INTRODUCTION This sen/ICE manual describes the servlce procedures Iur Ihe CEAOOF. Thrs Model SDCCIIIC Manual includes every snlvlcc pro- cedure that ls ol 5 specific nature to ”us particular model Basu: SGTVICP nrocedmcs that are CDlann to olher Honda Motorcycles/Motor Scooters Common Servlce Manual This Model Specific Service Manual should be used logethei WIth the Common Service Manual In order to provide complete servicerniormation on all aspects of this motorcycle. Follow the Maintenance Schedule lSectlon 3) recom mendations to ensure that the vehicle is in peak operat- lrlg condition and me emrsslon levels are within the standards set by the us. Environmental Protection Agency and the Calllorrll'a All Resources Boald. Perlorming the lirst scheduled malrltenance ls very lrn- portant. It compensates Ior the lnltial wear that occurs during the break-in periodr Section 1 and 3 apply (0 the whole motorcycle, seclion 2 illustrates procedures It)! removal/installation of com- ponents that may be required to perlorm service de» scrlbed in the Iollowlng sections. While section 4through 15 describe parts 0! the motor- cycle, grouped according to locatlorls. Find the section you want on this page. then turn to the table of contents on the Iirst page of the section Most sections describe the service procedure through a system illustration. Reter to the next page for details on how to use this manual. If you don't know the source 01 the trouble, go to sec- tlon 13, TROUBLESHOOTING. ENGINE AND DRNE TRAIN- GENERAL INFORMATION l r MAINTENANCE LUBRICATION r—__—___ COOLING SYSTEM fig l_______—_.,,_ FUEL SYSTEM .5! L ENGINE REMOVAL/INSTALLATION fig CLUTCH/G EARSHIFT LINKAGE CRANKSHAFT/TRANSMISSION CHASSIS FRONT WHEEL/SUSPENSION/STEERING III REAR WHEEL/SUSPENSION IE BRAKES IE' CHARGING SYSTEM/ALTERNATOR I ll IGNITION SYSTEM ' I E! ELECTRIC STARTER/STARTER CLUTCH IIEI IT ALL INFORMATION, ILLUSTRATIONS. DIREC- I 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 OBLIV GATION WHATEVER. N0 PART OF THIS PUBLIr CATION MAV BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRIT- TEN FUR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE 0F MAINTENANCE 0N HONDA MOTORCYCLES OR MOTOR SCOOT- ERS. ELECTRICAL y LIGHTS/METERS/SWITCHES E E! WIRING DIAGRAM TROUBLESHOOTING Date or Issue: August, 1989 © HONDA MOTOR (20., LTD IMPORTANT SAFETY NOTICE —»4 m lndicaxes a sxrong possibility a! severe yersonal lnjury or deal. if instructions are nol (allowed. CAUTION: Indlcales a possibility u' equipment damage il instructions are no! lollowed. NOTE Gives helplul lnlavmallon. De‘ailed descripllons oi slandard wavkshop procedures, savely principles and selvlce operallons are nox Included. u l5 lmporlnm m not: ma this manual mmains some waminos and czufions against some spemlic service melhods Wthh could cause PEHSONAL lNJURV to service personnel or could damage a vehlcle or render it unsale. Please understand (ha! thDse warmngs could ncu cover all conceivable ways in which service, whether or new recommended by Honda. migm be done or cl the possibly hazardous consequences 0! each concelvable way, nor could Honda mvesllgate all such ways. Anyone using servxce procedures or tools, wnemer or not recommended by Honda, mus! Sam's/y himse/l thoroughly (hat neilher personal safely no! vehicle salely Wl" be jeopaldlzed by the sen/ice melhuds on tools selected. 1. GENERAL INFORMATION GENERAL SAFETY 1-1 MODEL IDENTIFICATION 1‘3 SPECIFICATIONS 1-4 TORQUE VALUES 1-14 TOOLS 1-16 LUBRICATION AND SEAL POINTS ll CABLE AND HARNESS ROUTING 1-19 EMISSION CONTROL SYSTEMS 1-25 EMISSION CONTROL INFORMATION LABELS (U.S.A. Only) 1—28 GENERAL SAFETY Carbon Monoxide II the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in an en- closed area. Awnnllllllll; - The axhautr contains poisonous carbon monulide gas that can cause loss of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacua— tion system in an enclosed area. Gasoline Work in a well ventilated area. Keep cigarettes. Names or sparks away lrom the work area or where gasoline is stored. - Gasoline ls extremely flammable and is expluslva under canain conditions. KEEP OUT OF REACH OF I CHILDREN. Hot Components 1mm - Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear Insulated gloves or wait until ‘he angina and exhaust system have cooled barons handling these parts. Used Engine/Transmission on Used engine oil (or transmission oil in tworsxrokesl may cause skin cancer it repeatedly left in contact with the skin In! prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible aher handling used oil. KEEP OUT OF REACH OF CHILDREN. Brake Dust Never use an air hose or dry brush to clean brake assemb- lies. Usa an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos libers. - Inhaled asbestos fibers have been found to cause respiratory Lliseasa and cannsrt Brakb Fluid CAUTION - Spitting fluid an painted. plastic or rubber parts will damage them. Place a clean shop (awel over these pans whenever the system is serviced KEEP our 0F REACH OF CHILDREN. 1—1 I GENERAL INFORMATION Coolant Under some condltlons, the ethylene glycol in engine cool- ant is combustible and its flame is not Visible. If the ethyl- ene glycol does lgnlte. you Will not see any llame. but you can be bulned. l_ - Avoio spilling engine coolant on the exhaust system 1 or engine parts. They may be hot enough to cause . the coolant to ignite and burn without a visible flame. . ~ coolant (ethylene glycol) can cause some skin irritar tion and is poisonous it swallowed. KEEP out 0F REACH OF CHILDREN. ‘ - Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. 1 ~ Keep hands and clothing away trorn the cooling lan, ‘ as it starts automatically. it it contacts your skin. wash the affected areas immedi- ately with soap and water. It it contacts your eyes, ilush them thoroughly with fresh water and get immediate medi— cal attention. Ii it is swallowed, the victim must be forced to vomit then rinse mouth and throat with llesh water before obtaining medical attention. Because at these dan- gers, always store coolant in a sale place. away from the reach of children. Nitrogen Pressure For shock absorbers with a gas lllled reservoir 'AwAnNING —-r#—~ ‘- . V I? ~ Use only nitrogen to pressurize the shock absorber, . The use ol an unstable gas can cause a fire or explo- sion resulting in serious injury. 1 - The shock absorber contains nitrogen under high pressure. Allowing fire or heat near the shock ab~ sorber could lead to an explosion that could result in . serious injury. Failure elease the pressure from a shock absorber r To prevent the possibility cl an explosion, release the ni- trogen by pressing the valve core. Then remove the valve stem lronl the shock absorber reservoir. Dispose oi the all in a manner acceptable to the Environmental Protection Agency EPA). Salute disposal of the shock absorber, release the nitrogen by pressrng the valve core. Then remove the valve stem from the shock absorber. Battery Hydrogen Gas 81 Electrolyte The battery gives 01f explosive gases: keep sparks. flames and clgaretlas away. Provide adequate venti- lation when changing The battery contains sulfuric acid (electrolyte). Con- tact with skin or eyes may cause severe burns Wear pvotectiw clothing and a lace shield. —— ll electrolyte gore on your skin. flush with water. — Ii electrolyte gets in your eyes. flush with water hr at least 15 minutes and call a phys an. Electrolyte is poisonous. — ll swallowed, drink large quantities of water or milk and (allow with m'lk of magnesia or vegetar hie oil and calla physicians KEEP OUT OF REACH OF CHILDREN. 1—2 I' , MODEL IDENTIFICATION GENERAL INFORMATION Q)! ’ A M II) FRAME SERIAL NUMBER The irame serIaI numbel is stamped on Ihe rIght side of the steering head. I3) VEHICLE IDENTIFICATION NUMBER The engine serial number is stamped on the right side oi the crankcase, The VehicIa Identification Number (VIN) Is Inca‘cd on the saiery camiicauon label on the main min of \he frame tube. I4) CARBURETOR IDENTIFICATION NUMBER (5) comm coo: muff/rm The carhuretar identification numbev is on the tea: side of each carburetor. The color code label is attached on [he Ielt frame tube under the seat. When ordering a color coded part, always specvly as designated color code 1—3 GENERAL INFORMATION SPECIFICATIONS Displacement Compression ratio Valve train Intake valve opens at 1 mm lift Intake valve close at 1 mm lift Exhaust valve opens at 1 mm lift Exhaust valve close all mm lift Lubrication system Oil pump type Cooling system Air filtration , Crankshaft type Engine weight (dry) Firing order Cylinder arrangement Front 0 CCU“ — General l ITEM SPECIFICATIONS W? l . We “gm; ,, cg DIMENTIONS Overall length 24035 mm (80.1 in) Overall width 705 mm l27.8 in) Overall halghi 1,025 mm (404 in) Wheelbase 1,370 mm (53.9 in) Seal height 775 mm (305 in) Foot peg height 335 min (13.2 in) Ground clearance I30 mml511nl Dry weight ‘ 170 kg (375 lbsl Curb weight 183 kg I403 lbs) Maximum Weight capacity 157 kg (347 lbs) FRAME Frame type Diamond Front suspension Telescopic fork Front wheel travel 130 mm (5.1 in) Rear suspension Swingarm Rear wheel travel 110 mm [43 in) Rear damper Gas-tilled damper @3 Front tire size 110/70—17 54H Rear tire size MONO—I7 66H Tire brand (Bridgestone) Front/Rear 6547/6543 Tire brand (Dunlap) Front/Rear K505F/K505 Tire brand (Yokohama) Front/Rear — Tire brand (lRCl Front/Rear — Front brake Hydraulic disc brake Rear brake Hydraulic disc brake Caster angle 25°30 Trail length 99 mm (3.9 in) Fuel tank capacity 11.5 lit (3.04 US gall 2.53 Imp gal) Fuel tank reserve capacity 3.5 lit l0.92 US gel, 0 77 Imp gal) ENGINE Bore and stroke 550 X 42.0 mm (2‘17 X 1.65 in) 359 cm1 (243 cu in) 1 1 .5 : 1 Gear driven DOHC, 4 valves per cylinder 5° ATDC 33° ABDC 33° BBDC. 33° EBDC (California) l 5° BTDCI 10u BTDC (California) Forced pressure and wet sump Trochald-tvpe Liquid cooling system with cooling fan Paper filter Unit-type, 6 main journals 57 kg 1126 lbs) 1 —2—4—3 Vertical 30“ in line four ll GENERAL INFORMATION F General [Cont'dI ITEM SPECIFICATIONS CARBURETOR Carburetor type V606 Throure bore 32.5 mm (1.28 mi DRIVE TRAIN Ciurch system Wet, multiplate CIUiCh operation system MEChanICaI type Transmission 6-spsed canstant-mesh Primary reduction 2.181 196/44) m Secondary reduction — i I $3 Third reduction — Final reduction 2.733 (41/1 SI Gear ratio Isl 3.307 (43/13) Gear ratio 2nd 2.352 (40/17) Gear ratio 3rd 1,575 (30/16! Gear ratiu 4th 1,590 (35/22) .\ I 3 Gear ratio 5th 1‘434133/23i ' v" Gear ratio 5th 1.333 (32/241 Gear ratio reverse — Gearshift pattern Left foot operated return system 17N72~3—475~6 ELECTRICAL ignition system Full transistor ignition Starting system Starter motor Charging system Triple phase output alternator Regulator/rectifier type SCR shorted/triple phase full-wave rectification Lighting system Battery AC regulator type A iii 4. GENERAL INFORMATION Unit: mm (lni F Lubrication Engine oil capacity at draining at disassembiv at oil filter change Recommended engine all OlL VlSCOSITIES item ——— SAE zuw-so — -- .. SAE 20w: 0 . . - SAE IDW—do‘ _ _- . . snF tow—:0 o 20 40 so so loo ‘r -20 -lo 0 lo 20 30 no -c Oil pressure at oil pressure switch on pump loter tip clearance ® body clearance ® and clearance @ (3 (D I ® ._..l._ Standard Service |irnil 2.9l‘ (306 US at, 2.55 imp qti 3.5!(310 us qt, 3.08 Imp qri 3.11‘i3.28 US qt, 2.73 imp qt) HONDA 4~slroke oil or equivalent. API sen/ice classification SF or $6, The viscoslties shown in the charl may be used when the average temperature in your riding area is within the indicated range. 490 KPa r5 kgrcmi. 71 psi) 0.10 (0.00M 0‘15fl0t22 (0006—0009] 0.02—0.07 10.001 —o.003l iii! 0.15 (0.006) 0.35 (0.014“ 0.1010004] Jet neeidle clip posltion Pilot screw initial openlng Pilot screw high altitude adjustment Air screw initial opening (California) Air screw high altitude adjustment Float level Carburetor vacuum difference Base carburetor (For carburetor synchronization) Idle speed ' (California) Choke type Throttle grip iree play Acceleralur pump clearance Secondary air supply system All injection control valve vacuum pressure —— Fual system Carburetor identification number VGOSB (California) VGOGC Main Set #105 (High altitude) —— (2, 3i —— i1, 4) (Front) —— (Rear) —— Slow jet #35 See page 6-13 1/2 turn in from initial opening 8.0 (0.31) Within 30 mmHg 11.2 ian) No. 2 carburetor 1,300 2100 ml 1,400 1' 100 rpl' Manual byrslaner 2—6 (0.03—0.24) Reed valves are built into the ASV 360 mmHg (i4,2 ian) Iiiiiiiiiliiiiiiiiiliiiil 1-6 iii 0 l I: GENERAL INFORMATION Unit mm lin) 7 Cylinder head hem Cylinder compvcssion Cylinder compressltm dillerence Valve clearance IN (cold) EX Cylindel head warpage Cam lube heigm (D IN IN lCalllornla model) EX EX (Calilmnla model) Camshalt runout ® Camshaf! oil anaranrn m _, <_@ Hold Hold Camshah journal on. Camshaft holder I.D. Valve Stem OD. IN EX Valve guide IID. IN EX Stem-lo-gulde clearance IN EX Valve guide projection above cylinder head In) IN EX Befove guide installation: h 1. Cnlll the valve guldes In the Ireez» el section of a vefrlgarator fol /% about an hour. 2. Heat the cylinder head Io Valve seat width Valve spying free length IN 130°C r140°C l275°F~290°Fl EX inner IN inner EX ou‘ev IN outer EX Rocker arm LD. IN EX Rocker arm shalt 0.D. IN EX Rocker arm-(o~rockev arm shah clearance Valve llfmr 0.0. Valve liner bore |.D. Hydraulic lash adjuster assist spring free lengm Hydraulic lash adjuster Commassinn snake with kemsene Slandavd k280i 1,320 kPa ‘12 8713 Z kglcmz. l82— 188 psII/400 rpm Within 30 mmHg ll 2 ianl of each other 0.12—0.18l0.005——0.007I 0.177023 l0,007»0.005l 331,070—153,230 (1.3020—l .3083) ~33.120733.280 ll JOBS—1.3102) £1 OED—0.082 (0.0008700024) 22.959A22 980 l0.903970.9047l 1775—1750 (01436—01492) 1755—3770 (GAME—0.1484) 3.800—3312(01496—01253) 3.800‘3312(0.1496~0.1253l 13.37—13.77 l0.526—D.542) 11.52—11.92 l0.454—D.469I 0.9~1,l MOSS—0.043) 39.40 (1,551) lllllllllllllg l l S Nice limh 0.1 [0.004) 333211.300) 33.07 [1.302l 0.05 (0.002) 0.10 (0.004) 223710.904) 3.70 (0,145) 3.69 (0.145] 3.89 l0,153) 3 89 (0.153) “A m OOZI . lllllllllllll- 1-7 GENERAL INFORMATION Unit: mm (in) # CylindeI/pislon Main journal Oil clearance Main ioumal bearing selection See page 10-6 Item Standard Service limit Cylinder l D. ‘ 55.000—55010i2 ”554—2 1657) 55.10 (2,169) Cylinder oul ol round # 0.10 (0.004) Cylinder taper i 0.10 (0.004) Cylinder warpage — 0.1010004) Fislon mark direction Wlih ")N" maik lacing lo the inlake side 7 Piston O D. (D) 54.950#54.990(11638—11650) 54.90 (2.161) Piston OD. measuremem poinr (H) 10 (0.4) — szw'i pin hole I D. (d) 14002714008 (0.5513—0.55l5) 14.05 (0.553) Cylindev-la-pislon clearance 0010—0050 (00004—00020) 0.10 (0.004) Piston pin OD‘ 13354—14000 (05509-06512) (3.9810550) AX“ Piston»m-plsmn pin clearance D.002—-0.0l4 (00001—00006) 1104 (0,002) '4 Conneciing iod-to»pislan pin clearance (1016—41040 (00006—00016) 006 (0002) Top iing-lo-ring gloova ciearanée 0015—0 050 (00006—00020) 0.03 (0.003) Secnnd ring-m-ring groove clearance 0,015— 050 (00006—00020) 0.08 (0.003) Top ring and gap 0.13—0.28 (0.007-0.01 1) 0.5 (002) Second ring and gap 0.18—0.33 (000770.013) 0.5 (0.02) Oil ring (side (ail) end gap 0.2—0.7 (0.01 —0.03) 1.1 (0.04) Top ring mark Inslall with xhe marked side up — Second ring mark Install wilh (he marked side up — — Crankshaft Cnnneciing rod small and LD. 14016—141334 (05518—05525) 14.07 (05541 Connecting rod big end side clearance 0.05—0.20 (0002—0008] 0.30 (0.012) radial clearance — * Crank9 U27FER9 0.8—0.9 (0031—0035) 16" BTDC at idle Advance starr l 1,700 rpm stop ‘ _ Full advance _ __ Alternator excizer coil resistance (Ar 20°C/68"Fl —— — Ignrtron curl resistance (Primary: at 20°C/68°Fl 2—4 ll — [Secbndary with plug capl 23—27 kn —— (Secondary without plug wire) 13— 1 7 kl? '— Pulse generator resistance (At 20°C/68°Fl 340~420 Y2 —— Lights/meters/switches Fill/Iain fuse 30 A —— fl Fuse 1D A x 4 —— Headlight lhigh/low beam) 12 V 60/55 W — Tall/brakelight 12 V 3/32 CP — License light —— — Position light bulb — — Front turn signal/runing light — —— Front turn signal light 12 V 32 CP x 2 ~— Rear turn signal light 12 V 32 CP x 2 — Instrument lights 12 V 1,7 W x 3 — Oil pressure warning indicator 12 V 1,7 W —— Tail/brakellght warning indicator — —— .‘ Side stand indicator 12 V 1.7 W ‘ Law fuel indicator — — E Coolant temperature indicator — — Url temperature indicator —— _ High beam indicator 12 V 1.7 W — I Turn signal indicator 12 V 17 W — Neutral indicator 12 V 17 W ‘ Reverse indicator — _ Overdrive indicator — — Oil temperature sensor resistance — — Fuel unit resistance (at full level) — —— (at low level) —— — Fuel pump flow capacity ("rim/minute) ‘ 560 cc (22.3 US 01, 2312 Imp 02) min. ~ Coolant temperature sensor resistance 80”C (176°F) 47—57 9 — 1205Cl243’F) 114—1817 — Fan mo'ror switch Starts to clrse r' ' ‘ 38—toz°c mos—neon — Stops to oprvn lx )3—97°C l199—207°Fl *— \ » GENERAL lNFOFlMATION ‘ TORQUE VALUES STANDARD TORQUE VALUES _ l Torque i "am Torque l N-mlkg-m,f1-lb) ; N-m lkg-m, mm 5 mm bc' 1 510,511.51 5 mm screw 410 4. 3) 6mm bu l 1011.0,71 5mm screw 910 9,71 8 mm 120* 22l2.2,16) 6 mm flange ball (8 mm head) 9109.7) 10 mm be 1 35115.25) 5 mm flange ball (10 mm head) and nut 12112.9) 11 mm w- ‘ 55 v5 5. 40) . 3 mm Hanna hall and nut 27 (2 7. 20) ; .0 ”1.1....“ W. W. ....- 4014 0. 29) Torque spa: lsted below are (or Impovtanl (as‘eners. Others should be tightened 10 standard mrque values listed above. 4. Apply 5111:: 55 10 the slldlng surlace. ENGINE ltem O'ty Thread Torque Remarks dla lmml N~m kg-m n-u: Lubrication: on pump 6' ‘ sarocket bolt 1 6 15 1.5 11 NOTE 1 Oil pressure :11 1 —-— 12 1,2 9 NOTE 2 Oil dram b 1 12 35 3.5 25 oil filter b0.s 1 20 18 1.8 13 Oil filtev 1 20 10 1.0 7 Cylindel head cvlindav/plslon: v bol! B 6 10 1 .0 7 13011 16 5 12 1 .2 9 Cylinder he: \ar bramhar plate bolt 2 s 12 1.2 9 NOTE 1 Cylinder h is! nut 12 6 30 3.0 22 Cylinder he. ~omzing bolt 2 6 12 1.2 s Cvlindei ma. 9 bolt 1 6 10 1.0 7 Cyllnder St '. 12 8 25 2.6 19 Spark plug 4 10 11 1.1 a Clutch/gearslfl'fi linkage: Crankshaft we can 1 30 7 O 7 5 Timing hole CE: 1 14 1O 1..) 7 Clutch center~ ~ nu! 1 20 85 8.5 61 NOTE 3 Gearshift sax-1:2 return spring pin 1 B 23 2.3 17 Crankcase:yankshafmransmission: Connecting rod nut B 7 24 2.4 17 Crankcase b0“. 8 mm) 12 8 24 2.4 17 8 mm x 65) 1 8 27 2.7 20 6 mm] 1 9 6 12 1 .2 9 .ser crankcase) 1 20 30 3,0 22 at crankcase) 1 14 25 2.5 19 NOTE 2 Neuxral 5w 1 10 18 1.8 13 NOTE 2 Drive sure :91! 1 1o 55 5.5 do Akemator: Flywheel 17: Z 1 10 a5 8.5 61 3mm mum Starter Clu 1 10 85 a 5 51 If" 3 1:" (a «:7? «1 ed GENERAL INFORMATION FRAME Hem my Th'ead Torque . Remarks 5'3 1mm) N-m kg-m ‘ 1111) Frame/exhausl system: Exhaust pIpe joint mu 8 6 12 1.2 9 Mquer muuming ball 2 8 22 2 2 16 Side srand pivoI 1.3011 1 10 10 1.0 7 Srde stand we: lack nm 1 1o 27 2.7 20 1 Side sIand switch moummg bolt 1 6 30 3.0 22 Gearth rmdal ininI bah I e 12 I 2 9 GI-ur\-l11:pedn111w v12“ - 1, 1 S 2* '1 7 1": NO IE ‘ FooIpeg slay bolt 4 E 27 2.7 20 Righr 1DoIpeg mountlng boll 1 1O 38 3.8 27 Cooling system: Temperature sensoI — 10 1.0 7 NOTE 2 Fan moIor swuch 15 15 1.8 13 NOTE 2 Fuel system: Fuel valve nm 1 22 23 2.3 17 Fuel Iank cap mounting Wk 3 4 3 0.3 2 Engine moum: Engine mount nut (from) 2 10 40 4.0 29 Eng1ne moum run (rear/upper) 1 10 50 5.0 36 Engine mount nut (rear/lower) 1 10 50 5.0 36 Adjusling ball 1 20 15 1.5 11 Adjusting bull lock nu! 1 20 65 6.5 47 Engine sub frame nu! 4 10 45 4.5 33 Engine bracket ban 6 10 40 4.0 29 Front: Handlebar pinch bah 2 B 27 2.7 20 Handlebar weight screw 2 6 10 1.0 7 NOTE 1 Axle bolt 1 14 60 6.0 43 Axle pinch bolt 4 8 22 2.2 16 Fork pmcn non (upper) 2 7 11 1.1 8 Fork much boll llawerl 2 10 50 5.0 36 Fork Cap bolt 2 37 23 2.3 17 Fork sacks! bah 2 o 2:) 2.0 14 NOTE 1 Steering s1em nut 1 24 105 10.5 76 ‘ Sreering head bearing ad1uszment nut 1 26 25 2.5 18 ‘ Ignition swilch mouming hell 2 B 25 2 5 18 Rear: Axle nur I 16 90 9.0 65 Driven sprocke( mu 5 10 65 6,5 47 Shock absnrber mouming nul (upper) 1 1O 45 4.5 33 Shock absorber mounting nut (lower) 1 1O 45 4.5 33 Shock absorber lower joint lock nut 1 14 65 6.8 49 NOTE 1 Swingarm pivm nut 1 14 110 1|.0 80 Brake: Front caliper pad pin plug 1 10 2.5 0.25 1.8 pad pin 1 1O 18 1 .B 13 bracket bnlt 2 B 27 2.7 20 pin bolt 1 w 23 2.3 17 NOTE 1. 4 bracket pin ban 1 ~— 13 1,3 9 NOTE 1. 