIRE - NEUTRAL SWITCH E OIL PRESSURE SWITCH WIRE I . GENERATOR - PULSE GENERATOR WIRE WIRE - SIDE STAND I8) NEUTRAL I7) SIDE STAND (s) FUEL pUMp SWITCH WIRE SWITCH WIRE SWITCH WIRE ' ALTERNATOR WIRE (11) MAIN WIRE HARNESS (I l SPARK UNII I12] DIODE / 1-99 i__—————— GENERAL INFORMATION t Calflomll Modal Only (3) TO AVCV ND. 4 TUBE Ib) RADIATOR RESERVE TANK OVERFLOW TUBE (12) N0. 3 INTAKE ” " magg“ MANIFOLD 110) No. IO TUBES (18) T0 PCV (19) TO AVCV (13) OVRINGS [(14) AIR INJECTION (9) No. 15 TUBE (21) No‘ 10 TUBE (AVCV) (16) AIR SUCTION VALVE GENERAL INFORMATlON INJECTION TUBE (No‘ 15) m A m (3) No. 1 TUBE (4) No‘ 4 TUBE (6) PCV (5) AVCV (9) Na. IO TUBE (7) No. 4 TUBE ( ) a-WAY JOINT 1 -94 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Prutuctlon Agency and Calrromia Air Resources Board (CARE) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1 , 1983 comply with applicable noise emle- sion standards Ior one year or 6.000 km (3,730 miles) after the time 0' sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms at the Dietributor's Warranties for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control at hydrocarbons is very important because, under certain conditions, they react to lorm photochemical smog when subjected to sunlight. Carbon monoxide does not react in the some way, but it in toxic. Honda Motor 00., Ltd. utilized lean carburetor settings as wall as other systems. to reduce carbon monoxide and hydro» carbons. CHANKCASE EMISSION CONTROL SYSTEM The crankcase emissiun control system routes crankcase emissions through the air cleaner and Into the combustion chamber. Condensed crankcase vaoora are accumulated in on air/oil separator and drain tube which must be emptied periodically‘ Refer m the Maintenance Schedule (page 374). The drain tube needs to be checked Iur oil accumulation more lrequently iI the ma- chine has been ridden mostly at high speeds or in rain. I ) AIR CLEANER 2) CARBURETOR (3] <— : BLOW-BY GAS (4) CI: : FRESH AIR GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEMI (Eric-rut Calilumia model) The exhaust emission control system is composed of lean carburetor settings and no adjustment should be made except idle speed adjustment with the throttle stop screw. (Calilpmia model) The exhaust emission control system consists of a secondary air supply system which Introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge oi Iresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. This model has the air suction valve; it consists of read valves built into the air injection control valve. A reed valva prevents reverse air flow through the system The air injection control valve reacts to high intake manifold vacuum and will cut off the supply of fresh air during engine deceleration, thereby preventing afterpum in the exhaust sys- tem, No adjustments to the secondary air supply system should be made, although periodic inspection 0! the components is rec- ommended ' l1) INTAKE FORT 12) AIR lNJECTION CONTROL VALVE (3) AIR SUCTION VALVE ASSEMBLV l5) CARBURETOR (4) REED VALVES l6) EXHAUST PORT c: (7): FRESH AIR 1-76 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) This vehicle complies with the Calilomla Air Resources Board requirements Ior evaporative emission regulations, Fuel vapor lrorn the viral tank and carburetor: is routed into the charcoal canister where 'it is absorbed and stored while the engine is stopped When the angina is running end the purge control diaphragm valve is open Iual vapor in the charcoal canisV ter is drawn into the engine through the carburetor At the same time the air vent control valve is open and air is drawn into the carburetor through the vulva. (I) PURGE CONTROL VALVE (PCV) (2) FUEL TANK <1: (3) FRESH AIR (4) CA ISTER <):i : (5) FRESH AIR « :(6) FUEL VAPOR 7) AIR VENT ‘9 CONTROL VALVE (AVCVI NOISE EMISSION CONTROL SYSTEM TAMPEHING WIYH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or renderlng inoperative by any person, other then ler purposes of maintenance, repair of replace- ment. ol any device or element of design incorporated into any new vehicle for the purpose oI noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered innperetive by any pcrnon. AMONG THOSE ACTS PRESUMED T0 CONSTIYUTE TAMPERING ARE YHE ACTS LISYED BELOW: 1. Removal of, or puncturing the muffler, baflles, header pipes or any other component which conducts exhaust gases. 2. Removal 0!, or puncturing at any pen of the intake system 1 Lauk of proper maintenance. 4 V Replacing eny moving parts of the vechite, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. Only) 0 An Emission lnfurmmion Label is located on the rear fender W EM'SSION INFORMAT'ON (2) up DATE as shown. The seat must be removed Io read in I! gives basic lunerup specifications. VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL Almr making a high altixuds carbureml udiuslmem. attach an update label on the rear fender as shown. (3) VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) VACUUM HOSE ROUTING DIAGRAM LABEL (Callfornia model only) V‘DIIIII IIIISK [III-”IKE DIAGIAI The Vacuum Hose Routing Diagram Label is on me rear “‘6'“ ”“'”‘““"°"'“” EVA eonnws FAMILV— uzx fender as shown. The seat must be removed m read It. “I “on,” VEH IDLE Route the vacuum hoses as shown on this label. FRONT 0*" vE H I cLE To TO FUEL TANK Ii 'II 1 -99 2. FRAME/BODY PANELS/EXHAUST SYSTEM ’ SERVICE INFORMATION 2—1 SIDE covsn REMOVAL/INSTALLATION 2»3 TROUBLESHOOTING 2.1 EXHAUST SYSTEM REMOVAL/ SEAT REMOVAL/INSTALLATION 2-2 'NSTALLAT'O" 2'3 REAR ”lame REMOVAL, FUEL TANK REMOVAL/INSTALLATION 24 . INSTALLATION 2-2 SERVICE INFORMATION . I When removmg a cover, be caretul not to damage any tab or groovet - Do not service the exhaust s III while It Is hot. 7 r I NOTE Replace the exhaust pipe gaskets if the exhaust system is removed. Tighten the exhaust pipe joint nuts first, then the mounting hnits 0 Although it is possible to weld Inme cracked fremea and straighten some homes that are slightly bent it Is best to replace the lreme with a new one when it is damaged, 0 Generally speaking. plastic body panels cannot be repaired and therefore must be replaced. 0 It Is possible that a front end collusion will bend the steering head ol the frame, but not the fork, wheel or even the axle. ’ TROUBLESHOOTING - Fallure at the trout suspension, steering Or rear suspension may damage the heme enough to requlre replacement. - Relet to the auction 15 of the Common Service Manual lul IIOIII suspension and steering Inspections, - Reler to the section 19 of the Common Sen/Ice Manual lor rear suspension inspection. Abnormal engine vibration ' Cracked 0' damaged engine mounts - Cracked, damaged Or bent welded portions - Bent or damaged lrame - Englne problems Abnormal nolte when riding (bunglng'or cracklngl - Damaged or bent engme mounts . . Damaged welded polnts - Damaged or bent frame Stu" to em IWQ VIII." undi' ICCOIOIIIIDH 0' deceleration Bent Irame Bent Iork . - Bent swingarm FRAMEIBODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Insert the ignition kev into the seat lock/helmet holder and turn the key clockwise and push down the lever: release the seat locking. Pushing the sell as shown. remove the seat reamam. Align the seat hooks with the lrume hooks and push the seat forward. Pm” the roar of the Int down and look the scat securely. CAUTION - Apply urn-u to the nut Iocklng. - a. c-vn'lll not to plnch the WIN home“ between the net and the tram. REAR FAIRING REMOVAL/ INSTALLATION Remove the seat (above). Remove the bolts and collars. Release the hiring front bosses from the grommets. Remove the rear lairing rearward. Install the rear [airing in the reverse order at removeli (I) SEAT LOCK] HELMET HOLDER (I l COLLARS \ (2) BOLTS (4) FEAR FAIRING 2-2 SIDE COVER REMOVAL] INSTALLATION FRONT SIDE COVER Remove the bolts. Release the boss item the lrame grommet and remove the front side cover. Instell the side cover in the reverse order a! removal. NOTE I;- It it not necessary to remove the bolt ® as shown. REAR SIDE COVER Remove the following: seat (page 2—2). Release the rear Ieinnq lront bosses from the grommets (page 2-2). Remove the bolts and rear side cover. Install the side cover in the vaverse order of removal. NOTE | - It is not necessary to remove the bolt 0 as shown. EXHAUST SYSTEM REMOVAL/ INSTALLATION Remove the radiator lower mmlnting bolts and loosen the upper mounting bolt/nut (page 5-5). Swing the tadietor for- ward, Remove the Iollowing: — exhaust pipn joint mm. v muffler mounting bolts and exhaust pipe/"lumen — gaskets. - NOTE ‘ Replace the exhaust pipe gaskets II the exhaust system is removed. Install new gaskets and exhluit pipe/muffler. Tighten the exhaust pipe joint nuts lirst. TORQUE: 12 N-m [1.2 kflrm, 9 fl—IbI Then tighten the mulller mounting bolts. TORQUE: 22 "-11! (2.2 kg-ul. 13 fl-Ib) FRAMEIBODV PANELS/EXHAUST SVSTEM (1) FRONT SIDE COVER (2) BOLTS (I) RADIATOR I5) MUFFLER MOUNTING BOLTS I3) JOINT (4| EXHAUST NUTS PIPE/MUFFLER FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK REMOVAL] INSTALLATION - Galoli is extremely flammabla and I: axplosivo undo: "Ital" condnlon; Won. in n wnll until-ml nu, Smoking or nllowlng flnmau or spark: in the work am at whats ansollne is stand can can“ a fire or expla- :lon. Remove the seat [paga 24). Turn the lual valve OFF. Remove the fuel tank mauntmg bolts and lift the tank up Disconnect the tubes, and mmove the fuel tank. Install the lual tank in the reverse order oi removal. After installation, turn the fuel valve ON and check the fuel line for leakage. Install the seat (page 2-2)l (2) FUEL (1 ) BOLT TANK (3) BOLT/ NUT (5) 3522‘ (4) FUEL TUBE 2-4 3. MAINTENANCE ’ SERVICE INFORMATION 3-1 SPARK PLUG 3-5 §ERVICE ACCESS GUIDE 3-2 VALVE CLEARANCE 3-5 MAINTENANCE SCHEDULE 3-4 CARBURETOR SVNCHRONIZATION 38 AIR CLEANER 3-5 SIDE STAND 3-8 SERVICE INFORMATION 0 Refer (a the Common Service Manual for items not included in this manual. ’ O Raver to the specifications ISSClIon 1) I07 maintenance semca dam. 91 MAINTENANCE SERVICE ACCESS GUIDE - The (allowing shows the locations of the maintenance items Iisxed below and (he pans required (0 be removed (or that maimenanco Servico. Refer to (he Common Service Manual (or ilems not instructed in this manual. - Refer to section 2 (Frame/Body panels/Exhaust system), (he pans required to be remave (or service. For example: AIR CLEANER (Contamination, clogging, roplacemem) - Fuel tank Reserve Tank Cap (Coolanr llller) - Seer Brake Pedal (Air bubbles in system) Brake Hose (Leakage, de radarianr dama a) Brake Reservoir (Level check, fluid rcplnccmcnr) l "‘\ K. r __ .\ Caliper (Pad weal) a O a ' Tire (Wear, damage. pressure) thcl (Damage, runouK, corrosion) Brakelighl Swilch (Operarion) Oil filler Cap/Level Gauge (Level check, replacement) maintenance parts (service item) parts required to be removed for service Throttle Grin [Operaliom lree play) Manor Cylinder (Laval check, fluid replacement) Brake Lever (Air bubbles in a stem) Brake Hose (Leakage, degradalian, damage) Caliper ° (Pad wear) o “0 W7. . °a 0 Tire (Weerr damage, pressure) Wheel (Damage, runour. corrosion) Oil Filter (Replacement) Timing Hole Cap/Crankshaft Hole Cap (Valve clearance) . Air Cleaner (Contamination. clogging, rep(acement page 3-5) - anl vank MAINTENANCE Synchronization Adjusting Screw (Carburetor synchronization page 3-5) - Fuel tank Carburetor Choke (Operation) Clutch lever (Free play) . Headlight (Aim) ‘\ Steering Head Bearings (Damage) 9 0 Valve Clearance @ (page 3-6) PCV and AICV (Damage. laulty hose Daga 543) Reserve Tank (Coolant level) (Loose. wear. damage) ASV (Damage, faulty hose page 6A1 3) Spark Plug (Wear, damage) coloration) - Front side cuver Radiator Hose (Leakage) degradation, damage) Engine Oil Drain Bolt (Oil replacement) Suspension ' (Loose. wear, damage) 0 § Drive Chain (Free play, lubrication, replacement) Side Stand (page 3-3) Fuel Filter (clogging) Fuel Line (Damage, laakaga) Throttle Stop Screw (Idle speed) MAINTENANCE MAINTENANCE SCHEDULE Perform the PfiE-RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. I: Impact and Glenn, Adiun, Lubricare. or Repleca il necessary. R: Repl‘cl. L: Luerlcau The lollowlng Item. require some mechanical knowledge. Con-in items ipenicularly those marked ' end ' ‘I may require more Technical inlannerien and male. Consult your authorized Honda dealer. WHICH FREQUENCY COMESEVER ’ ODOMETER READING (NOTE II FIRST X 10” ”H 1 8 12 13 24 30 36 Refer ”EM NOTE It 1000 mi 0.6 A a 12 Is 20 24 to ply. - FUEL LlNE I I l NOTE 5 ' THROTTLE OPERATION I I l NOTE 5 - CAREURETOR CHOKE _ I . I I NOTE 5 AIR CLEANER NOTE 2 7 R R 3-5 ‘9 SPARK PLUG R AR#_R R R R a-E/NOTE 5 E - VALVE CLEARANCE I I 3.5 B ENGINE OIL R R R NOTE 5 g ENGINE OIL FILTER R R R R NOTE 5 w n g 2:32:23IIEATION I I ' 3'3’N0TE 5 3 ° CARaunETOR IDLE SPEED I I I I I I I NOTE 5 § nAOIATon COOLANT NOTE 3 I I R NOTE 5 ' COOLING SYSTEM I I I NOTE 5 ' gfiigregczéa NOTE 4 I I I NOTE 5 éztizztfltzfxfsm" "°T‘ ‘ ' ' No" 5 DRIVE CHAIN g BRAKE FLUID :4 BRAKE PAD WEAR S BRAKE SYSTEM “ “ E . BRAKE LIGHT SWITCH g - HEADLIGHT AIM g CLUTCH SYSTEM 3 SIDE STANDri g 7-7 SUSPENSION 5 - NUTS, aOLTs, FASTENERS z - - WHEELS/TIRES - - STEERING HEAO BEARINGS ' Should he servlced by an aurhdrized Honda dealer. unless the owner he: proper mole and serv a dale and is mechanically qualified. ' ' In The lnraresr ol salary, we racommend these items be serviced only by an authorized Honda dealer. NOTES: 1. At higher edema-r readings, repeat at the frequency intent-l est-blished here. 2. Service more lrequently when riding in unusually we: or dusty areas. 3. Replace every 2 years, or at indicated odometer interval, whichever comes first Replecement requires mechanical skill. 4. Californial type only. 5. Refer To the Common Service Manual. 3-4 AlR CLEANER Remove the following: — lual tank (page 274). ~ air cleaner case cover (page 873). Discard the air cleaner element in accordance with the main tenance schedule. Also, replace the element any time it is excessively dirty or damaged. install the air cleaner element with the 1} mark forward and the TOP mark facing up. Install the wire harness into the wire herneee clamp on the cover securely. SPARK PLUG NOTE - For deralied lnurumlons, refer to section 2 ol the Common Service Manual. Instruction for removal! installation of only the No. 2 and N0. 3 spark plugs I! given here. No. 1 and No. 2 plug can be removed easily only to remove the front side cover. Remove the lront aide covers (page 2-3). The spark plug wrench ls Included in the tool kit. Insert the plug wrench berween the heat guard plate and cyl- inder heed cover as shown, and set the wrench onto the spark plug. Turn the plug wrench and remove the spark plug. Then (ilt up the wrench With the plug, through the heat guard crate-hole. Pull the wrench out til the CVIiIIdei head. Remove the spark plug from the wrench. Install a new spark plug into the cylinder in the reverse order of removal. Tighren the spark plug 112 rum wlth an open end wrench to compress the plug sealing washer, VALVE CLEARANCE INSPECTION NOTE - Inspect and adjust valve clearance while the engine is cold (Below 35°C/95uF). Remove the following: 7 liming hole can (page 972). — crankshaft hole cap cover (page 972). — crankshaft hole can (page 972). 