fMdNUAL O ; ‘ SERVJC :i HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recomr mendetions to ensure that the vehicle IS in peak Operala mg condition and the emission levels are within the standards set by the U.S. Environmental Protection Agency and the CeliIornia Air Resources Board. Periorming the first scheduled maintenance is very im- portant, It compensates for the initial wear that occurs during the break-in period. Section 1 and 3 apply to the whole motorcycle 890* tion 2 illustrates procedures for removal/installation of components that may be required to perform ser- vice described in the Iollowing sections, Section 4 through 18 describe parts ol the motor cycle, grouped according to location. Find the section you want on this page, then turn to the table 0' contents on the Iirst page of that section. Most sections start with an assembly or system illus- tration, service information, specrlicetions and troubleshooting Ior the section. The subsequent pages gives detailed procedures. II you don‘t know the source of the trouble, go to sec- tion 20 Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIREC< TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST HONDA MOTOR (30., LTD, SERVICE PUBLICATION OFFICE CONTENTS I F7; | GENERAL INFORMATION E. \, :ll \ I FRAME/BODY PANELS/EXHAUST SYSTEM n ’7:7 \\X¥ E MI ENA firesiosg I L LUBRICATIONSVSTEM 1 k, ,% FUEL SYSTEM a L COOLING SYSTEM I ENGINE REMOVAL/INSTALLATION n I CYLINDER HEAD] VALVES DLUTCH/GEARSHIFI' LINKAGE CRANKCASE/TRANSMISSION \ CYLlNDER/PISTON/CRANKSHAFT ENE mm E GINE AND D 2 FRONT WHEEL/SUSPENSION/STEERING HEAR WHEEL/SUSPENSION CHASSIS HYDRAULIC DISC BRAKE \ If CHARGING SYSTEM/ALTERNATOR IE I a‘ IGNITION SYSTEM ' “I 0 _¥ l ELECTRIC STARTER/STARTER CLUTCH E use e K a LlGHTS/METERSISWITCHS II:- KM WIRING DIAGRAMS IE. EEK | TROUBLESHOOTING E. g INDEX 8. %. R , I a l Data ol issue: December, 1994 O HONDA MOTOR Cot, LTD. ¥ I—‘GENERAL SAFETVW 1-1 ‘ SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-4 TORQUE VALUES 1-13 TOOLS 1-16 1. GENERAL INFORMATION LUBRICATION & SEAL POINTS 1-18 CABLE & HARNESS ROUTING 1-20 EMISSION CONTROL SVSTEM IU,S.A, only) 1-28 EMISSION CONTROL INFORMATION LABELS (U.S.A. only) 1-31 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. - The exhaust contains poisonous carbon monioxitlre gas that may cause lose at consciousness and may lead to death. Run the engine in an open area or with an exhaust evacu- ation system In an enclosed area. Gasoline Work in a well venlilaled area. Keep cigarettes, llamas or sparks away Irom the work area or where gasoline is stored. - Gasoline dev cert n non CHILDREN. y flammable and is exploaive un- _/ ons. KEEP OUT OF REACH OF‘ Hot components - Engine and exhaust sysle hot and rein .in hot for some in aka the engine Is run. W sulated gloves or wait until the engine and exhaust system have cooled beIore handling these parts. Used enginelttanemiaeion oil - Used engine oil may cause skin cancer N rep edly' ‘ left in cont at with the akin for prolonged perlods, Al- though t I unlikely unleu you