4 From maszer cylinder reservmr cover screw 2 4 6 0.6 4 Front brake disc bolt 6 B 30 3.0 22 Rear caliper pad pin plug 1 10 2.5 0.25 1.8 pad pin 1 Io 16 I .8 ‘3 mounting bolt 1 a 23 2.3 17 pm bolt 1 — 23 2.3 1/ Nult 1, 4 Rear master cylinder push rod jornl lock nur 1 — 17 1,7 12 Rear brake disc ban '89 4 6 40 4.0 29 After '89 4 8 43 4.3 31 Erake hose bolr 4 1o 35 3.5 25 1-15 GENERAL INFORMATION TOOLS The tools for the ball bearing removal and installallon are nor contained in “us list. Reler lo section 1, Ball Bearing Replacement, ol the Common Service Manual. The newly designed tools are indicated with ‘ mark in [he llsl. Description Tool number Alternative tool Ref. secu’onls) Oil llller wrench Vacuum gauge Oil pressure gauge Oll pressure gauge attachment Rotor holder Antifreeze resrer Cooling system tester Flual level gaugc Vacuum pump Pressure pump 'Valve guide driver (guide removal] installtiom ‘Valve bucket hole prolecxor Valve spring compressor 'Valve spring compressor artachment ‘Valve guide reamer, 3,8 mm_ Valve seat cutter, 22 mm (45" W, EX) Valve flat cutter, 22 mm (32° INl Valve (lat cutter] 21.5 mm (32“ EX) Valve interior cutter, 22 mm (60° IN, EX) 'Cutter holder Piston ring compressor Piston base Compression gauge ’Compression gauge attachment ‘Clutch center holder 07HAA—PJ7OIOO 07404—0030000 07505—3000000 07510—4220100 07725—0040000 Commercially available Commercially available 07401—0010000 ST—AH—260—MC7 ST—AH—ZSE—MC7 O7JMD—KY20100 O7JMG—KV20100 07757—0010000 O7JME—KYZD1OO 07JMH—KY20100 07780—0010701 07730—0012601 07750—00! 2500 07780 —00 14202 O7JMH — KYZOZOO 07554 — 2500000 07958—4130000 07305—0010000 O7JMJ —KY20100 07GMB—KT801OO clally available in Jar equivalent commer- U.S.A, —U.S,A. only —u.s.Al only —07JMH-KY2010A (U.S.A. only) or equivalent commeb cially available in U.S.A. —079 54— 2350000 —07953—2500001 lusA. only) jor equivalent commer- cially available in U.S.A. —Nut available in U,S.A. 07HGBiOO‘I 000A (U.S.A, only] 14,15 mmmmm mmmmmabhmw mmwmmmw moo 1-16 ll'" ,0 lid ll“ 19 «17,349 (Conr'dl GENEHAL INFORMATION Description Bearing remover head, 20 mm Bearing remover shair Drivel Altachment, 42 x 47 mm Anachmenr, 52 x 55 mm Pilot, 20 mm Fork seal driver Fork seal driver attachment Lock nut wrench, 30 x 32 mm Steering stem sucker Ball race remover — alrachmem ~driver Bearing race remover Driver Attachment, 37 x 40 mm Steering stern driver Bearing remover head, 17 mm Attachment, 24 x 26 mm Pilot, 17 mm Film, 22 mm Shock absorber compressor —screw assembly Shock absorber compressor anachmem - Driver pln Driver shaft ‘Needle bearing remover anachment Tool number 07746—0050600 0774Gm0050100 07749~0010000 07746—0010300 07746—0010400 07745—0040500 07947—KA50100 07947—KF00100 07716—0020400 07916—3710100 07953—MJ10000 07953—MJ10100 O7953—MJ10200 07946—3710500 07949—3710001 07746—0010200 07946—MBOOOOO 07746—0050500 07746—0010700 07746—0040400 07746—0041000 O7GME—0010000 07GME—OO10100 07959—MBIOOOO 07GMD—KT80100 07946— MJ00100 O7GMD7KT70200 l Rel secrronls) l1l ll 11,12 11,12 Allcrnallve lool MJ1000A), Driver (07945—3710001l and Attachment 37 x 40 mm (07746— 00102001 JAllachmem l07953~ 11 mNoI available in U.S.A. 12 07959—3290001 —Not available in USA 12 Pilor, 22 mm (07746— 0041000) and Driver lO7749—0010000l —Nol available in USA. 12 Driver 107949— 3710001) —NOI available in U.S.A. 12 Bushing remover (M967X7038 , xxxxxr Altachment. 28 x 30 mm 0784641570100 12 Attachment, 32 X 35 mm 07746—0010100 12 Pilot, 15 mm 07746—0040300 12 Snap ring pliers 07514—3230001 12, 13 Rotor puller 07733—0020001 437933, 21 60000 14 (us A only) Christie ballery charger MC1012/Z 14 Battery tesler BM—21o 14 Digital multitester (Kowm o7411—ooztcoo ~KS 32—003 14, 15, 15. lU, J) 17 Analogue resrer 07308400’ 001 {SANWAI 14, 15, 16, orTHmSH ‘IWAl 17 Tcrx bit (T40) 07703—00 100 —or r commer- 17 :16 la in us 1-17 GENERAL INFORMATION LUBRICATION AND SEAL POINTS ENGINE Palm Material ”is” l Remarks - lnrake and Exhaust valve stem sliding surlace 'Camshafl journal -Connecling rod small end-plslon pin sliding surface -Transr ’ssion gear shifter groove . Cramshalx main journal bearing sliding surface - Conr‘ecting rod bearing sliding surface Molybdenum soiurion imixulre of ihe engine uil and molybde- num dlsulfide grease wllh me IBIlO l : 1i ' Upper crankcase maxing surface Liquid sealant Do not apply sealant to (he Oll passages and near the main journal bearings ' Shaft journals ' Sliding surface - Oil p-sssure swiich Sealant Do nor apply sealant to the - Farr new: swiich oil pressure switch thread ' Then—i0 sensor head as shown. ‘ Neutral swlrcn ‘ Gear teeth Engine oil FRAME Fain! Malerlal Remarks - Cenrer srand pivot - Side stand pivcr ~ Brake pedal pivot - Gearshifr pedal pivot . Steering head bearings ‘ Dust seal lips - Clutch lever pivot - Thronle cable ends - Swingarm pivot bearings - Seal locking rab - Rear wheel driven flange bearing - Wheel bearings - Speedometer gear - Brake caliper seals ' Caliper-piston sllding surface ~ Master cylinder piston cups ' Master Cylinder-piston sliding surface Multipurpose grease DOT 4 Brake fluid - Brake caliper pivots - Brake caliper pivot boots - Hear brake master cylinder push rod head Silicone grease - Speedometer cable ~ Thronle cable ' Chuke cable - Clu‘ch cable Light weight oil ~ Handlebar grip inside surrace Honda Bond A ur Honda Hand Grip Cement (USA. only) I'i" «v.9 II" @ elf; @ GENERAL INFORMATION CABLE AND HARNESS ROUTING I1I6P~WH|TE CONNECTOR I27 GPrfiED CONNECTOR IMETERI IMETEFII I3) 6P~BLACK CONNECTOR [TURN SIGNAL SWITCH) I6) SIP-BLACK CONNFCTOR (IGNITION SWITCHI (4) 6P»GREEN CONNECTOR ITURN SIGNAL SWITCHI (5) 9P»RED CONNECTOR (STARTER SWITCH, ENGINE STOP SWITCH) I7) BRAKE HOSE I8) CLUTCH CABLE I15) THROTTLE CAELE HANDLEBAR SWITCH WIRE 114) RIGHT HANDLEBAR 1o CHOKE CABLE swncn I I I11) IGNITION SWITCH WIRE 1 MAIN I 3' WIRE III) TURN SIGNAL HARNESS WIRES ' 1-19 '- GENERAL INFORMATION (21 CHOKE CABLE \ l‘ I n m? (3) SET THE wme HARNESS SECURELY § \ , HARNESS (4) THROTTLE (9) SPARK PLUG WIRE ROUTTNG (a) No 2 s. No, 3 m SPARK PLUG WIRES (5) SET THE No. 2 & ND. 3 SPARK PLUG WIRES SECURELY 112) THROTTLE CABLES (11] CHOKE V I \(' K‘!‘ , ‘— 113) SET THE No.1 & ‘ / No. 4 SPARK l PLUG WIRES SECURELY {7’ CLUTCH CABLE (10) SPARK PLUG WIRE ROUTONG :TT (16)ND.1& No‘ 4 SPARK PLUG I15) SFEEDOMETER WIRES CABLE 1-20 I GENERALINFORMATION (I) SPARK I2) DIODE (3) BATTERV (4) MAIN II" / TERMINALS I 9 UNIT IIaCIng :a \he snde) O \ WIRE HARNESS IIW‘T'TEJEI, r4: ' - _ '\i:';r. /‘0 Q i V (5) CLIP Q - MAIN WIR—E“ , HARNESS ' . SPARK PLUG I“ \ ‘ " ¢ WIRE ”m; i‘ %A _ (6) WIRE GUIDE _ / - IGNITION COIL WIRE w - NEUTRAL SWITCH BI OIL PRESSURE SWITCH WIRE - PULSE GENERATOR WIRE ‘ - SIDE STAND ‘ . ‘3’ CLAMP SWITCH WIRE - MAIN WIRE HARNESS . ALTERNATOR WIRE I7I RESERVOIR - REAR BRAKE LIGHT SWITCH (10, NO} 1 & Na 4 SPARK HOSE WIRE PLUG WIRES (11] AIR HOSE \ E \‘* (9) Ell-EJIQSERATOR (12] SIDE STAND Em CONNECTOR SWITCH (3P) CONNECTOR 3. ITaICRANKCASE ’ BREATHER J 'I I“; ‘ )1 TUBE V (14) CLIP ‘ . - MAIN WIRE ,‘ HARNESS .‘ ' - SPARK PLUG l“ WIRE I20) REAR r :77» .\ BRAKE ? H SE 0 ' (15)No.2&NO.3 O L ‘ ‘., SPARK I ‘ k PLUG WIRES ' ,. ,(16) ALTERNATOR ’ \/I3PI CONNECTOR IISI I'- v EL TANK IITION COIL CAUTION I AIN TUBE ’I CONNECTOR ' Install [he brake ,wilch with ‘4“, , . _ __ V - __ , GENERAL INFORMATION MI REGULATOR/ I2) FUEL (3) FUEL CUT‘OFF RECTIFIER REL Y I‘" " FILTER A K I», 5 fly , ‘ ' . m; I “’ ’9‘? ‘9! J) 0 g \ \ ".;‘.'I"'¥G?.§3WK£~’ was“ , . . 1 IIIWIRE GUIDE (. ,. », . -|GN|T|ON COIL WIRE \ . - ‘ .;_. . - NEUTRAL SWITCH V '1‘. . \ & OIL PRESSURE (9) PULSE SWITCH WIRE GENERATOR - PULSE GENERATOR WIRE WIHE [BI NEUTRAL I7) SIDE STAND (6) FUEL PUMP - SIDE STAND SWITCH WIRE SWITCH WIRE SWITCH WIRE ' ALTERNATOR WIRE .(11) MAIN WIRE HARNESS (10] CLAMP I ' I / : //\§ UNIT (12) DIODE 1 -22 GENERAL INFORMATION ' Camornia Model Only 0T“ 39 [I (3) TO AVCV No. 4 TUBE 121N015 (PW ’ TUBE ‘” 0 H) FUEL TANK AL ./ (5) RADIATOR RESERVE Tf NK {V FRFLDW T‘ BE } (12) No. 3 INTAKE (11) Nov 4 INTAKE MANIFOLD MANIFOLD (10) No, 10 TUBES y (13) O-RINGS TUBE ' :9 116) CTLSlEJCTr \J h 1-23 »I- A I GENERAL INFORMATION w No. 5 TUBES 12) AIR INJECTION TUBE (No. 15] (4) No. 4 TUEE (3) Na, 1 TUBE : bk Mini») :—_— ‘9) (9) Na. 10 TUBE GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S Environmental Prator‘ MP r may and California Air Resources Board (CARS) require manuiacturers l0 certrly that their motorcycles comply with am, e exhaust emissions standards during their uselui life. when Operated and maintained accurdmg to the instructions provided and that motorcycles built altcr January 1, 1983 comply with applicable ncuse emis- sion standards Ior one yealor 5,0001:m(3,730 miles] alter the time 0| sale to the ultimate purchaser] when operated and maintained according to the InSIrUCUDnS provided. Compliance with the terms oi the Distributors Warranties Ior Honda Motorcycle Emissron Control Systems is necessary in order to keep the emissions system warranty in etiect SOURCE OF EMISSIONS The combustion process praduces carbon monoxide and hydrocarbons. Control 01 hydrocarbons is very important because under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way. but it is toxic Honda Motor Cur, Ltd. utlllzed lean carburetor settings as well as other systems. to reduce carbon monoxide and hydro- carbons CRANKCASE EMISSION CONTROL SYSTEM The crankcase emission control system routes crankcase emissrons through the air cleaner and into the combustion chamber. Condensed crankcase Vapors are accumulated in an air/oil separator and drain tube which must be emptied periodicallyi Refer to the Maintenance Schedule (page 3-4), The drain tube needs to be checked lot oil accumulation more frequently iI the ma- China has been ridden mostly at high speeds or In rain. (1) AIR CLEANER 12] CAHBUHETOR (3) 4— :BLOW-BY GAS [4) <2! :FHESH AIR \ 'fi — ' 1-25 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (SECONDARY AIR SUPPLY SYSTEM) (Except California model] The exhaust emiSSlon control system l5 composed oi lean carburetor settings and no adjustment should ue made except idle speed adjustment with the throttle stop screw. (California model] The exhaust emisslon control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust part. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. ThlS charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon moncxide into relatively harmless carbon dioxide and water vapor. This model has the air suction valve; it consists of reed valves built into the air injection control valve. A reed valve prevents reverse air tlow through the system. The air injection control valve reacts to high intake manilold vacuum and will cut all the supply cl lresh air during engine deceleration, thereby preventing alterburn in the exhaust sys» tern. No adjustments to the secondary air supply system should be made, although periodic inspection ol the components is rec- ommended. ~ ii) INTAK PORT (2) AIR INJECTION CONTROL VALVE (3) Am SUCTION VALVE ASSEMBLY [5) CARBURETOR (4] REED VALVES (6) EXHAUST PORT L/ (2:: (71V FRESH AIR Idle ‘III ('9 BUS! BUS! rt oi IoId sys- II I? 5W Lew. GENERAL INFORMATION EVAPORATIVE EMISS 1 CONTROL SYSTEM (California model only) This vehrcle ComleCS with rrw (.rrlilornla Arr Resources anrd requrremenls (or evaporatrve emISSIDn reguIalIOns. Fuel Vapor horn [he luel rank and carburetors IS routed mil) [he charcoal canislcr Where ir rs absorbed and slored whlle IhE engine rs stopped. When [he enng is running and rhe purge CDnIrDI diaphragm valve is open fuel vapor in rhecharcoal canis» ter is drawn into the engine through the carburetor. At the same time the an vent control valve is open and all Is drawn into the carburetor through lhe valve. I1) PURGE CONTROL VALVE (FCVI (Z) FUEL TANK ® C (1: I3) FRESH AIR (4] CA lSTER <3: :(5) FRESH “In « : re) FUEL VAPOR CONTROL VALVE (AVCV) G (7) AIR VENT NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SVSTEM IS PROHIBITED: Federal law prohibits the Iollawlng acrs orxhe causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maimenance, repair 01 replace mentl or any device or element or design incorporated into any new vehicle (or the [‘x *pose of noise control prior to its sale or delivery to the ultimate purchaser or while It is in use; or (2) [he use of the vehicIe aher such device or elemental design has been removed or rendered inoperative by any person. 'I. 2. 3t 4. AMONG THOSE ACTS PRESL..‘ [D To CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: Hem' v or puncturing Urc muIlIer, names, neaoer plpES or any other component which conducts exhausr gases. Re w :r puncturing ol any part c! the inrake system Laak r maintenance. F ‘ moving parts or the vechilel or parts of the exhaust or intake system, with parts other than those specirred . cturerr 1—27 me GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. Only) An EmisSlOl’I lnlormauon Label is localed on the real tender as shown The 555! must be removed to read ix, ll gives DESIC lune-up speclflcauans VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL Alter maklng a high almude cavburetov adjustment, attach an update label on the rear fender as shown. @III VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) The Vacuum HOSE Hauling Diagvam Label is on [he rear lender as shown. The seat must he removed ‘0 read it. Home the vacuum hoses as shown on this label. l1! EMISSION INFORMATION 12 UPDATE LABEL ) l3) VACUUM HOSE ROUTING DIAGRAM LABEL [Calilurnln model only) VADIIUM IIIISE ROUTIIIG DIAGRAM ENGINE mmu-mnoasnuvs E\APOHATWE nva-sszu CALIFORNIA yam“: FHONT OF VEHICLE To r0 ovmmn F uEl. IANK CANI TER fig “r -750 1—28 ii (9 Ill.’ '99 ill” #9 - 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION 2-1 SIDE COVER REMOVALIINSTALLATION 2.3 TROUBLESHOOTING 2-1 EXHAUST SYSTEM REMOVAL] I SEAT REMOVAL/INSTALLATION 2-2 'NSTALLAT'ON 2'3 REAR FAIRING REMOVAL, FUEL TANK REMOVAL/iNSTALLATiON 2»4 INSTALLATION 2—2 SERVICE INFORMATION - When removing a cover, be careful not to damage any (at) or groove, m _ V ,, ‘ > . _._ .,s _ ,,,,, s ) Do not servrce the exhaust system while it IS hot. i NOTE - Replace the exhaust pipe gaskets ii the exhaust system is removed. . Tighten the exhaust pipe joint nuts first. then the mounting bolts. I Although it is possible to weld some cracked frames and straighten some frames that are slightly bent il is best to replace the frame with a new one when it is damaged. 0 Generally speaking, plastic body panels cannot be repaired and thereiore must be replaced. I It is possible that a front end collusion will bend the steering head of the irame, but not the fork, wheel or even the axles TROUBLESHOOTING - Failure of the front suspension, steering Or rear suspension may damage the irame enough to require replacement. - Refer to the section 18 oi the Common Service Manual for front suspension and steering inspections. - Refer to the section ‘0 of the Common Stamina Manual [or rear suspension Inspectlont Abnormal engine Vibraiion - Cracked or damaged engine mounts - Cracked, damaged or bent welded portions ~ am or damaged frame - Engine problems Abnormal noise when riding lhanging Dr cracking) - Damaged or bent engine mounts ‘ Damaged welded points - Damaged or bent frame Steers to one side when under acceleration or decelert ‘Li . Bent frame - Sent fork - Bent swingarm FRAME/BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL/INSTALLATION Insert (he lgnirion key into the sear lock/helmet holder and (um [he key clockwise and push down rhe lever; release rhe sear locking. Pushmg the sear as shown, remove the sear rearward. Align me sear hacks with the frame hooksand push me seal forward Press rhe rear of (he sear down and lock rhe sear securely. CAUTION ~ Apply grease to rhe seal locking. Ea careful not (0 pinch the wire harnass belween IhB seat and the lrame. REAR FAIRING REMOVAL/ INSTALLATION Rgmnva the <flat (nhnvn) Remove the belts and callers. Release the fairing lrunt bosses from the grammars. Remove the rear fairing rearward. Insrall the rear fairing in the reverse order of removal, I‘ll SEAT LOCK/ HELMET HOLDER (l ) COLLAHS (2] BOLTS (4) HEAR FAIRING SIDE COVER REMOVAL/ INSTALLATION FRONT SIDE COVER Remove the bolts Release the boss from the frame grommel and remove the Iron! side cover. Install the side cover In the reverse order oi removal. NOTE I ~ It is not necessary to remove the bolt ® as shown. ‘I REAR SIDE COVER Remove me following: — sear (page 2-2). Release the rear fairing Iront bosses from the grommets [page 2-21. Remove the bolts and rear side covert Install the Slde cover in the reverse order 01 removaL NOTE - It is not necessary to remove the bolt ® as shown‘ I EXHAUST SYSTEM REMOVAL/ INSTALLATION Remove [IIE rBdlaIOr lower mounting bolts and loosen the upper mounting bolt/nut (page 5-5II Swing the radiator for- ward, Remove the following exhaust pipe mint nuts. — muffler mounting boIts and exhaust pipe/mumer. — gaskets. NOTE Replace the exhaust pipe gaskets IS remove the exhaust system Install new gaskets and exhaust pipe/mquIer. Tighten the exhaust pipe jOInI nuts firstt TORQUE: 12 III-m [1.2 kg~m, 9 ft-Ib) Then tighten the muffler mounting bolts. TORQUE: 22 N-m (2.2 kg-m, 1G "-IbI FRAME/BODY PANELS/EXHAUST SYSTEM III FRONT SIDE COVER \ \ 12) BOLTS SIDE COVER I2) BOLTS I1) RADIATOR I5) MUFFLER MOUNTING BOLTS I3I JOINT (4i EXHAUST NUTS PIPE/MUFFLER FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK REMOVAL/ INSTALLATION Awnnuma certain conditions. Walk in a well ventilated area. Smnklng or alluwing Names or sparks in the work area or whale gasoline is stored can cause a fire or explo- siDn. Remove the sear (page 2-2). Turn the luel valve OFFr Remove rhe fuel rank mounting bolts and lift the rank up. Bhumnem the tubes, and remvve me fuel tank. Install (he fuel rank in rhe reverse order of removal, After lnstallation. mm the luEl valve ON and Check the luel line for leakage. Install thz seat (page 2-2). Gasoline ls extremely flammable and is explosive under (Zl FUEL TANK l3) BOLT/ NUT l4] FUEL TUBE 3. MAINTENANCE III. @ SERVICE INFORMATION 34 VALVE CLEARANCE 3-5 SERVICE ACCESS GUIDE 3—2 CARBURETOR SYNCHRONIZATION 3~8 MAINTENANCE SCHEDULE 3-4 DRIVE CHAIN 3-8 V AIR CLEANER 3~5 SIDE STAND 3-8 I {I @ SPARK PLUG 3-5 SERVICE INFORMATION (If. 0 ReIer to the Common Service Manual for Items not incIuded in this manual. - Refer to the specifications [Section 1) (or maintenance service data. I;- I- I % .