7 air cleaner case (page 6-3). MAINTENANCE (1) TIMING HOLE CAP 6;; (2) COVER [3) CRANKSHAFT HOLE CAP 2—5 MAINTENANCE Remove the redieror lower mounting bolts and loosen the upper mounting bolt/nut. Swing the radiator lurward. Remove the cylinder need never (Dede 8-2). Rotate the crankshaft clockwise. Align the T mark (Yellow colored line) on the flywheel with the index mark on the right crankcaee cover. Each timing mark (EX and IN) on the camshalt more should be aligned with the cylinder head upper surface. ll each timing mark is lacing outaide, No. 4 cylinder piston is at TDC (Top Deed Center) on the compression stroke. as to Step 1‘ ll aach timing mark is lacing inside, Nu. 1 cvllndev platen Is at TDC (Top Dead Center) on the communion stroke. go to sup 7 Step 1: Insert the leeiev gauge between the cam lobe and valve bucket. Measure the valve clearance as tollow: 7 No. 2 (IN) , Nu. 3 (EX) - No. 4 (IN/EX) Step 2: Insert the feeler gauge between the com Int-re and valve bucket. Measure the vulva clearance as lollow: — No. 1 (IN/EX) 7 No. 2 (EX) NU. 3 (IN) VALVE CLEARANGES: IN: 0.11-0.18 mm l0.005—0.007 In) EX: 0.17—0.23 mm [0.007—(1009 in) Rotate the crankshaft 360 degrees and align the T mark with the index mark again and go to Step 2 or 1 to check other valve clearances. (1) BOLT/NUT l2) RADIATOR l3) BOLTS (1) T MARK (YELLOW COLORED LINE) ’ \A {7/ \\ i“, \b/lzx INDEX ’0 MARK ; (1) INIAKE (2) EXHAUST CAM SHAFT CAM SHAFT (3) TIMING MARKS (lacing outside) RIGHT VIEW (I) INTAKE (2) EXHAUST CAM SHAFT CAM SHAFT i (3) TIMING MARKS (lacing inside) 3—6 7—— MAINTENANCE SHIM SELECTION Ii the clearance is not correct: Remove the Camshafts (page B»Z). Remove the valve buckets and shims (page 86). NOTE Dc not allow shims to tell into the crankcase. The shlmis) may occasionally stick tn the bucket. Mark the positions al I" buckets and shims to ensure correct Icassamblv. It is easy to remove the valve bucket with a valve lapping tool or magnet. Remove the shims with tweeters or a magnet. Clean the valve buckets with compressed air. l1) SHIM Measure the shim thickness with a minrnmnter and reccrd it. NOTE Sixty-five different shims are available in thickness;- tervels of 0.025 mm. The thinnest is 1.200 mm the thickest is 2.800 mm. To confirm you! shim choice. you may use the following lormnla: I — lh — c) + d I new shim thlcltnuu b: "corded 1!.le doll-nu c d : Ipcclllod "Ive clumnuu (IN: 0.1! mm EX: 0.20 mm) : old shim thlcltnou example: I): rucordod VIIVI clo- nce: 0.18 mm 182 d: old lhll’n thlckn 1.850 mm ‘ c: Ipsellled valve clearance: 0.15 mm - (0.18 , 0.151 + 1.850 .a - 1330 now ahlm thickness -— 1.875 mm 1.80 mm 1.825 mm 1.85 mm 1.875 mm NOTE - It the required thickness oi the new shim is more than 2.800 mm, the valve seat is probable heavily camoned. Refine the seat, recheck valve clearance and reselect the shim. MAINTENANCE CARBURETOR SYNCHRONIZATION NUlk - For detailed instuctians, reler to section 2 of the Common Servlca Manuel. The inlormatlon here only in- dicates locations of the plugs lor the adapters and the evnohronlutlon adjustlng screws. Before inspection, remove the luel tank mounting bolts (page 274) and move the tank rearward with the fuel tube connected. CAIBURETOR VACUUM DIFFERENCE: Whhil 30 mmHg (1.2 MM!) BASE CAREURETOR: N0. 2 CARIURETOR SIDE STAND Check the side stand ignition cut-oil system: 7 Place the motorcycle on its center stand and raise the side stand. — Start the engine with the transmission in neutral, then shift the transmission into gear with the Clutch lever squealed. ~ Move the side stand lull down, , Thu nnulna should crop is the tide stand is lowered. N there is a problem with the system, check the side stand switch (Section 15!. Check the side stand switch mounting bolts lor looseness. (4) No, l (3) No. 3 (2) No, 4 SCREW SCREW SCREW [2) SIDE STAND 3—8 4. LUBRICATION SYSTEM SERVICE INFORMATION 4—1 OIL PUMP REMOVAL/INSTALLATION 4-3 TROUBLESHOOTING 4—1 OIL PUMP DISASSEMBLYIASSEMBLV 4-4 LUBRICATION SYSTEM DIAGRAM 4-2 I S ERVICE INFORMATION n Uud engine all (or transmission all In twtruroknl mlv can" IkIfl cute-r ll repeatedly [on In contact with the skin for From-d period:- Akhoueh lhls In milk-Iv unhn vou handle used all on - daily basis, it is still udvlublo to thoroughly with your hands with soap Ind water ll soon as possible after bending used oil. KEEP OUT OF REACH OF CHILDREN‘ T The oil pump can be serviced with the engine installed in the lreme, Replace the oil pump as an assembly For on pressure chock, rater to section 4 ol the Common Service Manual; lor the switch location, see page l7~2 af this manual. For all pressure warning light inspection, reler to section 25 or the Common Service Manuall When removing and installing the oil pump use care not to allow dust or dirt to enter the engine Alter the oil pump has been installed, chick that there are no on leaks and that oil pressure is correct, ROUBLESHOOTING all level low No oil prluuro ' Oil consumption - Oil level too low ) - External oil leaks - on pump drive chaln or oil pump drive/driven sprocket - Worn piston ring or incorrect piston ring installation - Oil pump damaged [pump shaft) - Wum valve guide or anal - Internal oil leeks 0" rontsmlnulen (White appearance) 0!! pro-lure wnmmg light doe: not work well - From coolant mlxing with oil - Refer to section 25 DI the Common Service Manual A leultv water numo mechanical seal ~ faulty cylinder head gasket High all prenure Pressure relief valve stuck closed Plugged uil Killer, gallery or metering entice Incorrect oil being used Lew oil pres-urn I . Pressure relief valve stuck open Oil pump worn or damaged Internal all looks Incorrect oil being used Low oil level LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM “EXHAUST H I ' Illb I CAMSHAFT (2) INTAKE ‘ ‘ t ‘ CAMSHAFT I3) PISTON . I4) CONNECTING \ HOD (5) CRANKSHAFT (5) OIL PRESSURE SWITCH ._..— _. 1 4 IL ORIFICE ( )0 (7) OIL ORIFICE (13) MAINSHAFT (12) COUNTER- SHAFT 8) OIL PUMP 111) OIL FILTER (9) OIL STRAINER (10) OIL PRESSURE RELIEF VALVE OIL PUMP REMOVAL/INSTALLATION LUBRICA‘I'ION SYSTEM DRAIN BOLT 35 (315, 25) 07725— 0040000 CLUTCH OUTER SPRDCKFT ROI T available in U S A or equivalent commsrcially 15(1.5,I1) (BI Ci (ll) -(rc) 1-16) REOUISITE SERVICE Exhaust system removal/installation (page 23) Engine ail draining (location: page 3-3, step: section 2 or the Common Service Manual) . Clutch diussemblv (page 9v4)/asumblv (page 9-8) PROCEDURE O’ty REMARKS REMOVAL ORDER - Installatlan is In the tavern ordnr of removal. (1) Oil pan bolt 12 At installation, tighten the bait: in a gradual. crisscross pattern. (2) on pan I (3) Gasket I (4) Ralief valve 1 (5) 0»ring 1 (6) Oil strainer 1 Clean With the non-flammable solvent. . (7) O-ring 1 (8) Oil pump driven sprocket unit I NOTE: - Install the clutch outer onto the mainshaft temporarily . (page 9-8), hold the Ilywhul with the rotor holder and remove (or torque) the bolt. - Apply a locking agent to that tip of the threads (approx. 6 mm/0,2 in) (9) Washer 1 (IO) OII pump driven sprocket 1 At installation, install with the grouves facing insidei . (11) on pump mounting bolt 2 (12) on pump l (13) Dowel pin 2 LUBRICATION SYSTEM OIL PUMP DISASSEMBLY/ASSEMBLY PUNCH MARK GIROOVE (3) (1) Balers rnsralling them, clean all rsmovad pens moroughly with clean engine Oll. Ruler to sectlon 4 of the Common Servrce Manual for rnspecllon ln'ormatlon, Rafa! m paan 1-H lnr / Install the water pump drain bolt and cylinder drain bolt: with new sealing wash-"S. and connect thu aionon tube to the re- , / fl. “we .3"... (3) SUITABLE RESERVE TANK REMOVAL/ INSTALLATION Drain the coolant from the reserve tank (see above). [1) BOLT (3] RESERVE TANK Remove the rnunwing: — shock absorber (page 12-4), 7 rcaerve tank Inuunlillg bolt. 7 collar and reserve tank. Install the reserve tank in the reverse order all removal. COOLING SYSTEM THERMOSTAT REMOVAL/INSTALLATION FRONT REQUISITE SERVICE Fuel tank removal/installatlon (page 2-4) Coolam draining (page 5-3) ‘ Coolant ralill (section 5 o! the Common Service Manual) . Air clean" mass removal/installation (page 6-3) (1) l2) (3) (4) (5) (6) (7) (B) (9) PROCEDURE O’lv REMARKS REMOVAL ORDER - Installation is In the reverse order at removal. Ihermostat cover mounting bull 2 Siphon tube 1 Radiator host: 2 Install them with "0" marks facing up. Thermo sense! connector 1 Thurmnslm cover 1 04mg 1 Thermostat 1 Install the thermostat with Its hole side lorwalds. Thelma sensor 1 A! Installation. auplv sealant to the threads. Thermntmt hnusing 1 COOLING SYSTEM RADIATOR REMOVAL/INSTALLATION l3] REQUISITE SERVICE - Coolant draining (page 5-3) - Coolant refill (section 5 of the Common Service Manual] (1) (2} (3] (4) (5) (fl) PROCEDURE O'ty REMARKS REMOVAL ORDER - Installation Is In We reverse order of removalr Radiator hose 2 Install them with "0" marks facing up. Hm molar switch connector 1 Radiator lower mounting be“ 2 Rudiator upper mounting bolt/um 1/1 Fen motor connector 1 Cnllar 4 COOLING SVSTEM RADIATOR DISASSEMBLY/ASSEMBLY l3) l2) FAN MOTOR GROUND TERMINAL REQUISITF SERVICE ' Radiator removal/installation [page 5-5) PROCEDURE O’tv DISASSEMBLV ORDER l1l Radiator shroud attaching screw 4 . (2) Left and right radiator shroud 2 (3) Humor grille I (4) Fan motor shroud muulllillg bolt/nut 1/2 (5! Fan mnmr mounting nut 3 (6) Fan motor 1 (7) Cooling Ian 1 (a) Fan mmm Installation (page 8-5) (8] Sealing washer 1 (9) Camshaft Idle gear case 1 (10) Carburetor insulator 4 Al Installation, align the insulator groove with the engine lug, With the ’9 UP mark facing upwards (carburetor Slde). CAMSHAFI' IDLE GEAR CASE INSTALLATION Install the camshaft idla gear case dowal pins properly. NOTE - Wilhou! the dowal pin; installed properly. the camahlh idle gear may nm be able to ho installed omo the crank- shaft timing gaarr Install the camshah idla gear case onto me CVlindaL while moving the idle gaar lightly with (he gaar case held. the gear case should be lined up allgmly Irom the cvlindar. InslaII a new aaallnq washer and mounting bolts. Tighten bolt: in a gradual, la Ihown. CYLINDER HEAD NUT/BOLT INSTALLATION Install the cylinder head special nula as shown. Do not tighten them yer, Install (he cylinder head mounting bolts, Tighten this special nuts and mounrlng bolts In a gradual, crisscross panem. TORQUE: Special nut: 30 N-m (3.0 kq-m. 22 h-lhI Mounting bolt: 11 N-m (1.2 kg~m, 9 h»lh) CYLINDER HEAD/CYLINDERIPISTON I1) IDLE GEAR CASE (2| DDWEL PINS M (5 CORRECT d (3) TIMING GEAR (4) INCORRECT (3) BOLT means (9 , \- -@ (2) SEALING " Z WASHER (1) SPECIAL NUT FRONT (1) BOLT (2) SPECIAL NUIS CYLINDER HEAD/CYLINDERIPISTON CYLINDER HEAD DISASSEMBLYIASSEMBLY HANDv LAPPINU TOOL (1) \_ ta) s In} [3) -ipaqo 877) °o DOWN NOTE - Store the valve components in the same order they were installed so they can he reinstalled in the original positions. Refer to uction 9 of the Comman Service Manual tn: vnlvn guidi- inspection/replacement. RFOUISITE SERVICE - Engine removal/installation (page 72) - Cylinder head removal/installatinn [page 3.4) - Camshaft removal/installation (page 872) PROCEDURE O‘tv REMARKS DISASSEMBLY ORDER - Assembly is in the tavern order 0' disassemblvt (1) Valve bucket I6 NOTE: - Remove using e hendlepping tool. Do not damage the cylinder heed rbucket sliding surface, (2) Valve shim 16 (3) Valve Cotter 32 Removal/installation (page 3-7) (4) Retainer 16 15) Valve spring 16 Install them with the narvow pltch end laclng downt (6) Valve 16 (7) Stem seal l6 (8) Spring seat 16 (9) Valve guide 16 Be sure to duplicate the planar valve guide installed length (page 1»7) CYLINDER HEAD/CYLINDERIPISTON .— VALVE COTTERS REMOVALIINSTALLATION Remove the valve buckets and shims. lnstall mu cyllnflu head pmleclov imu xhe cylinder head- buckat sliding suvlace. VALVE nucxn HOLE norm-ran onua—xvzmoo r-\ (1] VALVE BUCKET HOLE PROTECTOR Illlflill the valve sprung compvessor onto the valve and com puss mo valve spring. (1) ATTACHMENT Flomuvc (or insulll the valve cutters. VALVE SPRING COMPRESSOR ATTACHMENT 07JME—KV201DO .IALVE SPRING commssson o1751—oo1oooo \/ (2] COMPRESSOR 8-7 CYLINDER HEAD/CYLINDERIPISTON CYLINDER/PISTON REMOVAL/INSTALLATION (1) c10l1.0, 7) 8-8 NOTE CYLINDER HEAD/CYLINDERIPISTON E- Rate: to section 10 ol the Common Service Manual tnr piston and piston ring inspection. ' REQUISITE SERVICE - Engine removal/installation (page 7-2) - Camshaft removal/installation (page B~2l - Cylinder head removal/installation [page 5 4| PHUCEDUNE O’ty REMARKS . REMOVAL ORDER . Installation is in the levelse ordel of Iemuval. (1) Water int bolt 3 (7) Wateu int 1 (SD 04mg 1 (4) Cylinder mounting bolt 1 {5| Cylinder 1 . l6) Gasket I Inatall with the UP mark lacing up and lmwardt (7) Dowel pin 2 l8) Piston pin clip 8 l9) Fiaton pin 4 (10) Pistan 4 Install them with the IN mark faclng to the intake side. (11) Human top ring 4 4- Install the top and sacond vings with the markings . (12] Piston ascend ring 4 I facing up. (13) Piston all Vina sat laid. rails and spacer) ‘ ' Space the ring and gaps l20° apart. - Space the side tail gene 20 mm (0.8 in) 07 move apart, 9. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 9-1 TROUBLESHOOTING 9-1 RIGHT CRANKCASE COVER REMOVAL] INSTALLATION 9-2 CLUTCH REMOVAL 9-4 GEARSHIFT LINKAGE REMOVAL] INSTALLATION 9-6 CLUTCH INSTALLATION 9-8 SERVICE INFORMATION 0 Clutch and gearshilt linkage maintenance can be done with the engine in the frame. 0 Engine oil viscoslty and level have an ellect an clutch operation. when the clutch does not disengage or the vehicle ”up. with clutch disengaged, inspect the engine oil and oil level belore servicing the clutch system. Do not damage the cover-case mating surface. Never allow Ioreign materials to get into the engine. .0... should be amend the. same amount. TROUBLESHOOTING clutch lever too hard - Damaged, kinked or dirty clutch cable - Improperly routed clutch cable - Damaged clutch lifter mechanism ' Faulty clutch filter plate hearing Clutch wlll riot dlungage or motorcycle creeps wIth clutch dlunglgad . Too much clutch lever free play - warped pletalel - Oil level too hlgh, improper oil viscosity or oil additive need Clutch allpe . Clutch lifter sticking ~ Worn clutch dlscs . - Week clutch springs No clutch lever lree play Clean any geeket off the crankcase cover-'crenkcasa mating surlace. ll the ahih lorlla, drum and transmission lauuile servrcing, remove the engine and separate the crankcase (Section 10). II it is no longer clear which bolt belongs In which hole, insert all bolts in the holes and check the exposed length: each Hard to shut - Misadiusted clutch cable - Damaged or bent shift fork - Bent shift Iork shaft - Worn gear dogs - incorrect engine oil viscosity - Incorrect gearshift linkage gnidn plate installation Jumpa out 0' gear - Damaged or bent ehift fork - Bent shilt Iork shalt - Damaged stepper arm - Worn gear engagement dogs or slots - Damaged SI’II" drum cam grooves CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL/INSTALLATION REQUISITE SERVlCE CLUTCH/GEARSHIFT LINKAGE ' Engine oil draining (drain bolt location: page 3-3, step: section 2 01 the Common Service Manual) 114) Timing mark hole cap/O-ring PROCEDURE O'ly REMARKS REMOVAL ORDER . lniullution is in the reverse order 01 removal. (1) Clutch cable 1 (2) Alternator wire connector 1 (3) Righ‘ crankcase cover bolt 14 NOTE: - At installation, apply a locking agent to the two bolt threads. (4) Right crankcase cover 1 Disconnect (or connect) Ihe Alternator 3P connector. (5) Gasket 1 (6) Dowel pin 2 (7) Clutch lifter pin 1 (8) Return spring 1 (9) Spring pin 1 NOTE: - Drive in I new spring pin using a pin driver until the pin does not int-flare with the lifter arm as shown. (‘01 Clutch llher arm I (1 1 ) OII seal I (12) Crankshaft hole cap cover 1 (13) Crankshaft hale cap/Owing 1/1 1/1 CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL [page 975) REQUISITE SERVICE - Right crankcase cover removal (page 9-2) PROCEDURE O’ty REMARKS (1) Clumh Iifwr plaw bolt 4 Remove them in a gradual. crisscross pattern. (2) Clutch Iiher plate 1 (3) Clutch lifter plate bearing 1 (4) Clutch spring 4 (5) Clulch cemer lack nut 1 Removal (page 9-5) (6) Luck washer 1 (7) Clutch assembly — Refer ‘0 page 1-10 fer specifica‘ion. (8) Clutch center 1 (9) -— spring seat 1 (10) 7 [udder sprlng 1 (11) clutch friclion disc C 1 Larger LD, disc/Color: black (12) — clutch plate a 1 Color: grey [13) Clutch fricfin disc B 4 Smaller |.D. disc (14) — nlumh plate A a Color: silver (15) — clutch friction disc A 1 Smaller |.D. disc/Calm: black (16) pressure plate 1 Refer to section 1 1 of the Common Service Manual for inspecfion Inlormelion. (17) Oil pump driven Snrocke! 