handle used oil on a daily baeea. It is still ed ble to thoroughly wash your hands wlth soap and water as soon as ponlble IR" handling uaed oll. KEEP OUT OF REACH OF CHIL- DREN. Brake dust Never use an an nose or dry brush to clean brake assem- blies. Use an OSHA-approved vacuum cleaner ov alternate method apploved by OSHA, designed to minimlle the haz- ard cause by alrborne asbestos fibers. _ - Inhaled asbestos Iiberl have been Iound to cause vel- piretory disease and cancer. Brake fluid CAUTION - Spilllng Iluid on painted, plastic or rubber parts will damage them. Pla clean shop towel over the a parts whenever the system Is serviced. KEEP OUT OF REACH OF CHILDREN. GENERAL INFORMATION Coolant Nitrogen Pressure Undar some conditions, the ethylene glycol in engine For shock absorber with a gas-tilled reservoir: coolant Is combustible end its Home in not visible. II the ethylene glycol does ignite, you will not see any flame, but you can be burned. - Uu only nitrogen to pressurize the shock absorber. The no. of In unstable g can cause a fire or explo- slon resulting In lotion n|ury. The Ihoclt ebcorbor cont-inc nitrogen under high - Avoid spilling engine coolant on the exhaust system or swim inm- "my in" In hot Ohm-9h to “I!" pressure. Allowing r or but no r the shock eh- tho coolant to lgnito and burn without I visible corbor could lend to an explosion that could result In Ileme. urloul Injury. - Coolant [ethylene glycol) can couse some skin irrltn- - Felluro to release the pressure from I shock obsorber tlon and is poisonous iI swallowed. KEEP OUT OF boloro disposing of it my load to a possible exoloslon REACH OF CHILDREN. and III'IWI Injury if it II honed or pierced. . Do not remove the rldlltor cop when the engine is hot. The coolnnt is under pressure Ind could scold To prevent the possibility of an explosion, release the ni- VOU- trogen by pressing the valve core. Then remove the valve ~ Kata h-ndl Ind clothing Iw-v irom the cooling in. stem Irom the shock absorber reservoir. Dispose or the u it starts automatically. oil in a manner acceptable In the Environmental ProteCr tIDn Agency (EPA). II it contacts your skin, wash the affected areas immedir ately with soap and water. I! it contacts your eyes, flush Before disposal of the shock absorber, release the nitro them thoroughly with fresh water and get immediate gen by pressing the valve core. Then remove the valve medical attention It it IS swallowed, the Vlcllm must be stem from the shock absorber. forced to vomit. then rinse mouth and throat with fresh water before obtaining medical attention. Because of Battery Hydrogen Get It Electrolyte these dangers. always store coolant in a safe place, away Irom the reach ol children. - The battery give: of! explosive gnu; ltnp :pnrlrs, Ilamo and cigarettes owny. Provldo edequtte von~ tllotlon when charging. The battery cont-Ins sulfuric acid (electrolyte). Con- tact with Ikln or eyes may clue. to o bums. Wur protective clothing and e loco shield. -II ctrolyto got: on your skin. Ilush with water. -II electrolyte get: in your eyes. flush with water (or at Inst 15 minutes and call a physicio immediately. Electrolyte is poisonous. - II swallowed. drink lorgo qua ntitiot of water or mill and Iollow with milk ol magnolia or vegetable oil and cell I physician. KEEP OUT OF REACH OF CHIL- DREN. SERVICE RULES 1.Use genuine HONDA or HONDA»recommended parts and lubrication: or their equivalents Parts that do not meet HONDA's design specifications may damage the motorcycle. 