- ? MAINTENANCE SERVICE ACCESS GUIDE - The following shows the locations ol the maintenance items listed below and the pans required to be removed (or that . maintenance service. Refer to the Common Service Manual lor items not instructed in this manual. (l‘ - - Reler to section 2 (Frame Body panels/Exhaust svstem). the parts required to be remuve lor sen/ice For example. AIR CLEANER (Contamination, clogging, rcplacemenll — - mai-rtenance parts (servrce item) - Fueltank *i7,,i,m,iw *7 parts required to be removed (or service Reserve Tank Cap (Coolant lilier) . Seat Throltle Grlp (Operation. lree play) Master Cylinder Brake Pedal (Air bubbles ln system) [Level check, fluid replacement) Brake Hose (Leakage, degradation, damage) Brake Reservoir (Level check, lluld replacement) Brake Lever (Air bubbles in system] Brake Hose (Leakage, degradation, damage) Caliper (Pad wear) Caliper ' (Pad wear) 1 Tin: Tire (Wear, (Wear, damage, pressure) damage, pressure) Wheel Wheel (Damage, (Damage, runout, corrosion) runout, corrosion) Brakellgh! Swrtch (Operation) , , Oil Filter (Replacement) Oil filler Cap/Level Gauge Timing Hole Cap/Crankshaft Hole Cap (Level check, replacement) (Valve clearance) MAINTENANCE (haw I. 0 ‘ Alr Cleaner Synchronlzallcn Adiusllng chew (Comaminanon, clogglng. vcpmcemcnl page 3-5l lcarbuyelor synchronization page 3-8) ' Fuel lank - Fuel lank ice Cavburewr Choke (Operatlon) PCV and AICV (Damage, laully hose page 6-15) ‘l' mum" ‘EVE' “"55 may} Reselve Tank (Coolant levell ‘ ‘39 Headlight (Aiml Steerlng Head Bearings (Damage) Valve Clearance (page 3.5) 1 Suspen5lon (Loose, wear, damage] Suspensmn 4 (Loose, weal, damage) Asv lDamage, faulty hose page 545 \ Spark Plug (Wear, damage, colorallm 9 ~ Front side cover Radiator Hose (Leakage, degradation, ) \— Engine Oil Drain Rnh lm rt. Drive Chain [Flea play, Iubricalion, replacement) Side Stand (pass 378) Fuel Fillel (clugglngl Fuel Line (Damage, leakage) \— Tlmmls Smp Screw (Idle weed) MAINTENANCE MAINTENANCE SCHEDULE Perlarm the PRE-FIIDE INSPECTION in the Owner‘s Manual at each schemlllrd marnxenance ImrIorI l. Inspecr and Clean, Adlusl, Lubrlcate, or Replace II necessary. Fl: Replacer L: Lubncalz The lallowmg iIems requlre some mechanical knowledge. Cerraln Items (palllculally Ilmse marked ‘ and ' ‘I may requIlE more Iechnlcal lnlormanon and tools, Consult your authonzod Honda dealelI WHICHEVEH COMES FIRST FREQUENCY ODOMETER READING (NOTE II Reler to page NOTE 5 NOTE 5 1-5/NOTE 5 3~5 3-5/NOTE 3-5 NOTE 5 NOTE 5 x IOOOkm 1.04 64 Ile I '2 2 elazo 38. onoo 4I8II2—IISI20 24 | __Il I NOTE FUEL LINE THROTTLE OPERATION CARBURETOR CHOKE AIR CLEANER ‘ SPARK PLUG VALVE CLEARANCE ENGINE OIL ENGINE OIL FILTER CARBURETOR SYNCHRONIZATION CARBUHETOR IDLE SPEED RADIATOR COOLANT COOLING SYSTEM SECONDARY AIR SUPPLY SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM DRIVE CHAIN BRAKE FLUIU BRAKE PAD WEAR AKE SYSTEM 5 RELIGl-T‘FSLIJITCH HEADLIGHT AIM CLUTCH SYSTEM SIDE STAND SUSPENSION NUTS, BOLTS, FASTENERS WHEELS/TIRES STEERING HEAD BEARINGS ‘ Should be serviced by an authorized Honda :1 qualified. " ‘ In the interest of safety. we recommend these Items be serviced only by an authoriled Honda dealer. NOTES: 1 Ar higher odometer raadingS. repeat a: (he Irequencv inrewal established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Replace every 2 years, or at indicaIed odomeIer Inlervall thchever comes lilst. Replacement requires mechanical sklll 4. Calllornia type only, 5. Reler m the Common Service Manual, 3-8/NOTE 5 NOTE 5 NOTE 5 NOTE 5 EMISSION RELATED ITEMS NOTE 5 NOTE 5 3-8/NOTF _ NOTE 5 NOTE 5 NOTE 5 WNOTE 5 NOTE 5 NOTE 5 3'8 NOTE 5 NOTE 5 NOTE 5 NOTE 5 ealer, unless the owner has proper tools and service data and is mechanically . NONAEMISSION RELATED ITEMS 0 ‘- |Ulle AIR CLEANER Remove the rollowrng: -— luel tank (page 2~4l, — arr cleaner case cover (page 63!. Discard the air cleaner element in accoldance with the main» tenance schedule. Also, replace the element any time rt is excessively dirty or damaged. install the air cleaner element with the 1} mark lorward and the TOP mark facing up. Install the wire harness into the wire harness clamp on the cover securely. SPARK PLUG NOTE - For detailed instructions reler to section 2 or the Common Service Manual. Instruction for removal/ installation of only the No. 2 and No. 3 spark plugs ls given here, No. 1 and No.2 plug can be removed easily only to remove the front side cover. . Remove the front side covers (page 2~3l. The spark plug wrench is included in the tool kit. Insert the ulug wrench between rhe heat guard plate and cyl- inder head cover as shown, and set the wrench onto the spark plug. Turn the plug wrench and remove the spark plug Then lift up the wrench with the plug, through the heat guard cross-hole. Pull the wrench out of the cylinder head. Remove the spark plug {rum the wrench Install a new spark plug into the cyllnder in the reverse order 0! removal. Tighten the spark plug 1/2 turn with an open and wrench to cnmpress the plug sealing washer. VALVE CLEARANCE INSPECTION NOTE - inspect and adjust valve clear; cold (Below 35°C/95“F). Remove the following: » timing hole cap (page 9-2). ~ crankshaft hole can cover (Dag > crankshaft hole cap {page 972 , alrcleaner Ease (page Brill \ > .. while the engine is l MAINTENANCE l2) PLUG WRENCH MAINTENANCE Remove me ladialor lower mounting bells and loosen the upper mourning bolt‘nut Swing me radiator lorward. Remove rhe cylinder head cal/er (page 8-2). Roiaie ms crankshail clockwlse. Align (he T mark (Yellow calmed llnel on the flywheel with (he index mark an me right crankcase cover, Each timing mark (EX and IN) on The camshali gears should be aligned will-l lhe cylinder head upper surluce, If each liming mark is facing outside, No. 4 cylinder piston is 5‘ TDC (Tap Dead Cemer) on The compression stroke] gr: [0 Step 1, If each timing mark is facing inside, ND. 1 Cylinder piston is at TDC (Top Dead Center) an the compression stroke, go to Step 2, Slep 1: Insen the reeler gauge belween the cam lobe and valve bucket Measure (he valve clearance as lullow: W No. 2 (IN) — No. 3 (EX) — Nor 4 (IN/EX] Step 2 Insert the leeler gauge bexween she cam lobe and valve bucket. Measure the valve clearance as follow: — No.1 (IN/EX) — No, 2 (EX) a No, 3 “Ni VALVE CLEARATIJCES: lN: 0.12—0i18 mm (ODDS—0.007 in) EX: 0.17—0.23 mm (0.007—0.0051n) Rotate the crankshaft 360 degrees and align the T mark wim the index mark again and go to Sxep 1 or i to check other valve clearances. (2) RADIATOR l3) BOLTS (1) T MARK (VEL OW COLORED LlNE l’-“4 in, ,xl @lflg (2i EXHAUST CAM SHAFT (1i INTAKE CAM SHAFT (3) TIMING MARKS (facing outside) RIGHT VIEW (1) lNTAKE (2] EXHAUST CAM SHAFT CAM SHAFT i3) TlMlNG MARKS (facing insidel RIGHT VIEW i l i a: SHIM SELECTION if the clearance is not corrccl Remove rhe Camshahs (page 872). Remove lhe valve bunkers and shims (page 8 6i - Do nor allow shims l0 lall imo the crankcase. The shimisi may occasionaily srl’ck r0 rhe DUCKEL - Mark the positions of all buckels and shims to ensure correct reassembly. - I! is easy to remove the valve bucker with a valve lapping Ioal or magnel. . Remove the shims with lweezars or a magnet. Clean me valve DUCKelS with compressed air. Measure rhe shim thickness with a mrcrcmerer and record it. NOTE - Sixty-live different shims are avaliable in ihickness in- tervals 010.025 mm. The lhinnesr is 1.200 mm the rhickest is 2.800 mm. To conilrm vour shim choice. you may use the following formula: = (b — c) + d : new shlm :hickness : rscorded vain clearance : specified valve clearance (IN: 0.15 mm EX: 0.20 mm) : old shim thickness examplo: b: recorded valve clearance: 0.18 mm :1: old shim thickness: 1.850 mm c: specified valve clearance: 0,15 mm 0.13 - 0.15) + 1.850 1.880 new shim thickness = 1.875 mm NOTE ' If the required thickness oi xhe new shim is more than 2.800 mm. the valve seat is probable heavily carboned. Reiace rhe seat, recheck valve clearance and reselect the shim. MAINTENANCE til 4‘ e: MAINTENANCE CARBURETOR SYNCHRONIZATION NOTE - For detailed instuctions, reler to section 2 at the Common Service Manual. The information here only in- dicates locations at the plugs tor the adapters and the synchronization adjusting screws, Beiore inspection, remove the fuel tank mounting bolts lpage 2-4) and move the rank rearward with the fuel tube connected. CAREURETOR VACUUM DIFFERENCE: Within 30 mmHg (1.2 ian) BASE CARBURETOH: No. 2 CARBUHETDR DRIVE CHAIN Place the motorcycle on its side Stand, shift the transmission in neutral, and turn thr: ignitien switch uir, Inspect the drive chain free play midway between the sprockets on the lower chain run. FREE PLAY: 15—25 mm (5/5—1 ini CAUTION - Excessive chain free play 50 mm (2 in) or more, may damage the frame. SIDE STAND Check the side stand ignition curali system: — Place the motorcycle on its center stand and raise the side stand, 7 Start the engine with the transmission in neutral, then shift the transmission into gear with the clutch lever squeezed, — Move the side «anti run down ~ The engine should stop as the side stand Is loweredi If there is a prabiem with the system, check the side stand switch (Section 15). check the side stand swrtch mounting bolts for Iooseness. IZI SIDE STAND 3-8 ,4 m ll] 9 4. LUBRICATION SYSTEM SERVICE INFORMATION 4-1 OIL PUMP REMOVAL/INSTALLATION 4-3 TROUBLESHOOTING 4-1 OIL PUMP DlSASSEMBLY/ASSEMBLY 4-4 LUBRICATION SYSTEM DIAGRAM 4-2 SERVICE INFORMATION - Used engine oil (or transmissiun oil in two-strokes) may cause skin cancer" repeatedly Ielt in contact with the skin lor prolonged periods, Although this is unlikely unleae yau handle used oil on a pally basis, it is still advisable to thoroughly wash You! hands with soap and water as soon as possible alter handling used oil. KEEP OUT OF REACH OF CHILDREN. The Oil Dump can be serviced with the engine installed in the frame Replace the oil pump as an assembly. For oil pressure check, refer to section 4 oi the Common Service Manual; for the switch location, see page l7»2 of this manual. I For oil pressure warning light inspection, refer to section 25 of the Common Service Manualt When removing and installing the oil pump use care not to allow dust or dirt to enter the engine. Alter the all pump has been installed, check that there are no oil leaks and that oil pressure is correct. TROUBLESHOOTING Oil level low No ail pressure - Oil consumption - Oil level too low - External oil leaks - Oil pump drive chain or all pump drive/driven sprocket - Worn piston ring or incorrect piston ring installation ~ Oil pump damaged (pump shalt) - Worn valve guide or seal ‘ Internal oil leaks Oil contamination [White appearance) Oil pressure warning light does not worlt well . From coolant mixing with nil - Refs! to section 25 or the Common Service Manual — faulty water pump mechanical seal e izultv cylinder head gasket High nll pressule - Pressure reliel valve stuck closed ~ Plugged oil filter, gallery or metering oriliea - Incorrect all being used Low all pressure - Pressure relief valve stuck open - Oil pump worn or damaged ' Internal oil leaks - Incorrect all being used ' Low Oil i9\ El LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM \1, ‘IIII I'IIII‘L‘I <———-(I) EXHAUST CAMSHAFT I2) INTAKE CAMSHAFT (3) PISTON (4) CONNECTING ROD \I [5) CHANKSHAFT (14) OIL OHIFICE—O \1 \I I: (6) OIL PRESSURE SWITCH ._ _ .V. _. _. (7) OIL OHIFICE (13) MAINSHAFTfi. (12) COUNTER an” SHAFT MT (11) OIL FILTEFI [10) OIL PRESSURE RELIEF VALVE IE) OIL PUMP (SI OIL STHAINER OIL PUMP REMOVAL/INSTALLATION LUBRICATION SYSTEM DRAlN BOLT 35 (3.5, 25 CLUTCH OUTER SPROCKET BOLT \\ O7725~0040000 or equivalent commercially available in U.S.A. (6i 7| '7 E ' 0 l5(1.5. ill (11) i REQUISITE SERVICE Engine oil draining (location: page 34L step: section 2 01th:; Common Service Manual) @ - Exhaust system removal/installation (page 2-3) . Clutch disassemblv (page Bail/assembly (page 9-3) PROCEDURE Q‘ty REMARKS REMOVAL ORDER - Installation is in the reverse order of removal. (1) Oil pan bolt 12 At installation. tighten the bolts in a gradual, crisscross pattern. (2) Oil pan 1 , [3i Gasket 1 (4) Relief Valve i (5) (Hing I l [S] Oil strainer 1 Clean with the non-flammable solvent. (7) O-ring 1 (Bl Oil pump driven sprocket bolt 1 NOTE: - Install the clutch cuter onto the mainshalt temporalli, (page 9-8). hold the flywheel with the rotor holder and remove (or torque! the bulk. - Apply a locking agent to the tip ol the threads (approx. 6 mml0.2 in) (9) Washer 1 (10) Oil pump driven sprocket 1 At installation, install with the grooves lacing insidei (1 ‘1) Oil pump mounting bolt 2 [12) Oil pump 1 @ Dowel pin 2 LU BRICATION SYSTEM OIL PUMP DlSASSEMBLY/ASSEMBLY l9) PUNCH MARK GROOVE I W ' SIDE l1) NOTE - Before ins‘alling lham, clean all removed parts thoroughly with clean engine oiL - Refer to section 4 of the Common Service Manual for inspectian inlormation, - Refer la page 1-6 fur specification REOUISITE SERVICE ~ UII pump removal/Installation (page 4-3} PROCEDURE my REMARKS DlSASSEMBLY ORDER . Assembly is in the reverse order of disassemblv. (l) on pump cover attaching screw 2 NOYE‘ - install ihe dowel pins. then tighien the screws. (2) Duwel pin (3) Oil uump cover (4) Outer ruror (5) Inner mmr (6) Drive pin (7) Pump shaft Insiall with ils punch mark facing the cavern Install ‘he romr, aligning its groove with the drive pin. A._._._._‘N Install with the tab side facing the cover (water pump side)‘ (a) Washer is) on pump body i lit? 5. COOLING SYSTEM I SERVICE INFORMATION 5.1 THERMOSTAT REMOVALI TROUBLESHOOTING 5-1 INSTALLAT'O” 5'4 SYSTEM FLOW PATTERN 5‘2 RADIATOR REMOVAL/INSTALLATION 5-5 RADIATOR DISASSEMBLY/ ASSEMBLY 5'8 COOLANT DRAINING 5-3 WATER PUMPDISASSEMBLY/ RESERVE TANK REMOVAL] ASSEMBLY 5_7 INSTALLATION 5-3 I SERVICE INFORMATION - Wait until the engine is cool beiore slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scaldingt ~ Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. — II any coolant gets in your eyes, rinse them with water and consult a doctor immediatelyt — II any coolant is swallowed, induce vomiting, gargle and consult a physician immediatelvt 7 li any coolant gets an yaur skin or clothes, rinse thoroughly with plenty or water. - KEEP OUT OF REACH OF CHILDREN Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. All cooling system service can be done with the engine in the frame. Avoid spilling coolant on painted surfaces. For coolant replacement, reIer to section 5 of the Common Service Manual; in this manual, only the coolant draining proce- dure is described. After servicing the system, check for leaks with a cooling system tester. I For fan motor switch and thermo sensor inspections, refer to section 25 of the Common Service Manual: (or the switch and sensor locations, see page 17-2 of this manualt TROUBLESHOOTING Engine temperature too high Coolant leaks - Faulty temperature gauge or thermo sensor - Faulty oil pump mechanical seal - Thermostat stuck closed ~ Deteriorated Orring - Faulty radiator cap ' Faulty radiator cap - Insufficient coolant - Damaged cylinder gasket - Passages blocked in radiator, hoses or water jacket - Lonse hose connection or clamp - Air in system - Damaged or deteriorated hoses ' Faulty cooling fan motor - Faulty Ian motor swttch ' Faulty water pump Engine temperature toe law ‘ Faulty temperature gauge or thermo sensor ' Thermostat stuck open ' Faulty fan motor switch COOLING SVSTEM SYSTEM FLOW PATTERN (3) RADIATOR CAP (" a agg,‘ V l2) THERMOSTAT w THERMO SENSOR . H) COOLING FAN l6) RESERVE (a) RADIATOR SWITCH (7) WATER PUMP m COOLANT DRA:.-..:.t: NOTE - For coulant replacenlenl, reler to sectlon 5 cl me I L Comman Sen/lee Manu‘ l CAUTION Walt until the engine is cool below servicing [he cool- ing system. Removing the radiator Cap while the engine is hot and the coolant is under pressure may cause seri- ous scalding. To drain the coolant, remove the following: — fuel tank lpage 2-4). — heat rubber and radiator cap. _ water pump dlaln bolt and sealing washer. Remove the cyllnder drain bolts and sealing washers and drain the coolant completely from the system, NOTE F California model has the only left drain bolt. 1 Place a suitable tray under the siphon tube joint at the re- serve tank and disconnect the siphon tube lram the reserve tank. Drain the coolant from the reserve tank. install the water pump drain bolt and cylinder drain belts with new sealing washers, and connect the siphon tube to the re- serve tank. RESERVE TANK REMOVAL] INSTALLATION Drain the conlanl from the reserve tank (see abnve]. Remove the following: — shock absorber (page 12-4). — reserve tank mounting bolt. — collar and reserve tank. Install the reserve tank ll" le . w ' r-‘ .7 of removal. I1) RADIATOR \\ \: (ZI DRAIN BOLT/ SEALING WASHER (ll CYLINDER DRAIN BOLTS/ SEALING WASHERS (1i SIPHONQ/O (2) RESERVE K TUBE 0 ‘ TANV COOLING SYSTEM THERMOSTAT REMOVAL/lNSTALLATlON FRONT REQUISITE SERVICE - Fuel tank removal/installarion [page Z~4l - Coolan: draining (page 53] Coolant refill (section 5 ol the Common Servrce Manual) - Air cleaner case vemoval/lnsrallation (page 6-3) PROCEDURE Q'ty REMARKS REMOVAL ORDER - installafinn is in xhe reverse order of removal. (1) Thermosiat cover mounting bolt 2 Siphon tube 1 Radiator huse 2 install them with ”0" marks lacing up. Thermo sensor connector 1 Thermos‘al cover I O»ring 1 Thermastar 1 Install the mermosta‘ wiih its hole side forwards. Thermo sensnr 1 A! installation, apply sealant to me threads. (9) Thermostar housing 1 Q ’ 'mm' 'x,-‘-.A.-.._..,.. COOLING SYSTEM RADIATOR REMOVAL/INSTALLATION j REQUISITE SERVICE . Coolant drarning (pane 5-3» - Coolant refill (socrion 5 cf rhe Common Service Manuell PROCEDURE G'ty REMARKS REMOVAL ORDER - Insrallaxion is in me reverse order of removal. l1l Radiator hose ’ Install {hem wrxh "0" marks lacing up. (2) Fan maror swirch connecmr (3) Radiator lower mounting bolt (4) Radiator upper mounting boll/nu! ‘l (5) Fan motor connector (8) Collar ‘ 5—5 COOLING SYSTEM RADIATOR DISASSEMBLY/ASSEMBLY l3l FAN MOTOR GROUND TERMINAL REQUISITE S ERVICE - Radiator removal/Installatlon (page 5-5) PROCEDURE O'ty REMARKS DISASSEMBLY ORDER - Assembly is in the reverse order of disassembly. (ll Radiator shroud atlaching scvew 4 (2) Left and right radiator shroud z ‘ At installation, allgn the grille tabs with the shroud grooves (31 Radiator grille I At installation, align four gville giooves with the vadiatov lugs, (4) Fan motel shroud mounting bolt/nut 1/2 At Installation, install the fan motor ground wire terminal properly as shown. (5) Fan motor mounting nut 3 [6) Fan motor 1 install the fan motor, with the motor wirehamess facing down, (7) Cooling lan I At installation, align the {an groove with the motor shaft. (8) Fan motor switch 1 At installation‘ apply sealant to the threads. CAUTION: - Do not over-tighten the (an mom! switch, or tha radia» tor may be damaged. l9) Orring 1 +8.- ill l COOLING SYSTEM WATER PUMP DlSASSEMBLY/ASSEMBLY ill “O—xWATER PUMP SHAFT NOTE I - ii the mechanical seal is damaged, the water pump must be replaced as an assembly REQUlSlTE SERVICE - Coolant draining [page 5-3) - Gearshift spindle joint removal/installation (page 9-5) - Engine oil draining (drain bolt location: page 3-3, step: - Water pump side cover lemoval/insta‘ “in (page 72) section 2 of lllu Common Service Manual) - Coolant refill lsectlon 5 ol the Common Service Manual) PROCEDURE Q’tv REMARKS l DISASSEMBLV ORDER '7 7 ‘ V Al - Assembly Em the reverse order 0! dlSusucmbly. (1) Radiator hose 2 l (2) Water pump mounting bolt 2 NOTE: - Before removing bolts, loosen the pump cover bollsl3l. (3) Water pump cover bolt (4) Water pump Side cover stay l5) Water pump cover (6) Orring (7) Water pump body 4‘...“ At installation, align the pump shaft slot with the oil pump shaft. ‘ (Bl O-ring l 6. FUEL SYSTEM SERVICE INFORMATION 5-1 CARBURETOR COMBINATION 5.10 TROUBLESHOOTING 6-2 PILOT SCREw ADJUSTMENT 6‘13 AIR CLEANER CASE REMOVAL/ HIGH ALTITUDE ADJUSTMENT INSTALLATION 6»3 IU.S.A. Only) 5-14 CARBURETOR REMOVALI FUEL PUMP/FILTER 645 'NSTALLAT'ON 6'4 EMISSION CONTROL SYSTEMS CARBURETOR SEPARATION ea (California Model Only) 6-15 CARBURETOR DISASSEMBLY/ ASSEMBLY 6>8 SERVICE INFORMATION m Gasoline is extremely flammable and Is explosive under certain conditions. Work in a well ventilated area. Smoking or al- lowing flames or sparks in the work area or where gasoline ls stored can cause fire or explosion. . Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind. resulting in loss of Vehicle control, CAUTION - To prevent damage, be sure to remove the diephragms belore cleaning airend (uel passages with compressed air. The diaphragms might be damaged. NOTE » if vehicle is to be stored tor more than one month, drain the float chambers. Fuel left in the float chambers may cause clogged Jets resulting in hard starting or poor driveability. c When disassembling fuel system parts. note the locations of the O-rings. Replace them with new ones on reassembly. 0 Beiore removing the carburetors. place a suitable container under the carburetor drain tube, loosen the drain bolts and drain the carburetors. e Mter removing the carburetors. cover the intakepmt ol‘ the engine with a shop towel or cover It with pIeces of tape to pre vent any foreign material rrom dropping into the engine. 0 The vacuum chamber and float chamber can be serviced with the carburetors assembled. For fuel tank removal/installation. see page 2—4. California Model Only: All hoses used in the secondary eirsupply and evapoisi emission control systems are numbered for identification. when connecting one of these hoses, compare the hose nuw it with the Vacuum Hose Routing Diagram Label. page 1-29. and carburetor tubes, page 642. 6—1 {I g FUEL SYSTEM TROUBLESHOOTING Engine won't start No fuel to carburetors e luel strainer clogged _ fuel lube clogged 4 float valve stuck — float level misatljusted 7 fuel tank cap breather hole clogged — fuel pump malfunction . Too much fuel getting to the engine , air cleaner clogged — flooded carburetors ' intake air leak - Fuelcontaminatedldeterlorated . Slow circuit or bystarter circuit clogged - ignition malfunction Engine stalls, hard to start, rough idling ' Fuel line restricted - Ignition malfunction - Fuel mixture too lean/rich - Fuel contaminfled/deteriorated - Intake air leak ~ Idle speed misadjusted ~ Fuel pump malfunction - Pilot screw misadjusted - Slow circuit or bystarter circuit clogged - Float level misadjusted - Fuel tank breather tube clogged - Emission control system malfunction (California Model Onlyl —— air vent control valve iAVCV) faulty —— purge control valve (PCV) faulty ~ loose, disconnected or deteriorated noses of the emission control system Atmbum on discoloration - Lean mixture in slow circuit - Emission control system malfunction (California Model Only) — secondary air supply system faulty — loose, disconnected or deteriorated hoses of the emission control system Backfiring or misfiring during acceleration . Ignition system faulty - Fuel mixture too lean Poor performlnce (driveability) and poor fuel economy - Fuel system clogged - Ignition malfunction - Emission control system malfunction [California Model Onlyl — air vent control valve IAVCV) teulty e loose, disconnected or deteriorated hoses of the emission control system Lean mixture Fuel jets clogged - Float valve faully > Float level too low - Fuel line restricted - Carburetor air vent hole for tube) clogged - California Model Only: air vent control valve (AVCVI faulty ‘ Intake air leak ' Fuel pump malfunction - Vacuum piston faulty - Throttle valve faulty Rioh mixture - Bystarter valve in ON position - Float valve faulty . Float level too high - Air lets clogged - Air cleaner element contaminated - Flooded carburetors it ll} I) CV) FUEL SYSTEM L REQUISITE SERVICE ‘ 3 - Fuel rank removal/installation (page 2-4) \ A % PLUG WIRES SPARK SPARK PLUG WIRES PROCEDURE O’ty REMARKS AIR CLEANER CASE REMOVAL ORDER - Installation is in ‘he reverse order of removalr [1) Main wire harness 1 Install It imo the wire harness clamp of the case cover l2l Hm guard plate v (3) Air cleaner case cover 1 - (4) Air cleaner Element 1 Install it wilh me 1} mark forwards and with » mark facing up. l5ll Alr cleaner Case boll/collar 2/2 (6) Crankcase breather tubs 2 (7) Air hose - 1 Except California Model (SI Air injection tube (ML '15) 1 California Model Only (9] Air cleaner case 1 - Align the holes of the conneming tubes with rhe Blr jars. - Install the spark plug wires as shown. SUE AIR CLEANER CASE REMOVAL ORDER (Except California Model) no» Atlflthlng screw (11) Sub air cleaner case cover (12) Sub air cleanar element (13) Sub air cleaner case - Installation is In the reverse order of removal. NOTE: ' For element cleaning, refer m section 2 (AIR CLEANER: Oiled Urethane Foam Element) ol the Common Service Manual. 