1 Removal (page 4'3) (18) Clutch outer 1 NOTE: - Turn the crankshah clockwise and lace lhe flywheel "T” mark up so as not to interfere the primary driven gear with the crank weighl. - Du nut srill remove the needle bearing and outer guide, (19) Needle bearing 1 (10) Oil pump drive wrecker/drive chain 1/1 (21) Clutch outer guide 1 CLUTCH CENTER LOCK NUT REMOVAL If you have the universal type of the clutch center holder, you wrll be able to use it. Unsteke the nut. Set the clutch center holder to the pressure plate bosses and loosely install the nuts. CLUTCH CENTER HOLDER omen—00100” (U.S.A. only) Temporarily remove the tool and tighten nuts; then reinsull the clulch center holder mm the bosses Use at leut two clutch lifter plate bolts to secure the tool to the clutch. Hold the clutch cantor holder and remove the lock nut as shown. I! you do not have the above holder, use the below holder. Unsteke the nu Remove the clutch center lock nut as shown, CLUTCH CENTER HOLDER 07GMB—KT80100 (Nut IvllllbII In U.$‘AJ CLUTCH/GEARSHIFT LINKAGE (1) CLUTCH CENTER HOLDER \ . (3) NUT/WASHER PLATE BOLTS 2) CLUTCH LIFTER (1) CLUTCH CENTER HOLDER (2) HOLD CLUTCH/GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL/INSTALLATION (11) (12) \ / (13] GUIDE PLATE/DRUM SHIFTER ASSEMBLV SPINDLE ASSEMBLV U :\ :1 L xii]; ——_— NOYE Make sure the gears nkage can be operated properly after assembly. . REQUISITE SERVICE - Right crankcase cover removal/installation (page 9-2) CLUTCH/GEARSHIFI' LINKAGE . Clutch removal/installation (page 9744 9-5) PROCEDURE O‘tv REMARKS . REMOVAL ORDER - Installation is In the reverse order of removal. (1) Gearshift spindle ioin! belt ‘I (2) Gearshift spindle joint I At installation. align the punch marks on the joint and spindle. (3] Gearshih spindle i (4) Spindle return spring 1 (5) Washer 1 . (6) Shiner collar 1 (7) Guide plate mounting boil 2 (0) Guide plan/drum slnller assembly , Assembly: as Illustrated (9) — guide plate 1 Install onto dowel pins properly, or shiit to hard. (l0) — ralchlt pawl 2 Fowl orientation as shown . (l l) — plunger 2 (12) — spring 2 (13) — drum ahiitar 1 (14) Collar I (15) Dowel pin 1 (16) Stopper arm spring 1 (17) Spring collar 1 (18) Stopper arm 1 (l9) Waenar ‘I . (20) snm drum center bolt 1 At installation, torque alter applying a locking agent to bolt threads. (2|) Shift drum center l At installation, align the drum center groove with the dowel pin. (22) Dowel pm 1 CLUTCH/GEARSHIFT LINKAGE CLUTCH INSTALLATION (LS, 11) [5) 85 [8,5, 61) ‘ CLUTCH/GEARSHIFI’ LINKAGE REOUISITE SERVICE - Gearshift linkage installation (page 9-6] - Right crankcase cover installation [page 9-2) PROCEDURE O'ty REMARKS (1) Clutch eutar guide l (2) Oil pump drive sprocket/drive chain 1/1 (3) Oil pump driven sprocket I At lnstallation, install with the grooves facing inside. (4) Washer I (5) Oil nump drive sprucknl bolt 1 Apply zr locking agent to the threads. Installation (page 4-3). (6) Needle hearing I (7) Clutch outar 1 Installation (see below) (8) Clutch assemblv , (9) — prauure plate 1 (10) — clutch friction disc A 1 Smaller ID. disc/Color. black (11) — clutch plate A 4 Color: silver (12) — clutch friction disc 8 4 Smaller ltD. disc (10) — clulull plate 5 I Color: grey (14) — Clutch Iriction disc C 1 Larger LD. disc/Color: black (15) — iudder spring 1 Face the dished side 01 the iudder sprang to the outside. (16) — spring seat 1 (17) — clutch center 1 (18) Lock washer 1 With the OUTSIDE mark iecing up. 119] Clutch Center Inck ml! 1 Installation (page 9710) (20) Clutch spring 4 (21) Clutch llfter plate 1 (22) Clutch lifter plate bearing 1 Install it with the marked side facing nut. (23) Clutch liiter plate bolt 4 Install them in a gradual. crisscross pattern. CLUTCH OUTER INSTALLATION Turn the crankshaft clockwise and face the flywheel "1’" mark up so that the primary rlrivnn get! dues net intarlerc wiul lllH crank weight. Align the serrated teeth of the primary driven gear with the drlve gear teeth, as shown, and temporarily Install the clutch outer onto the mainshaft. While holding the clutch outer and pushing in on it lightly. rutate the all pump driven sprocket bolt. Install the clutch outer properly, aligning the clutch outer holes with the oil pump drive sprocket trusses. [1 l CLUTCH Rx (1) CLUTCH OUTER HOLE (2) SPROCKET BOSS CLUTCH/GEARSHIFT LINKAGE CLUTCH CENTER LOCK NUT INSTALLATION I! 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 clutch CLUTCH CENTER HOLDER 07HGB— OOIOOOA (U.SLAL OMVI Hold the Clutch cantor holder and torquc the clutch center lock nut as shown. TORQUE: 86 N-m (8.6 kn-m. 61 h-lbl Stake the lock nut onto the mainshalt. ll you do not have the above holder, use the below holder. Hold the Clutch center as shown and torque the clutch center IOCK nut. CLUTCH CENTER HOLDER 07GMB—K‘I’80100 (Not Ivnlllhle ln U.STAJ TORQUE: 85 N-m (3.5 kD-m, 61 R-l‘hl . Stake the lock nut onto the mainshaft. (1) CLUTCH CENTER 0 HOLDER ~ , \/ _ "EL. \ \‘L (2) CLUTCH \ \ LIFTER ._ \ ,E ' PLATE (3) NUT/WASHER BOLTS [1 ) CLUTCH CENTER HOLDER /' / __ 10. CRANKSHAFT/TRANSMISSION ’ SERVICE INFORMATION 10-1 TRANSMISSION REMOVAL] TROUBLESHOOTING 10-1 'NSTALLAT'M ‘ °'8 TRANSMISSION DISASSEMBLY/ CRANKCASE SEPARATION 10—2 ASSEMBLY 1040 CRANKSHAFT/CONNECTING ROD REMOVAL/INSTALLATION 1M CRANKCASE INSTALLATION 1 0-1 2 ’ CRANKSHAFT BEARING REPLACEMENT 10-6 SERVICE INFORMATION 0 Remove the engine and separate the crankcase to inspect the crankshaftl connecting rod and "ansmlsslon. I Son/Ice POIntE Service Item Removed Componems . Connechng rod 7 7 Cylinder head [page 3-4) i Cylinder/PIston (page 1+8) - Crankcase Separation (page 10-2) CIHIIMIIIHII - Starter clutch (page 16-8) Flywheel (page 14~7l Crankcase separation (page I0 2) Connecting rod hearing cap (page 10-4) Tren;miaaron crankcase separatlon (page 10-2) Gearshift linkage (page 9-6) - 0 Prior to assembling the crankcase halves, apply a sealant to their mating surface. Wipe o" excess sealant thoroughly, Mark and atom the bearing inserts to be sure or their correul locations for reassembly, II the Inserts are improperly installed they will block the oil hoIasl causing Insuflicient Iubrication and eventual Engine selzure. o II it ie no longer clear which hall Mlnnu< In which hole. inun all bolts in the holes and check the exposed lerrgrlrs; each should be exposed the Same amount‘ TROUBLESHOOTING Excessive noise Trammlulon jumps out pl gear - Wnrn connecting rod bcurlngs - Worn gear engagement dogs or slots - Bent connecting rod - Bent shin Iork shaft ' Worn C'lnkshafi main bearing . Damaged shift drum stopper arm - Damaged OI bent shilt fork Hard to ehm - Broken shin linkage return spring - Improper clutch Operatron o Damaged shift drum cam grooves . Incorrect engine oil viscosity - Incorrect clutch adiustment . Bent shift forks ’ ' Eont Ghifl fork :Ihah ' Bent shift fork claw - Damaged shm drum cam gmnws ~ Bent snil‘r spindle cRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION l2) 1 0-? ——— CRANKSHAFT IT RANSMISSION REOUISITE SERVICE - Engine (page 7-2) - Starter motor (page ‘65) - Clutch/nil pump driva chain (page 9-4) - Oil pan (page #3) - Lell crankcase cover (page 16-6) PROCEDURE O‘ty REMARKS (1) Upper crankcase bolt (6 mm) 6 Balls (2 psc/marknd A on she crankcase) have sealing washers. (2) Lower crankcase ball (6 mm) I3 Bolts (2 psc/muked A on the crankcase) have sealing washers (3) Lower crankcase bolt (8 mm) l3 Bolts (12 951:) have sealing washers. (4) Lowar crankcase l (5) Down pin 3 (6! Oil fin. 2 CRANKCASE BOLTS LOCATION (1) BOLTS: 26 psc Loosen all bulls in a gradual, urlsscross panarn, Bolts location: as shown A- boll With a sealing washer Clean any liquid sealant of! the crankcase mating surfacel (l) BOLTS: 6 psc I J UPPER CRANKCASE in"! CHANKSHAFI'ITRANSMISSION CRANKSHAFTICONNECTING ROD REMOVAL/INSTALLATION 1 0-4 ,_———_# NOTE CRANKSHAFTITRANSMISSION Determine the replacanwnt bearing color code according to the main bearing selection table (page 10-6) or the connect ing rod bearing selection table (page 107). Mark 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. Reler to page l-S lor crankshaft and rod specification. Refer to section 14 of the Common Service Manual for hearing inspection. REQUISITE SERVICE . Reler to Service Inlormation (page 10-1) PROCEDURE O’ty REMARKS REMOVAL ORDER (ll Connecting rad bearing can nut 8 . l2) Bearing cap 4 (3) Connecting rod 4 (4) Connecting rod bolt 8 Do not remove them without necessary. (5) Connecting roo bearing B Wlpe all oil from the boning seating areas. (6) Crankshaft 1 [7) Crankshaft main journal bearing 12 Wlpa all oil from the hearing seating areas. . INSTALLATION ORDER (7) Cranulmlt muln journal bearing 12 [he bearing tabs should be aligned with the grooves in the crankcases. (ll) Crankshaft 1 Install it onto the upper crankcase with the flywheel side lacing to the clutch side. (5) Connecting rod bear-no R NOTE- - The bearing oil hole should be aligned with the oil hole in the connecting rod. . (4) Connecting rod bolt 3 (3) Connecting rod 4 NOTE: - Face the oil holes to the intake side, (2) Hearing cup 4 install them with the code letters read properly. (1) Connecting rod hearing cap nut 0 Apply oil lo the nut threads and torque them In gradual, crisscross pattern, CRANKSHAFT/TRANSMISSKJN CRANKSHAFT BEARING REPLACEMENT MAIN JOURNAL BEARING SELECTION Record the crankcase LD. code loner: from the pad on (he left aim: n! the crankcase. NOTE - Letters (A, B or C) on the uppel cmnkcuo are the codes In: the main journal I.Drs from the left. Record ma corresponding main journal 0.0. code numbers from the crank weight. NOTE Numbevs (I or 2) on me crank weight are the cades tor the main jaumal 0.D.s hem me |eh. Cross relerence the case and journal codes to dalevmine tho lepluL‘HmBnl DBMIHG color coder Cvlnkc-u A i c ‘9 5°“ 33 000— 33.0097 330n— 33.008 mm 33.016 mm 3102‘ mm ern mmr \ n 2992— 11 29907 ”92999 0.0 code I 2995 In) 1 2999 ml 13002 n) 29.992 30.000 mm u was LISH my 29.984 29392 mm 2 (”805” ‘80: ml Yellnw Gm" Blown I Pm Volluw Gum aunng xhlckmm Brown: Thick Green: Yellow: Pink: Thin l1) CRANKCASE LD. CODE (1) MAIN JOURNAL O.D.CODE (1) MAIN JOURNAL BEARINGS [2) COLOR CODE 1 0-6 CRANKSHAFTITRANSMISSION CONNECTING ROD BEARING SELECTION Record (he connecting rod LDI code numbers on (he rod. . NOTE - Numbers (1 or 2) on (he connecting red are the codes var (he connscxing mu l.D.s. ' (1) CONNECTING ROD LD. CODE . Record \hs crankpin 0.D. code loner: from lhe‘ crank weight. NOTE - Letters (A or ED on the upper crankcase are the codes for Ihe cvankpln 0.0,: Irnm the left. (1| CRANKPIN O‘D‘ CODE Cross rem-nu (In: uraukuin and rod codes to deterrmne the replacement bearing color code. I" CONNECT'NG “09 BEARINGS Cunneumq rod 1 2 ‘2) COLOR CODE \ '-° ”a" 32,992 33001 7 3) U00 mm 33.003 mm Clankmn n 29397 «1,2992 7 0 D £003,777 1,2992 Int ‘.2595 ml 29.932 7 some mm A u I808 \ ran my “’"W GM“ 15 534 29 mar mm . ’ u r3057! raormr “W" 9”” Bearing lhicknsu Brown: Thin Black: Blue: Thick CRANKSHAFT/THANSMISSION TRANSMISSION REMOVAL/INSTALLATION 1 (LR CRANKSHAFTITRANSMISSION REQUISITE SERVICE - Rater to Service lniormation (page 10-1) PRUCEDURk Cl'w asuanxs REMOVAL ORDER - Installation is in the ravnru order of removal. (1) Countershaft assembly 1 At installation. align the bearing groove with the sat ring and align the oil seal with the case groove. (2] Countarshaft bearing set ring I . i3) Mainahaft haaring am pm. bolt 2 (4) Mainshah bearing sat plate 1 (5) Needle bearing 1 (fl) Washer 1 (7) Mainsheft M1 gear/spline washer/M6 gear — At installation, race the M6 gur angagamant dogl ior- ward the M4 gear. (5) Mainshah assembly 1 . (9) Center shift iork bolt 1 flamove after bending down the lock washer tab. Install and hand new lock washer tabs as shown. (10) Lock washer I Install a new lonk washer. ('I 1) Shin lurk shalt 1 At installation, face the shaft llattad surface side iorwerd the drive sprocket, (12) Right shift fork 1 Instell them with tha identification marks (R; Right. C: . (I 3) Center ahih talk 1:} Center. L: Left) facing torward the clutch side. (14) Left shift fork 1 (15) Shift drum bearing set plera bolt 1 (1 5) Dawel pin 1 (17) Shlit drum bearing set plate 1 (1B) Shift drum bearing 1 Install with the bearing stopper near the outside. (19) Slilil drum 1 1 0-0 CMNKSHAFTITMNSMISSION TRANSMISSION DlSASSEMBLY/ASSEMBLY I MAINSHAFT (7) (5) (10) (11) (14) ALIGN OIL HOLES : SHIFTER GEAR GROOVE *7. : GEAR SLIDING SURFACE NOTE and bushings‘ REOUISITE SERVICE - Trunnmissinn removal/installation (page 10-8) - Apply molybdenum solution to the miner gear gluuvest Apply oil to all allalng surface of the malnshuft, countersink - Install ma mum Wuhan and snap rings With the chlmlered edge facing to the thrust load side. - Refer to section 13 of the Common Service Manual for inspection inlormation, PROCEDURE O'ty REMARKS MAINSHAFT DISASSEMBLY ORDER (1) Needle bearing (2) Thrust washer (3] M2 gear [171) (4) Sniina washer (5i M6 gear (241') (3) M6 spline bushing (7) Spline was!!!" (5) Snap ring (9) M3 (1 STD/M4 (22T) shifter gear (10) Snap ring (1" Saline washel (12) M5 gear (231') (13) M5 bushing (14) Thrust washer (15) Mainshaft bearing (16) Malnshaft (Ml gear/Ian - Assembly is in the reverse alder ul disassembly. Align the oil holes of the bushing and mainshah. Install it with ma bearing stepper near the outside an 4" # CRANKSHAFT IT HANSMISSION 'COUNTERSHAFY (23) (24) (22) (20) (17) (16) 5) f P , PP? %5@P§N H7) (13; 9(5) (8) 7' :smrren GEAR . GROOVE ~7. :GEAR suomo FA E (2) (1--ma)<1)(151(12)(m (a) (7) (5) (y 5”" C r‘nocmufie O'Iv REMARKS COUNTEHSHAFT DISASSEMBLY ORDER ‘ Assembly is in the reverse 0'68! 0' disassembly‘ (1) Hearing Install wnh me sealed side vecmg omsnde. ' (2) Thrust washer (3) c1 usdl man (4) Need|e bearing (5) Thrust wuhev (6) C5 shiher any (33T) (7) Snap ring (8) Spline washer (9) 03 gear (SOT) (W) (:3 snlina bushing (11] Lock washer (12) Gplina waslm . (13) C4 geav (35T) (14) CA spline bushing (15) Spline washav . (16) Snap ring (17) C6 shifts! gear (32T) (18) Snap ring (19) Spline washer (20) C2 bushing (21) c2 gaal men (22) Thrusx washer ' (73) Oil seal (24) Bearing (25) Coumershah Align the ml holss o! the bushing and countersnan. Alxgn the all holes of (he bushing and countershah. )ns(all with the bearing stopper near (he outside. CRANKSHAFTITRANSMISSION CRANKCASE INSTALLATION (4) 612 [1.2. 9) (2) i 12 (1.2, 9) (3) —_ CRANKSHAFT/TRANSMISSION REGUISITE SERVICE - Crankshaft/connecting rod insrallatian (page 10-4) - Transmission installation (page 1078) . PROCEDURE Q'ty REMARKS ll) OII orifice 2 (2» Dowel pin 3 (3l Lowur crnnkcua 1 (4) Lower crankcase bolt (6 mm) 13 ' (5) Lower crankmsn he“ (8 mm) 12 » Crankcasa installation (see below] (5) Lower crankcase bolt (8 mm x 65) I (7D Upper crankcase bolx (6 mm) 6 CRANKCASE INSTALLATION Apply a lighl bu! muraugn coating or sealant re the upper crankcase mating surlace excepl to me main beallng jo'urnul ‘ ° bolt manng areas and the all passage area as shown. ( l (1) SEALANT . AREAS D Sm the mainshaft and countershan into naunal position first, m C6 SHIFTER GEAR (hen slide the us shifter gear mm the (:2 gear [2nd gear 00- . siliun) as shown, to Base upper crankcase rnsranamn. (2) C2 GEAR ,‘—_.—_—— xx ORANKSHAFI'ITRANSMISSION Sat xhe shift dlum in the 2nd gear posixion as shown. NOTE (2) " " FORK F The shiftevrpln of the Ian shift lmk (marked “L"l _\ I should be located as shown. (1) "L" FORK Align the |sh sh"! fork (marked "L") with the C6 shifter gear, and the light shin fork (marked ”H"! mm the C5 shih» ‘7) er gear first, then |owe1ing the lower crankcase, align the SECON 1% center shih 107k (marked "C") with the M3/M4 shifter gear, Fog-"ON ! A bl (h k . “em 9 e m" CBS” (6) cs SHIFTER a) "R" Make sule each cvankcase is assembled securely, 9 FORK 4) C5 ( SHIFTER [ ) M3/M4 SHIFTER l Inamll the crankcase hulls und seallng washers as shown (1) son's: 25 pec l NOTE - Four 6 mm bolts (marked A on the evenkcese) have sealing wanhcra. - Twelve 8 mm balls ['0' the C'Bnkshaf‘ mam joumals) have sealing washers ‘2’ - Four 8 mm bolls (marked A on the cvenkcase, (Q), @, LOWE ‘ ® and Q!) Is black in color. CRANK- ‘ 3} SEALING i CASE WASHERS Tighten ell crankcase bolts in a git-dual, criuevess puncrn, beginning wixh large! diamemr bolts livst as shown. TORQUE: 8 mm cmnkclle ball: 24 N-m (2.4 kg-m, 17 h-lbl 3 mm 1 ea cunkceu boll (£1): 27 Nvm (2‘7 kg-m, 20 n-Ib) ”’ BOLTS: 6 ”5° 8 mm evankoasu bolt: 12 N-m (1.1 hum, 9 "-1!” l '7 . , (2) . 