2. Use the special tools designed for IhIs product. 3. Use only metric tools when servicing this motorcycle. Metric bolts, nuts, and screws are not interchangeable with English fasteners. The use oi incorrect tools and Iasreners may damage the motorcycle Linstall new gaskets. O-rings. cotter pins, lock pistes, etc. when reassembllng. 5.When tightening a series bolts or nuts. begins with the largerrdiameter oi inner bolts firsr, and tighten to speciiied torque dlegonally, in incremental steps nuless a particular sequence is specilled. Silicon parts in cleaning solvent upon diesssembly. Lubricate any sliding surfaces before reassembly. [After uumbly, check all parts for proper installation and operation. than. all Iloctrical wires as shown on pages 1720 through 127, Cable and Harness Routing. 0‘ GENERAL INFORMATION MODEL IDENTIFICATION (I) FRAME SERIAL NUMBER The Irsms serial number is stumped on thy right side ol the stesring hand. (2) ENGINE SERIAL NUMBER (3) VEHICLE IDENTIFICATION NUMBER The engine serial number is stamped on the right a! the The Vehicle Identification Number (VIN) is attached on upper crankcase, right side ol the Iramei (I) CARBURETOFI IDENTIFICAYION NUMBERS (5) COLOR LABEL The carburetor identification numbars are on the carbure- Tho color label is attached on the Irums under the right tor body imaks aids as shown. side cover as shown. GENERAL INFORMATION SPECIFICATIONS (Calllornia typo) Maximum weight capacrly (U SA. type) * GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 2,055 mm (90.9 in) Overall wrdth 685 mm (27.0 in) Overall helght 1,135mm (44.7 in) Wheelbase 1,405 mm (55.3 In) Seat height 810 mm (31.9 in) Ground clearance 130 mm (5.1 in) Dry Welght (49 state/Canada type) 184 kg (406 lbs) (California type) 186 kg “08 lbs) Curd weight [49 state/Canada type) 206 kg (454 lbs) 208 kg (459 lbs) I76 kg [388 lbs) Bore X Stroke Displacement Compression ratio Valve train Intake valve opens at 1 mm (0.04 in) llft (49 state/Canada type) (California type) Intake valve closes at 1 mm (0.04 in) lilt (49 state/Canada type) (Calliorms rvpe) Exhaust valve opens at 1 mm (0.04 In) lift (49 state/Canada type) (Calilornia type) Exhaust valve closes at 1 mm (0.04 In) lllt (49 state/Canada type) (Calilomla type) Lubricatlon system Orl pump type Cooling system Air filtration Engine weight (49 state/Canada type) (California Iype) Firing order Cylinder number ‘ (Canada type) 180 kg (397 lbs) 77 FRAME Frame type Dramond Front suspensmn Telescaplc lork Front wheel travel 113 mm (4.65 in) ; Rear Suspension Swmgerm ‘ Rear wheel travel 109 mm (0 29 In) Rear damper Nrtrogen gas filled damper