6—3 FUEL SYSTEM CARBURETOR REMOVAL/INSTALLATION (7) Cahfomia Model omy r1.“ FUEL SYSTEM . Gasoline is extremelyflammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or al» lowing llamas or sparks in the work area or whara gasoline is slored can cause a lire or explosion. 0n REQUISITE SERVICE - Fuel lank removal/installation (page 24) . Carburetors draining . Air cleaner case removal/installation [page 6-3) {31“ 9 PROCEDURE Q’tv REMARKS j ' REMOVAL ORDER -lnstallation it in the reverse order of remaval (1) Insulator band 4 Only loosen the screws (2) Choke cable 1 (3) Throttle cable 1 , (4) Fuel tube 1 al' 0 is) No. in vacuum lube (from the AVCV) 1 Calilornia Model Only u, r 16} No. 4 lubé (from the AVCV and PCV) 2 California Model Only (7) Carburetors 1 l8) Insulator 4 Each insulator has the identification number as shown. I At installation, align the insulator groove with the engine lug, with the 9 UP mark facing upwards lcarbretor side). 6-5 FUEL SYSTEM CARBURETOR SEPARATION F m" A CAREUHETOR N0. 3 CARBURETOR CARBURETOR (19) No‘ 1 CARBUHETDR ll: 3 REQUlSlTE SERVICE Fuel rank removal (page Mi ’1‘" , - Air cleaner case removal {page 63) ll ) ~ Carburetor removal [page 8-4) 4 Calilornia Model Only: AVCV and PCV rubes removal lrom carburetors > :\-.A.;.-mzm.m.wu FUEL SYSTEM PROCEDURE O'ry REMARKS lli (ll lal l4) (5) l6) 17} (El (9) Separate No, 3/No. 4 carb. fram ND. 1/ Nor 2 carb.. Bystarrer arm shalt Spring Bvslartar arm Choke cable holder Hear bracket Front breaker No. 3 carb. svnchronizarion spring Air joint pipe l3-way)/D-ring Fuel joint pipe l3~wayl/O-ring _.d_._.(_._... 1/2 1/2 l10l (11) l12i “Si (14] Separate Nor 3 cerb‘ horn No. 4 carbn Nor 4 cam, synchronization spring Thrust spring Air ioini pipe (rubber) Air vent pipe/O-ring Fuel joint pipe l2-way)/O~ring 1/2 1/2 r15) [15) (17) (18) (19) l20l Separate No. 1 carbv from No, 2 carb.. AVCV and PCV as an assembly No. 1 carb, synchronizatiun spring Thrust spring Air joint pipe (rubber! Air vem pipe/O-ring Fuel iolm pipe l2-wav)/0-ring 1/2 1/2 California Model Only ‘ FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY FUEL SYSTEM amber can be serviced with the carburetors assembled. \‘ . - The pilol screws are lactory Dre-set and should not be removed unless Ihe carburetors are overhauled. Turn each pilot mi a? screw m and carelully count the number oi turns before it seats lighlly. Make a note oi this to use as a rarerance when relnsrallmg the pilot screws. if new pilot screws are lnSlalled, turn pilot screws out to the initial opening (page 1-61 REQUISITE SERVICE ‘ - Fuel tank removal/installation (page 2-4) - Carburetor separation (page 6~61lcomolnation (page 6-10) [5N ) - Air cleaner case removal/installation (page 6-3] - Carburetor synchronization (page 3-8) 1 * - Carburetor removal/installation (page 6-41 PROCEDURE O’ty REMARKS DISASSEMBLY ORDER ‘ Assembly is in the reverse order of disassembly. . - Vacuum Chamber a)“ ’ (1} Vacuum chamber cover screws 4 At installation, first tighlen the two screws on the dowel Vii l pin side. l2) Vacuum chamber cover 1 l3) Spring 1 l4) Diaphragm/vacuum piston 1 (5) Jet needle holder 1 Turn the holder 90" counterclockwise while pushing it in and remove it. (6) Spring 1 (7) Spring holder 1 At installation, align holder claws with piston grooves. 18) Jet needle 1 (9i Washer 1 Float Chamber [10) Float chamber cover screws 4 At installation, first tighten the two screws on the dowel pin sidar - Gt '. r111 Float pin 1 NOTE: . - For removal oi the Not 1 (or No, 3) carburetor float pin wlth the carburetors assembled. first remove the No. 2 ior No. 4) carburetor float chambert 112) Float 1 For float level inspection, refer to the section B of the .‘ Common Service Manualt (13) Float valve 1 l1 4} Valve Seal 1 [15) Sealing washer 1 (l 6i Fuel filer 1 [17) Main let 1 (18) Needle jet '1 (19) Slow Jet ‘ Bystanu Valve (20) Valve nut 121) Spring (22) Bystarter valve p at Screw (23) Pilot screw Canada model: No. 1 and No, 4 carburetor pilot screws are shorter than thosa tar Nut 2 and Nov 3. - (24) Spring (2 5) Washer [26) O-ring 6—9 FUEL SYSTEM CARBURETOR COMBINATION DE 4 {CARBURETOH (14; us. No. 1 CAREURETOR 6-10 FUEL SYSTEM REOUISITE SERVICE ~ Carburetor assembly (page 5-8) )1)“ r) PROCEDURE Q'lv l REMARKS Ass ble No. 1 carb. with No, 2 carb.. ' No, 2 carburetor is the base carburetor. 11) FLIel [oint pipe l2-wavl/0Aring 1/2 (2) Air vent pipe l3»way)lO~ring NZ (3) Air jolnt pipe (rubber) 1 1. (4) Thrust spring 1 a?“ ) (5) No) I carb. synchronization spnng 1 )6) Front bracket 1 (7) Front bracket screw 4 The shorter. Do not trghten screws yet. [8) Fuel ioint pipe (3~wav)/Orring 1/2 Onto the No. 2 Carburetor. (9) Air joint plpe (3-wayI/O-ring 1/2 Onto the No. 2 carburetor. Aaaemblo Nu. 3 Barb. wllh ND. 4 can)“ (10) Fuel joint pipe (2-way)/O-rlng 1/2 (11) Air vent pipe (3-wayl/O—ring 1/2 ()2) Air joint pipe (rubber) l ‘ (13) Thrust spring 1 ()4) N014 carbt synchronization spnng 1 (15) Front bracket screw 2 The shorter. Do not tighten screws yet. Do not install two screws of the (rent bracket/choke cable holder vet. l- Assemble No. 1/Nu. 2 calbt with N0. 3/ No. 4 carbm (15) Not 3 carbi synchronization spring 1 l'l7) Hear bracket 1 (18) Rear bracket screw 8 Tighten them. (19) Front bracket screw 6 Tighten them. (20) Choke cable holder 1 Use two longer front bracket screwst q , (21) Bystarter arm 3 (22) Spring 1 (23) Bystarter arm shaft 1 (24) AVCV and PCV as an assembly 1 Callilornia Model Only (25) AVCV and PCV tube — Calilomia Model Only: page 6712 6-11 FUEL SYSTEM ‘ CALIFORNIA MODEL ONLY: AVCV AND PCV TUBES ROUTING (3) No 2 (5) No. 4 . CARBUHETOR CARBUHETOR (1M m No.1 / (4) No, 3 CARBURETOR (1) N0 5 TUBE CAREURETOR x . —77 (12) No, 5 was :9) No. 6 mass (13) Na. 6 (14) AVCV TUBES (“1 AVCV 11m PCV H 5) NIL 6 TUBES [15) N0 5 TUBES (19) AVCV (18) PCV (17] No‘ 10 TUBE 6-12 PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE . H the engine must be running to do some work, make sure the area is well ventilated, Neverrun the engine in an enclosed area. The axhausl contains poisonous carbon monoxide gas that may cause loss of con- sciousness and lead to death. NOTE ' The carburetors must be removed and separated in order to remove the No. 2 and 3 pilot screw limiter CBDS‘ . Make sure the carburetor synchronization is within specification before pilot screw adjustment. - The pilot screws are iactory pre-set and no adjustment is necessary unless the pilot screws are replaced. ~ Use a tachometer with graduations at 50 rpm or small~ or that will accurately indicate a 50 rpm change. 1. Turn each piiot screw clockwrse until it seats lightly, then back it out to the specification given. This is an ini- tial setting prior to the final pilot screw adjustmenti INITIAL OPENING: 273/8 turns out CAUTION o the pilot screw seat ghtened ag 2. Warm up the engine to operating temperature, Slop and go riding for 10 minutes is surricient. 34 Attach a tachometer according to its manufacturer's in- structions, 4. Adiustthe idle speed to the specified rpm with the throtv tie stop screwt IDLE SPEED: 1,300 : 100 rpm [Californim 1,400 2 100 mm] 54 Turn all pilot screws 1/2 turn counterclockwise from ti 2 initial setting. 6‘ lithe engine speed increases by 50 rpm or more, turn l pilot screws out by successlve 1/2 turn increments on I engine speed does not increase, 7‘ Adjust the idle speed with the throttle step screw 3, Turn the No, 2 carburetor pilot screw in until the engi: speed drops 50 rpm. 9. Then turn the No. 2 carburetor pilot screw count: clockwise to the linal opening from the position obtain: in step B. FINAL OPENING: 1 turn out 10. Adjust the idle speed with the throttle stop screw. 1 I. Perform steps 8, S and 10 for the No. 1, 3 and4 carbul tor pilot screws. 12, Apply LaetitiaQ 601 or equivalent to the inside of ti limiter caps. Place the caps over the pilot screws so tn they can be turned clockwise only. This will prevent a iustmeni in the cuunterclcckwlse direction Whl( richens the luel mlxture. NOTE l'l) PILOT SCREWS ill Na. 1 AND No 3 CARBURETOR LlMlTEH CAPS [Zl No. 2 AND No. 4 CARBUHETOR LlMlTER CAPS 6—13 FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT (U.S.A. Only) When the vchlcle is ll) be operated contlnuously above 2,000 m (5.500 leetl, the carburetor must be readjusted as lollows to improve driveabililv and decrease exhaust emissions, Warm up the engine to operating temperature. Stop and go riding 107 10 mlnules ls sullicrent. Turn each pilot screw Clockwlse 1/2 tum. Adlust the mile speed to 1,300 2 100 rpm ICalliornla 1,400 2 100 lpml with the throttle stop screws. HIGH ALTITUDE SETTING: 2.000 ml6,5001tl min. NOTE ~ This adjustmenr must be made at high altitude to ensure proper hlgh altitude operation, ‘ Attach a Vehicle Emlssicn Control lnlormatlon Update Label onto the rear tender as shown in the label position illustration. NOTE - Do not attach the label to any part that can be easily re- moved tram the vehicle. memlnlc - Operation at an altitude lower than 00 m (5.000 feet) with the carburetors adjusted tor high altitudes may cause the engine to idle roughly and the engine may stall in trafl'lc. When the vehicle is to be operated contlnouslv below 1,500 m (5.00!) feet). turn each pllol screw counterclockwise 1/: turn to its original position and adjust the idle speed to 1 ,300 : loo rpm (Calltornia: 1,400 a 100 rpm]. Be sure to make these adlustments at low altitude. Remove the Vehicle Emlssion Control lrlformatlon Update Label that is attached to the rear lender (as shown above) after adjusting for low altituder I1) PILOT SCREWS (I I UPDATE UPDATE LABEL VEMlClI EMISSION £11le INFURH JICXDA L'ClDR Elle ITS. ATIDII UPIME TRIS VEIIIIZU IIAS KEN Al'llllslfll Tl) IIAI‘ROVI [KISSIDN NNYRDL HHMMANCC WHEN OPERATED Al lllSlI AlTITIIX. ALTITIM MURIAIE ADIUSIMLIT llSlRUCllllNS AR( AVAILABLE Al YWI Alll‘llflkllm HIIKBA DEALIK “‘21 I? \‘Amunrivn‘fiWdi'LXiSijniufiud. v - FUEL PUMP/FILTER Turn llre Incl valve OFF Remove lhe rearrlolt srde cover lpage 2-3I. Remove Ihc Iuel pump and luel rilrer r0 me Ien Insrzrll [he lucl lllrcr and pump rn Ihrz reverse order ol removal uel I or orlenlallon as shown, ”‘ _‘ 7 _‘I EMISSION CONTROL SYSTEMS (California Model Only) EVAPORATIVE EMISSION CONTROL SYSTEM PURGE CONTROL VALVE (PCV) AND AlR VENT CONTPOL VALVE (AVCV) REMOVAL Remove the rorrowmg: — luel tank (page 242; — air cleaner case (page S—Sl — carburetors (page 6-4) Disconnect the tubes from PCV and AVCV, and rema. L ' : set plate from the No 1 carburetor flaar chamber cover. Hemove the PCV and AVCV. Inspect the PCV and AVCV (refer to secrion 7 or the Common Service Manual). Install the 3CV and AVCV in the reverse order cl removal. NOTE ~ For PCV and AVCV tubes roaring, see page 1724. CUT-OFF (3) FUEL PUMP RELAY lZl PCV (1) AVCV 4) $ET PLATE (Bl TUBES 6—15 FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM NOTE - The ASV has reed valves built into the AICVV l W I I Remove me fuel zank (0393 2-4), Disconnecl me air injecnon lube (No. 15 lube) hum me air i I” N" ‘5 WEE cleaner case K4 ’11. '/ .. Disconnect me vacuum tube (No. 10 lubei horn (he ASV. - Install the plug onto the No. ‘IO vacuum (ube and Connect (he vacuum pump :0 me Asv. V172) A’snv Ferlorm the secondary air supply system inspecxion (reler to section 7 0' (he Common Service Manual). SPECIFIED VACUUM: 360 mmHg [14.2 ian) AIR SUCTION VALVE (ASVI REMOVAL Remove two bolts and air sucKion valve as an assemblvi Disconnect (he (allowing from the ASV, —— No. 10 vacuum tube. (5) VACUUM — No. 15 air injection tube. PUMP — air supply hoses. . Remove bolts, air injection pipes and gaskets, i Remove the reed valve covers and reed valves. Install the all suction valve in xhe reverse order oI removal. a 9 in ND. 15 TUBE ‘2’ GASKET ‘ u @333 :% [A (. ‘IIII 4A (6) AIR HOSES 19) REED VALVE 7. ENGINE REMOVAL/INSTALLATION (j), } 'SERVICEINFORMATION 7.1 ENGINEREMOVAL/iNSTALLATION 7-2? SERVICE INFORMATION ;* ) O A floor jack or other adjustable support is required to support and maneuver Ihe engine CAUTION Do notjack up the motorcycle using the oil mm. a The foiiuwing r‘nmpanen(s can be acrview with the engine installed in the frame: H ) — alternator (Section 14) r 7 camshak (Seclian 5) ~ carburetors (Section 5) — clutch (Section 9) — gearshift linkage (Section 9) — oil pump (Section 4) 7 pulse generator (Section 15) — starter clutch (Section 16) — starter motor (Section 15) — water pump (Sectiun 5) The felinwing components requrre engine removal (or service: — connecting rod (Section 10) — crankshaft (Section 10) — Cyiinder (Semion 8) fl 3 — Cyiinder head (Section 8) 7 piston (Section 5) — transmission (Section 10) ENGINE REMOVAL/INSTALLATION T ENGlNE REMOVAL/INSTALLATION ‘ F ) c 40 (4'0, 29) ' r27) ‘ :25) e15” 5‘11) (21) . @p ,. ‘ _,/; \. "3‘“?‘% 6; “(c7 @‘(271 DRIVE SPROCKET BOLT M E @ SP EDOMETEH GEAR BOX JOINT 29i ENGINE REMOVAL/[NSTALLATION NOTE ‘ _.__,__gg‘ ,4, .t 1 r Turn the ignition swllcll OFF and disconnect llie battery ground (~1 cable CAUTION i - Do not jack up the motorcycle using th REQUISITE SERVICE - Exliausl system removali‘insrallatlon lpage L31 ' Engine oil dralnlng llocatlon' page 3-3, step: section 2 ol ~ Fuel tank removal/installation (page 2-41 the Common Service Manual) ~ Air cleaner case removal/installation (page 63) - Remove the radiator lower mounting bolts and loosen the ~ Carburetor removal/installation (page 64) upper mounting bolt/nut lpage 5-5). Swing the radiator - Coolant draining (page 5.31 forward. - Coolant relill (section 5 nf the Common Selwcc Manual) PROCEDURE O’ly REMARKS l REMOVAL onoen ~lnstallalion is in the reverse order oi removal. _’ 111 Spark plug cap 4 (Qli F'ulse generator 2P mini lblus) connector 1 131 Alternator 3? (black) connector ‘1 (4) Neutral switch/oil pressure switch 2P mini (black) connector l (5] Starter motor cable 1 16) Engine ground cable 1 (7) Water hose joint/O~ring 2/2 1 ‘i On the starter motor (3) Clutch cable 191 Gearshift spindle loint At installation, align the punch marks on the JDII’II and spindle 1101 Water pump side cover ‘1 (l1) Speedometer cable 1 1121 Drive sprocket cover 1 CAUTION: ' Make sure the drive sprocket ball is allgned with the speedometer gear box joint securely as shown. 113) Jrive chain guide 1 (141 Dowel pin 2 (151 Water lruse 1 [16) Drive sprocket bolt 1 NOTE: . Hold the motorcycle on its side stand . '- the transmission in 6th gear. With the brake per: n npplietl i remove (0! Install) the drive sprocket bolt. 1171 Washer 1 (18) Drive sprocket 1 Lonsen the drive chain. (19) Engine mount bolt (rear/lower) 1 (20) Adjusting bolt lock nut 1 (211 Adjusting bolt 1 [22) Special washer 1 With its lab facing down. (23) Engine mount bolt lFrontiasher 2/2 (24) Engine sub frame bolt 4 (25) Engine sub frame ‘1 l26) Engine bracket bolt 2 Only remove the left/lower and right/lower boltsr (27) Bolt cap 2 (281 Engine mount bolt lrear/upoerl/oollar 1/1 Install the colior on the left side. 1291 Engine assembly 1 Move the engine out or the (fame to [he left. CAUTION. -Care'ully align mounting points with the izck lo prevent damage to mounting bolt threads. wire harness and ca- bles. *1 m 8. CYLINDER HEAD/CYLINDER/PISTON NI [3 senvrce INFORMATION 34 CYLINDER HEAD DISASSEMBLV/ TROUBLESHOOTING 3-1 ASSEMBLY 8'5 CYLINDER/PISTON REMOVAL/ CAMSHAFT REMOVAL/INSTALLATION 8-2 CYLINDER HEAD REMOVAL/ Q) / INSTALLATION 8-4 INSTALLATION 8-8 SERVICE INFORMATION o The camsnart can be removed tor servrce wrtn the engine mounted in the frame, , P a Camshalt lubricating oil is fed through oil passages in the cylinder head. Clean the all passages before assembling the cyl» Q) ‘- indsr head. Fill the cylinder head all packets with the clean engine oil of the proper type and viscosity. - Clean all disassembled parts with cleaning solvent and dry them by blowing them otf with compressed air before inspec- “on. a Before reassembly, lubricate the camshatt journals and cam lobes with a molybdenum oil solution. When disassembling, mark and store the disassembled parts to ensure that they are rainstailad in their proper locations Be careful not to damage the mating surfaces by using a screwdriver when removing the cylinder, Do not strike the cylln» der too hard during disassemblvl even with a rubber or plastic mallet, to prevent the possibility or damage. 0 Take care not re damage the cylinder walls and pistons. 0 Store the valve and piston components in the same order they were installed so they can be reinstalled in the original posr~ IanS TROUBLESHOOTING @I Engine top-end problems usually arroct angina periormance. These can be diagnosed by a compression or leak down test, or ‘ by tracing noises in the top-end with a sounding rod or stethoscope. lt performance is poor at low speeds, check tor white smoke in the crankcase breather tube. ll the tube is smokey, check tor seized piston rings NOTE - For cylinder compression and leakdown test procedures, reler to section 3 of the Common Service Manual. Rough idle Excessive smoke - Low cylinder compression - Worn valve stem or valve guide . ~ Damaged stern seal Low compression - Worn cylinder, piston or piston rings - Incorrect valve shim adjustment (page 35] - Improper installation or piston rings - Burned or bent valves - Scored or scratched piston or cylinder wall ‘I;. - Incorrect valve timing ‘ Broken valve spring Excessive noise ' Uneven valve seating - Incorrect valve shim adjustment (page 3-5) - Leaking or damaged head gasket - Sticking valve or broken valve spring - Warped or cracked cylinder head - Damaged or worn camshatt ~ Loose spark plug - Damaged camshaft drive gear - Worn, stuck or broken piston rings - Worn or damaged cylinder and piston Abnormal ndise (piston) - Worn cylinder and piston Compression too high - Worn piston pin or piston m hole - Excessive carbon build-up on piston top or combustion - bearing chamber CYLINDER HEAD/CYLINDER/PISTON CAMSHAFT REMOVAL/INSTALLATION . x (_.A a l2l 10(‘1.0r 7N €120.23) REQUISITE SERVICE ~ Fuel tank removal/installation (page Ml ~ Air cleaner case removal/installation (page 5.3) - Remove the radiator lower mounting bolts and loosen the upper mounling bolt/nut (page 5-5lt Swing the radiator lorwardr (7) Cam>|lal|lmldm (8) Dowel pin PROCEDURE Cl'tv REMARKS J REMOVAL ORDER r Installation is in the reverse order of removal, (ll Heat guard plate 1 (2) Cylinder head cover bolt 8 Ar installation, tighten the bolts in a gradual. crisscross pattern (3) Washer 5 Install them with the "UP” mark facing up (4) Cylinder head COVE! 1 Install with the "6:" mark forwardr (5) Gasket ' 1 NOTE: - Apply Three Bond 1521 or equivalent to the head cover and install the gasket onto the cover with tabs racing forwardr (6) Camshaft holder bolt 16 NOTE: . Before removing bolts, turn the flywheel clockwise and insert suitable pins into the cam gear holes to ease the installation of camshaft serrated gearsr Take care not to drop pins into the crankcase and that the pins do not in» terfere with the cylinder head. Camshaft installation (page 873) til he or .A; 9 CAMSHAFT INSTALLATION Remove the Iollowing: , crankshaIt hole cap cover (page 9A2l. 7 crankshalt hole cap lpage 9-2), — timlng mark hole can (page 9-2), Rotate the crankshalt clockwlse and align the llywheel "T" mark (Yellow colored line) with the cover index marki Lubricate the camshalt [curnals and cam lobes with a molyb- denum all solution. Lay the EX marked lExhaust) camshaft onto the cylinder head with EX mark line as shown and lay the IN marked (In- take) camshaft with IN mark line as shown, In this position, the No. 4 piston is at TDC on the compres~ slon stroke. Install the dowel plns onto the camshatt holders and lnstall the camshalt holders ln their original positions. NOTE . Each holder has identification marks. EXL: Exhaust camshait- EXR: Exhaust camshaft~ Left Right INL: Intake camshaft~ INR: Intake camshait» Lelt Right Tighten the camshaft holder bolts in a gradual, crisscross pattern. TORQUE: 12 Nvm l1.2 kg»m, 9 ft-lb) Turn the crankshaft counterclockwise so as not to interfere the camshaft serrated gear holder pins with the cylinder head. Remove the holder pins from each camshaft gear. NOTE Take care not to drop the pins Into the ctankcas fiecneck the valve ttmlng. CYLINDER HEAD/CYLINDER/PISTON l2] EXHAUST III INTAKE CAMSHAFT CAMSHAFT \ (4) ”IN“ MARK LINE [5) T MARK (Yellow colored line) (6) lNDEX MARK (l I DOWEL PINS [3) DOWEL PINS (I) PINS 8—3 CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL/INSTALLATION l l i 630 l3,0, 22) REQUISITE S ERVICE - §§§®ine removal/installation (page 7-2) ~ Camshaft removal/installation (page 8~Zl PROCEDURE Q'ty REMARKS REMOVAL ORDER - Installation is in the reverse order of removal. (1) Cylinder head special nut 12 - Installatlan {page 8-5] (2) Cylinder head muhnting bolt 2 (3) Cylinder head assembly 1 (4) Gasket 1 Install with the UP mark facing up and rearward. (5) Dowel pin 2 16) Camshaft idle gear case bolt 5 (7) Camshaft idle gear case dowel pin 2 v Installation lpage 8v5l IE) Sealing washer 1 (9) Camshaft Idle gear case 1 (10] Carburetor insulator 4 A! installation, align the Insulator groove with the. engine lug. with the 1] UP mark facing upwards (carburetor sidel. . m, In: Tig cri TC a W CYLINDER HEAD/CYLINDER/PISTON AM HAFT IDLE GEAR ASE IN TALL ION C S C S AT ”1 SELER [4) INCORRECT Install me camshall idle gear case dowel pins properlvl CASE NOTE I i V II I - Withoutlhe dowel pins installed properly, the camsnali 1 idle gear may not be able to be inslalled onto the crank- I shaft liming geal. ‘5 CORRECT install the camshaft idle gear case anta the cylinder. I2) DOWEL i " While moving Ihe idle gearlightly with the gear case held, the P'NS " gear case should be lifted up slightly from the cylinder. ‘3’ WWW GEAR Install a new sealing washer and mounting bolts, Tighten “I BOLTS ® belts in a gradual, as shown, CYLINDER HEAD NUT/BOLT INSTALLATION install the cylindal head special nuts as shown. Do not tighten them yet. Insrall the cylinder head mounting bolts. Tighten the special nuts and mounting bulls in a gradual, crisscross pattern, TORQUE: Special nut: 30 N-m (3.0 rig-m, 22 ft—lbl Mnuming bolt: 12 N-m (1.2 kg-m, 9 ft-lb) /" (3) BOLT WASHER l1) SPECI AL NUT l . LJOL__' CYLINDER HEAD/CYLlNDER/PISTON CYLINDER HEAD DlSASSEMBLY/ASSEMBLY HAND- LAPPlNG TOOL ( 8._m aka) 3 ®:l31Cs§fi]lpage 8-7) g (4] W NOTE - Rem lu senior. 