0 _ UPPER O CRANKCASE o , a l O (31 SEALING 0 WASHERS 1n_14 4 1 1. FRONT WHEEL/SUSPENSION/STEERING . SERVICE INFORMATION 1 1-1 FRONT WHEEL DISASSEMBLY/ TROUBLESHOOTING 1 1-1 ASSEMBLY 1 1 ‘5 RIGHT HANDLEBAR REMOVAL, FORK REMOVAL/INSTALLATION 11 -6 INSTALLATION 1 1-2 FORK DISASSEMBLY 1 1 »8 LEFT HANDLEBAR REMOVAL] FORK ASSEMBLY 11-10 ’ 'NSTALU‘T'O" ‘ “3 STEERING STEM REMOVAL/ FRONT WHEEL REMOVAL] INSTALLATION 1 1-12 INSTALLATION 1 1.4 . SERVICE INFORMATION Rldlng an dnmnged rlme imnllrl tale ope “on 01 the vehicle - A contaminated broke - or pad reducu stopping power. Dioc-rd contemlneted pads and ole-n is contaminated disc with - hlnh quolltv b 0 deg! Ilng agent. - Inn-led ubutoll flh-r- new bun iound to come resulrutory ulleeu and cancer. Never use In alr hon or dry brulh to clnn bro 0 uumblieo. Us. In OSHA-upprnvod vncuum cleaner Or Iltemata method Ippmved by OSHA designed to mlnlmlre (h. hallld Gained by llrborn. lblllnn mull. Refer to the section 13 inr hruke system information. Refer to the section 17 for light, meter and switch inlormalion. Tubeless tire removal, repair, and remouting procedures are covered in the section 16 ul the Common Service Manual. ll the motorcycle has been involved in an accident, Inspect the llama very cerelully at the steering head and at the engine . mounts. Tllueu ale the areas rnosl likely to sulier damage. Ii is possible to bend the lreme steering head without bending the lurk tubes or even the front IXIBL I For wheel, fork or steering slum removal, a Jack or other support is required to support the motorcycle. Do not use the oil filter as an jack point. TROUBLESHOOTING led steering Wheel turn. hurl - Steering tiuau bearing adiustmenr nut too tight - Faulty wheel bearing .- Faulty steering head hearings . Brake drag [page 1311 - Damaged steering stern laces - Bent lront axle . Insulticrent tire pressure ' - Faulty tlrc Suh suspension - Weak lurk spring Steers to one side or does not track straight - Insuliicient lime in lulk - Bari! lurk - Low "Uld level In lork - Bent ircnt axle: wheel installed incorrectly - Low tire pressure ~ Faullv sleeilng head healings - Bent frame Hard suspension l - Warn when! hcurlng - Incorrect iiuld weight . Worn swingarm pivot - Bent iork tubes - Clogged lork lluid passage Front wheel wobbllnq - High tire pressule - Bent rim ' Worn from wheel bearings From suspension noisy . Faulty tire ~ InsuffICIent lluld In folk ~ Unbalanced tire and wheel - Loose iork lasteners FRONT WHEEL/SUSPENSIONISTEERING RIGHT HANDLEBAR REMOVAL/INSTALLATION NOTE - Using wires, hang the front brake master cylinder at least as high as the position it Wu originally installed at to prevent air lrom getting into the master cylinder. Do not twist the brake hose. - Route the cables and wire harnesses properly (page 149), - Adjust the throttle cable after installation. PROCEDURE U'ty INSTALLATION REMARKS REMOVAL ORDER ' lnstallation is in the reverse order at removal. (ll Front brakelight switch connector 2 (2) Master cylinder 1 Align the holder and with the punch mark on the. handle- bar and face the holder UP mark upward. Tighten the upper bolt first, then the lower belt, (3) Right handlebar switch housing screw 2 Tighten the front screw first, then the rear screw, (4) Right handlebar switch housing I (5) Throttle ceble nut I (6] Throttle calbe 2 Don't bend or distort the cables. (7) Handlebar weight 1 Align its bass with the inner weight. (8) Throttle pipe 1 (9) Throttle grip 1 Apply Honda Bond A or Honda Hand Grip Cement (USA. only) to the inside surface at the grip. (10) Stop ring 1 Install into the tork groove properly. [1 1) Handlebar pinch bolt I Tighten with the handlebar pushing forward. (12) Right handlebar 1 Align the handlebar bass with the top bridge slot. 11-2 FRONT WHEEL/SUSPENSION/STEERING LEFT HANDLEBAR REMOVAL/INSTALLATION NOTE - Route the cables and win- harnewec properly (page 148). - Adjust the clutch cable after installation. PROCEDURE O’tv INSTALLATION REMARKS REMOVAL ORDER . Installatlon is in the reverse order of removal. (1) Clutch switch connector 2 (2) Clutch level assembly 1 Align the holder and with the punch mark on the hand|8~ bar and lace the holder UP mark upward. Tighten the upper bolt first. then the lower bolt. (3) Lell handlebar switch housing screw 2 Tighten the front screw first, then the rear screw. (’1) Left handlebar switch housing I (5) Choke cable 1 fi (6) Handlebar wnight 1 Align rts boss with the inner welght. (7) Handle grip ‘I Apply Honda Band A 0! Honda Hand Grlp Cement (U.S.A. only) to the inside surlace of the grip. (8) Stop ring 1 Install into the fork groove properly. (9) Handlebar plnnh hnlt l Tighten with the handlebar pushlng torwam. [10) Left handlebar 1 Align the handlebar boss with the top bridge slot. —- FRONT WHEEL/SUSPENSIONISTEERING FRONT WHEEL REMOVAL/INSTALLATION - A com-minm-d bl.k. disc or pad reduced stopping power. Disc-7d oontlmlnuod pad! Ind clean a conumin-lld like with A hlflh qu-Iliy hul- decreasing mm. - Inhaled llbIllol fibers have been found to uuu ruplruory din-n and cancer. Never me n Ill how or dry brulh la nlnun brake nu-mbllu. Um an OSHA-Ipprov-d vacuum clam: or mom-n method unmoved by OSHA dulgned to m|nlmizu the hazard caused by airborne “besto- flbcn. CAUTION [- Do not nu an on mm u - i-ck palm. NOTE - Do net depress the brake Icvcr when me caliper is IEIIIUVELl, 0' ii will be dlmcult to ram the disc between the brake Dads. REQUISITE SERVICE - Raise ihe from wheel 0" the ground by placing a jack or oiher suppon under the engine. PROCEDURE O'lv REMARKS REMOVAL ORDER . Installation Is in the reverse order of removal. (1) Axle bolt 1 (2i Axle pinch mm 4 Only loosen the bolts. (3) Axis Shaft 1 {4) Front wheel assembly 1 (5) Left side collar 1 Shane! one (6) Righl side collar 1 Longer one 11—4 FRONT WHEEL/SUSPENSIONISTEERING FRONT WHEEL DISASSEMBLY/ASSEMBLY 30 (3.0, 22) - A com-minted brake disc or pad reduces napping power. Dlmrd contaminated pea: and clean a mtamlnated dllc wllh - high quality broke mruung mull - Alwavs renlece wheel bearings as a sat. - For wheel bearing replacement, refer to the section 1 or the Common Service Manual. REQUISITE SERVICE . Front wheel removal/Installation [page 11-4) PROCEDURE O'ry ASSEMBLY REMARKS bISASSEMBLY ORDER - Assemlflv is in the reverse order of disassamhlv. (1] Right side collar 1 Longer collar (2) Lelt side collar 1 Shorter collar (3) Brake dlsc bolt 6 Wipe a" all the grease on the bolt surface. (4) Brake disc 1 Install with the stamped side outward as shown. [5) Due! seal 2 Apply grease to me dust seal lips and install them With the lip side facing inside. [6] Right wheel bearing [6004 UU) 1 (7r Distance collar : I (8) Left wheel bearing 46004 UUI : 1 NOTE: l - Drive |n me left side bearing first. then the right side bearing. (9) From wheel/tire [ m 11-5 mom WHEEL/SUSPENSIONISTEERING FORK REMOVAL/INSTALLATION (6) GROOVE éHfi TOP BRIDGE UPPER SURFACE 11—6 FRONT WHEELISUSPENSIONISTEERING CAUTION . snupon m removed caliper with .- pan. or wire so am It do" no! rung Irom (In bnkn he“. Do mu min m- huh“ Mu. NOTE - Do not depress the brake lever when (he caliper is removed, or if will be difficult to refit the disc bemoan the brake pads. I Buiuru lemoving the fork, loosen (he fork can boil: bu‘ sfili do not remove in REQUISITE SERVICE - Righr handlebar removal/inamlluhon lpall 1172) - Front wheel removal/installation (page 1174) - Len handlebar removal inmnarion (page n-a) PROCEDURE O'tv REMARKS REMOVAL ORDER ' Installefion is in Ihe reverse order OI removal. (I) Front fender bolt 4 (2) Front lender I (3) Brake noae clamp 1 Inst-II It With me from lender as shown. ‘(dl caliper bracket boll 2 (5) Caliper assembly 1 (6) Meter mounting boil 2 Move me meter assembly forward. (7) Fork pinch bolt (lower) 2 Only loosen the bolls. (8) Fork pinch bolt (upper) 2 Only loosen the bolts. NOTE: ' Be careful not to let the fork leq drop when loosening (he Dlnch boil. (9) Fork assembly 2 Ar Installation, align the fork grooves wim the lop bridge upoer surfaces. 11-7 FRONT WHEEL/SUSPENSION/STEERlNG FORK DISASSEMBLY (11% ‘ ©4——"2] (10) t HIE!) (12 15) ( (0 ‘——(13) FRONT WHEEL/SUSPENSION/STEERING HEQUISITE SERVICE - Fork removal (page 1176) ' PROCEDURE Q'ry REMARKS (1) Fark cap bolt 1 ' The ion: up bolt in under hlgh pressure. Uu cam who" hounlng the bolt (3) Spacer (4) Spring seat (5) Fork splng (6) Dus‘ seal (7) Stnnnnr rung (5] Fork socket bolt . NOTE: ' - Temporarily install the spring and fork cap bolt ll dillicukv is encountered in removing the socket boll. ' (2) Orring Aha: removing, pour our any remalnlng fork oil. j—When removing them, do nm damage me lork tube. (9! Sealmg washer l (10) Fork piston 1 (I U Fork piston ring 1 NOTE: . . Do nor remove it unless it is necessary ro replace. (12) Rebound spring 1 (13) Fork lube 1 (l4) 0" seal 1 us) Back up ring 1 (16) Slldev bushing 1 (17] Fork tubs bushing 1 NOTE: - Do no! remove it unless it is necessary to replace. (18] Oil lock piece l ('9! York slider l FRONT WHEEL/SUSPENSIONISTEERING FORK ASSEMBLY Tighlar Coils Down ' t [14! (13 (12H (11 HO) 9! // ‘ . { ) x‘__0) 20 (1.0, 14) c 22(2.2,16) 11 an —— NOTE Clean all sassambled part . HEOUISITE SERVICE - Fork installation (page 1176] FRONT WHEEL/SUSPENSION/STEERING PHOCEDUHE O'ty REMARKS . (t) Fork slider I (2) Fork piston ring 1 Replace with e new one it it was removed lrom the pis' ton. (3) Hehound spring 1 (4) Folk piston assembly 1 Insert into the fork tube (10). (5) Oil luck piece 1 install onto the piston (4L (6) Fork tube bushing 1 Replace with e new one .i it was removed irom the tork p (7) Fork tube 1 (8) Selling washer 1 (9) Fork socket belt I NOTE: - Temporarily install the fork spring and iork cap bolt so . thet the piston is held in piece when the socket bolt is tightened. (10) slider bustling 1 (11) Beck up ring (12) Oil seal (13] Stopper ring (14) Dust seal (15) Fork spring (16) Spring seat [17) Spacer llBI (Hing . (19) Fork cap bolt NOTE: - Wrap vinyl tape around the fork tube top end to avoid damaging the oil scnl during the oil seal installeliou. - Drive in it securely, using iork seal driver (07947— KASOIOO) and attachment (07947 7 KFODi 00). Install into the slider groove securely. NOTE: - After installing it, compress the talk tube fully and pour the specified amount 0' lurk fluid (page 1-11) into the 107k tube, NOTE: - Wipe oil off the spring thoroughly using a clean lint tree cloth and install with tightly wound coll end Ieclng down. Tighten lightly. being careful not to crossrthreed the bolt; after instanlng the fork into the steering stern, torque the bolt. FRONT WHEELISUSPENSION/STEERING STEERING STEM REMOVAL/INSTALLATION 7 W [a)czs(2.5,1a) - glam H7) ©‘(91 (I7) g (C SHOHTER TABS: F\ ‘ -Bend down LONGER TABS: 35nd up ( I D} 11-19 é FRONT WHEEL/SUSPENSIONISTEERING NOTE - Bearings should always be replaced as a set- rnner and outer races. . Remove the (ark, after loosening the steering stem nut. - Check the steering head bearing prelued (page 1-11) after torquing the stem nut. REOUISITE SERVICE . Front wheel removal/installation (page 11 4) - Fork removal/installation [page 11-6) PROCEDURE O’ty REMARKS REMOVAL ORDER (1) Steering atem nut I Alter removing, renrove tlre lurk. (2) Washer 1 (3) luni'inn ewirr‘h rnnnnctor 2 Disconnect inside the headlight case (page 1-19). (4) Top bridge 1 (5) Headlight/Stay assembly 1 Support with a piece or wire so that they do not hang from the cables or wire harnesses. (6) Lock nut 1 NOTE: - Remove, after straightening the lock washer tabs. (7) Lock washer I (U) Steering head bearing adjuhllllerrt Irul 1 l9) Duet seal 1 (mi Starring sum 1 (11) Upper inner race 1 (12) Upper bearing 1 (13) Lower bearing 1 (14) Lower inner race 1 rReplace il they were removed. (1 5) Dust seal 1 - Use race remover attachment (O7953—MJ1000A) with (16) Upper outer race 1 driver (0794973710001) and attachment. (1?) Lower outer race 1 37 x 40 mm (0774670010200) (or upper outer race removal. - Us. race remover (0794673710500) with driver (079497371000!) and attachment, 37 x 40 mm (07746—00102001 (or lower outer race removal. INSTALLATION ORDER (17) Lower outer race 1 7 Replace as a set, il necessary. [16) Upper outer race 1 - Use attachment. 52 x 55 mm (0774670010400) and (15) Dus‘ seal 1 driver (07749—0010000) (or lower outer race installa‘ l14) Lower inner race 1 tron. (13) Lower bearing 1 - Use attachment, 42 x 47 mm (07746—0010300) and (12) Upper bearing 1 driver (07749 70010000) (or upper outer race installe- (1 1) Upper inner race r «on, ' Usc stccring stcm driver (07946—MEOOOOO) (or lower inner race installation. (‘0) Steering stem 1 (9) Dust seal 1 l8) Steering heed bearing adjustment nut 1 Installation: refer to section 18 or the Common Service [7) Lock washer 1 F Manual (Retainer~Tvpe Ball Bearings). (6) Lock nut 1 (5) Headlight Stay assembly I (4) Top bridge 1 (a) Ignition switch connector 2 Connect them (page 149). [2) Washer 1 (1) Steering stem nut 1 Temporarily install lork and torque the nut. 11 1Q ’_—_——_ 12. REAR WHEEL/SUSPENSION SERVICE INFORMATION 12-1 SHOCK ABSORBER DISASSEMBLY/ TROUBLESHOOTING 1271 ASSEMBLV ”'5 SWINGARM REMOVAL/ REAR WHEEL REMOVAL/ INSTALLATION 12-2 INSTALLATION 12-7 SWINGARM DISASSEMBLV/ REAR WHEEL DISASSEMBLY/ AssEMBLv 12,3 ASSEMBLY 12-8 snocx ABSORBER REMOVAL/ INSTALLATION 12-4 SERVICE INFORMATION u- - Th- Bhock nbwrhor connlm nitrogen undnr high mums. Do not nlow lir- or I'm! mar (ha Ihoclr ‘ththl. - Balnm dIspeuI of The shock number, "In“ ma nlmgun (sup: mlon 19 of tho Common Survlca Manual: Drllllng palm: pan. 1-11) - A conundrum: but. dlu: or and reduces 31090an pow-r. Dilurd com-mutated pod- and clan - conumlrmed dine with a hlgh quollty huh dour-ulna agent. - lnh-kd “ballot llborl h-v- boon found (0 emu uplrltory menu and clncar. Never uu In lIl' hose or dry bmsh to clun huh I: mbl Us. In OSHA-Ippmvlll vacuum clamor or unomno mothod approved by OSHA dulluncd m mlnlmlu tho hut-I'd cuuud by airborne "be-to: lib-n. - Rhflng on damngod rims Imp-In ul- upurullun M m vchlcln. I Refer to the section 13 for brake system inlorrnmion, O Tubeless lire removal. repair, and remounting procedure: are covered in the section 16 of the Common Service Manual. TROUBLESHOOTING Rur whul wobbllng led wnpohulon - Bem rlm - Damaged shock absorber upper or lower baanngs - Worn rear wheel bearings ' Incorrect suspension adjuslmanl - Faulty rlre - Hem damper rod - Unbalanced tire and wheel . Damaged swingarm pivm bearing ‘ Law tire pressure - HIglI lure pressure - Faulty swlngurm pivor bearingls) Rm Iulpnnllan noilv Wheel (um! hard - Loose lasleners - Faulty wheel bearings) - Brake drag (page 131) - Bem rear axle Soft Busponsion Wank spring - lncorrocl suspension adjustmem - on lankaga from damper unit - Low tire pressure REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL/INSTALLATION (4] (3) - A contaminated hmka dlslc a: pad undue” flopping pow" Dlucum conumln-tcd y-dl und chin a cont-mlnntad dllc wlth a hlgh qunllty brake manning lgcntt - Inhaled "but” lib-u have been "mud to Anna "salutary din-u Ind cane." Nave: use In air has- or dry brush to clean bilkl uumblhl. Uu In OSHAvIpprovld vlcuuln chino! of ultimate mlthod lpplovld by OSNA damned to mlnl . tho hazard c-uud by lirbom "but” "but. NOTE - Put the motorcycle on its center stand. - Do not dauress the brake pedal when the calipev is removed, or in will he difficult to run: the disc between the brake pads. - Support the removed callper with a piece of win: so that it does not hang (mm the brake hose, Do not twist the Duke hose. - Adjust the olive chain free play adiustment ahev installing the wheel. PROCEDURE O'ty REMARKS REMOVAL ORDER ' Installation Is In the reverse Older of removal, (1) Ram axis nm 1 l2) Dviva chain adjusting nut 2 Loosen Ihe lock nuts and loosen the adjusting nut fully. (3] Drive chain 1 Move the rear wheel lorward, and disengage the dvivfl chum lrnm the driven sprocket, (4) Rear axle 1 lb) Hear wheel assembly 1 . (6) Left side collar l (7) Right side calla! 