with reserve tank Front tire SIZE 120/60 ZR 17 Rear tire srze 180760211 17 Tire brand (Bridgeslone) Front BT5OF RADIAL G Rear BTSOR RADIAL J (Michelin) Front MACADAM 90X Rea! MACADAM 90X Front brake Hydraulic dual disc Rear brake Hydraulic single dISC Caster 25‘ 10‘ Trail 94 mm (3.7 In) Fuel tank capaclty 17.0 E (4.5 US gal, 3.7 Imp gal) Fuel tank reserve capacrty 3 0 2 (0 8 US gal, 0 7 Imp gal) ENGINE Cylinder arrangement Vertical 30 inllne (our 65.0 X 45.2 mm (2.56 X 1.78 in) 600 cm“ (36.6 curm) I2 : 1 Silent multi-Imk chain driven DOHC 15‘ BTDC 75‘ BTDC 35' ABDC 40' ABDC 38' EBDC 40 EBDC TATDC -10' ATDC Forced pressure and wet sump Trochord Liquid cooled VISCOUS paper element 61.9 kg (136 4 lbs) 62.3 kg (138 4 lbs) 1 - 2 —~ 4 7 3 GENERAL INFORMATION — GENERAL (cont'dl ITEM SPECIFICATION CARBURETOR Carburetor type Constant velocity _ Throttle bore 36 mm (1,4 in) DRIVE TRAIN Clutch System Multi-plata, wet Clutch operating system Cable operating Transmission 6-speed Primary reduction 1,863 (82/44) Gear relic 1st 2328 (4111‘) Gear ratio 2nd 2.062 (33/16) Gear ratio 3rd 1.647 (28/17) Gear ratio 4th 1363 (26/19) Gear ratio 5th 1.200 (Zl/ZD) ‘ Gear ratio 6th 1086(25/23) Final reduction 2.866 (43/15) I Gear shilt pattern Left foot operated return system 1 - N — 2 - 3 — 4 — 5 — 8 g ELECTRICAL Ignition system Full trensinorizod ignition 3 Starting system Electric starter motor ‘ Charging system Triple phase output alternator Regulator/rectifier type SCR shorted/triple phase. lull-wave rectification , Lighting system Battery ‘1‘ f .m—un-i GENERAL INFORMATION r— LUBRICATION SYSTEM “m“ m’“ “m ITEM STANDARD SERVICE LIMIT Engine oil capacity at draining 3.‘ I (3.8 us qt, 3.0 Imp qt) _ at disassembly 11.2 2 (ti US qt, 3.7 Imp qt) _ at oil lilter change 3.7 2 (3.9 US qt, 3.3 Imp qtl _ Recommended engine oil Use Honda 5N4 4-atroka Oil or equi- _ valent API Service Classification: SF or 56 Viscosity: SAE 10W—40 Oil pressure at oil pressure switch (80'C/176'F) “(It We (50 kg/cm’, 71 psi) at 6.000 _ rpm Oil pump rotor tip clearance 0.15 (0.000) 0.20 (0.003) body clearance 0.15 - 0.22 (0.006 - 0.009) 0.3510014) end clearance 0.02 - 0.07 (0.001 — 0.003) 0.10 (0.00!) Oil pump drive sprocket collar OD. 34.060 — 34.075 (1.3405 — 13115) 34031135) Oil pump dnve sprocket ID» 35.025 — 35.075 (1.3789 - 1.3009) 35.10 (138) — FUEL SYSTEM ITEM SPECIFICATIONS Carburetor identification 49 state type VP61A "umber California type VPazA Canada type VPGOA Mein jet 49 state, Canada type No. 1/4 carburetor: #135. No. 2/3 carburetor: #138 California type #1355 Slow jel #40 Pilot screw Initial/final openmg See page 5722 high altitude adjustment See page 5-23 Float level 13,7 mm (0.54 in) idle speed #9 state. Canada type 1,200 1 100 rpm Celilornie type 1,400 x 100 rpm Carburetor vacuum eiflerence Within 30 mmHg (1.2 ian) Base carburetor: No. 3 Throttle grip lree play Z—Gmmll/lZ -l/4 in) GENERAL INFORMA‘HON — COOLLING SVSTEM ITEM SPECIFICATIONS Coolant capacity radiator and engine l 2.5 l (0.63 US gel. 0.53 Imp gel) reserve can k 0.35 l (0.09 US gal, 0.03 Imp