0 of me Common Semicfi Manual lor valve guide inspection/replacement. REQUISITE SERVICE Engine removal/installation (page 7-2] - Cylinder head removal/installation (page 874) Camshaft removal/installation (page 8-2) Store the valve camponents in me same order they were lnstalled so rhey can be reinstalled in [he original positions, PROCEDURE O’ty REMARKS DISASSEMBLY ORDER - Assembly is in the reverse order of disassembly. (1) Valve bucket 16 NOTE: ’ - Remove using a handlapplng moi. Do no‘ damage the cylinder head -bucks( sliding surface. (2) Valve shim 16 (3) Valve cotter 32 Removal/Installation (page 8-7)’ (4) Retainer 16 (5) Valve spring 16 Install them with the narrow pitch end facing dawnr (6) Valve 16 (7) Stem seal 16 (8) Spring seat 16 (9) Valve guide 16 Be sure to duplicaxe \he proper valve guide installed length [page 1-7) e9 .9 > C”? CYLINDER HEAD/CYLINDEH/PISTON VALVE COTTERS REMOVAL/INSTALLATION Remove the valve buckets and shims. Install the cylinder head protector into the cylinder head» bucket sliding surlace. 3 look VALVE BUCKET HOLE PROTECTOR 07JMG—KY20100 Install the valve spnng compressor onto the valve and corn~ press the valve spring. Remove lo: install) the valve cutters. VALVE SPRING COMPRESSOR ATTACHMENT O7JME7KY20100 VALVE SPRING COMPRESSOR 07757—0010000 ‘1 r-\ H] VALVE BUCKET HOLE PROTECTOR (1) ATTACHMENT (2) COMPRESSOR 8—7 CY. UNDER HEADICYLINDER/PISTON CYLINDER/PISTON REMOVAL/INSTALLATION 8-8 CYLINDER HEAD/CYLINDER/PISTON NOTE [ 4 Fisher to section 10 of the Common Service Manual lor piston and piston ring inspection. ‘| REQUISITE SERVICE - Engine removal/installalion (page 7-2) - Camshalr removal/insiallalion [page 8»2) - Cylinder head removal/Installation (page 874) PROCEDURE O'ty REMARKS 7 REMOVAL ORDER ~ Installalion is in tha reverse order of removal. (1) Waterjoint bolt 3 (2) Water joint 1 I3) Orring 1 (4) Cylinder mounting bolt 1 [5i Cylinder 1 (6i Gasket 1 Install with the up mark facing up and forward [7) Dowel pin 2 (s) Piston pin clip 3 19) Piston pin 4 (10) Piston 4 Install Ihem with the IN mark lacing tu Ihe intake side. rill Piston [on ring 4 —- Install the (op and second iings with the markings (12) Piston second ring A; facing up, (13) Pisron oil ring set lsude lalls and Spacer) 4 - Space the ring and gaps 120° apart. - Space \he side rail gaps 20 mm [0.81m or more apart 8—9 9. CLUTCH/GEARSHIFT LINKAGE w. SERVICEINFORMATION 9-1 CLUTCH REMOVAL 3-4 TROUBLESHOOTING 9-1 GEARSHIFT LINKAGE REMOVAL] RIGHT CRANKCASE COVER REMOVAL/ INSTALLATION 9-6 INSTALLATION 9-2 CLUTCH INSTALLATION 9»8 SERVICE INFORMATION 0 Clutch and gearshift linkage maintenance can be done with the engine In the frame. I Engine oil viscosity and level have an effect on clutch operation. Whenthe clutch does not disengage or the vehicle creeps with clutch disengaged, inspect the engine oil and all level before servicing the clutch system. Clean anv gasket off the crankcase coverrcrankcase mating surface. Q/ Do not damage the cover-case mating surface. Never allow foreign materials to get into the engine, If the shift forks, drum and transmission require servicing, 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 should be exposed the same amount TROUBLESHOOTING Clutch lever too hard Hard to shill - Damaged, kinked or dirty clutch CabIe ' Misadjusted clutch cable - Improperly routed clutch cable ' Damaged or bent shift fork - Damaged clutch lifter mechanism ~ Bent shift fark shaft - Faulty clutch lifter plate bearing ~ Worn gear dogs ' Incorrect engine oil viscosity Clutch will not disengage or motorcycle creeps with clutch - Incorrect gearshift linkage guide plate installation disengaged - Too much clutch lever free play Jumps out of gear - Warped platels) - Damaged or bent shift fork - Oil level too high, improper oil viscosity or oil additive - Bent shilt fork shaft - Damaged stopper arm - Worn gear engagement dogs or sl -< Clutch slips - Damaged shrlt drum cam grooves - Clutch lifter sticking - Worn clutch discs - Weak clutch springs - No clutch lever free play used CLUTCH/GEAHSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL/INSTALLATION 90;» \.., REQUISITE SERVICE CLUTCH/GEARSHIFT LINKAGE . Engine oil draining ldrein bolt location: page 3-3, step: section 2 oi the Common Service Manual) PROCEDURE Q’ty REMARKS [REMOVAL ORDER - Installation is in the reverse order a! removal, 11) Clutch cable 1 (21 Alternator wire connector 1 [3) Flight crankcase cover bolt 14 NOTE: ~ At installation, apply a locking agent to the two bolt threads. (4) Right crankcase cover 1 Disconnect (or connect) the Alternator 3P connector. [5) Gasket 1 (6] Dowel pin 2 (7) Clutch “rm pin 1 (8) Return spring 1 (9i Spring pin 1 NOTE: ~ Drive in a new spring pin usmg a pin driver until the pin does not interfere with the litter arm as shown. i101 Ciutch lifter arm 1 (1 1) Oil seal 1 (12) Crankshaft hole cap cover 1 (131 Crankshaft hoie cap/O-ring 1/1 1141 Timing mark hole cap/O‘ring 1/1 9—3 CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL ,9. REQUISITE SERVICE Right crankcase cover removal (page 9-21 x I ' % i181 Clutch outer 119) Needle bearing 120) Oil pump drive sprocket/drive chain (211‘ but” uulu- ullld'.’ 1/1 PROCEDURE O'tv l REMARKS I (11 crurcn Killer plate bolt 4 Remove m a gradual. crisscross pattern. ' (21 Clutch lifter plate 1 . (3) Clutch mm pram bearing 1 j (41 Clutch spring 4 l (5) Clutch Center lock mu 1 Removal mega 9-5) (Si Lock washer 1 (7) Clutch assembly v Refer to page 1-10 for specification. (8) A clutch center 1 (9) — spring seat 1 (10) # judder spring 1 [11) — clutch lriction disc C 1 Larger |.D. disc/Color: black (12) — clutch plate 8 1 Color: grey (13) — Clutch irictin disc B 4 Smaller ID. disc (14) — clutch plats'A 4 Color: silver [15) — clutch friction disc A 1 Smaller |.D. disc/Color: black (16] 7 pressure plats: 1 Refer to section 11 of the Common Service Manual for inspection information. (17) Oil pump driven sprocket 1 Removal [page 4-3) NOTE: ~ Turn the crankshaft clockwise and face the flywheel "T” mark up so as not to interfere the primary driven gear with me crank weight. - Do not still remove the needle bearing and outer guide. “a! £9 a l h CLUTCH CENTER LOCK NUT £- :,l\‘.t’)VAL If you have the unlversal type ol lhe‘ will be able to use it. 1% ccnlevhcldel, you Unslake the nut. Set lhe clutch celllel holder to the pressure plalc lmsses and loosely install (he must CLUTCH CENTER HOLDER O7HGB—001000A (U.S.A. only) Temporarily remove the tool and tighten nuts: then reinstall the clutch center holder onto the bosses. Use at least two clutch lifter plate bolts to secure the tool to the clutch. Hold the clutch centev holder and remove lhe lock nut as shown. ll you do no! have the above huldev, use the below holder. Unstake the nuL Remove the clutch center lock nut as shown. CLUTCH CENTER HOLDER OVGME~KT801OO [Not available in U.S.A.l CLUTCH/GEARSHIFT LINKAGE [1) CLUTCH CENTER HOLDER lZl CLUTCH . ‘ —' LIFTER l3) NUT/WASHER PLATE BOLTS l1) CLUTCH CENTER HOLDER (Zl HOLD CLUTCH/GEARSHIFT LINKAGE GEARSHIFT LINKAGE REMOVAL/INSTALLATION GUIDE PLATE/DRUM SHIFTER ASSEMBLY CLUTCH/GEARSHIFT LINKAGE ' a, .an be operated properly alter assembly, .N [a REQUISITE SERVICE - Right crankcase cover :umovtiI/mwallation lpage 94) - Clutch removal/installation {page SM, 9-8) PROCEDURE Q'ty REMARKS : )3 REMOVAL ORDER - Installation is in the reverse order of removal, i v (1) Gearshilt spindle joint ball 1 l2) Gearshift spindle joint 1 At installation, align the punch marks on the [aim and spindle, (3) Gearshift spindle (4) Spindle return spring (5) Washer l6] Shifter collar (7) Guide plate mounting bolt (8) Guide plate/drum shifter assembly (9) — guide plate (10) — ratchet pawl (11) s plunger (12) — spring [13) — drum shifter (14) Collar (15) Dowel pin Assembly: as illustrated Install onto dowel pins properly, or shift to hard, Pawl orientation as Shown. _._...NN~_.]N_. _._._. (16) Stopper arm spring (17) Spring collar (18) Stopper arm Q‘ (19) Washer At installation, torque after applying a locking agent to bolt threads. At installation, align the drum center groove with the dowel pin. i (20) Shift drum center bolt (21) Shift drum center i [22) Dowel pin h~ _- is 9-7 avs. cg“)- CLUTCH/G EARSHIFT LINKAGE CLUTCH INSTALLATION CLUTCH/GEARSHIFT LIN KAGE CLUTCH CENTER LOCK NUT INSTALLATION ll you have the universal type of the clutch center hulder, 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 07HGE—001000A (U.S.A. only) Hold the clutch center holder and torque the clutch center lock nut as shown. TORQUE: 35 Nut (55 kg-m. 61 ft-lb) Stake the lock nut cntn the mainshaft. If you do n0! have the above holder, use the below holder. Huld the clutch center as shown and torque the clutch center lock nut. CLUTCH CENTER HOLDER 07GMB—KTBO1OD (Not available in UlS.A.) TORQUE: 85 NW! (8.5 kg-m, 61 ft-lb) Stake the lock nut onm the mainshaft‘ l‘ll CLUTCH CENTER HOLDER \ l2) CLUTCH LIFTER PLATE BOLTS . a (3) NUT/WASHER m CLUTCH CENTER HOLDVER/ / ‘ Mn...» ' 10. CRANKSHAFT/TRANSMISSION m [a SERVICE INFORMATION 10—1 TRANSMISSION REMOVAL/ l TROUBLESHOOTING 10-1 'NSTALLAT'ON 10'8 TRANSMISSION DISASSEMBLV/ CRANKCASE SEPARATION 10-2 ASSEMBLY 1040 CRANKSHAFT/CONNECTING ROD . REMOVAL/INSTALLATION 104 ORANKOASEINSTALLATION 10—12 @ CRANKSHAFT BEARING REPLACEMENT 10-6 . d3 SERVICE INFORMATION 0 Remove the engine and separate the crankcase to inspect the crankshaft, connecting rod and transmission 0 Service Points Service item Removed Components Connecting rod . Cylinder head (page 8-4) - Cylinder/Piston [page 5-3) - Crankcase separation (page 10»2) fl Crankshaft - Starter clutch (page 15-8) Flywheel (page 14-7) Crankcase separation (page 10-2] Connecting rod bearing cap (page 10-4) Transmission crankcase separation (page 10-2) Gearshift linkage (page 9-6) I Prior to assembling the crankcase halves, apply a sealant to their mating surlace. Wipe off excess sealant thoroughly. 0 Mark and store the bearing inserts to be sure of their correct locations for reassemblyi If the inserts are improperly installed they will block the oil holes, causing insufficient lubrication and eventual engine seizure. 0 If it is no longer clear which bolt belongs in which hole, insert all bolt: in the hell; and check the exaoaed lengths; each should be exposed the same amount. TROUBLESHOOTING « i Excessive noise Transmisslon Jumps out cl gear ' . Worn connecting rod bearings . - Worn gear engagement dogs or slots _ Bent connecting rod > _ - Eent shift fork shaft‘ 7' Worn crankshaft main bearing ’ V V - Damaged shift drum stopper arm _ , - Damaged or bent shirt fork Hard to shift 7 V ,V . , . '- Broken shift iinka’ge’relurn spring ,- Vlmproper clutchoperation' ‘ _ , v . ,‘_ Damageqshiftvdtum cam'grqoves " 'lncb‘rrectengine oilvisoositv ‘ r. ' I 1 " " . , “I ’ . -" , 5 ' incorrect clutch adjustment ' 7 ‘ ' , : .- , " j , Bent shift forks ’ ' Bent shift fork shaft Bent shift fork claw Damaged shift drum cam grooves Bent shift spindle 10—1 CHANKSHAFTITRANSMISSION CRANKCASE SEPARATION 10-2 {W 9 E; % % r REQUISITE SERVICE - Engine (page 7-2) Clutch/oil pump drive chain (page 9-4) Lelt crankcase cover (page 15-8) CRANKSHAFT/TRANSMISSION - Starter molar lpage 16-5) on pan (page 4-3) PROCEDURE O'lv REMARKS (1) Upper crankcase bolt (6 mm) 6 Bolts (2 psc/marked A on (he crankcase) have sealing washers‘ (2) Lower crankcase bolt (6 mm) 13 Balrs (2 psc/marked A on the crankcase) have sealing washers. l3) Lower crankcase bolt (8 mm) 13 Bans (12 psc) have sealing washers. (4) Lower crankcase 1 (5) Dowel pin 3 (5) Oil orifice 2 CRANKCASE BOLTS LOCATION Loosen all bolts in a gradual, crisscrass paneln. Bolu location' as shown bolt wilh a sealing washer Clean any liquid sealanl off the crankcase mating surface. l‘i) BOLTS: 26 use (1) BOLTS: 6 psc (Z) UPPER CRANKCASE 10—3 GRAN KSHAFT/TRANSMISSION CRANKSHAFT/CONNECTING ROD REMOVAL/INSTALLATION N OIL HOLE FACING TO INTAKE SIDE 10-4 Y ' ~ CRANKSHAFT/TRANSMISSION NOTE - Determine the replacement bearing color code according to the main bearing selection table (page 10-6) or the connect- 0 ) ing rod bearing selection table (page 10-7)t - Mark and store the bearing inserts to be sure of their correct locations tor reassembly. - At installation, apply molybdenum solution to the main journal bearing and connecting rod bearing surface. - Reler to page 1-8 (or crankshaft and rod specification. - Refer to section 14 of the Common Servlce Manual for hearing Inspection REQUISITE SERVICE - Refer to Service Information (page 10~1l PROCEDURE O’ty REMARKS REMOVAL ORDER (1) Connecting rod bearing up not a m ) (2) Bearing cap 4 (3) Connecting rod 4 (4) Connecting rod bolt 8 Do not remove them without necessary. [5) Connecting rod bearing 8 Wipe all oil from the bearing seating areas. (6) Crankshalt 1 (7i Crankshalt main iournai bearing 12 Wipe all oil irom the bearing seating areas. lNSTALLATION ORDER (7! Crankshaft main journai bearing 12 The bearing tabs should be aligned With the grooves in the crankcases. ' (5i Crankshaft 1 Install it onto the upper crankcase with the flywheel side facing to the clutch side. (5) Connecting rod bearing 8 NOTE: . The bearing oil hole should be aligned with the oil hole ‘ in the connecting rod. ) (4) Connecting rod bolt 8 (3) Connecting rod 4 NOTE: - Face the oil holes to the intake side. (2) Bearing cap 4 Install them with the code letters read properly. (1) Connecting rod bearrng cap nut 12 Apply 01' to the nut threads and torque them in gradual, crisscross patternt 10-5 CRANKSHAFTITRANSMISSION CRANKSHAFT BEARING REPLACEMENT MAIN JOURNAL BEARING SELECTION Record rhe crankcase MD, code leuers from the pad on [he ran side of me crankcase NOTE - Letters [A] B or C) on me upper crankcase are the codes for rhe main journal l.D.s from rhe left. Record (he corresponding main journal 0.D, code numbers from rhe crank weight. NOTE . Numbers (1 or 2) on the crank weight are the codes ior xhe marn rournal (10.5 from me ran. Cross reference the case and journal codes to derermine the replacement bearing color code. 11} MAIN JOURNAL 0.D.CODE Crlnkcasa A E , 7 C ”3- “"5 nooo— 33 cos— aarow— "' 31005 mm 33.0‘ 5 mm 3102A mm Main lemma! (1 2992— ”2995— [1.2998— 0.Dr 5062 1.2595 m) LZSQE in) L30021n| 29.952~30‘000 mm V I (1.!505—1Janin) Plnk Yullow Grlen 25384—29392 mm 2 ”.1305—1JBUSK") Yel‘nw Green Brown Bearing thickness Brown: Thick Green: Yellow: Pink: Thin (1] MAIN JOURNAL BEARINGS 10-6 CRANKSHAFT/TRANSMISSION I CONNECTING ROD BEARING SELECTION Record the connecting rod |.D‘ code numbers on me rod. NOTE - Numbers (1 or 2) on the cunnecxing rod are [he codes for [he connecting rod ID 5. / .) (1) CONNECTING ROD |.D, CODE Record the crankpl‘n 0.D. code letters from the crank weighL NOTE - Letters (A or B) on the upper crankcase are (he cades for the crankpin O.D.s from rhe left, l1) CRANKF’IN 0.D. CODE Cross reference the Crankpin and rod codes KO determine the . replacemem bearing co‘or code. “I CONNECTING ROD BEAF (2) COLOR CODE \ Connecnngwd I z ‘n Eh”, 32-352‘ 33 001* 33.000 mm 31003 mm Crankpin (usag— (1.2992— 03. cude 1.2992 in) 1,2995 in) 29.552—30.00° mm A l1.1808—1.|8Hin) ”I“ 5'3“" 25.95‘—ZS.55‘ mm ‘ s Hues—1.1307 in) 6"" BMW" Bearing thicknass Brown: Thin Black: Blue? Thick CRANKSHAFT/TRANSMISSION TRANSMISSION REMOVAL/INSTALLATION 10—8 REQUISITE SERVICE ~ Refer to Service Information (page 10-1) CRANKSHAFT/TRANSMISSION 6) ’) (31 Ml (7) Mainshaft M2 gear/spline washer/M6 gear (3) Mainshaft assembly (9] Center shift fork bolt PROCEDURE O'ty REMARKS REMOVAL ORDER ' Installation is in the reverse order oi removalc ll) Countershalt assembly 1 At installation, align the bearing groove with the set ring and align the oil seal with the case groove (2) Countershaft bearing set ring 1 Mainshalt bearing set plate bolt 2 Mainshalt bearing set plate 1 (5i Needle bearing 1 l6) Washer 1 [10) Lock washer i install a new lock washer. (11) Shift fork shalt I At installation, lace the shaft liatted surface side lorward the drive sprocket. (12) Right shift (ark ‘l Install them with the identification marks (R: Flight, C: (13) Center shilt 1crk iICenter, L: Left) lacing forward the clutch side. (14) Left shift fork 1 (15) Shilt drum bearing set plate bolt 1 (16) Dowel pin 1 H7) Shift drum bearing set plate 1 (18) Shilt drum bearing 1 Install with the bearing Stepper near the outside. (19) Shift drum 1 At installation, face the M6 gear engagement dogs for- ward the M4 gear, Remove after bending down the lock washer tab. Install and bend new lock washer tabs as shown 1 1 I CRANKSHAFT/TRANSMISSION TRANSMISSION DISASSEMBLY/ASSEMBLY - MAINSHAFT ALIGN OIL HOLES ”eggpfigl I12] ”3’ (MI l3) . us) :SHIFTER GEAR It '. _‘__ . _ ' Gnoove : GEAR SLlDING E SURFACE (ZI I4I I7) (8) I10} I11) I14) NOTE - Apply molybdenum solution to the shifter gear grooves. Apply ail ro all sliding surface of the mainshalt, coumershalt and bushlngsl - lnsxall the rhrust washers and snap rings with the chamlered edge facing lo the thrust load side. - FleIer to section 13 of the Cammon Service Manual for inspection inlormalicn. REOUISITE SERVICE ~ Transmission removal/installation (page 1043) PROCEDURE D’ty REMARKS MAINSHAFT DISASSEMBLY ORDER - Assembly is in the reverse order of disassembly. (1) Needle bearing (2) Thrust washer (3) M2 gear (17T) (4) Spline washer (SI M6 gear (241:) (6) M6 spline bushing l7) Spline washer ' I3) Snap ring I9) M3 (1GTI/M4 IZZT) shifter gear (10) Snap ring I11) Spline washer I12) M5 gear (23TI II 3) M5 bushing (14) Thrust washer (15) Mainshaft bearing (16) Mainshafl (M1 gear/13H Align the all holes of the bushing and mainshak. Install it With the bearing stopper near the oulside. 10-10 ' {it /) CRANKSHAFT/TRANSMISSION ' COUNTERSHAFT (Z3) (2) {19)1181116l115i112lii1l is) 17) 15i (171113) (9) (6) (20) (19) (,7, mail [16) : SHIFTER GEA GROOVE :GEAR SLIDING SURFACE .aimai (2) PROCEDURE O'ty REMARKS COUNTERSHAFT DISASSEMBLY ORDER - Assembly is in the reverse order of disassembiy. (1) Bearing 1 lnsxall with the sealed side lacing outside. l2i Thrust washer 1 (3) C1 gear (423T) 1 l4) Needle bearing 1 (5i Thrust washer 1 (6) C5 shifter geav‘433T) 1 (7i Snap ring ' 1 18) Spline washer 1 (9) C3 gear (EDT) 1 (10) C3 spline bushing 1 Align me oil holes of lhe bushlng and counlevshai!