1 9,0 - REAR WHEEL/SUSPENSION REAR WHEEL DISASSEMBLYIASSEMBLY 6 4014.0, 29) (14) (13) ii) 5 “WXl l l l ’ ,‘Ic 6516.5,47) A conundrum! brake disc or ma manna: mopping pouch blue-rd conumlnltad pad: and clean I contaminated dim: wlth I hlgh nullity hmke Gunning wont. NOTE - I'm driven wruulel removull loosen the sprocket nuts wrth the driven flange installed into the wheel hub. - Replace wheel bearings as 9 sets ' For wheel bearing replacement, rcfcr tn the section 1 0' the Common Service Manual. REQUISITE SERVICE - Rear wheel removal/installation (page 1272) PROCEDURE Q'ly ASSEMBLY REMARKS DlSASSEMBLV ORDER , - Assembly is in the reverse order 01 disassembly. (1) Right side collar 1 (2) Left side collar I (3) Right dust seal Ij—r Apply grease to the dust seal lips and install them With (4) Left dust seal 1 the llp side lacing Inside. (5) Driven flange assembly I (6) — driven flange collar 1 l7) — driven flauue bearing (6204 Ul 1 Install with the sealed side lacing out. (8) 7 driven sprocket nut 5 (9) 7 driven sprocket 1 (10) 7 diiven flange 1 (1 1) O-ring 1 (12) Rear wheel damper A 113) Brake disc bolt 4 114) Brake disc 1 [15) Lelt wheel bearing (6303 UU) 1 116) Distance collar 1 117) Right WIIUBI Dealing (6303 UU) '| NOTE: - Drive in the rlght Side bearing first. [hen the lell side bearing. [18) Rear wheel/tire 1/1 REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION 45 (4,5, 33) NOTE - Put the motorcycle on it center stand. removing the shock absorber from the frame. - Before removing the shock absorber for disassembly, adjust the shock absorber to position I (for lightest leads) baiare REQUISITE SERVICE - Fuel tank removal/installation (page 24) REMARKS (3) Shock absorber assembly PROCEDURE O'ty REMOVAL ORDER (1) Shock absorber mountina bolt (Unmrl 1:|——At installation install them from the left side. (2) Shock absorber mounting bolt (lower) 1 ' Installation is in the reverse order of removal. NOTE: - Remove il upwards from the frame. - Install with the drain tube forward. 19 is REAR WHEEL/SUSPENSION SHOCK ABSORBER DISASSEMBLY/ASSEMBLY 5" &\® / 08 (0‘8, 491 : / - The Ihoclr lbwrbcl conulnl nmnw under high pnIl - Bufon dllpolll of th- Ihocll lbwrbfl, '1th 1h. nitrogen (Slap: notion 19 01th. Common Savlcc MIMI-l; Drllng point: p.9- 1-11) Do not allow firs or hut nur tho shock lbtorb-rl NOTE - Adjust the shock absorber to position I (for lightest loads) balms removing the shock absorber lrom the lrame. - For Iawar joint n-adle bearing "placement, one next page. REOUISITE SERVICE - Shock absurber ramnvaI/inrtallation (Dig! 1274) PROCEDURE D'ty REMARKS DISASSEMBLV ORDER - Assembly is in the reverse order of disassembly, (1) Lower ioint 1 NOTE: - Removal/installation (page 126) - At installation, align (ha Iuwar joint with the seat stopr per pin. (2) Seat stopper 1 (3) Spring seat 1 (4) Spring 1 Install with the taper and facing to the adjuster, (5) Adjumr 1 (6) Lower joint lock nut 1 (7) Dumper rubber 1 (8) Damner 1 — REAR WHEEL/SUSPENSION LOWER JOINT REMOVAL/INSTALLATION Install the shock absorber compressor and attachment on the rear shock absorber as shown. SHOCK ABSORBER COMPRESSOR 07GME—0010000 (Not avallabk in U.S.A.I or 0795973290001 — screw assembly OTGME70010100 ATTACHMENT O7959—MB10000 Turn the compressor handle and slowly compress the spring. Hold the lower joinr and loosen the lock ‘nm (turn the nu: clockwise). Remove the lower join! and clean a" any lacking egem lrom (he rhreaua. lnsmllntion: Apply a locking agem m the damper threads, Install rhe lower joint securely onto the damner rad. Hole the lower joint and torque the lock nun ronouz: 68 Mom (6.8 kg-m, 49 mm Make sure the Lower Jolnr ls ellgned wltn the seat sropper pln and remove the compressor. LOWER JOINTS NEEDLE BEARING REPLACEMENT Remove the dust seals. Hold the ioint with a suitable mnl Press the needle bearing out oI the joinl. 5 Tom. DRIVER PIN 07GMD—KT80100 (Nat Iv-ilable In U.S.A.l ur PILOT, 22 mm 07746—0041000 DRIVER 0774970010000 Pack a new bearing WIth grease. Press she bearing mm the joint until mp bearing surfer: flushes wirh the joint surface as shown. D VER 07749r0010000 ATTACHMENT, 2‘ x 26 mm 07746—00107!” PILOT. 17 mm 0774670040400 II) ATTACHMENT (2) COMPRESSOR (I) LOCK NUT (2) LOWER JOINT (1) DRIVER I /(2) NEEDLE BEARING l5) SUITABLE TOOL [1] DRIVER (2) NEEDLE HEARING 1 9-2 REAR WHEEL/SUSPENSION SWINGARM REMOVAL/INSTALLATION 3/ )110i11.o,30) \fg” 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 Dadsl - Support the removed caliper with a piece oi wire so that it does not hang lrom the brake hose. Do not twist the brake hose. ' Ii rieuesseiv, loosen the rear engine mounting nut near the swingaim pivot to ease the swingarm removal/installation, REQUISITE SERVICE . Rear wheel removal/installation (page 12-2) PROCEDURE Q'tv REMARKS REMOVAL ORDER ' Installation is in the reverse order of removal. ii) Rear brake caliper (2) Brake hose clamp (3] Shock absorber lower mounting bolt (4) Swingarm pivot nut (5) Swingarm nivot shaft (6) Swingarm assembly 1 2-7 REAR WHEEL/SUSPENSION SWINGARM DISASSEMBLY/ASSEMBLY NOTE - For pivot bearing reolacemam, see nex‘ page. REOUISITE SERVICE Rear wheel removal/installation (page 1272) ' Swingarm removal/installerion (page 12-7) PROCEDURE O'tv ASSEMBLY REMARKS DISASSEMBLV ORDER ' Assembly is in the reverse order of disassembly. (1! Drive chain adjus‘er 2 Ins(all ‘hsm with ‘he UP mark facing up and the index mark lacing out. (2) mm pivm collar (3] Left pivot collar (4) Drive chain cover (5) Drlve chain sllder (6) Flight dust seal (7) Lo“ dust Goal (5) Dislance collar (91 Snap ring (10] Ball hearing (I l) Needle hearing Apply grease w :he lip. Inslall it into the groove securely‘ Replacement (page lZ-S) _.~_._._._..._._._. 1 2-8 o I SWINGARM PIVOT BEARING REPLACEMENT Press the righ‘ pivot bearings (ball bearings) nut o! the swing» arm. DRIVER SHAFT 07946— MJOOI 00 (Not Ivalllbln in U.S.A.I 0f DRIVER 07949—3710001 SeI xhe neadla bearing remover onto she left-pivot bearing (needle beefing) as shown. Press the bearing au! 0! the swingarm. NEEDLE BEARING REMOVER ATTACHMENT 07GMD—KY70200 [Not In M. DRIVER SHAFI' O7546—MJ00100 In U‘S.AJ or BUSHING REMOVER M967X—038—XXXXX DRIVER 0794973710001 Prnnn mu nuodlu bearing into the sw|ngarm wim me marked side facing our. NOTE - The bearing surface should flush wiIh Ihv pivo‘ inside REAR WHEEL/SUSPENSION (I) DRIVER 4 WW -(3) NEEDLE BEARING REMOVER ATTACHMENT surface as shown. DRIVER 0774970010000 ATTACHMENT. 28 x 30 mm 0794671870100 PILOT, 22 mm 07746—0041000 Press one ball bearing (inner bearing) imo (he swingarm first, men press in another on mp of it (outer bearing). UHIVEH 07749—0010000 ATTACHMENT, 32 x 35 mm 07746—0010100 PILOT, 15 mm 077‘6—0040300 (1 ) DRIVER (2) ATTACHMENT (4) NEEDLE BEARING \ (3) PILOTr (2) ATTACH- MENT ‘ ~ 131 PILOT (1] DRIVER (4) RA! 1 BEARINGS~ 13. BRAKES . SERVICE INFORMATION TROUBLESHOOTING FRONT BRAKE PAD REPLACEMENT REAR BRAKE PAD REPLACEMENT . FRONT BRAKE CALIPER REMOVAL] INSTALLATION REAR BRAKE CALIPER REMOVAL] INSTALLATION FRONT BRAKE CALIPER . DISASSEMBLY/ASSEMBLY REAR BRAKE CALIPER DISASSEMBLYI ASSEMBLY 13-1 13-1 13-2 133 134 13-5 1 3-6 13-7 FRONT MASTER CYLINDER REMOVAL/INSTALLATION 1 3-8 REAR MASTER CYLINDER REMOVAIJINSTALLATION 1 3-9 FRONT MASTER CYLINDER DISASSEMBLY/ASSEMBLY 1 3-10 REAR MASTER CYLINDER DISASSEMBLY/ASSEMBLY 13-1 1 BRAKE PEDAL REMOVAL] INSTALLATION 13-12 O SERVICE INFORMATION with I high quIllty brIkI Weaning IgIrIl. A nnmnmlnn'od but" till: or pad reduces napping power. Discard cont-mlnItId pads urld clun I contnmlnetad dlu: Inhaled Isbnton flbIr: have been lot-id to cauu lleIutnry dim-u and cancer. Never use In elr hour or dry brush to chart brIIII IsIImblIII. UII In OSHA-Ippmved vIcuum clIInIr or alternate rnIthod IpprovId by OSHA dIIionId to minimize the huIrd caused by airborne nib-etu- IlbIrs. O Spilled braku Iluid will severely damage instrument lenses and painted SHHIICIR It Is also harqul to 80m. rubber pans. Be very careful whenever you remove the reservoir can: make sure the front reservoir is horizontal Iirst. I Never allow contaminants (dirt, water, etc.) to get into an open reservoir. I Once the hydraulic system has been opened] or if the brakes leel spongy, the system must be bled. I Always use ircsh DOT 4 brake fluid from a sealed container when servicing the system. Do nut mix ailierent types ol fluid as they may not be compatible. 0 Always check brake operation beiore rldinq the mmnmycle TROUBLESHOOTING . Brake lIvIr/pedIl Ioft or spongy - Air bubbles In the hydraulic system Leaking hydraulic system Contaminated brake pad/disc Worn caliper piston seal Worn msrrtor cylinder piston cups Wurn brake pad Contaminated cllipel Caliper not sliding properly Worn brake pad/disc Low Iluid level Clogged Iluid passage Werped/uel‘ormed brake disc Sticking/worn caliper plstan Sticking/worn master cylinder piston Warn brake disc Contaminated master Cyllndnr Bent brake lever/pedal Brake lover/nodal hard ' C caged/restricted brake system - Sticking/worn caliper piston - Caliper not sliding properly - Clogged/Iaslvictad Iluid passage - Wurrl caliper piston seal ‘ Sticking/worn master cylinder piston - Bent brake layer/pedal BrIltu drIn ' Contaminated brake pad/disc Misalignod wheel - Worn brake pad/disc . Warped/deformed brake disc - Caliper not :lIding properly 111 BRAKES FRONT BRAKE PAD REPLACEMENT - A com-mm!“ bull. disc or pod nduou Hooping powor. Discard manila-Md pod! ma chin I cannula-rod dlu: with I high quality bull- d-gruting 006M. - Inholod two-Io: lib-n hon bun lound m mu ruplrnory dluau and may. Nov-7 uu In sly hon or dry bruuh lo clun brake summon“. Uu In OSHA-Approval: "mm chum or them-u mum! nwevod by OSHA damned to minlmiz- (in Mum cauud by Airborne amnion Hm. - Aft-r real-comm, ammo tho brak- lovar to not the clllpcr platom again“ the pods. NOTE . Do not depress lhe brake level whan me caliper is removed, or it will be difficull (a ram the disc belwaen the brake pads. 4 - Replica brake pads as a sat, - Apply a (run of silicone grease sum the pad pin so as no! in ms: it. REQUISITE SERVICE - Pushing the caliper against (he disc, push lho caliper plslons all (ha way in to allow the installation of new brake pads. PROCEDURE O'lv INSTALLATION REMARKS r REMOVAL ORDER - Installation Is in me reverse order of removal. (1) Par: pin plug 1 (2) Pad pm I lnsan me pin, pushing the pads against the and spring. (3’ Brake pad 2 Align the pad lug with ma pad relainer as shown. 1')" BRAKES REAR BRAKE PAD REPLACEMENT ,1.8l (1) 615113.13) / 61311317) A contImIn-tnd huh disc or pad reduces stopping power‘ Dlmrd com-mlnntod pad; nnd clean I contemlnntod disc with n high quality brake dean-sing agent. - lnhnlod «baton fibers have been lound to cluu respiratory Alan. and cancer. Never uu In nir hole or dry brush to clean brake assemblies. Use an OSHA-approved vacuum charm or nltemate method approved by OSHA dulpmd to mlnlmlu tho hex-rd caused by nlrbornn uboston "bent - After "pine-mum, op-nt- th- huh pedal to un tho clllper Dlflml ng-inst the pads NOTE . Do not depress the brake pedal when the caliper is removed, or it will be difficult to relil the disc between the brake pads. - Replace brake pads as a set. . Apply a thin coating of silicone grease unto the pea pins to prevent rust and allow easy pad movement‘ REQUISITE SERVICE - Pushing the uuliuel againsl the disc, push the caliper piston all me way in to allow the Installation of new brake pads. PROCEDURE O'ty REMARKS REMOVAL ORDER (ll Caliper mounting ball 1 Remove the bolt and swing the caliper upwardt (2) Pad pin plug 1 (a) Pad pin 1 (4) Brake pad 2 lNSTALLATION ORDER (1) Brake pad 2 Align the pad lug with the pad retainer as shown, (2) Pad pin 1 Insert rhc pin, pushing the pads against the pad spring. (3) Pad pin plug 1 (4i Caliper mounting bolt 1 1 1-1 BRAKES FRONT BRAKE CALIPER REMOVAL/INSTALLATION ( ) - A com-mlnnod brlIll dluc or and roducu stopping power. Dlmrd conumlnaud pads and claw I Dom-Inhaled dllc wllh u hluh quullty Brain dngrnnung Igor“. - Inhaled "hallo: fibers have how round to uuu "salutary dlulu Ind OII'ICOI'. vaor use III III hou ur dry brush to clan brake numbllu. the In OSHA-smut! v-cuum clunor or llama. method nppmv-d by OSHA dulgmd ta mlnlmiu th- huard cluud by whom. ”banal fibon. NOTE - ll you rumov- (he calinnr pistons, remove the caliper bracket bolts (4) balms disconnacring (he braka hose (3): nd place a pan under the caliper to catch the draining fluid and squeeze the brake lever slowly to push out the pistons. REQUISITE SERVICE - Brake pad romovuI/installnlion (page 13-2) - Brake fluid replacemunt/air bleeding (sauliun ‘7 0' ma Commnn San/ice Manual) PROCEDURE O'ty REMARKS REMOVAL ORDER - Installation is in me reverse order of removal. [1] Brake hose bolt 1 [2) Sealing washer 2 (3) Brake hose 1 At installation, press rha hose and against the stopper while lightening the hose bolt. (4) Caliper bracket bolt 2 (5) From brake caliper assembly 1 3-4 BRAKES REAR BRAKE CALIPER REMOVAL/INSTALLATION - A cont-mlnltod brako film: or pad "duo“ stopping power. Dllclrd contaminant! pad: and chin l com-mlnlt-d dim: wlth I high qtlolny Malta Marc-ulna count. - Inn-M I'M-ton fiber: haw In." lound to uuu mph-tow dluuc cod cane-r. N-v-r Inc an air lung or dry mum to clurl bull ammbllam Uu an OSHA-apmvod vccwm m or chimn- method away-d by OSHA designed to rrllnlrrllzo tho Murd uuud by Ilrbamn ”buta- Run. NOTE Bcfarc diaconnccting (ha brake how (I ). Blue a pan under the nnlipm to catch the draining fluid and squeeze the brake lever slowly to push out the piston. REQUISITE SERVICE - Brake pad removal/installation (page 1373) ' Braku fluid tenlacemem/air bleeding (sectian ‘7 oi the Common Service Manual) (4) Rear brake caliper assembly PROCEDURE Q'ty REMARKS REMOVAL ORDER - Installallon is in ma raverse order or removal. (1) Walru- hnse hnlt I Temporarily install the caliper onto the bracket. (2) Sealing washer 2 (3) Brake hose 1 At lnstallarion, press the hose end against the stopper while tightening the hose halt. 13-5 BRAKES FRONT BRAKE CALIPER DISASSEMBLY/ASSEMBLY Q-rfil c 23 (2,3, 17) C) 2.5 [0.25. 1.8) l" PAD SPRING ORIENTATION AS SHOWN e : l8) DUST SEALS - : (9) PISTON SEALS - lunar-a u butol «um Mva nun mum to mu respiratory am... and comer. Never uu an a: hm or dry bani. .2 clean br lumblln. Us. In OSHA—approved vacuum chemr or ohm-la mothod approved by OSHA dulgned to mlnlmllo the hazard Gounod by nlrbomo naboalol fibers. REOUISITE SERVICE ' Front brake pad remavel/inatallatian (page 132) - Front brake caliper removal/installation (page 13-4) - Brake fluid replacement/air bleeding (section 17 of the Common Service Manual) PROCEDURE O’ty REMARKS DISASSEMBLY ORDER - Assembly is in the reverse order of disassemhly. (ll Pm spun“ I Note the spring direction as shown. (2) Caliper bracket l (3) Blocks! pill bull buul I (A) Caliper pm bolt boot 1 Install Into the bracket groove securely. (5) Bracket pin bolt 1 . Apply a locking agent to the threads and torque it. Apply (El Callper pIn ball 1 j Slllcane grease to the pin. (7) Caliper piston 2 Install them with the conceived side away from the pad. (8) Dual seal 2 j- CAUTIONl (9) Piston seal 2 - s. car-M not to damage on piston sliding surface when remavlng seals. BRAKES REAR BRAKE CALIPER DISASSEMBLY/ASSEMBLY PAD SPRING ORIENTATION AS SHOWN clun broke numb mlnlmln the hazard «unit by Ilrbom- «bum mun. - Inhaled “bonus llbnls have been louml Io uuu ruplrnlury ulna“ and cane-L Navur uu an alr lien or dry brush to Us. In OSHA-approved vacuum ckoncr or Insulate method approved by OSAH dulgned to nEOUISITE SERVICE - Rear brake pad removal/lnstallmion (page l3~3) - Brake fluid replacement/air bleeding (sec‘ion 17 of the Common Service Manual) ' Rear brake caliper removal/insiallation (page 13-5) REMARKS PROCEDURE O'ty DISASSEMBLY ORDER lli Pad spring I (2) Pivot collar I (3) Pivm boot 1 l4) Caliper pln bolt book i (5] Caliper pin bolt 1 (6) Caliper piston 1 (7) Dust seal 1 [Bl Piston seal 1 - Assembly is in me reverse order or disassemblv. Note the spring diraclion as shown, Apply silicone grease to the sliding surlace, Install into the bracket groove securely. Apply a hacking agent to the threads and (orque it. Apply slllcone grease to the pin. Install il with the opening toward the pad. - CAUTION: - Be careful not in damage me nlston slidlng surface when ramovlng souls, BRAKES FRONT MASTER CYLINDER REMOVAL/INSTALLATION REQUISITE SERVICE ~ All bleeding (section 17 of the Common Service Manual) PROCEDURE O'tv INSTALLATION REMARKS REMOVAL ORDER - Inuallaxion is In tho ravcrss order of removal. [1) Right reawiew minor 1 (2) Brake lever pivot bolt 1 [3) Blska lever I [4) Brake hose bolt 1 (S) Sallinu Wdhllul 2 (6) From brake llgm swnch conneclor 2 (7) Mun" cylinder hwldev bolt 2 Thightsn me upon! bull first, then the lower ball. (8) Master cylinder holder I Face the UP mark upward. (9) Master cvlindel assembly I Align the holder find with the punch mark n0 the handle bar. 1‘) O BRAKES REAR MASTER CYLINDER REMOVAL/INSTALLATION REQUISITE SERVICE - Blake fluid replacement/a" bleeding (section 17 of the Common Service Manual) PHOCEDURE O'lv REMARKS REMOVAL ORDER - Installation is in the reverse mum of removalv (1) Brake hose bolt 1 (2] Sealing washer 2 [3) Brake hose 1 [4) Master cylinder mounting boll 2 Only loosen me bolts. (5) ruulpau blaukul Llull 2 [6) Reservoir hose iaint 1 17) o ring 1 (8) Push rod joim i inmn il imm me “wrong side wim a new Boner pm. (9) Master cylindey assembly 1 Remove the mounting balm (4) and mama: cylindar BRAKES FRONT MASTER CYLINDER DISASSEMBLY/ASSEMBLY 2 (8) (page 1-17) NOTE - Replace the marital plsluil, sullng. uuus. sluvuer ulalu, slum ring and bum as a sat. ' The masler cvllndel piston, cups and swing musl be inslallsd as a sell REQUISITE SERVICE - Air bleeding (seclion 17 of the Commun Service Manual) - From masmr cylinder removal/installation (page 13»B) PHOCEDURE O'tv ASSEMBLY REMARKS DISASSEMBLY ORDER ' - Assembly is in the reverse order of dlsassembly. (ll Reservoir cover 1 (2l Diaphragm plate I [3) Diaphragm 1 (4) Front brakeliuht swrtch 1 (5) Boat 1 (6) Snan ring 1 CAUTION: - a. can-in m. lnlp rlng I: fully seated in ma groan, (7) Stopper plate 1 (8) Master piswrl assembly I (9) Spring 1 Install il wilh its small coil and (award the pisxon. 13-10 REAR MASTER CYLINDER DISASSEMBLY/ASSEMBLY BRAKES rfil 4) t » (page |-‘ 7) PUSH ROD INSTALLATION LENGTH film I 7 [1 V7, ‘ 1 2) - .36 46 mm (1.8 in) \ ® NU | I: ‘ Replace the master piston, spring, cups. snap ring and boat as a set. - Yhe master cylinder piston. cups and spring must be installed as . set. REQUISITE SERVICE - Brake fluid veplacemant/Blv bleeding [section 17 of the Common Service Manual) - Rear master cylinder removal/installation (page 13-9) PROCEDURE Q’ty ASSEMBLY REMARKS DISASSEMBLV ORDER - Assembly is in the reverse order cl disessemblv. (1] Push rod joint 1 Adjust the joint installed length as shown. Face the joint tab side as shown (2] Boat 1 (al Snap ring 1 CAUTION: - B- een-in the men ring In lullv mud in the groove. (4) Punh rod 1 Apply silicone grease to the rod Meet (5] Master piston assembly 1 (6) Spring 1 Install it with its small coil and toward the piston. 12-1 1 BRAKES BRAKE PEDAL REMOVAL/INSTALLATION HOOK AS SHOWN NOTE [T Adius‘ me brake pedal hiigm afrar installanon. PROCEDURE O'W REMARKS REMOVAL ORDER ' Installmlon is in me reverse order of removal. (1) Foomeg stay bolt 2 (2) Push rad IOIM 1 Install It item the footpeg side wi‘h a new cotter pin. (3) Foomeg mouming bolt 1 Apply a locking agent to the bolt threads. (4) Wave washer 1 (5) Rear brakeugm swnch spring ! (6) Brake pedal return spring 1 (7) Flight rampeg 1 Align the voorpeg with me stay groove. (8) Brake pedal 1 Apply grease m we pedal pivot 13-12 14. CHARGING SYSTEM/ALTERNATOR SERVICE INFORMATION 14—1 CHARGING SYSTEM INSPECTION 14—4 SYSTEM LOCATION 14—2 REGULATOR/RECTIFIER 14—5 CIRCUIT DIAGRAM 1 4-2 ALTERNATOR 14-7 TROUBLESHOOTING 14—3 NOTE SERVICE INFORMATION m 0 Always turn 0" the ignition switch helore disconnecting eny electrical component, CAUTION - Som ctrlcel component: mly be demegod It tennlnalo or connector: or. connected or dlwonnemd while the Igni- Iha battery gives off explotlve gnu]: keep tperlto. flame, and cigarettes owey. Provide odogulto vontllltlon when charging or using the battery In an enclosed spice. the battery contain- eullurle acid (electrolyte). Contact with Iltln or eyn mly canoe severe burns. Wear protective clothing and a loco ohleld. — ll electrolyte got- on your «In. flush with water. — It electrolyte gete In your eyes, Men with water lot It lent 15 minute: nd call I physician Immedlltely. Electrolyte Io pol-ammo, ll endowed. drink lune mammal o! var-tor or mllt Ind lolow with mlllt ol Inmate or vege- table oil and call a physician. KEEP OUT OF REACH OF CHILDREN. tlon twitch ll ON and current It present, For extended storage, remove the battery. give it a lull charge, and store I! in a cool. dry place For battery remaining in a stored motorcycle. disconnect the negative battery cable lrorn the battery terminal. The maintenance lree betterv must be replaced when H reaches the end of its service life, J CAUTION The battery cape should not be removed. Attempting to remove the healing caps from the cells may damage the bet- lury. Battery can be damaged ll overcharged or undarcherged, or if left to discharge lor long periods. These same conditions contribute to shortening the “lite spen" of the battery. Even under normal use, the perlormenoe of battery deteriorates alter 2 — 3 years. Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop Quickly and eventually die out For thie mutton, rhn rhhroing eystem is nhnn sllspnntnd In he the problem. Battery overcharge often results lrom problems in the battery Itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery, Under these conditions, the electrolyte level goes down quickly. Before troubleshooting the charging system, check lor proper use and maintenance of the battery. Check if the battery is lrequently under heavy load, such as having the headlight and terllrght ON for long periods ol time without riding the motor- cycle. The battery will sell-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sullation from lorming. Filling a new battery with electtnlyte will produce some voltage, hm in order to achieve its maximum performance. always charge the battery. Also, the battery life is lengthened when it is initial~charged. When checking the charging system. always follow the steps in the troubleshooting llow chert (page 14—3). For battery testing/charging, refer to section 22 of the Common Service Manual. For charging system luualiull, see page 1472. 14-1 CHARGING SVSTEM/ALTERNATOR SYSTEM LOCATION (1) ALTERNATOR (2) MA|N FUSE [INTO STARTER RELAY I4) BATTERY SWITCH) (3) REGULATOR/ RECTIFIER CIRCUIT DIAGRAM I1) ALTERNATOR (2) MAIN FUSE I 30A 7 v v v G RIW I3) REGULATOR/ RECTIFIER G» a (4) BATTERY 14-9 TROUBLESHOOTING Bonny ovorchnrglng - Faultyregulator/rectifier Bonny undomharglng Measure the battery current leakage (Leak test) (mg: 1474) CHARGING SYSTEM/ALTERNATOR Check the regularorfiecmier unit inspection (page 14-6) —INCORRECT —J CORRECT Inspect the charging voltage (page 14-4) ' NOT CHARGING Check tho Voltlg“ OI the regulator/rectifier but Ljery charging line ”1'9 ground lino (page 14-5) NORMAL Check the alternator (charging coll) resistance at the regulator/rectifier connector (page 14 5) NORMAL INCORRECT CORRECT shorted “Iire harness Faulty ignition switch Faulty raguIntor/reclilier CORRECT C heck the battery uaing a Honda Battery Tang I INCORRECT CORRECT Electric system overloading Faulty battery —ABNORMAL—>~ Open circuit in wire harness - Poorly connected connectors —ABNORMAL ——-I (innings charging coil et alternator (page 1477) ABNORMAL NORMAL Poorly connected aIternator connector Faulty alternator — ABNORMAL »- Faulty regulator/rectifier Check the TI‘BQUIBIONYGCIIIIQT unit inspect-on (page 146) NORMAL L——o - Faulty battery ‘I/L'J CHARGING SYSTEM/ALTERNATOR CHARGING SYSTEM INSPECTION LEAK TEST Turn off the ignition switch, and disconnect the ground (Al cable from the battery. Connect the emmeter H) probe to the ground cable and the ammetar (—l probe to the battery (-l terminal. With the ignition switch all, measure the leakage current. NOTE - When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current Ilow larger than the range selected may blow DUI the IUSB in the (8516'. . While measuring current, do not turn the ignition on. A lulflflnn (titan nf min-n! may hlnw am the his: in the tester. SPECIFIED cunnsm LEAKAGE: 0.01 mA llllx. if current leakage exceeds the specified veiue, a shorted cir- cuit is likely. Locete the short by disconnecting connections one by one and measuring the current. CHARGING VOLTAGE INSPECTION NOTE Before periorming this test, he sure that the battery is fully charged whose voltage between its terminals is greater than 12.8 v. Start the engine and warm it up tv operating temperature, then turn the ignition switch OFF. Connect a multitester between the battery terminals. DIGITAL MULTITESTEH 0741 1 70020000 or KS—AHM—32—003 (USA. only) CHARGING SYSTEM/ALTERNATOR Disconnect the starter relay swttch connector and remove the main fuse [30 A), Reconnect the cannector onto the relay ‘ (I) MAIN 2 swltch. FUSE l )CDNNECTOH . Connect the ammeler as shown (3) STARTER RELAY CAUTION SWITCH - Bu uanrlul nut to “hurl any taster probes. (4) AMMETER - Although the current could bl measured when the em— rrtet-r is connected between the battery positive tormlr ml and the positive cable, e sudden surge of current to the etnrter motor could damage the errrmeter. - Always turn the Ignition off when conducting the test. Dieconnectlrtg the mummy or wlros when current is flowlng may dlmlqe the emulator. . Start the engine and increase the engine speed gradually. REGULATED VOLTAGE: 14.0—16.0 VI5,000 rpm CHARGING CURRENT: 0‘8 A15,000 rprrt REGULATOR/RECTIFIER m muLucia/RscypigrlK WIRE HARNESS INSPECTION / ‘ Remove the rear fairing (page 272i Disconnect the regulator/rectifier connector and measure the following between connector terminals of the wire harness side. . Item Terminals Specification Battery Red/White (H and Battery voltage charging line ground [7) should resister. ’ Uroundline Greenandgruund Continuilyexist. Charging coil Yelluw and Yellow 0.1 70.5 n line l20°C/68°F) CHARGING SYSTEM/ALTERNATOR UNIT INSPECTION Remove the regulator/rectifier. Inspect the regulator/rectifier unit by measuring the resisA tance 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 it the probes touch your finger. - Use the lollewing recommended muttltestert Using another menulecturer’e equipment may not allow you to obtain the npouiflcd values. This is due to the characteristic of semiconductors., which have dit- UM: m terent resistance value depending on the applied volt- + Q) (1) ® (D G) age. 7 (T) \ w e- u: u: SPECIFIC MULTITESTER: \ ‘ . a _ 07411-0020000lKOWA 0‘9"“ M”) (5 0.5—10 \ 30»500 mssoo 107200 — KS—AHM—aZ—OO3 ® (LEI—‘0 30~500 ‘\ 30—500 ”17200 (KOWA DIgIt-l typo; USA. only] (A) 0.57 to 30 , 500 so eoo ~ to 200 v 0730370020001 [SANWA Analogue Kym] _ _ _ _ _ YH—SH [KOWA Analogue "POI ® I 20 0.5 I0 05 10 0.5 10 - Select the following range. SANWA t KOWA teeter . when using the KOWA multitester, remember that all reeuirtue should be multiplied hy IOO. - An old, weak multitester battery could cause Inaccu- rate readings. Check the battery it tho multiteatcr rcgil ters incorrectly. Replace the regulator/rectifier unit if the resistance value be- tween the terminals Is abnormal. install the regulator/rectifier in the reverse order at removal. NOTE - install the qrnund wire mtn the ragttlntnr/ractifie' lower mounting bolt properly as shown. l1) REGULATOR/ RECTIFIER G) i in: 5. l2) BOLT m a: m / (3) GROUND WIRE 0.57M) i (Ts—to \\ 307500 30—506 107200 .. e 0.5410 1—20 0.5—I0 0.5710 0.5»10 ALTERNATOR CHARGING COIL INSPECTION NOTE It is not necessary to remove the allalllalm llulll the engine. Disconnect the alternatar 3P black connector and measura the resistance bctwean conneclor terminals (Yellow and Yelr low). STANDARD: 0.1705 n (20°CIOB"FI Check for contlnuity between the Vallow wire terminal and ground. There should be no continuity. STATOR COIL/FLYWHEEL REMOVAL] INSTALLATION Remove the Iollowing: 7 right cranknau: mum (ma 9-2). — flywheel bolt. 7 washer. — flywheel. 7 woadruff key‘ Remove the bolt and stator wlre harness clamp. Removo the bolts and statorl Apply slacking agent :0 the stator mounting bolt thraads‘ INSTBII [he SIBIOI' And tlghtan the bolts securely. 5m the wire harness grommet into the cover groove and ".7 utall the clamp. Clean any material 0" the crankshalt. Install ma following: — wuudlu" lay. 7 flywheel. _ wather — flywheel bolt. TUROUE: BS N~m (8.5 kgrm, 61 «lb! — right crankcase cover [page 92) CHARGING SYSTEM/ALTERNATOR (1) ALTERNATOR CONNECTOR (I) WOODRUFF KEY I4) FLVWHEEL m (page 147) (3) BOLT - -(page 1717) (Z) GROMMET BOLT (4) FLYWHEEL (3] son (03981‘171-[page1-17) 15. IGNITION SYSTEM SERVICE INFORMATION 1 5— 1 IGNITION COIL 1 5-6 SYSTEM LOCATION 15-2 PULSE GENERATOR 15-8 CIRCUIT DIAGRAM 1 5-2 SIDE STAND SWITCH 1 5-8 TROUBLESHOOTING 15-3 IGNITION TIMING 1 59 IGNITION SYSTEM INSPECTION 1 5-6 SERVICE INFORMATION 0 When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 153). o The transistorixed ignition system use an electrically controlled ignition timing system. No adjustments can be made to the ignition timing. 0 A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect. I The spark unit may be damaged it dropped. Also, if the connector is disconnected when current is flowing, the excessive voltage may damage the unit. Always turn off the ignition switch belore servicing. . A faulty ignition system Is often related to poorly connected connectors. Check those connections before proceeding. 0 Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine crankr ing speed as well as no spark at the spark plugs. 0 Use spark plugs of the correct heat range. Using spark plugs with an incorrect heat range can damage the engine. Rater to section 2 ol the Common Service Manuel. 0 For neutral switch inspection, refer to section 25 of the Common Service Manual; to: switch location, see page 15-2 of thls manual (SVSTEM LOCATION). O For the ignition switch and engine stop switch inspection. check Ior continuity on the continuity chart at the WIRING DIA~ GRAM, page 184. Disconnect each switch connector inside the headlight case (page 1-19) and check it. o For side stand inhibitor system instructions, see page 15-5 ”NOTE" ol the troubleshooting, IGNITION SYSTEM SYSTEM LOCATION (1) SIDE I2) ENGINE (4) MAIN (5) FUSE (-I BATTERY (7) SPARK STAND W STOP SWITCH (3) IGNITION INDICATOR I 'I NEUTRAL SWITCH /A\§"1\\ IT 1) SPARK PLUG I16 PULSE (8) SIDE STAND GENERATOR SWITCH CIRCUIT DIAGRAM I4I MAIN ('IZI IGNITION (5) FUSE FUSE 3° A SW'TC” 10 A (1) SIDE STAND SWITCH INDICATOR 68> —Q./'b—R —c/c>n/aI——qro—I3I/BI EV/Bl down (2) ENGINE STOP (5)2351. (6) BAYTERY SWITCH 3.: G ‘0 A Ia) SIDE —aI/w—o/o—ITI STAND G/W ‘2 SWITCH To Tachometer up . Ell/W W5 I Y/Bu my v Bu/V T‘ (10) PULSE GENERATOR R (3) IGNITION m__. W COILS W I" m 32%“ (9) NEUTRAL i I I V SWITCH [11) SPARK PLUGS w (4 r23 (3‘: T.