‘ [11) Lock washer I ~ (12) Spline washer 1 (13) C4 gear (351') 1 e? (14] C4 spline bushing 1 Align the oil holes of the bushing and counlershah. (15) Spline washer 1 (16) Snap ring 1 (17) C5 shifter gear (32T) ‘l 418! Snap ring 1 (19) Spline washer 1 (20) C2 bushing 1 (21) C2 gear MDT) 1 (22) Thrust washer 1 (23l Oil seal 1 (24) Bearing 1 Install with the bearing stopper new the outside. (25] Countershait 1 10—11 CRANKSHAFT/TRANSMISSION CRANKCASE INSTALLATION (4) V 7 ‘ ’c1zn.2,sx (E 10—12 «1—way CRANKSHAFT/TRANSMISSION REQUISITE SERVICE - Crankshah/connecting rod insrallarion (page 10-4) - Transmlssion insrallatlon (page 10-8) 0 3 PROCEDURE O’w REMARKS (H Oil orifice 2 l2) Dowel pin 3 13) Lower crankcase 1 l4) Lower crankcase bolt (6 mm) 13 l ) 15) Lower crankcase bolt [E mm) 12 - Crankcase installatlon (see below) (6) Lower crankcase boll [8 mm x 65) 1 (7) Upper crankcase bolr (6 mm] 6 CRANKCASE INSTALLATION Apply a light bur thorough coating or sealam \0 me upper crankcase mating surface except to ‘he main bearing journal bull mating areas and me on passage area as shown. l1) SEALANT AREAS “ Set the mainshah and countershaix inm naulral position lirsz, _ then slide rha C6 shifter gear onto the CZ gear (2nd gear po- C sixinn) as shown, to easa upper crankcase installation. . (?\ c2 GEAR 10-13 as m ufi‘mwwmzw’-&%- m (peg: 1‘17) (C SHORTER TABS: (\- Bend down LONGER TABS: - Bend up (10) d : NOTE FRONT WHEEL/SUSPENSION/STEERING - Remove the fork, alter loosening the steering stem nutt . Bearings should always be replaced as a set- inner and outer races. - Check the steering head bearing preload (page 1<1 1) alter torquing the stern nut, REQUISITE SERVICE - Front wheel removal/installation (page 114) - Fork removallinstalialion (page 11-6) PROCEDURE O'tv REMARKS REMOVAL ORDER (1) Steering stem nut 1 Alter removing, remove the (ark. (2) Washer 1 (3) Ignition switch connector 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 1 (8) Steering head bearing adjustment nut 1 (9) Dust seal 1 (10) Steering stem , 1 (11) Upper inner race l 1 (12) Upper bearing 1 , (13) Lower bearing 1 (14) Lower inner race 1 - Replace ll they were removed. (15) Dust seal 1 - Use race remover attachment (07953—MJ1000A) With (16) Upper outer race 1 driver (07949—3710001) and attachment, (17) Lower outer race 1 37 x 40 mm (07746—0010200) for upper outer race removal. - Use race remover (07946—37105001 with driver (07943—3710001) and attachment, 37 x 40 mm (07746—0010200) for lower outer race removal. INSTALLATlON ORDER (1/) Lower outer race 1 - Replace as a set, if necessary, (16) Upper outer race 1 - Use attachment, 52 x 55 mm (07746—0010400] and (15) Dust seal 1 driver (07749—0010000) for lower outer race installa- (14) Lower inner race 1 tion. (13) Lower bearing 1 - Use attachment. 42 x 47 mm [07746—0010300) and (12) Upper bearing 1 driver (0774970010000) for upper outer race installa (11) Upper inner race 1 tion. W - Use steering stem driver (07946—MEOOOOO) (or lower Inner race installation (10) Steering stem 1 (9) Dust seal 1 (8) Steering head bearing adjustment nut 1 Installation: refer to section 18 of the Common Service (7) Lock washer 137 Manual (Retainer-Type Ball BearingsL (6) Lock nut 1 ' (5) Headlight Stay assembly 1 (4) Top bridge 1 (a) ignition switch connector 2 Connect them (page 1-19). (2) Washer 'l (1) Steering stern nut 1 Temporarily install fork and torque the nut. 1 11—13 12. REAR WHEEL/SUSPENSION 7) SERVICE INFORMATION 12-1 TROUBLESHOOTING 12—1 REAR WHEEL REMOVAL/ INSTALLATION 12-2 REAR WHEEL DISASSEMBLY/ I ASSEMBLY 12-3 SHOCK ABSORBER REMOVAL/ INSTALLATION 12-4 SHOCK ABSORBER DISASSEMBLY/ ASSEMBLY 12-5 SWINGARM REMOVALI INSTALLATION 12-7 SWINGARM DISASSEMBLY/ ASSEMBLY 12-8 ) SERVICE INFORMATION point: page 1-11) with a high quality brake degreasing agent. minimize the hazard caused by airborne asbestos fibers. l - Riding on damaged rims impairs sale operation ol the vehicle I Refer to the section ‘13 Ior brake system information. ' The shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorberr ~ Before disposal ol the shock absorber, release the nitrogen (Step: section ‘IB of the Common Service Manual; Drilling A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to I Tubeless tire removal, repair, and remounting procedures are covered in the section is of the Common Service Manual. TROUBLESHOOTING Rear wheel wobbling - Bent rim Worn rear wheel bearings - Faulty tire ' Unbalanced tire and wheel Low tire pressure Faulty swingarm pivot bearing(sl Wheel turns hard - Faulty wheel bearinglsl . Brake drag (page 13-1) - Bent rear axle Salt suspension - Week spring . Incorrect suspension adjustment ' Oil leakage from damper unit - Low tire pressure Hard suspension ' - Damaged shock absorber upper or lower bearings Incorrect suspension adiustment - ‘Bent damper rod - Damaged swingarrn pivot bearing - High tire pressure Rear suspension noisy . Loose fasteners “ _ H 12-1 REAR WHEEL/SUSPENSION SHOCK ABSORBER REMOVAL/INSTALLATION 0 45 (4.5, 33) NOTE - Put the motorcvcle on it center stand. ' Before removing the shock absorber for removing the shock absorber (mm the lrame, disassembly, adjust the shock absorber to position I (for lightest loads] before HEDUISITE SERVICE . Fuel tank removal/installation (page 2-4) PROCEDURE Q'ly REMARKS REMOVAL ORDER - Installation is in the reverse order 01 removal. (1) Shock absorber mounting bolt (upper) lj‘At installation, install them lrarn the ion side. (2] Shock absorber mounting bolt (lower) 1 (3) Shock absorber assembly 1 NOTE: - Remove it upwards from the frame. - lnstall with the drain tube forward. 12-4 fill ——v———_. , v - Rt, ,. WHEEL/SUSPENSION SHOCK ABSC. . iSASSEMBLY/ASSEMBLY (page 12~6l Awtmu is The shock absorber contains nitrogen under high pressurer Do not allow fire or heat near the shock absorber. '9 01‘ 1) - Before disposal ol the shock absorber. release the nitrogen (Slep: section 19 of the Cummcn Service Manual: Drilling point: page 1—11) NOTE Adjust the shock absorber to position l (for lightest loads) before removing the shock absorber from the frame. For lower Joint needle nearing replacement, see next page REQUlSITE SERVICE lJ - Shock absorber removal/installalion [page 124) PROCEDURE O'ty REMARKS DISASSEMBLY ORDER - Assembly is in we reverse order of disassembiy. (ll Lower joint 1 NOTE: ' Removal/Installation (page 12-6) - At installation, align the lower joint with the seat stopr per pint (2] Seat stopper i3l Spring seat (4i Spring fl (5i Adjuster (6) Lower joint lock nut l7) Damperrubber (Si Damper Install with the taper and lacing to the adjusxr FIEAFI WHEEL/SUSPENSION LOWER JOINT REMOVAL/INSTALLATION Install the shock absorber compressor and attachment on the rear shock absorber as shown. SHOCK ABSORBER COMPRESSOR D7GME—DO10000 (Not available in U.S.A.) m 07959—3290001 (THEME—0010100 07959—MB10000 — screw assembly ATTACHMENT Turn the compressor handle and slowly compress the spring. Hold the lower joint and loosen the lock nut (turn the nut clockwise). Remove the lowerjoim and clean off any locking agent from ‘he threads. @allation: ppIy a locking agent to the damper threads. Install the lower joint securely unro'lhe damper rod. Hole the lower Ipint and torque rhe lock nut, TORQUE: 68 N-m (6.8 kg-m, 49 lt-Ihl Make sure the Lower joint is aligned with the seat stopper pm and remove the compressor. LOWER JOINTS NEEDLE BEARING REPLACEMENT Remove the dust seals. Hold the joint with a suitable tool. Press the needle bearing out of the Ioint. IVER PIN . I w or PILOT. 22 mm DRIVER O7GMD— KTSO 100 (Not available in U.S.A.) 07746— 0041 000 07749—0010000 Pack a new bearing with grease. Press the bearing Into the joim until the bearing surface flushes with the join! surface as shown. DRIVER ATTACHMENT, 24 x 26 mm PILOT, 17 mm 07749—— 0010000 07746- 00 1 0700 07746—0040400 (1) ATTACHMENT (2) COMPRESSOR Iii LOCK NUT I2) LOWER l3] ALIGN [1| DRIVER FIN AZ] NEEDLE BEARING I3] SUITABLE TOOL [1i DRIVEH I2) NEEDLE BEARING w . ATTA H I <\\_\\2 REMOVAL/INSTALLATION 13_9 REAR BRAKE PAD REPLACEMENT 13.3 FRONT MASTER CYLINDER FRONT BRAKE CALIPER REMOVAL] DISASSEMBLV/ASSEMBLY 13.10 'NSTALLAT'ON 13'4 REAR MASTER CYLINDER REAR BRAKE CALIPER REMOVAL! DISASSEMBLY/ASSEMBLV 13-11 'NSTALLAT'ON 13'5 BRAKE PEDAL REMOVAL] FRONT BRAKE CALIPER INSTALLATION 1 3-12 DISASSEMBLY/ASSEMBLY 13-6 REAR BRAKE CALIPER DISASSEMBLY/ ASSEMBLV 13-7 SERVICE INFORMATION A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and dash a cantaminated disc with a high quality brake degreasing agent Inhaled asbestos fibers have been lound to cause resplratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies, Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the halard caused by airborne asbestos fibers. EV“... OI I Spllled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts Be very careful whenever you remove the reservoir cap: make sure the front reservoir is horizontal first. 0 Never allow contaminants ldirt. water. etc.) to get into an open reservoir. I Once the hydraulIc system has been opened, or ii the brakes leel spongy, the system must be bled. 0 Always use fresh DOT A brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatlble. a Always check brake operation before riding the motorcycle. TROUBLESHOOTING Brake lever/pedal soft or spongy Brake lever/pedal hard - Air bubbles in the hydraulic system . Clogged/restricted brake system Leaking hydraulic system . Sticking/worn caliper piston Contaminated brake pad/disc - Caliper not sliding properly Clogged/restricted iluid passage Worn caliper piston seal Sticking/worn master cylinder piston Bent brake lever/pedal Worn caliper piston seal Worn master cylinder piston cups Worn brake pad Contaminated caliper - Caliper not sliding properly - Worn brake pad/disc Brakes arag Contaminated brake pad/disc - Misaligned wheel - Worn brake pad/disc Warped/deformed brake disc - Caliper not Slldlng properly Low fluid level Clogged fluid passage Warped/deformed brake disc Sticking/worn caliper piston Sticking/worn master cylinder piston Worn brake disc BRAKES FRONT BRAKE PAD REPLACEMENT - A cantaminated brake disc or pad reduces stopping puwer, Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimile the haxard caused by airborne asbestos libers. - Altar replacement, operate the brake lever to seat the caliper pistons against the pads. NOTE - Do not depress the brake lever when the caliper is removed, or it will be difficult to refit the disc between the brake pads. - Replace brake pads as a set. - Apply a thin ct silicnne grease onto the pad pin so as not to rust it. REQUISITE SERVICE - Pushing the caliper against the disc, push the caliper pistons all the way in to allaw the installation of new brake pads. PROCEDURE O'tv INSTALLATION REMARKS REMOVAL ORDER - Installation is in the reverse order of removal. (1) Pad pin plug 1 (2) Pad pin 1 Insert the pin, pushing the pads against the pad spring. (3) Brake pad 2 Align the pad lug with the pad retainer as shown. 1 3—2 3 ll BRAKES REAR BRAKE PAD REPLACEMENT (4) 018l1.8,13l (1) W, \l / W a 23 (2.3, l7) A contaminated brake disc or pad reduces stopr ig power. Discard contaminated pads and clean a contaminated disc ‘ with a high quality brake degreasing agent. Inhaled asbestos fibers have been lound to cal: clean brake assemblies. Use an OSHA-approw minimize the hazard caused by airborne ashes' After replacement, operate the brake pedal to NOTE Do not depress the brake pedal when the ca" padst Replace brake pads as a set. esplratory disease and cancerr Never use an air hose or dry brr. acuum cleaner or alternate method approved by OSHA designed it.- iibers. ‘ t the caliper pistons against the pads. J 5 re-woved. or it will be dillicult to relit the disc between the brake ~ Apply a thin coating of silicone grease onto ' . ’1 ‘ “s to prevent rust and allow easy pad movement. REQUISITE SERVICE - Pushing the caliper against the disc, push the on all the way in to allow the installation of new brake pads PROCEDURE 1 REMARKS REMOVAL ORDER (1) Caliper mourtiv bolt Remove the bolt and swing the caliper upward. (2) Fact pin pl: 1; (3) Pad pin (4) Brats pa: INSTAJ JRDER (1) Brain Align the pad lug with the pad retainer as shown. (2) [’5’ Insert the pin, pushing the pads against the pad Spring- (3) F W Ml C 71' 7 7 AF‘ *_ 13-3 BRAKES FRONT BRAKE CALIPER REMOVAL/INSTALLATION A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agentt - inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hone or dr clean brake assemblies Use an OSHA-approved Vacuum cleaner or alternate method appraved by OSHA designed to minimize the hazard caused by airborne asbestos fibers. v brush in NOTE - ll you remove the caliper pistons, remove the caliper bracket bolts [4) belore disconnecting the brake hose (3); and 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 removal/installation (page 13-2) Brake fluid replacement/air bleeding (section 17 of the Common Service Manuel) PROCEDURE O'ty REMARKS I REMOVAL ORDER - Installation is in the reverse order ‘ ' ) [1] Brake hose bolt 1 (2) Sealing washer 2 (3) Brake hose 1 At installation, press the hose end against me while tightening the hose bull. 14) Caliper bracket belt 2 l {5) i From brake tiJripef asstmibly r l.“ 1 '2_/l, list: in: 1er end 13. REAR BRAKE CALIPER REMOVA L/INSTALLATION - A contaminated brake disc or pad reduces stoppin with a high quality brake degreasing agent. clean brake assemblies. Use an OSHA—approved vac minimize the hazard caused by airborne asbestos lib NOTE lever slowly to push out the piston. Inhaled asbestos fibers have been round to cause res 9 power. Discard contaminated pads and clean a contaminated disc piratorv disease and cancert Never use an air hose or dry brush to uum cleaner or alternate method approved by OSHA designed to ersr . Before disconnecting the brake hose [1), place a pen under the caliper to catch the draining fluid and squeeze the brake @ REQUISITE SERVICE . Brake pad removal/installation (page 13-3) Brake fluid replacement/air bleeding (section 17 of t Summon Service Manual) r REMARKS Brake hose bolt (2) Sealing washer (3) Brake hose $ {4) Ram brzi-er w l J PROCEDURE I ) REMOVAL ORDER i (1) i - Installation is in the reverse order of removal. Temporarily install the caliper onto the bracket. while tightening the hose bait. A! installation, press the hose end against the stopper 4 \RAKES \ FRONT BRAKE CALIPER DISASSEMBLYIASSEMBLY .7, ‘ l“ PAD SPHIWENTATION AS SHOWN 63‘ (Si DUST SEALS N '19) PlSTON SEALS - inhaled asbestos fibers have been lound to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers. REOUlSlTE SERVICE - Front brake pad removal/installation (page ld-Z) - From brake caliper renluvel/iiisldiluliuli (page 13-4) - Brake fluid replacement/air bleeding (section 17 of the Common Service Manual) PROCEDURE D’tv REMARKS DIS/ASSEMELY ORDER - Assembly is in the reverse order of disessembly. (1) Pad Spring Note the spring direction as shown. (2} Caliper bracket (3) Bracket pin boil boot (4) Caliper pin bolt boot (5) Bracket pin bolt (6) Caliper pin bolt (7) Caliper piston (6) Dust seal (9) Piston seal install into the bracket groove securelyi Apply e locking agent to the threads and torque it, Appl»l j silicone grease to the pin. , Install them with the cancaved side away from the pali : CAUTION: - BE careful not no damage the piston sliding surface when removing seelsi NM».-.-.r.....d 13—6 mm a, '3‘ ‘6' BRAKES REAR BRAKE CALIPER DISASSEMBLY/ASSEMBLY g. '8 ‘7’ ( ii PAD SPRING ORIENTATION AS SHOWN ® \ , - Inhaled asbestos fibers have been tound to cause respiratory disease and cancerr Never use an air hose or dry brush to ‘ e {9 clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSAH designed to ‘ minimize the hazard caused by airborne asbestos fibers. REQUISITE SERVICE Rear brake pad removal/installation (page 133) ' Rear brake caliper removal/installation (page l3-5i - Brake Hula replacement/arr bleeding (section 1/ of the ' Common Service Manual) PROCEDURE O'ly REMARKS J DISASSEMBLY ORDER ' Assemhiy is in the reverse order of disassemblv. l1) Pad spring 1 Note the spring direction as shown. (2] Pivot collar 1 Apply silicone grease to the sliding sur (3) Pivot boot 1 (9 l4) Caliper pin bolt boot 1 Install into the bracket groove securelyr (5] Caliper pin bolt 1 Apply a locking agent to the threads and torque itr Apply silicone grease to the pin (6) Caliper piston Install it with the opening toward the pad. (7) Dust seal 1 1T7 CAUTION: (8) Piston seal 1 . Ba caraiul not to damage the piston sliding surface (9 when removing seals. 13—7 BRAKES FRONT MASTER CYLINDER REMOVAL/INSTALLATION 0 35 (3.5, 25) REOUISlTE SERVICE - Air bleeding [secrion 17 of the Common Service Manual) PROCEDURE Q'ly INSTALLATION REMARKS l REMOVAL ORDER 'lnsrallatlon is in the reverse order or removal. ill 1 Right rearview mirror 1 121 ’ Brake lever pivot bolt 1 [3) Brake lever 1 14) Brake hose bolt 1 15) Sealing washer 2 16)‘ From brake light swi‘ch connector 2 v 6% Master cylinder holder bolt 2 Thigmen the upper boll firsll rhen the lower bOIL . Master cylinder holder 1 Face the UP mark upward, (9) Master cylinder assembly 1 Align the holder and with the punch mark no me handle- bar. 13-8 REAR MASTER CYLINDER REMOVAL/INSTALLATION BRAKES REQUISITE SERVICE - Brake fluid replacement/arr bleeding (saction 17 of the Common Service ManuaU PROCEDURE I (Try I REMARKS REMOVAL ORDER - InstaHatmn is in the reverse order 0! removal. (1) Brake hose bolt 12) Seahng Washer 13) Brake hose (4) Master cylinder mounting bolt (5) Footpeg bracket bolt (6) Reservoir hose [oinr (7) Owing (8) Push rod joint (9) Masrer cylinder assembly Only loosen the bonsr d4....NN_NA _J Install it from the footpeg side wixh a new cotter pin, Remove the mouming bolts (4) and master cylinder. 13—9 BRAKES FRONT MASTER CYLINDER DISASSEMBLY/ASSEMBLY g m c s (0.5, 4) (6] r7323 (page 1-17) (4) NOTE - fiepldm: the master piston, spring, cups, supper platel snap ring and boot as a set, - The master cylinder piston, cups and spring must be insralled as a set REQUISITE SERVICE - Air bleeding [section 17 oi the Common Service Manual] - From masrer cylinder removal/insxallazion lpage 13-6) PROCEDURE O’ty ASSEMBLY REMARKS A DlSASSEMBLY ORDER ' Assembly is in the reverse order of disassembly, (1] Reservoir cover 1 (1) Diaphragm plare 1 (3) Diaphragm 1 (4) Front brakelighi switch 1 (5) Booi 1 (6) Snap ring 1 CAUTION: - Be canain the snap ring is fully saated in the groove‘ (7) Stopper plate 1 (8) Masier piston assembly 1 (9) Spring 1 |nsta|l it wilh its small coil and toward the piston. 13-10 Q it BRAKES PUSH ROD INSTALLATlON LENGTH 11.8 ml NOTE ( - Replace the master piston, spring. cups. snap ring and boat as a set. [\(I - The master cylinder piston, cups and spring must be installed as a set, REQUISlTE SERVICE - Brake fluid replacement/air bleeding (section 17 of the Common Service Manual) - Rear master cylinder removal/installation (page 13-9) PROCEDURE C ASSEMBLY REMARKS DISASSEMBLV ORDER - Assembly is in the reverse order of disassemt , (1) Push rod joint Adiust the joint Installed length as shown‘ Face the , tab side as shown, (2) Boot (3) Snap ring CAUTION: . Be certain the snap ring is luily seated in the groove. Q (4) Push rad Apply silicone grease to the red head. (5) Master piston assembly (6) Spring Install it with its small coil end toward the piston. BRAKES BRAKE PEDAL REMOVAL] INSTALLATION NOTE J - Adjust the brake pedal hgight and check for proper Drak: light switch adimtment alter installation. r PROCEDURE 9 2 REMARKS REMOVAL ORDER Footpeg stay bolt Push rod joint Footpeg mounting bolt Wave washer (5) Rear brakelight switch spring (6) Brake pedal rétuvn spring (7) Right footpeg (Bl Brake pedal _r_.a_...._._tN - Installatiun is in the reverse order 01 ramoval, Install it from the footpeg side with a new cotter pin. Apply a locking agent to the bolt threads. Align the (optpeg with the stay groove. Apply grease tn the pedal pivot. 13-12 14. CHARGING SYSTEM/ALTERNATOR SERVICE INFORMATION 14>‘l CHARGING SYSTEM INSPECTION 144 SYSTEM LOCATION 14-2 REGULATOR/RECTIFIER 14-5 CIRCUIT DIAGRAM 14-2 ALTERNATOR 14~7 TROUBLESHOOTING 14-3 SERVICE INFORMATION - The battery gives off explosive gases; keep sparks. flames, and cigarettes away, Provide adequate ventilation when charging clr using the battery in an enclosed space. . The battery contains suliuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a 'ace shield, — It electrolyte gets on your skin, flush with water. — if electrolyte gets in your eyes. flush with water lot at least 15 minutes and call a physician immediately. - Electrolyte is poisonous. H swallowed, drink large quantities of water or milk and follow with milk at magnesia or vege- table oil and call a physician. . KEEP OUT OF REACH OF CHILDREN. 