— I %I- I— = , F 1 5—9 TROUBLESHOOTING No spent at all plugs lFIultv input system) Check for loose or poorly Gunnaatcd spark unit COI’II’IBCIO'. — ABNORMAL—>- | NORMAL Check let loose or poorly connecleu ignition coil 4P mini connector. NORMAL V — ABNORMAL —->- Check if battery voltage Is measured between power input line (Black/White) and ground (Green) at the spark unit connector with the igni- tion switch ON and the engine stop switch at RUN (page 15-6). — N0 VOLTAGE —>- BATTERY VOL AGE MEASURED unit connector (page 15-6) Measure the pulse generator resistance at the NORMAL —l_ spark unit connector (page l576). Check the neutral switch lor continuity at the — ABNORMAL 4. NOHMAL U chalk the side stand switch Hi the spark unit cojnector (page 15-6). GOOD D . Faulty spark uIlil _ ABNORMAL IGNITION SYSTEM ll there is no spark et all plugs, the problem could be at the input ol the ignition system (pulse generator, power input crrcuit oi the spark unit, neutral switch, side stone switch or spark uth Poorly connected connector Poorly connected connector Faulty ignition switch or engine step switch Open circuit in wire harness Loose or pool Contact ol related circuit can nectors —ABNORMAL—> Check the pulse generator (page 1 B] 7 ‘l— l NORMAL ABNORMAL - Feulty pulse gener- ator Open circuit between the unit and pulse genelr 0K0! Lease or poor contact of the pulse generator connector Check the neutral switch. NORMAL ABNORMAL - Faulty neutral switch Open crrcuit between the unit and neutral switch Loose or poor contact of the neutral switch connectors Check the Side stand switch (page 15-5). NORMAL ABNORMAL Feullv Side stand switch Open circuit between the unit and Bide stand switch Loose nr pom contact at the side stand swuch connectors 1%-? I; IGNITION SYSTEM No spark at silt-Ir ignition group - If there is no spark at either group, the problem il suspected in the primary coil side oi the ignition system (ignition coil, or unit and ignition coil circultL s 't n the i nition coil rimar terminal HN° 59““ '—1 W' c . 9 D _V condition Remove the laulty pair ignition coil and check connection between the faulty pair and good — . . . . ir Tr I ark m 'l a sin remains with the ignition coil resistance (page 157). pa ‘ y D 3’ g ‘ Iaulty pair ABNORMAL "No Spark" condition - Faulty ignition coil shifts to other pair - Faulty spark plug wire ' . . . OUT OF 2":2“;:&°::;::::fl";° if??? ”mm” °°" “ — STANDARD—w Four or loose Contact or ignition coil 4P mlnl D P 9 ' VALUE connector GOOD - Open circuit between the unit and ignition coil - Faulty spark unit No spark at an: plug (Trauma in .0de col aide) - Faulty spark plug is most likely. Replace (warren?! bad spark plug) wnn knownfi good spark plug and conduct spark test SPARK—>- Original spark plug no good. N0 SPARK ark test on good lgnrtlen co Put the spaxpligiwlra on and measure resus- —NORMAL——@ict tanea of ignition secondary uuil (page 15-7). A OUT OF STANDARD VALUE SPARK Remove the spark plug wire, and measure the OUT OF resustance 0' ma Ignition secondary coil [page —$TANDARD—>- Faulty ignition coil 1 5-7). VALUE ‘l‘ ,fi_— _ GOOD . not contact 0! spark plug wire ~ Faulty spark plug wire — IGNITION SYSTEM Engine stuns. but Ilde "and switch do” not function It I". NOTE . The side stand switch should function as lollows: - When the transmission is shifted into a gear from neutral with the side stand down. the ignition shuts oil and the engine will stop. . When in neutral, the neutral swrtch line (a) of the spark unit is connected to ground via the Side stand switch. thn the side stand is up, the side stand switch line (bl ol the spark unit passes to ground we the side stand switch. The spark unit monitors lines (e) and (h). and provides spark only when one or both of those lines is connected to ground . via the neutrxl switch or the side stand switch. Check the side stand indicator lor lunction. NORMAL —>- Open circuit in Green/White wire 1* ABNORMAL Check the e e stand sw ch (page NORMAL —>- Loose or poor contact 04 related connectors . Open circuit in Green/White wire ABNORMAL - Burnt |ndlcaIOl bulb - Fanny side stand switch IGNITION SVSTEM IGNITION SYSTEM INSPECTION CIRCUIT INSPECTION Remove the seat. Disconnect the connector from the spark unit and conduct these tests at the connector. Item Terminals Specification Puwer source input line BIAhk/WhlIB H) and ground (A! Battery vultags should resistor with the ignition switch ON and the engine stop switch at HUN. Pulse gnnerator coil Yellow and White/Yellow 3407 420 n (20°CI65“F) Ignition primary coil No. 1—4: Black/White and Yellow/Blue No. 2 73: Black/White and Blue/Yellow 2—4 0 (20°C/68"F) Neutral switch line Light Green/Red and ground Continuity into neutral No continuity in any gear except neutral Slde stand switch line Green/White and ground Ground line Green and ground Continuity with the side stand up No continuity with the side “and down Continuity INSPECTION Ulsconnect the ignition coil 4P mmr connector under the fuel tank and measure the primary Corl resistance between the terminals INIUW. - No. I 74 primary coil' Black/White and YeIIow/Blue - No. 273 primary Cori: Black/White and Blue/Yellow STANDARD: 2774 (I I20°Cl68°FI 1 5-6 (1] IGNITION COIL CONNECTOR Disconnect the spark plug caps Irom the spark plugs and measure the secondary coil insisisiicu with the spark plug 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 rm (ZONE/83°F] Remove the ignition coil, disconnect the spark plug wires and measure the primary and secondary coil resistances as shown. STANDARDS: Prlmnry coll: Z—A ll I20°CI68°FI Second-w coll: 13—17 I10 (20°CI68°Fl REMOVAL/INSTALLATION Disconnect the ignition coil 4? mini connector under the fuel tank. Ruiiiuvu the bolts and collars. Disconnect the ignition primary terminals Irom the coils and remove the ignition coil as an assembly. Remove hnlts and No. 2—3 ignition coil first. then remove bolts and No. I is ignition coil. Install thr: ignition coils in the reverse order DI removal. NOTE - Connect the spark plug wlre properly as shown (right). - Connect the ignition coil primary terminals properly as shown above. IGNITION SYSTEM l1) SECONDARY COIL COIL (1) BO T/COLLA (2) IGNITION COIL ASSEMBLY IGNIT|ON SYSTEM PULSE GENERATOR INSPECTION NOTE - It is not necessary to remove the pulse generator from me engine. Disconnect the pulse generator 2P mini blue connector under The fue| tank and measure the rasismnce be‘ween White/ Yellow and Yellow (erminals. STANDARD: 340—420 Tl (ZINC/63“!” REMOVAL/INSTALLATION Remove lhe left crankcase cover (page 16-8). Remove the bolrs and pulse generator. lnsl-ll the pulse generator and wire clamp, and rigmen lhe bolts securely. Set the wire harness arcmmer into the cover groove. Install rhe left crankcase cover (page 1678). SIDE STAND SWITCH INSPECTION Disconnecl (he side sland 3P mini green nnnnaclor under the fuel tank and check for continuiry belween each terminals as below. There should be conllnully between me 0—0 positions on the continuny chart. (1) PULSE GENERATOR (1) BOLTS (2) GROMMET (3) PULSE GENERATOR (1) SIDE STAND SWITCH Green/While Yellow/Black Green Slde sland down Slde stand 70 up (3) DOWN 1 5-9 ——_— IGNITION SYSTEM REMOVAL/INSTALLATION Disconnect the side stand connector. Remove the water Dump side cover. With the side stand up. remove the side stand switch mount- ing bolt and side stand switch. Install the switch in the reverse order of removal. TORQUE: . Sid. and [witch mounting eon: 30 N-m (3.0 lg-m. 21 h-lh) NOTE - Align the Iwitch pin with the aide stand hole and align the switch groove with the side stand return spring . holding pin. (1) SIDE STAND SWITCH ‘ WIRE . Route the side stand antch wire harness properly as ahown. , . f . HARNESS . . . \ IGNITION TIMING Warm up the engine. Stop the engine and connect a timing light to the No. 3 cvlin~ dcr snark plug Wire. NOTF - Read the instructions for timing light for operating, . Remove the following: 7 crankshaft hale can cover (page 9-2I. — crankshaft hole cup (page 972]. ’ v timinu mark holc can (page 9-2). (1) TIMING LIGHT Start the engine and lat it idle. The timing II current i! the F mark aligns with the crankcase (1) F MARK . cover index mark. (3) AISVANCE START NOTE - if the correct timing could not be ubseived. connect a timing Ilght to the No. 2 cylinder spark plug wire and re- chnck the ignition timing. . Increase the cnginc speed by rotating the "with: stop screw on the carburetor, make sure the F mark begins to move counterclnckwise at appmximsteiy 1.700 mm. l # 16. ELECTRIC STARTER/STARTER CLUTCH . sERVlCE INFORMATION 16-1 STARTER MOTOR DISASSEMBLYI sverM LOCATION 1 e2 ASSEMBLY 1 6‘6 STARTER CLUTCH REMOVAL] CIRCUIT DIAGRAM 1 6-2 INSTALLATION 1&8 TROUBLESHOOTING 16-3 . STARTER MOTOR REMOVAL] INSTALLATION 18-5 injury, SERVICE INFORMATION - Alwnyn turn the lgnltion lwltch OFF before servicing th- stutor motor, The motor could wddenlv stun, cuutlng nriout I A week buttery may be unable to turn the starter meter quickly enough. or supply adequnle Ignition current. a II the current i: kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may no» anmngm - For the lollowing component Inspections, rein to the Iollowlng pages; for the parts locations, see page 16—2 0! this manual (SVSTEM LOCATIONL Clutch switch diode Section 24 ol the Common Service Manual. Starter motor Sectlon 24 of the Common Service Manual. Section 74 at m Common Service Manual (”A" clrcuit typcI. sum" relay switnh . Clutch switch Section 25 OI the Common Service Manual. Neutral switch Sectmn 25 of the Common Servlce Manual. lgnltlon swltch Slde stand swnch Check lor contlnultv on the contlnuity chart ol the WIRING DIAGRAM, page lB-Ii Disconnect the switch connector inside the headlight case (page LISI and check It. (Page 151) ELECTRIC STARTER/STARTER CLUTCH SYSTEM LOCATION (1) SIDE STAND SWITCH (2) NEUTRAL (4) STARTER RELAV SWITCH/ MAIN FUSE 30 A (3) STARTER swncn I5) FUSE SWI CH GN 0N SN TC (9) NEU HAL (I O) STARTER (6) BATTERY (7) CLUTCH (BI SIDE STAND momn swncu (I II IGNITION (4) STARTER SWITCH RELAV (a) BATTERY SWITCH @- R/Bl R __ (10) STARTER T MOT a ‘5) FUSE (5) (4) MAIN ° 10 A US FUSE I 10 A Bl/Bv El - LC/o— V/R (2| NEUIHAL I3) STARTER (é) (12) CLUTCH INDICATOR —Lg/R SWITCH SWITCH (SI LII/R — Gm G/R 0/ NEUTRAL I7) CLUTCH SWITCH SWITCH G/W move (1) SIDE STAND 7 up SWITCH INDICATOR V/Bl . (3) SIDE STAND SWITCH 1 6-2 TROUBLESHOOTING Starter motor will not turn . Check for a blown out main or sub luaes before servicing. - Make sure the battery is fully charged and In good condition. Check for Innae or poorly connected battery teri minals, and opened or shorted battery cable. —ABNORMAL—>- i NoriMAL Check to: loose or poorly connected starter reley switch terminals and 4P connector. — ABNORMAL—>- i NORMAL motor cable, and opened cable. Check for loose or poorly connoctad starter — ABNORMAL a»- I NORMAL with the ignition switch "ON", push the starter swrtch and check lor a "click" sound Iran the starter relay switch. ELECTRIC STARTER/STARTER CLUTCH Poorly connected battery terminale Open or short circuit in battery cable Poorly connected terminals or 4? connector Poorly connected motor cable Open clrcult in motor cable CLICKS —> NO CLICK Connect the starter motor terminal to the hat- tery positive terminal directly. (Because a large amount ol current flows, do not use thin wires) Disconnect starter relay switch connector. and Llisuk the relay cull ground wire llnaa as below for continuity: 1. Green/Red terminalrollltoh owixdh diode neutral switch line (with transmission into neutral and clutch lever released.) 2, Green/Red terminal-clutch switch-side stand switch line (in any gear except neutral, and with the clutch lover pulled in and the side stand up.) I CONTINUlTY Connect the starter relay switch connector. With the ignition switch ON and the starter switch pushed, measure the starter relay volt- age at the starter switch connector (between Velloleed (+1 and ground l—ii. —-NO CONTINUITY-u- — N0 VOLTAGE —>- i VOLTAGE APPEARED Check the starter relay 5 tch npnra nn NORMAL—>- ABNORMAL—N l l Starter Starter motor motor do" not turn turns 1 - Faulty starter motor Loose or disconnected starter motor cable Faulty starter relay switch Feullv neutral switch Faulty clutch switch diode Faultv clutch switch Faulty side stand switch Loose or poor contact ol connector Open circuit in wire harness Faulty ignition switch Faulty starter switch Blown out main or sub iuses Loose or poor contact of connector Open Circuit in wire harness Looeo or poor contact of the starter relay switch connector Faulty starter relay switch 1 GI) 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. — ABNORMAL —>- Faulty side stand switch t Burnl bulb NORMAL - Open circuit in wire harness I i Check the clutch switch operation, '— ABNDRMAL —>' Faulty clutch switch NORMAL Check the side stand switch (page 15-8). ABNORMAL—>- Faulty side stand switch NORMAL L—r 7 7. - Open circuit in wire harness ' Loose or poor contact 0' connector Start-r motor tum: alowly - Low specific gravity in battery (or Dead battery) - Pburly connected battery terminal cable - Poorly connected starter motor cable - Faulty starter motor - Poorly connected battery ground cable Stlrtnr motor turns, but engine does not turn - Starter motor is running backwards 7 Case assembled improperly 7 Terminals connected improperly - Fuultv starter clutch - Damaged or faulty starter pinion - Damaged reduction gears Starter rel-y twitch "cllclr’fi hut onglm do" not turn over - Crankshalt does not turn due to engine problems r Excessive reduction gear iriction 1 6-4 ELECTRIC STARTER/STARTER CLUTCH STARTER MOTOR REMOVAL/INSTALLATION - Turn m- ignition twitch OFF‘ 7 7 REQUISITE SERVICE - Fuel tank removal/insxallation (page 2-4) m (2) (3) (A) E) ,, REMOVAL CHEER PROCEDURE Starter motor cable Starter motor mnuming bolt Ground cable on engine Staner motor 94mg (My -d..n.. REMARKS - |nsmllation is in the reverse order of removal. 16-5 ELECTRIC STARTER/STARTER CLUTCH STARTER MOTOR DISASSEMBLY/ASSEMBLY ALIGN 12c F—-_————_ REQUISITE SERVICE Starter motor removal/installation (page 16-5) PROCEDURE ELECTRIC STARTER/STARTER CLUTCH Q‘ty ASSEMBLY REMARKS DIGASGEMBLY ORDER - Assembly IS In the reverse order of drsassemblv. (1) Set screw 2 (7) 99? plate 2 [3) O-nng 2 (4) Front navel/Orring 1/1 Align the index marks on the covet and case. (5) Orring 1 (6) Motor case 1 NOTE: - Inrall with the groove Slde lacing to the brushest ‘ Align the index marks on the rear cover and case. (7) O-Iirlg 1 (8) Lock washer I (9) Insulated washer 1 (‘0) Washer 1 (1 1 ) Armature 1 (12) Shims — Record and store the slums m the same order they were installed so they can be reinstalled In the original posi- trons. (13) Brush terminal holding nut I (111) Wuslwl | (15) Insulated washer 3 7 bigger (1) 7 smaller (1) — smaller (ll (16) O-ring 1 (17) Brush holder assembly 1 Align the holder tab with tha raar cover gram/e. (‘8) Brush and terminal l (19) Rear cover 1 ‘1‘"! ELECTRIC STARTER/STARTER CLUTCH STARTER CLUTCH REMOVAL/INSTALLATION l (page 15-9) 6 85 (8.5, 61) ALIGN THE WIDE GROOVE . AMONG THE CHANKSHAFT SPLINES AS SHOWN — ELECTRIC STARTER/STARTER CLUTCH REQUISITE SERVICE - Right crankcase cover removal/installation (page S~2i PROCEDURE G'ty REMARKS REMOVAL ORDER - Installation is in the rover” order at removal. (I) Lalt crankcase cover bolt 7 Install the pulse generator wire clamp properly as shown. [2) L6" CPIHKCISO cover I (3) Gasket 1 . m Dowel ain 1 (5) Starter clutch boIl 1 Removal and installation (page 16-9). (6) Waaher 1 (7) Pulse rotor 1 Install it with the marked aide lacing out. (E) Starter clutch assembly — l9) — starter driven gear 1 (10) — needle bearing 1 (1 1) — atarter clutch I At installation, make sure the ataner clutch roller ia In- stalled properly into the clutch housing (12) Spline washer I13) Starter drive gear shaft 1 . (14) Starter drive gear 1 STARTER CLUTCH BOLT REMOVAL] [1) FLYWHEEL INSTALLATION x- -' ” CAUTION Sat the rotor holder onto the flywheel. . eoron women mus—oomooo or equivalent eommerclellv available in ulstAt ‘ . (2, HOLDER (3) STARTER CLUTCH BOLT Hold the rotor holder and remove the starter clutch bolt WIth a helper‘ Set the rotor halder and hold it onto the engine bracket as shown (4) HOLDING POINT 17/, 1%? . Tighten the starter clutch bolt to the specilred torque. TORQUE: 65 N-m (8.5 harm. 31 h-lb) 17. LIGHTS/METERSISWITCHES ’ SERVICE INFORMATION 1 7-1 METER REMOVALIINSTALLATION 1 7-5 SVSTEM LOCATION 17-2 METER DISASSEMBLY/ASSEMBLV 1 7-6 HEADLIGHT REMOVAL] TACHOME‘I’ER INSPECTION 17‘7 'NST‘LU‘T'W "’3 IGNITION SWITCH REMOVAU TURN sIcNAL LIGHT 1 74 INsTALLATION 1 7-7 ’ TAILLIGHT 174 SERVICE INFORMATION Halogen headllght bulb becom aura to lot It cool down baton nrvicing. - Use a lleme and heated water/coolant mlxture for the thermo unlor Inepectlon. Keep all flammable ma from the burner. Wear protectlve clothlng. glove: and eye protecfion‘ very hot whlle the headlight in ON. and rem-In hot tor a whlle a rlt chimed orna- way 0 Note the lollowinga when replacing the halogen headlight bulb‘ — Wear clean gloves while replacing the bulb. Do not put finger prints on the haaellght bulb, as they may create hot spots on the bulb and cause it to break. A it you Touch the bulb with your here hanos, clean It with a cloth melstened with alcohol to prevent its early failure. 