0 Always turn oii the ignition swrtch before disconnecting any electrical component, CAUTION - Some electrical components may be damaged it terminals or connectors are connected or disconnected while the igni- tlan switch is ON and current is present. o For extended storage, remove the battery, glve it a full charge, and store lt in a Cool, dry place. 0 For battery remaining in a stored motorcycle. disconnect the negative battery cable irom the battery terminal, NOTF l - The maintenance free battery must be replaced when it reaches the end of its service life. Tl CAUTION I - The battery caps should not he removed. Attempting to remove the sealing caps from the cells may damage the bat- tery. 0 Battery can be damaged it overcharged or undercharged. or if left to discharge for long periods. These same conditions contribute to shortening the "life span” of the battery Even under normal use, the performance of battery deteriorates after 2—3 years, 0 Battery voltage may recover atter battery charging, but under heavy load. battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often results from problems in the battery itseli, which may appear to be an overcharge symptom. ll one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess xoltage to the battery. Under these conditions, the electrolyte level goes down quickly 0 Before troubleshooting the charging system, check lor proper use and IT: tenance or the batteryr Check ii the battery is 'reauemlv under heavy load, such as having the headlight and taillight C long periods oi time without riding the motor» cycle. I The battery will selirdischarge when the motorcycle is not in use. Fc son, charge the battery every two weeks to prevent sultation from forming. O Filling 3 new battery with electrolyte will produce some voltage, is: acnleve lts maximum perlorrrrarrce, always charge the battery. Also, the battery life 5 le_ ‘rhened when it i- :d. , Wt”: chm, .3 [he .c “A." t . ,. m. PM“ 7.. nntmn rlnvv chart inane 1473). 3 For comer, rcvznlg _, or: r _ ~' C mvrr 'l' o For charging system location, see page ___—__ V __ ___.____. 1 4- i k—w , _. amend—3;"; :1 _— CHARGING SYSTEM/ALTERNATOR SYSTEM LOCATION I1) ALTERNATOR (2) MAIN FUSE (INTO STARTER RELAY SWITCH) 15) BATTERY (3) REGULATOR/ ‘ RECTIFIER I CIRCUIT DIAGRAM F M 39 e ‘ I2IMAIN FUSE U 30A Y Y v G R/W (4) BATTERY / FE & I3) REGULATOR] RECTIFIER I1) ALTERNATOR 14—2 34 6 CHARGING SVSTEMIALTERNATOR TROUBLESHOOTING Battery overcharging - Faulty regulator/rectifier Battery undevcharging Measure the batterv current leakage lLeak test) lCheck the regulator/manila umt Inspur‘llonl l (9599144) 4l—INLORRECT {93961443} ——l—" VAL‘_ _._ mm.— INCORRECT CORRECT - Shorted vyire harness CORRECT . Faulty ignition switch - Faulty regulator/rectifier Inspect the charging voltage (page 14-4) }—— CORRECT—> Check the battery using a Honda Battery Tester INCORRECT CORRECT NOT CHARGING ' Electric system overloading - Faulty battery w e Cheekthe voltages of [he regulator/rectifier bat ABNORMAL . 0 en H 1 m wire ha mess tery charging line and ground line (page 14-5) —’. Fgo'lycc::;‘ECIEd comracmrs .___T_ NORMAL V Checkthe alternatmlcharglng coillresistance at V V [he regulator/rectifier connector (page 145) —ABNDRMAL Checkrhe chargmgcml atalternator(page 14 7) ABNORMAL NORMAL - Poovlv cannected alternator NORMAL connector ~ Faulty alternator Check the regulator/rectifier unit inspection ABNORMAL —>- Faulty regulator/rectifier (page we) NORMAL |———————-—> - Faulty battery CHARGING SYSTEM/ALTERNATOR CHARGING SYSTEM INSPECTION LEAK TEST Turn off the rgnition switch, and disconnect the ground H cable lrcm the battery Connect the ammeter l+l probe to the ground cable and the arnrneter i~l probe to the battery (-1 terminal- With the ignition switch oft. 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 flow larger than the range selected may blow out the fuse in the tester. - While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the regeLL,_ SPECIFIED CURRENT LEAKAGE: 0.01 mA max, If current leakage exceeds the specilied value, a shorted cirr cuit is likely. Locate the short by disconnecting connections one by one and measuring the current. CHARGING VOLTAGE INSPECTION NOTE Belore performing this test, he sure that the battery l5 fully charged and that the voltage between Its termi» nals is greater than 12.8 V- tart the engine and warm it up to operating temperature, then turn the ignition switch OFF. Connect a multimeter between the battery terminals, DIGITAL MULTIMETER 07411—0020000 or KS—AHM—32—003 (U.S.A. only) 1 II A mtg ——-—————— m (0 Disconnect the starter relay switch connector and remove (be main (use (30 A), Reconnect the connector onto (he relay swilch. Connect the ammeter as shown. CAUTION . Be careful nor to short any tester probes. ~ Although the current could be measured when the am- meter is connected between the battery positive termi- nal and the positive cable, a sudden surge of current to the starter motor could damage the smmeter. Always turn the ignition off when conducting the test. Disconnacting me ammeter ur wires when current is flowing may damage the ammater. Start the engine and increase the engine speed gradually, REGULATED VOLTAGE: 14.0—16.0 V/5,000 rpm CHARGING CURRENT: oea AI5,DOU rpm REGULATOR/RECTIFIER me HARNESS INSPECTION Remove the rear fairing (page 22). Disconnect the regulator/rectifier connector and measure the following between connector terminals oi the wire harness side. CHARGlNG SYSTEM/AL (1) MAIN 2 CONN FUSE l l ECTOR [3) STARTER RELAY SWITCH (4) AMMETER lll REGULATOR/RECTIFIER Item Terminals Specification Battery Red/White H) and Eattery voltage charging line ground (-l should resisterr Ground line Green and ground Con! nuity exist. Charging coil Yellow and Yellow 0.1 7 0‘5 0 line 772/68”) 14-5 2° \ \ .. CHARGING SVSTEMIALTERNATOR UNIT INSPECTION Remove the regulator/rectifier. lnspect the tegulatovlrectlller Urllt by measuring the resis- tance between the terminals. NOTE 1 - There are two types oi the regulator/rectifier as shown. Select the proper resistance chart. - Resistance value will not be accurate it the probes touch your linger. - Use the following recommended multitester, Using another menulacturer’s equipment may not allaw you to obtain the specified values. This is due to the cheracterishc of semiconductors, which have dif- ferent resistance value depending on the applied volt- age. I, SPEClFlC MULTITESTER: ‘ — 07411—0020000 (KOWA Digital type) — KS-AHM—BZ—DOCl (KOWA Digital type: U.s,A. only) . -— 07308—0020001 (SANWA Analogue type) I — TH—SH (KOWA Analogue type) - Select me lollowing tange. SANWA tester: x H! KOWA tester: x 100 (l . When using the KOWA multitesrer, remember that all readings should be multiplied by 100. . An old, week multitester battery could cause inaccu- rate readings. Check the battery It the multitester regis- ters inconectlv. Replace the regulator/rectifier unit it the Ieslslance value be tween the terminals is abnormal. install the regulator/rectifier in the revetse order of removal. NOTE - Install the ground wire onto the regulator/rectifier lower mounting bolt groperly as shown, ~ [1) REGULATOR! P RECTIFIER l (3) GROUND WlRE , ‘ _‘ SE J'l : 5 Unit: m + _ (D ® (9 6) ® m as a: a: ® 0.5—“); 30—500 30—500 Io_2oo O 50 10—209 O umukn + _ (D ® ® (9 © (D m m m n, ® o.5—Io ao—soo 307500 10—200 @ c.5710 an no a (9 05-10 m n no be l4207>qrfirllol0§:l070.S—l0 W“ _ _14—6 .A_____‘_&. CHAHGi N , SYSTEM/ALTERNATOR ALTERNATOR CHARGING coIL INSPECTION NOTE ' - It lS not necessary to remove the alternator horn Ihe l ngInc DIsconnecz lhe alternator 3P black connector and measure the reSIstance between connector terminals (Yellow and Yel- lowl. STANDARD: 0.1—0.5 fl l20°Cl63°Fl Check lor continuity between the Vellcw wire terminal and ground. There should be no continuity. STATOR COIL/FLYWHEEL REMOVAL] INSTALLATION Remove the Iollowmg: « Iight crankcase cover lpege 9-2). — llywheel bolt. ., washer. — flywheel. — woodrulf key Remove the bolt and state: wlre harness clamp. Remove the bolts and stator. Apply a locking agent to the stator mounting bolt thlaad: Install the stator and tighten ch» bol's securely. Set the wire harness gtommu . to I we cover groove and in- stall the clamp. Clean any material on the crankshaft. Install the following: fi woodruff key. — flywheel. — washer. * llvwheel bolt. TURDUE. 85 N-III (5.5 kg-m, GT fl-lbl , vim newness mm hung" a I“ (1 l ALTERNATOR CONNECTOR (1) WOODHUFF KEY 15. IGNITION SYSTEM “ /@ SERVICE INFORMATION 154 IGNITION COIL 156 SYSTEM LOCATION 1572 PULSE GENERATOR 158 i CIRCUIT DIAGRAM 15.2 SIDE STAND SWITCH 15.3 TROUBLESHOOTING 15—3 IGNITION TIMING 158 Q (I IGNITION SYSTEM INSPECTION 15-6 SERVICE INFORMATION 0 When checking the ignition system, always follow the steps in the troubleshooting flow chart (page 15-3l. Q IQ O The transistorized ignition system use an electrically controlled ignition timing system, No adjustments can be made to the ignition time 0 A rough diagnosis can be made by identifying the cylinder whose spark tIming is incorrect. 0 The spark unit may be damaged if dropped. Also, iI the connector is disconnected when current is flowing, the excessive voltage may damage the unit. Always turn off the Ignition switch beIOre servicing. I O A IBUIIY ignition system is often related to poorly connected connectors, Check those connectrons before proceeding l a Make sure the battery is adequately charged Using the starter motor with a weak battery results in a slower engine crank» i ing speed as well as no spark at the spark plugs I Use Spark plugs of the correct heat range, Using spark plugs with an Incorrect heat range can damage the engine. ReIeI to section 2 of the Common Sen/ice Manual. - For neutral Switch Inseection, referto section 25 of the Common Service Manual; lor switch location, see page 15-2 of this manual (SYSTEM LOCATION), I For the ignition switch and engine stop swrtch inspection, check Iorcontinuity on the continuity chart of the WIRING DIAv GRAM, page 18-1. Disconnect each switch connector inside the headlight case (page 1—19) and check it. c For side stand inhibitor system instructions, see page 15-5 “NOTE” oi the troubleshooting IGNITION SYSTEM (1) SIDE (2) ENGINE I4) MAIN I5) FUSE I6) BATTERY STAND STOP SWITCH :USE 10 A (7) SPATRK o A UNI INDICATOR I3I IGNITION . I I ‘ __, I12I IGNITION SWITCH ‘ I9I NEUTRAL I II II SPARK SWITCH PLUG ' Ia) SIDE STAND I (10) PULSE SWITCH GENERATOR I4I MAIN I12I IGNITION FUSE 30 A SWITCH ‘5) FUSE IOA III SIDE STAND <9 ewb—Rac’ “WEI BIIBr SWITCH INDICATOR I2) ENGINE @ down STOP (6) BATTERY SWITCH ‘5’ :35: we. G W SIDE aIIw—o/o—BI— STAND GIw SWITCH To Tachometer up Bl/W Y’G Y/Bu ——W,Y l l— 7 I BuIv L; (10) PULSE I GENERATOR (3) IGNITION g g W“ COILS W m (7) 3:?“ (9) NEUTRAL v l SWITCH (HISPARK PLUGS ® 2 A? J— 15—2 TROUBLE. I ,gilNG Nu spark at all plugs (Faulty input system) at, - ll there is no spark at all plugs, the problem could be at the in of the spark unit, neutral switch, side stand switch or spark unit). l XV Check lor loose or o | ‘ p cry connected spark unit I ABNORMAL . con ctor _i — —’ I. R- __ NORMAL Check for loose or poorly connected ignition coil 4P mini connector. NOI;MAL ABNORMAL—>— Check if hatterv 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 HUN lpage 15-6). N0 VOLTAGE—>- BATTERY VOLTAGE MEASURED Measure the pulse generator resistance at the unit connector (page 156), r g» . \fi NORMAL Check the neutral switch tar cantiuuily II the ABNORMAL spark unit connector lpage 15-6), NORMAL Check the side stand switch at the spark unit ABNORMAL' connector (page may GOOD iii . V Faulty spark um IGNITION SYSTEN put of the ignition system (pulse genetator. power input circuit Poorly connected connector Poorly connected connector Faulty ignition switch or engine stop switch Open circuit in Wine harness Loose or poor contact ol related circuit Con- nectors ABNORMAL -' Faulty pulse gener~ BIOI Open circuit between the unit and pulse gener- ator Loose or poor contact of the pulse generator connector Check the neutral switch. NORMAL ABNORMAL Faulty neutral switch Open circuit between the unit and neutral switch . Loose or your contact of the neutral swrtch connectors Check the side stand switch (page 15»B)._7 ABNORMAL Faulty side stand switch NORMAL Open circuit between the unit and side stand switch . . Loose or poor contact at the side stand sWIlch connectors GNiTION SYSTEM No spark at nkher ignition group - If there is no spark at either group, Unit and ignition cail circuit) Switch the ignition coil primary terminal the problem is suspected in the primary coil side of the ignition sy "No Spark” condition connection between the faulty pair and good pair, Try spark test again. "No Spark" condition shifts to other pair Measure resistance of the ignition primary coil at spark unit cnnneclor (page 15-6). GOOD . Faulty spark unit No spark at one plug [Trouble in secondary coil side] lty spark plug is most likely. “__¢ Replace (suspected bad spark plug) with known i_gnod spark plug and conduct spark test, N0 SPARK Put the spark plug wire on and measure resis- tance of ignition secondary coil lpage 15-7l. OUT OF STANDARD VALUE Remove the spark plug wire, and measure the resistance of the ignition. secondary coil (page 15-7). ‘ | _ GO'OD - Poor Contact of spark plug wire - Faulty spark plug wile remains with faulty pair OUT 0F -— STANDARD -—>- VALUE NORMAL OUT OF VALUE the ignition coil resistance (page 15-7). stem (ignition coil, or Remove the faulty pair ignition Coil and check ABNORMAL - Faulty ignition coil ~ Faulty spark plug wire Poor or loose contact at ignition coil 4P mini connector Open circuit between the unit and ignition coll SPARK—v" Original spark plug no good Conduct spark test on good ignition coil. SPARK -——STANDARD—>- Faulty ignition coil 1 5—4 IGNITION SYSTEM Engine starts. but side stand switch does not function at all. NOTE The side stand switch should Iunctlon as lollows: - When the transmission is shifted into a gear lrorn neutral with the side stand down, the ignition shuts all and the engine WIII stop. When in neutral, the neutral switch line (a) at the spark unit is connected to ground via the neutral switch. when the side stand is up, the side stand switch line (bi oi the spark unit passes to ground Via the side stand switch. The spark unit monitors lines ta) and (b), and provides spark only when one or both of those lines is connected Io ground via the neutral switch or the side stand switch. Check the side stand indicator lor function. NORMAL —>- Open circuit in GreenNVhite wire ABNORMAL V G i {(0 Check the side stand switch (page 15-3). NORMAL—>- Loose or poor Contact ol related connectors - Open circuit in Green/White wire ABNORMAL ' Burnt Indicator bulb . Fauity side stand switch IGNITION SYSTEM IGNITION SYSTEM INSPECTION CIRCUIT INSPECTION NOTE , Follow the steps in the troubleshooting Haw chart Ior I servicing Remove the seat. Disconnect the connector Irom the spark unit and conduct these tests at the CCnnecror. Item Terminals Specification Power Source input line Black/White 1+) and ground I—I Battery voltage should resister with the ignition switch 0N and the engine stop switch at RUN. Pulse generator coil I Yellow and White/Yellow 340—420 II l20°CI65°FI Ignition primary coll I No.1— ‘ Neutral switch line I Light Green/Red and ground I Side stand switch line Green/White and ground BIack/White and VeIlOW/Elue . No 2A3' Black/White and Blue/Yellow Z —4 II I20°C/68°FI Continuity into naullal No contInuIry In any gear excepi neutral Continuity wilh the side sIand up No continuity with the side stand down Ground line Continuity Green and ground INSPECTION Disconnect the ignition coil 4P mInI connector under the fuel tank and measure the primary coil resistance between the terminals below. - No. 174 primary coil: Black/White and Yellow/Blue - No. 2—3 primary coil: Black/White and Blue/Yellow STANDARD 2 ,4 5‘ ‘20”Cr’6‘IDF) III IGNITION COIL CONNECTOR I 15-6 I/ II // ll x» Disconnect the spark plug measure the secondary CDII wire at each ignition pair: 7: the spark plugs and stance with the spark plug Not 1~4 secondary coil: between ENG 1 and ENG 4 wire No. 273 secondary coil' between ENG 2 and ENG 3 wire STANDARD: 23—27 kl] IZO°Cl68°FI Remove the Ignition coil] disconnect the spark plug wires and measure the primary and secondary coil resistances as shown, STANDARDS: Primary coil: 2—4 n120°CIEB°Fl Secondary coil: 13— 17 kf! (20”0/53°Fl REMOVAL/INSTALLATION Disconnect the ignition call 45’ mini connector under the tool zankr Remove the bulls and collars. Disconnect the ignition primary terminals from the coils and remove the ignition coil as an assembly Remove bolts and No. 2‘3 ignition coil firstl then remove bolts and No. 1—4 ignition coil. ‘ Install the ignition coils in the reverse order at removal. NOTE Connect the spark plug wire properly as shown (right). connect the ignition coil primary terminals properly as shown above IGNITION SYSTEM (1) SECONDARV COIL (2) PRiMARv COIL (2] IGNITION COIL I'll BO T/COL‘LAFI \ - ASSEMBLY I l ‘ _‘ l3) V/Bu ‘ ,, NITION SYSTEM ULSE GENERATOR ISPECTION OTE _ [Jr/”Pa - Ills not necessary to remove the pulse generatov 1mm I l I the englne. f,/.,.. or 2? mm} blue connecwr under liscunnect the pulse generat he resmance between White! 1E Iuel tank and measure t ’ellaw and Yellow terminalst STANDARD1340—420 f2 (20°C/68°F) REMOVAL/INSTALLATION Rem/ave the left cvankcase cover (page lG-Bl‘ =1» “we the bolts and pulse generatart Instrw pulse generate! and wive clamp, and ughten the bolts securely. Set the wire hamess grommet Into the cover gyoove. Install the left crankcase cave! Ipage 16-8). SIDE STAND SWITCH INSPECTION ini green connetlor under the Disconnect the Slde stand 3? m ty between each terminals as luel tank and check for continui below. are shqud be continuity between the o——O positions on tnfiltlnuity chart. Green/White Yellow/Black Green A Sude stand C down 0 Slde stand Cr 43 up 1 5—8 (1) PULSE GENERATOR CONNECTOR I (SI PULSE GENERATOR M 6 no F—f/a Ill SIDE STAND SWITCH (3) DOWN EE, __ 1mm int REMOVAL/INSTALLATION Disconnect the side stand connectort Remove the water pump side cover. With the side stand up, remove the side stand switch mount~ ing boil and side stand switch. Instau the switch m the reverse order of removal. TORQUE: Side stand switch mounting bolt: 30 NM [3.0 kg-m. 22 It-Ib) NOTE IGNITION SYSTEM - Align the switch pin with the side stand hole and align the switch gmwe with the side stand return spring hoiding pin. Route the srde stand swrtch Wire harness praperiy as shown IGNITION TIMING Warm up the engine. Stop the engine and connect a timing Iiaht tn the Mn 3 Cylin- der spark piug wire. NOTE I ~ Read the instructions for timing light '01 operating. Remove the following: — crankshaft hole cap cover (page 9-2). — crankshaft hole cap (page 9-2). — timing mark hole cap (page 9-2). Start the engine and let it idle. The timing is correct if the F mark aligns with the crankcase cover index mark. NOTE - If the correct timing could not be observed, connect a timing Iight to the No.2 cyiinderspalk plug wire and re check the ignition timing. Increase the Engine speed by rotating the th: :V' on the carburetor, make M F mare. uuunteruruu‘nwiee at (mi: .14 W 2 In.- m. a m: (1| SIDE STAND SWITCH (1) TIMING LIGHT I1) FMARK r3) NWANCE START C (it 16. ELECTRIC STARTER/STARTER CLUTCH SERVICE INFORMATION SYSTEM LOCATION CIRCUIT DIAGRAM TROUBLESHOOTING STARTER MOTOR REMOVAL/ INSTALLATION 15-1 16-2 16-2 16—3 16-5 STARTER MOTOR DISASSEMBLYI ASSEMBLY 16-6 STARTER CLUTCH REMOVAL! INSTALLATION 16-8 SERVICE INFORMATION injuryt Always turn the ignition switch OFF before servicing the starter motor, The motor could suddenly start, causing serious - A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. 