7 Be sure to install the dust cover after replacing the bulb. I Ghook the bnnory condition bolero parlorming any intipootion that requires proper battery voltage. I A continuity test can be made with the switches installed on the motorcycle. For the lollowing component locations. see page 17-2 of this manual (SYSTEM LOCATION): lor inspections. relor to the applicable pagea‘ Component Inspection method Remarks Clutch IWItch Section 25 of the Common ServiceiManuel Coolant temperature gauge} Thermo sensor Section 25 ot the Common Service Manual Temperature gauge removal (page 1776). Thermo sensor removal (page 5-4). Fan motor swltch Section 25 or the Common Service Manual fiamovaflpege§-6). Front brakellght swuch Section 25 of the Common Service Manual Fuel pump/Fuelcut-olj relav Horn Section 25 ol the Common Servlce Manual Section 25 of the Common Service Manual . Removal (page 6-13). Handlebar switches Ignition switch Check lor contlnuity on the continuity chart ol the WIRING DlAGRAM, page 1871. Swnch connectors are located inside the headlight case (page 1719). Neutral switch Section 25 of the Common Serwca Manual TORQUE: Ia N-m (1.8 kgrm, l3 lit-lb)“ Apply sealant to the threads. Oil pressure switch/warning light Section 25 of the Common Service Manual Oil oressure check: Section 4 ol the Common Service Manual Oil pressure switch torque: 12 N~m (1.2 kg-m. 9 ft-lb) Rear brakellght switch Section ZS of the Common Servlce Manual Turn slonal liqhts Section 25 of the Common Service Manual 3 terminals relay. 171 LIGHTS/METERS/SWITCHES SYSTEM LOCATION I?) COOLANT TEMPERATURE GAUGE (3) FRONT BHAKELIGHT SWITCH (4| OIL PRESSURE SWIT H C (6 BATTERY (I I IGNITION SWITCH (5) FUSE (I3) THERMO SENSOR (12) FAN MOTOR (I1) NEU HAL SWITCH SWITCH (9) FULL CUT- (7) REAR IIOI FUEL OFF RRAKFI IGHT PUMP RELAV SWITCH I3) TURN SIGNAL RELAV 1 7-9 LIGHTS/METERSISWITCHES HEADLIGHT REMOVAL/INSTALLATION . Halogen-headlight bulb bocomu very not while tM "Indium II 0N, and run-In hot lor I whll- nflor It I! tum-d OFF, Bl luv. to In R cool down below lowlclng. CAUTION . Wan! (loan glows whllo rwliclng tln bulb. Do not put fingor pnnu on the Modlatlt bulb, as they may ornate hot spots on tlu bulb und cause It to bro-kt - It you touch the bulb wlth your bur. lunch, clan It with I cloth molstortod wlth alcohol to provortt It: only lllluu. - Bo Inn to lnItulI the dull cont uhor raplaclng tln bulb, PROCEDURE O’tv REMARKS . (1 1 Screw (3i Dust cover (6) Connectors REMOVAL ORDER (El Headlight bulb oockot (a) Headlight bulb (5) Headlight assembly (7) Headlight case _._._._.u . Installation Is in the reverse order of removal. Install it with the TOP mark lacmg up, Connection (page 1718) Allgn the index marks on the case and bracket. 1 7-? LIGHTS/MHEHS/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove me screw and lens from rhe rurn slgnal case. Turn the bu|b socket counterclockwise and remove in Turn the lamb counterclockwise) and remove it, Install a new bulb in the reverse order of removalr TAILLIGHT BULB REPLACEMENT Remove the screws and lens from the (taillight case. Turn ‘he bulb counterclockwme Ind remove It. Install a new bulb in the vavarsa order of removal. (2) LENS [4) SOCKET \\ \_ l3) SCREW ‘ \\ (1) BULB (3) LENS (2) SCR WS 174 LlGHTS/METERS/SWITCHES METER REMOVAL/INSTALLATION BPVWHITE GP-RED . CONNECTOR REQUISITE SERVICE - Headlluht assembly removal (pugs 17-3) PROCEDURE O’ty REMARKS REMOVAL ORDER ' Installa‘ion is in the reverse order 0' lemovuL (1) Meter mounting bolt (2) Speedometer cable (3) Mafia! connectol (4) Mmcr usumlfley 6? mini White connacmr and 6? mini Red connecmr —-N—- V. LIGHTS/METERSISWITCHES METER DISASSEMBLY/ASSEMBLY Remove the five screws and the meter rear cover. Pull all Indlcator bulbs out of the meter houslng. Remove the wire harness clamps, and remove the nuts, washers and meter stay. Discannect the meter terminals, and remove the wire her- ness. Remove the screw and male! from cover. Remove the following: 7 two screws and tachometer. 7 trip mete! reset knob, four acrcm, speedometer gear joint and mm, 7 speedometerr Assemble the meter In the reverse order of dlsassembly. NOTE ' Connect the prone! color wire to the meter terminals. V/G: Yellow/Green G: Green B/ER: Black/Brown G/B: Green/Black G/L: Green/Blue (1) REAR (2) SCREW (3) WIRE (ll CLAMPS HARNESS (1) FRONT COVER (5) SPEEDD‘ METER (4] LlGHTS/METERSISWITCHES TACHOMETER INSPECTION Remove the headlight assembly (page 17-3). and disconnect the 6P mlnl Red connector and 6? minl White connector. (1) BP-WHITE (2) rP-RED Cnnnart n vnirmmnr attract: the Black/anwn (+) and moon (7) terminals ol the main wire harness side. Turn the ignition switch ON and battery voltage should rev sister. II there Is not U.Kw the electric tachometer do not catch power Irom the battery. Trace and repair the related wiring, sub luse end/or connectors. Disconnect the spark unit connector (page 1576). Check for cuntinuitv between the Yellow/Green wire termi- nals DI the 6? mini White Connector and spark unit cannot:- tor. Continultv axilu at all times. If than in no continuity, replace the main wire harness. ll all checks are O.K., replace the tachometer. (1) SPARK UNIT E T R CONNECTOR CONN C O IGNITION SWITCH REMOVAL/ INSTALLATION Remuvu IIIH iriuter us an assembly (page 17-5). Disconnect the 3? Black connector and 2P mini connector Inside the headlight case. Remove the bolts using the torx bit (T40) (07703— 0010100i end ionrtian switch. Remove the screws and separate the contact base lrom the cylinder. \& NOTE ~ ‘\ - Vou can separate the switch in all key position. i Apply a locking agent to the threads and install the ignition swrtcn In the reverse order of removal. l1) IGNITION SWITCH TONGUE: Switch mounting bott: 25 N-m (2,5 Ira-In. 18 ft-lbl (page 1»I7I 18. WIRING DIAGRAM 33l=s INSS 18-1 19. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH HARD TO START 1 9-1 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 Iusl flow lo carburetor NOT REACHING CARBURETOR —>» Clogged luel line at luel liner - sucking float valve REACHING CARBURETOR - Faulxy fuel pump . Iaully Iual pump relay - Clogged fuel tank venl hole - Loose or disconnactad fuel pump relay wire 2. PerImm spavk test WEAK OF! NO SPARK —> - Faulty following (Page 153): 7 ignilion Coll GOOD SPARK 7 pulse generator 7 neutral switch — spark unlt ~ side stand swilch — engine stop switch 3. Remwve and inspect spark plug WET PLUG —> - Mixluve loo vich - Carburelor flocded SPARKS ‘ Carburetor choke excessively closed - Cylindev Hooded . Air cleaner dmy ~ Faulty Purge Conrrol Valve (Califarnia model onlvl a Test cyllnder compression LOW COMPRESSION ——> - Impvopar valve (:IaarannP. (shim mo mick) COMPRESSION NORMAL . Valve stuck Dpen - Worn cyllnder and piston rings - Damaged cylinder head gaskel - Seized valve - Impropev valve timlng - llupmpel valve and seal cunlacl 5. Stan by followlng novmal procedure ENGINE STARTS BUT STOPS —“ Improper nhnke operallon - Carburetor Incorrectly adjuslea ENGINE DOES NOT FIRE - Intake pipe leaking - Imploper ignmon tlming (Faulxy spark unit 0' uulse geflelr alarl - Fuel contaminated 6. Stan with choke on 19—1 TROUBLESHOOTING ENGINE LACKS POWER Ir Raise wheels uIl ground and spin by hand WHEEL SPINS FREELV 2. Check tire pressure PRESSURE NORMAL 3. Check lor clutch slippage CLUTCH ENGAGED PROPERLY 4. Accelerate lightly ENGINE SPEED INCREASES 5. Chec ignition timing CORRECT 6. Cheek valve clear-ne- CORRECT 7. Test cylinder compression NORMAL 8. Check carburetor lor clogging NOT CLOGGED 9. Check spark plug condition NOT FOULED 0R DISCOLORED . Ghent oil level and ounditlon CORRECT WHEELS DO NOT SPIN FREELY—w PRESSURE LOW —>- CLUTCH SLIPS —>' ENGINE SPEED DOES NOT INCREASE—>- INCORRECT—m INCORRECT —~. T00 LOW——>- CLOGGED——>- FOULED 0R DISCOLORED —> - INCORRECT POSSIBLE CAUSE Brake dragging Worn er damaged wheel bearings Wheel hearing needs lubricevlnn Drive chain too tight Axle nut excessively tight Faulty tire valve Faulty clutch lifter system Wnrn nlutnh disc/plate Warped clutch disc/plate Week clutch spring Carburetor choke closed Clogged air cleaner Restrlcted fuel flow Clogged mulller Clogged luel cap varit hole Faulty luel pump Faulty luel pump relay Loose, broken or shorted wire or connection of pump relay Faulty spark unit Fuultv pulse generator Improper valve adjustment Worn valve seat Valve stuck open Worn cylinder and piston rings Improper valve timing Suited valve Improper valve and seal contect Carburetor not serviced lrequently enough Plugs not serviced lrequently enough Spark with iriuurrect neat range Oil level too high Oil level too low Contaminated all 1 9-2 6. ‘II. Rcmovl: cylinder head cover and inspect lubrication VALVE TRAIN LUBRICATED PROPERLY 12, Check Ior engine overheating NOT OVERHEATING 13. A: elerato or run at high speed ENGINE DOES NOT KNOCK VALVE TRAIN NOT LUBRICATED—b- PROPERLY . OVERHEATING _*>| ENGINE KNOCKS —-——>‘ POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition timing and valve clearance CORRECT 2. Check carburetor pilot screw adjustment CORRECT 3. Check for leaking intake pipe NO LEAKAGE 4. Perlurm the spark test GOOD SPARK INCORRECT INCORRECT ———D- LEAKING—fi- WEAK OR INTERMITTENT SPARK ——>- TROUBLESHOOTING POSSIBLE CAUSE Clogged all passage Clogged oil control orifice Contaminated oil Faulty oil pump Coolant level low Fan motor not working (Faulty fan motor switch) Thermostat stuck closed Excessive carbon buildup in corn bustion chamber Use of poor quality Iuel Clutch slipping Lean Iual mixture Worn piston and cylinder Wrong type OI Iual Excessive carbon build~up in comr bustion chamber ignition timing ton advanced (Faulty spark unit) Lean Iuel mixture POSSIBLE CAUSE Improper valve clearance Improper Ignition timing 7 Faulty spark unit — Faulty pulse generator Sea Fuel System [Section 8) of the Common Service Manual Loose carburetor Damaged insulator Faulty, carbon or wet fouled spark plug l-auity lollowing (page 15-3): 7 Ignition coil — pulse generator 7 neutral switch 7 spark unit — Side stand switch 7 engine stop switch 1 9-3 YROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED 1 Chm: ignirinn riming and valve clearance CORRECT 2. Dlsconneu TUB] line at carburetor FUEL FLOWS FREELY 3. Remove carburetors and check lor clogged jets NO COLGGED JETS 4. Check valve timing CORRECT 5, Check valve sprlng lenslon POOR HANDLING 7 1‘ ll sreenng IS heavy INCORRECT FUEL FLUW RESTRICTED —>' CLOGGED ———. ' INCORRECT ——. . WEAK ——.. - Check lim and suspension pressure 2 ll cilhcr wheel is wobhling ———.. 3, ll me motorcycle pulls lo one Side —— ~ POSSIBLE CAUSE Improper valve clearance Improper ignitlun liming 7 Faulty spark unir — Faulty pulse genslawr Fuel rank empty Clogqad fuel line Clogged vual cap vem hole Clogged luel valve Faullv lual pump or relay Clogged luel liller Clogged jars Camsnan not installed properly Faulty valve spnng POSSIBLE CAUSE Slaallng head bearing adjuslmenl nut (00 light Damaged steering head bearings Ben! sleerlng stem Excessive wheel bearing play Bent rim Improperly inalallcd wheel hub Swmgarm pivor bearing excessively worn Benl frame lncorrecl drive chaln adjustment From and rear wheels nor aligned Ban! lork legs aenl swingarm Benl lrame 1 9-4 Air Cleaner ................... Case Removal/Installation t Alternator ..... Brake Pedal Removal/Installation . Brakes ....... Cable and Harness Routing .. Camshaft Removal/Installation 8-2 Carburetor Combination .. 6-10 Disosscmbly/asscmbly 6 8 Removal/Installation 64 Separation ...... 6-6 Synchronization Charging System/Alternator . Circuit Diagram Inspection i Location Clutch Installation Removal Clutch/Gearshift Linkage Cnninnt Draining ,,,,, t Cooling System .i Flow Pattern Crankcase Installation . Separation ................... Crankshaft Bearing Replacement Crankshaft/Connecting Rod Removal] Installation ...... Crunkshah/Transmiss rl Cylinder Head disassembly/assambly 5-6 Removal/Installation 8-4 Cylinder Head/Cylinder/Piston . 8-1 Cylinder/Piston Removal/Installation B~8 Electric Starter Circuit diagram 15-2 System Location ..... 16-2 Electric Starter/Starter Clutch . 1671 Emission Control Information Le a s (U.S.A. only) Systems . . . Systems (California Model Only) Engine Removal/Installation Exhaust System Removal/Installs on V l-ork Assembly .. Disassembly Removal/Installation Frame/Body Panels/Exhaust oystem Front Brake Caliper disassemny/assembly 13-6 Removal/installation 13-4 Fad Replacement ......... 1372 Front Master Cylinder disassemblv/assembly 13710 Removal/Installation 13-5 Front Wheel disassembly/assembly . 11—5 Removal/Installation ..... 11-4 Front Wheel/Suspension/Steering . 11-1 Fuel Pump/Filter 0-13 Fuel System 671 Fuel Tank Removal/Installation 24 Gearshift Linkage Removal/Installation 9-6 General Information 171 General Saiety ....... 1V1 Headlight Removal/Installation ‘l 773 Ignition Coil .............. 15-5 20. INDEX Ignition Switch Removal/Installation 17-7 Ignition System 15-1 Circuit Diagram 15-2 Inspection 1 5-6 Location . 15»2 Ignition Timing 15-9 Left Handlebar Removal/Installation 1 1~3 Lights/Melers/Switchas 17-1 System Location 17-2 Lubrication and Seal Points Ha Lubrication System ........ 4,] Diagram . 4»2 Maintenance . 3-1 Schedule 3-4 Meter disassemblylussembly r 17-6 Removal/Installation . 17-5 Model Identification . 1-3 Oil Pump disossembly/aasombly . 4-4 Removal/Installation . Pulse Generator ..... Radiator disassembly/assambly Removal/Installation Rear Brake Caliper disassemblylassamhly . Removal/Installation , Pad Replacement ,, Rear Fairing Removal/Installation Roar Master Cylinder disassemny/nssembly . Removal/installation ...... Rear Wheel disassembly/assembly Removal/Installation . Rear Wheal/Suspens' n Regulator/rectifier .. Reserve Tank Removal/Installation Right Crankcase Cover Removal/Installation . Right Handlebar Removal/Installation Seat Removal/Installation Service Access Guide .. Sari/ice Information Brakes Charging System/Alternator Clutch/Gearshift Linkage Cooling System . Crankshaft/Transmission Cylinder Head/CylinderlPlston . Electric Starter/Starter Clutch . Engine Removal/Installation Frame/Body Panels/Exhaust System Front wheel/Siispension/Steering . Fuel System Ignition System . Lights/Meters/Switches V Lubrication System , Maintenance ..... Rear Wheel/Suspension . Shock Absorber disassemny/assembly Removal/Installation Side Cover Removal/Installation . Side Stand Switch Spark Plug Specifications . Starter Clutch Removal/Installation L INDEX Staner Motor disassembly/assembly ..... 16-6 Removal/Installation 16-5 Steering Stem Removal/Installation . 11712 Swingarm disassembly/assemblv 12‘s HumuvaI/luslallatiun . Tachometer Inspection . Taillight V .............. Thermostat Removal/Installltlo Tnnk Torque Values Transmission disassembly/assemblv Removal/Installation . Troubleshoonng ..... Blokes ..... Chargmg System/Alternate! ClulLlI/Gualallill Linkage Cooling System Crankshah/Transmlssion ‘ Cylinder Head/Cylinder/Piaton Elacmc Starter/Starter Clutch l6v3 mea/Bodv Panels/Exhaust system . 2-1 Front Wheel]Suspension/Steenng 1 1-1 Fuel System 6-2 Ignition System 15-3 Lubnuauuu Syslum 4.1 Real Wheel/Suspension . 12-1 Turn Signal Light .............N. l7-4 Valve Clearance 3~5 Water Puma disassembIV/assembly . 577 Winng Diagram 15-! 90-9