0 H the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter ”1% may be damaged manual (SVSTEM LOCATION). For the foliowing component inspections, term to the loilcwrng pages; rot Ihe pans locations, see page 15 2 04 this Side stand switch [page ‘iS-B) Clutch switch diode Section 24 of the Common Service Manual. Starter motor Section 24 of the Common Service Manual. Starter relav switch Section 24 of the Common Service Manual l"A" circuit type). Clutch switch Section 25 of the Common Service Manual. Neutral switch Section 25 ot the Common Service Manualt tgnitton switch Check for continuity on the continuity chart at the WlHING DIAGRAM, page 18-1. Difionnect the swmch connector inside the headlight case lpage 1-19] and check in 16—1 ECTRIC STARTER/STARTER CLUTCH {STEM LOCATION I‘II SIDE STAND SWITCH IA] SEAEJESRWITCH/ (6I BATTERV T L INDICA OR (2) NEUTRAL I3) STARTER MAIN FUSE 30 A ‘7} CLUTCH INDICATOR SWITCH _ gm—;_:a I5I FUSE DIODE , ’12) CLUTCH SWITCH IIII IGNITION , SWITCH I9I NEUTRAL ,. / SWITCH IIOI STARTER IBI SIDE STAND MOTOR SWITCH \ ,IRCUIT DIAGRAM [HI IGNITION I4) STARTER SWITCH I6) BAITERV gal/ITEH \‘f 6 er R/Bl R IIOI STARTER —: MOTOR I5I FUSE I5) I4I MAIN 10 A FUS FUSE _ 1 A - (IIQ BI/Bro BI 30 A Gm L I—o/o— Y/R I2I NEUTRAL @ (3) STARTER T H (12) CLUTCH INDICA 0 ~Lg/R SWITCH SWITCH I91 Lg/R ~K— GIR GIR 0/07 NEUTRAL SWITCH (7) CLUTCH G/W V SWITCH DIODE I‘II SIDE STAND : up SWITCH v IBI INDICATOR I8I SIDE STAND SWITCH 16—2 M ‘II . III {II III (II («0 (® ELECTRIC STARTER/STARTER CLUTCH Starter motor will not turn ~ Check lor a blown out mam or sub fuses before servicing. ~ Make sure the battery is lully charged and in good condition. Check lor loose or poorly connected battery ter- 1 _mrnals, andopened honed battery cable. l *ABNORMALfi- ._._. l . Check for loose or poorly connected starter relay switch terminals and 4P connector. ABNORMAL " | wont/mt Check for loose or poorly connected starter motor cable, and opened cablet ABNORMAL " l NORMAL With the ignition switch "0N”, push the starter switch and check for a "click” sound from the starter relay switch. l N0 CLICK Disconnect starter relay switch connector, and check the relay coll ground wire lines as below tor continuity: ‘l. Green/Red terminalclutch switch diode- nnlitral switch line (with transmission into neutral and clutch lever releasedrl . Green/Rea terminal-clutch swrtch»side stand switch line [in any gear except neutral, and with the clutch lever pulled in and the side stand up.) —No CONT|NU|TY~>r N | cozrrmuny Connect the starter relay switch connector, With the ignition switch ON and the starter switch pushed, measure the starter relay volt- —NO VOLTAGE»- age at the starter switch connector (between - Yellow/Red [+) and ground t—lt ' - l . VOLTAGE APPEARED - Check the starter relay switch operation, , ~NORMAL—>- h — \‘QRMAL—br Poorly Connected battery terminals Open or short circuit in battery cable Poorly connected terminals or 4P conneclur Poorly connected motor cable Open circuit in motor cable Connect the starter motor terminal to the bat- CLICKS tery positive terminal directlyt (Because a large ) r amount of current llows, do not use thin wir Starter Starter motor motor does not turn turns l - Faulty starter motor Loose or disconnected starter motor cable Faulty starter relay switch ' Faulty neutral switch Faulty clutch switch diode Faulty clutch switch Faulty side stand swrtch Loose or poor contact of connector Open circuit in wire harness Faulty ignition switch Faulty starter switch Blown" out main or sub fuses Loose or poor contact of connector Open circuit in wire harness Loose or poor contact of the starter relay switch connector Faulty sta -. r . .r 9v itch 16—3 _————T_ .LECTRIC STARTER/STARTER CLUTCH The starter motor turns 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. . . . ‘ V I . cm" .‘he 5“”, 5‘3" mm.” m '5 "We” “’9' l—1 ABNORMAL —» Faulty side stand switch ated w h the Ignition vatchicfll ' Bun“ bulb - Open circuit in wrre harness ." NORMAL Check the clutch switch operatlon. — ABNORMAL —>- Faulty clutch swltch a, NORMAL . . ur—Pi Check the side stand switch (page 15»8)l ABNORMAL —>- Faulty side stand switch NORMAL Lf’ - Open circuit in wire harness 6 r l (ll ~ Loose or poor Contact of connector Starter motor turns slowly - Low specific gravlty ll’i battery (or Dead battery) Poorly connecled battery terminal cable Poorly connected starter motor cable Faulty starter motor - Poorly connected battery ground cable :zlrter motor turns. but engine does not turn Starter motor is running backwards A Case assembled improperly — Terminals connected improperly Faulty starter Clutch 1 . Damaged or faulty starter pinion . y! («I ‘ Damaged reduction gears l Starter relay switch "click". but engine does not turn over - Crankshaft does not turn due to engine problems ~ excessive reduction gear friction 0) (lo 1 6—4 ELECTRIC STARTER/STARTER CLUTCH STARTER |\~1 .1 TOR REMOVAL/INSTALLATION AWARNING - Turn the ignition switch OFF, ‘J REQUISITE SERVICE - Fuel tank removal/insta‘latian {page 2-4) PROCEDURE O'ty REMARKS HEMOVAL ORDER - Installation r's in the reverse order of rer (1) Starter motor cable (2) Starter motar mounting bolt .y (@ (3) Ground cable on engine (4) Starter motor (5] O-ring _._._.~_ ECTRIC STARTER/STARTER CLUTCH 'ARTER MOTOR DISASSEMBLY/ASSEMBLY F @‘3} \i) g i .. /‘ > 110) (H) ‘ ‘ \ gfoa _\ 6 W9 \ E $3 1 0 ‘lf {0 E 9% [6) €on ALIGN ‘1‘“ ‘ AU" 1 6-6 k .’ ‘ ‘ : 4,. REQUlSlTE SERVICE . Starter motor removal/installation (page 165) ELECTRIC STARTER/STARTER CLUTCH PROCEDURE DlSASSEMBLV ORDER ll) Set screw (2) Set plate (3) o-rzng (4) Front cover/O-ring (5i Grins (6) Motor case (7) D-ring (8) Lock washer (9) Insulated washer (10) Washer ll 7) Armature (12) Shims lldl Washer (15) Insulated washer — bigger —— smaller — smaller (16) O-rlng li7l Brush holder assembly (13) Brush and terminal (19) Rear cover (i3) Brush terminal l’lDlding nur O'ty _._.\M~m (ll ll) l1l ASSEMBLY REMARKS ~ Assembly is in the reverse order of disassembly Alrgn the index marks on the cover and case. NOTE: - lntall with the groove side facing to the brushes - Align the index marks on tho mar cut/er and cases Record and store the shims in the some order thzy were Installed so they can he reinstalled in the original posr- lions. Align the holder tab With the rear cover groove. 16-7 LE(-2TRIC STARTER/STARTER CLUTCH STARTER CLUTCH REMOVAL/INSTALLATION O ‘(0 07 W ALJGN THE WIDE GROOVE AMONG THE CRANKSHAFT SPLINES AS SHOWN l 0 '0‘ w we REQUISITE SERVICE Fright crankcase cover removal/installation (page 3—2) ELECTRIC STARTER/STARTER CLUTCH PROCEDURE I cm REMARKS j ; REMOVAL ORDER 3‘ -|nslallalron :5 in the reverse order ol removal llll Left crankcase cover bolt ‘ 7 ‘ Install the pulse generator wire clamp properly as shown. (2) Lelt crankcase cover l (3) Gasket 1 W Dowel pin 1 (5) Starter clutch bolt 1 Removal and installation (page 16-9l. l5) Washer 1 (7) Pulse rotor 1 Install it with the marked side facing out. (E) Starter clutch assembly — (9) — starter driven gear 1 (10) — needle bearing 1 (11) — starter clutch 1 At installation] make sure the starter clutch roller is in« Stalled properly into the clutch housing. l12l Spline washer ‘l r13)‘ Starter drive gear shalt l Lll4)l Starter drive gear l l STARTER CLUTCH BOLT REMOVAL/ INSTALLATION CAUTION Do not hold the pulse rota Set the rotor holder onto the llywheel, ROTOR HOLDER 07725—0040000 or equivalent commercially available in U.S,A, Hold the rotor holder and remove the starter clutch bolt with a helper” Set the rotor holder and hold rt onto the engine bracket as shown. Tighten the starter clutch bolt to the specified tarque. TORQUE: 85 N-m (8‘5 kg-m, 61 frlb) l1) FLYWHEEL ' \ / / Rt l2] HOLDER (4) HOLDING EOINT Cram“: l' ' an 17. LIGHTS/METERS/SWITCHES r ’. SERVICE INFORMATION 17-1 METER REMOVAL/lNSTALLATlON 17»5 SYSTEM LOCATION 17-2 METER DISASSEMBLYIASSEMBLV 17-6 HEADLIGHT REMOVAL/ TACHOMETER INSPECTION i7-7 'NSTALLATION 17’3 IGNITION SWITCH REMOVAL/ TURN SIGNAL LIGHT 17.4 INSTALLATION 1777 ‘ . TAILLIGHT 17.4 SERVICE INFORMATION AWARNING a Note the following when replacing the halogen headlight bulb. — Wear clean gloves while replacing the bulb. Do not put Iln on the bulb and cause It to break. — It you touch the hull) with your bare hands. clean it with a cloth moistened with alcohol to prevent Its early lailure. — Be sure to install the dust cover after replacing the bulb 0 Check the battery condition before performing any inspection that requires proper battery voltage. O A continuity test can be made with the switches installed on the motorcycle. applicable pages. - Halogen headlight bulb becomes very hot while the headlight is ON, and remain hot '0! a while after it is turned OFF, Be sure to let it cool down belore servicing. - Use a heating element to heat the water/coolant mixture for thermo sensor inspection. Keep all flammable materials away from the burner. Wear protective clothing, gloves and eye protection. ger prints on the headlight bulb, as they may create hot spots For the following component locations, see page l7-2 of this manual (SYSTEM LOCATION); for inspections, refer to the Component Inspection method Remarks Clutch switch Section 25 ol the Common Service Manual Coolant temperature gauge/ Therma sensor Section 25 ot the Common Service Manual Temperature gauge removal (page 1745). Thermo sensor removal (page 54). Fan motor switch Section 25 of the Common Service Manual Removal (page 5-6}. Front brake light switch Section 25 of the Common Service Manual Fuel pump/Fuel cut-oft relay Section 25 of the Common Service Manual Removal (page 6-15). Horn Section 25 of the Common Service Manual Handlebar switches Ignition switch Check for continuity on the continuity chart of the WIRING DIAGRAM, page 18-h Switch connectors are located inside the headlight case (page 1719), Neutral switch Section 25 of the Common Service Manual TORQUE: 18 N-m (1.8 kg-m. 13 ft-lb) Apply sealant to the threads, Oil pressure switch/warning light Section 25 of the Common Service Manual Oil pressure check: Section 4 of the Common Service Manual Oil pressure switch torque: 12 N-m [1.2 kg-m, 9 ft—lbl Rear brakelight switch Section 25 of the Common Service Manual Turn signal lights Section 25 of the Common Service Manual 3 terminals relay. I ’fit 17-1 iHTS/METERS/SWITCH ES YSTEM LOCATION (2} COOLANT TEMPERATURE GAUGE (SI FRONT BRAKELIGHT SWITCH I4) OIL PRESSURE SWITCH I6) BATTERY H IGNITION SWITCH (5) FUSE I15) CLUTCH SWITCH I141 IIOHN I13) THERMO SENSOR I12) FAN MOTOR SWITCH {11) NEUTRAL 19) FUEL SWITCH CUT» (7] REAR (10) FUEL OFF ERAKELIGHT PUMP RELAY SWITCH (5) TURN SIGNAL RELAY rr‘ ._ .lGLlTS/METERS/SWITCHES CAUTION - Halogen headlight bulb becomes very hot while the headlight is ON, and remain hat for a while after it is turned OFFt Be sure to let It cool down before servicing. Wear clean gloves while replacing the bulb, Do not put finger prints on the headlight bulb, as they may create hot sums on the bulb and cause it to break, . H you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early lailure, Be sure to install the dust cover alter replacing the bulb. ‘J PROCEDURE O'ty REMARKS REMOVAL ORDER - Installation is in the reverse order of removal. (1) Screw 3 (2) Headlight bulb socket 1 (3) Dust cover I Install it with the TOP mark facing up. (4) Headlight bulb 1 (5) Headlight assembly 1 , l6) Connectors — Connection (page 1-19) (7) Headlight case ‘ 1 Align the index marks on the case and bracket, 17-3 {TS/METEHSISWWCHES RN SIGNAL LIGHT B REPLACEMENT we the screw and lens from the turn signal case. rhe bulb socket coumerclackwrse and remove it. :he bulb counterc‘ockwise and remove it, :1 new bum m me reverse order of remova‘ ILLIGHT B REPLACEMENT we me screws and ‘ens mm the raiuight case. flb counterclockwise and remove rt, new we in we reverse order or removal. (Z) LENS r" /' (4) SOCKET 5‘ (3) SCRwa (1) BULB , \ (Zr SCREWS / / " . (3) LENS r \ \ A O W _ w“ - ...-- lJGHTS/METERS/SWITCHES METER REMOVAL; ALLATION [SF-WHITE -D CONNECTOR , -’.ECTOR REQUISITE SERVICE - Heaangm assembly remuva‘ (page 1H) PROCEDURE G'ly REMARKS REMOVAL ORDER - lns‘allation is in the reverse order of removal. (1) Meter mounting ban 2 (2) Speedometer cable 1 (3) Meter Conneclol 2 SP mini While connector and GP mini Red connector (4) Meter assambley 1 17—5 ITS/METERS/SWITCHES TER DISASSEMBLY/ASSEMBLY ve rhe five screws and the meter rear cover. \ mdlcator bulbs out of the meter housing. vs the wire harness clamps, and remove the nuts, \rs and meter stay. neck the meter xermtnals, and remove the wire her- .1 [he screw and meter (rant cover, re the fo‘lowing: ) screws and tachometer. meter reset knob r screws. speedometer gear joint and 04mg edometert :ble the meter in the reverse order of disassembly, mnect the pruper color wire to the meter terminalst Vfiflow Omen G’ Umnn :SR, Black/Blawn G/B: Green/Black L’ Green/Blue (1) REAR COVER (2’ SCREW ( wt (5) Hit: 2’3th) (4) NUTS (1) CLAMPS t w, . (2) TERMINALS (3) W‘FiE HARNESS (1) FRONT COVER (5) SPEEDO- METER 0'0 TACHOMETER INSPECTION Remove the headlight assembly [page 17-3), and disconnect the 6P mini Pied connector and SP mini White connector. Connect a voltmeter across the Black/Brown 1+) and Green (—I lcrmlnals ol the main wire harness side. Turn the ignition switch ON and battery vollage should re» sister. it there is not O.l<., the electric tachometer do not catch power from the battery. Trace and repair the related Wiring, sub luse and/or connectors. Disconnect the spark unit connector (page 156). Check for Continuity between the Vellow/Green wire termir nals of the 6P mini White connector and spark unit connec- tor. Continuity exists at all times. it there is no continuity, replace the main wire harness. it all checks are 0 K,, replace the tachometer. IGNITION SWITCH REMOVAL/ INSTALLATION Remove the meter as an assembly Ipage 17-5l Disconnect the 3? Black connector and 2P mini connector inside the headlight case Remove the bolts using the rorx bit [T40] (07703— 0010100) and ignition switch Remove the screws and separate the contact base from the cylinder. NOTE I - Vou can separate the switch in all key position. I Apply a locking agent to the threads and install the ignition switch in the reverse order of removal. TORQUE: Switch mounting bolt: 25 N-m [2.5 kg-m, 18 ft-lb) LlGHTS/METERS/SWITCHES ill SPARK ,Irzr GP-WHITE UNIT ‘ :I CONNECTOR CONNECTOR D. j H) IGNITION SWITCH ’I7—7 18. WIRING DIAGRAM 8% IKE. \Nomoc a! s: as s .3. 18-1 ING DIAGRAM camp IE; \ NOmoo ,_ _. up .3 t1}.-. .il!. {[11 ...... 19. TROUBLESHOOTING . ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH HARD TO START 19-1 SPEED 19-4 ENGINE LACKS POWER 192 POOR HANDLING 19-4 POOR PERFORMANCE AT LOW AND . IDLE SPEEDS 19-3 ENGINE DOES NOT START OR IS HARD TO START POSSIBLE CAUSE . 1. Check fuel flow lo carburero! NOT REACHING CARBURETOR —>‘ Clogged fuel line or fuel filler ' Sucking float valve REACHING CARBURETOR ' Faulxv fuel pump . Faully fuel pump relay ~ Clogged fuel rank vem hole ‘ Loose or disconnected fuel pump relay wire 2 Perform spark lesr WEAK OR NO SPARK ——~.. Faulty loIlowing (page 153:: 7 ignmon corl GOOD SPARK — pulse generator — neutral switch 7 spark unir — side sland switch . — engine srop swirch 3. Remove and inspecr spark plug WET PLUG —-—-——~> - Mixture mo rich ‘ Carbulemr flooded SPARKS ~ Carburetor choke excessively dosed Cylindsr Hooded Air cleaner dirty Fauuy Purge Conuol Valve (Calilornia model only) 4. Test cylinder compression LOW COMPRESSION ———>- Improper valve clearance {shim too « xhickI COMPRESSION NORMAL ' Valve stuck open - Worn cylinder and pis‘on rings . ' Damaged cylinder head gasket ' Seized valve - Improper valve riming - Improper valve and seat pontact I 5. San by following normal procedure ENGINE STARTS BUT STOPS ——>. Improper choke opg[afi°n - Carburemr incorrectly sdjusred ENGINE DOES NOT FIRE . Intake pipe leaking ‘ - Improper ignition liming ‘ (Faulty spark unit or pulse gsner ator) Fuel contamlnaled . 6, Stan wlxh choke on ‘ 19—1 M'- AESHOOTING llE LACKS POWER l wheels oft ground and by hand EL SPINS FREELY v k tire pressure iSUHE NORMAL l k lot clutch slippage 'CH ENGAGED PROPERLY lerate lightly NF ”EED lNCFiEASES l l lt ignition timing RECT k yalve clearance IRECT v cylinder compression MAL K cai‘o retor for Clogglng CLOGGED ik spark plug condition IV FOULED on DISCOLORED 2k all level and condition RECT WHEELS DO NOT SPIN FREELV ——>- PRESSURE LOW———>. CLUTCH SLlPS —-—>- ENGINE SPEED DOES NOT lNCREASE—>- INCORRECT—._——>. INCORRECTfi———>. TOO LOW_———-—>t CLOGGED —-————" FOULED OR DISCOLORED ——f~ INCORRECT————v> ‘ POSSIBLE CAUSE Brake dragging 6 Worn or damaged wheel bearings Wheel bearing needs lubrication Drive chain too right Axle nut excessively tight Faulty me valve ‘ Faulty clutch lifter system Worn clutch disc/plate Warped clutch disc/plate » Weak clutch spring ‘vl Carburetor choke closed Clogged air cleaner Restricted fuel flow Clogged mulller Clogged luel cap vent hole Faulty luel pump Faulty luel pump relay Loose, broken or shorted wure or chneCllOn oi pump relay Faulty spark unit Faulty pulse generator Improper valve adjustment Worn valve seat Valve stuck open Worn cylinder and piston rlngs Improper valve timing Seized valve Improper valve and seat Contact Carburetor not serviced frequently enough Plugs not serviced frequently enough Spark with incorrect heat range Oil level too high Oil level too low Contaminated oil O n 12 13 Pl 11. Remove cylinder head cover and inspect lubrication VALVE TRAIN LUBRICATED PROPERLV l2. Check Ior engine overheating NOT OVERHEATING l3, Accelerate or run at high speed ENGINE DOES NOT KNOCK VALVE TRAIN NOT LUBRICATED—>r PROPEHLV - OVERHEATING __>‘ ENGINE KNOCKSH. POOR PERFORMANCE AT LOW AND IDLE SPEEDS . Check ignition timing and valve clearance CORRECT 2. Check carburetor pllol screw :slment CORRECT 3' Check for leaking intake pipe NO LEAKAGE . Perform the spark test GOOD SPARK INCORRECT INCORRECT ——————>~ LEAK!NG—~ ————> ' WEAK 0R INT: TENT SPARK —>- TROUBLESHOOTING FOSSIBLE CAUSE Clogged oil passage Clogged oil control entice Contaminated oil Faulty Oll pump Coolant level Inw Fan molor not working (Faulty Ian motor switch) Thermostat stuck closed Excessive carbon build-up in com- bustion chamber Use of poor quality fuel Clutch slipping Lean fuel mixture Worn piston and cvlinder Wrong type of fuel Excessive carbon buildup in corn- bustion chamber Ignlllon timing loo advanced (Faulty spark unltl Lean (uel mixture POSSIBLE CAUSE Improper valve clearance Improper ignition timing _ Faulty spark unit — Faulty pulse generator See Fuel Svslem (Section Bl nt mp Common Service Manual Loose carburetor Damaged insulator Faulty. carbon or wet fouled spark plug Faulty following [page 15-3): —< ignition coil — pulse generator neutral switch ~ spark unit side stand switch engine stop switch *- aLESHoorlNG R PERFORMANCE AT HIGH SPEED . POSSIBLE CAUSE . 6 O A k ignirion timing and valve INCORRECT _—————>~ improper valve clearance mce ~ Improper ignirron liming A - Faullv soark unil B 'ECT # Faulfy pulse generator B C rnnecf fuel line al carburetor FUEL FLOW RESTRlCTED M4 Fuel tank empty C - Clogged fuel line 6 ‘ c FLOWS FREELY - Clogged fuel cap vent hole ~ Clogged fuel valve - Faulty fuel pump or relay - Clogged fuel filter r , C we carburetors and check for CLOGGED __’—>- Clogged jets red jers IOLGGED JETS C t: valve timing INCORRECT __’——->- Camshaft not installed properly C C ‘FCT ' C C « valve spring rension WEAK _—_——4~~ Faulty valve sprmg C C R HANDLING —’Check fire and suspension pressure lr C C POSSIBLE CAUSE . . A S{eeflng head bearrng adlusrmem c nur loo righl C D E :rlng is heavy - Damaged sreerrng head bearings - Hem sfeerino stem -her wheel is wobbling ’———————> - Excessive wheel bearing play Er . Bent rim El - Improperly installed wheel hub (L . Swingarm pivot bearing excessivelv r worn . - Bent frame A El l E: e mowrcycle pulls to nne_side ————-———’ . Incorrect drive chain adjustmem ‘ F4 - Front and rear wheels not aligned - Bent fork legs - Bent swingarm Fr - Bent frame F, Fr Fr Fl Fl Fl Fl r‘. G l G v‘ H w \n u v.\m.¢- mm.- Air Cleaner ...... 35 Case Removal/Installation 6-3 Alternator . ..... 14»7 Brake Pedal Removal/Installation 13-12 Brakes .. H. 13~l Cable and Harness Routlng 1-19 Camsnalt Removal/installation 8-2 Carburetor Combination Disassembly/assembly Removal/Installation Separation Synchronization Charging System/Alternator r Circuit Diagram . Inspection Locatlon . Clulcl’l installation Removal . Clutch/Gearshift Linkage , Coolant Dralning Cooling System Flow Pattern . Cronkcase Installation l . Separation Cranksnalt Bearing Replacement ....... 10-6 Crankshaft/Connecting Rod Removal/ Installation 10-4 Crankshalt/Transmlssmn 10~‘I Cylinder Head disassembly/assembly 8—6 Removal/Installation 8—4 Cylinder Head/Cylinder/Piston 8-1 Cylinder/Piston Removal/Installatlon 8-8 Drive Chain 3-8 Electric Starter Circult diagram 16-2 System Location ........ 1672 Electric Starter/Starter Clutch ....... 164 Emission Control Information Labels (U.S.A, only) l-Zfi Systems . 1-25 Systems (California Model Only) 6- 15 Engine Removal/Installation , 2 Exhaust System Removal/Installation . 2-3 Fork Assembly 10 Disessemhly . Removal/Installation Frame/Body Panels/Exhaust System Front Brake Caliper disassembly/assembiv 13~6 Removal/Installation 13- 4 Pad Replacement ., 13- 2 Front Master Cylinder disassembly/assembly . 13 10 Removal/Installation ....... r 13- 8 Front Wheel disassemva/assembly 11-5 Removal/installation 11.4 Front Wheel/Suspension/Steering 11-‘l Fuel Pump/Filter 5-15 Fuel System b‘l Fuel Tank Removal/Installation .......... 2-4 Gearshl'l l_lnl