gal) Radiator cap relief pressure 108 — 137 kPa (1.1 - 1.41 kg/cm’.15.8 —19.9 psi) Thermostat begins to open 80 — 801N176 — 153T) (ully open 951: (203‘F) valve lift 3.0 mm (0.31 in) minimum Tharmo valve srarts (0 close 73 — 77'C (163 —171'F) — CVLINDER HEAD/VALVES ”"l‘: ""“ “"’ ITEM STANDARD SERVICE LIMIT Cylinder compression 1,275 — 1,314 We (13.0 —13.4 kn/cm', — 135 - 191 psi) Valve clearance I N 0.16 t 0.03 (0.006 t 0.001) — EX 0.22 1 0.03 (0.009 t 0.001) — Cylinder head warpaga — 0.10 (0.009) Camshaft Cam lobe 49 slate, Canada type 36.140 , 36.380 (1.4228 — 1.4323) 36.11 (1.422) new" 1N CaliIornia vae 34.540 - 34.790 (1.3599 — 1.3595) 34.51 (1.359) ‘. EX 49 state, Canada type 35300 — 35.540 (1.3990 — 1.3992) 35.27 (1.399) California type 33580 - 33.820 (1.3220 71.3315) 33.55 (1.321) Runout — 0.05 (0.002) Oil cleernce 0.02 — 0.002 (0.0009 - 0.0024) 0.1 (0.004) Journal 00. 23.959 - 23.990 (0.9433 — 0.9441) 24.955 (0.9925) Camshan holder I.D. 24.000 - 24.021 (0.9449 — 0.9457) — Valve and valve Valve mm 0.0. (N 3.975 — 3.990 (0.1565 - 0.1571) 3.965 (0.1561) ”um ex 3.955 - 3.900 (0.1561 - 0.1507) 3.955 (0.1557) Valve guide (.0. (N 4.000 — 4.012 (0.1575 - 0.1590) 4.04 (0.159) Ex 4000-4012 (01575—01580) I 4.04 (0.159) Slem-to-guide clearance IN 0.010 - 0.037 (0.0004 — 0.0015) 0.075 (0.0029) EX 0.020 - 0.047 (0.0009 — 0.0019) 0.085 (0.0033) Valva guide projection IN 13.1 — 13.3 (0.516 - 0.524) — “W" Mind“ "“d EX 11.3 — 11.5 (0.445 — 0.453) _ Seat width . (max 0.9 -1.1 (0.035 - 0.043) 1.5 (0.05) Valve spring Free length lnnar l 31.92 (1.257 l 30.62 (1.206) Outer 95.39 (1.392) 33.96 (1.333) Valve liner 0.0. 25.979 — 25.993 (1.0223 - 1.0233) 25.97 (1.022) 1 Bare Lo, 25.010 — 26.026 (1.0240 -1.0245) 26.04 (1.025) 1—7 GENERAL INFORMATION — CLUTCH/GEARSHIFT LINKAGE ”m" mm W ITEM summu: same: lerr Clutch lever free play 7 1020 (3/0 - 3/4) — Cluzcrnisipiring lree length 49.7 (1.90) 40.3 (1.90) '- cmmn disc thickness ' 2.92 - 3.0010115 _ 0.121) 2.5010102) Clutch plate warpage 7 — 0.30 (0.0m Clutch outer guide 010.77 34.975 — 34.991 (1.3770 — 1.3770) 34.965 (1.3700) I.D. 21.994 — 22.007 (0.0059 — 0.9504) 22017108563) Mainshafl CD. at clutch outer guide 21.980 - 21.99310365‘ - 0.8659) 21.95 (0.86‘) Unit: mm (in) — TRANSMISSION ITEM gunman SERVICE Lllvlrr mils. éear LD. M5. Me 28000 - 20.021 I1.1024— 1.1032) 29.04 (1.104) "“5“" c2. c3, c4 31000—31025 (1.2205— 1.2215) 31.04 (1.222) Gear bushing 0.13. M5. M6 27.959 — 27.990 (1.1007 - 1.1015) 279411100) 02 30.959—30990112109— 1.2197) 30.94 ( 1.210) c3, c4 30.950—30975112195- 1.2195) 30.93 (1.210) _G;{Bushing |.D. M5 24.905 — 25000109037 - 0.9045) 25.010 (0.9549) (:2 27.985-2B.008(1.1018— 1.1020) 20.021 (1.1032) GeaHo~bushing cleavana at M5, M6 gear 0.020 - 0.062 (0.0003 - 0.0024) — at c2, ca, C4 9997 0.020 — 0.070 (0.0000 — 0.0020) — Mainshan 0.0. M M5 goal bushing 24.907 — 24900109830 - 0.9835) 24960109927) .1 010(0)) omer guide 21.900 - 21.993 (0.0554 — 0.0059) 21.95 (0.9094) Cauntershafl 0.0. 0162 gear bushing 27.957 — 27.900 (1.1011 — 1.1010) 279011.101) Ganr‘bushing-lo-shafl at M5 gear 0.005 9 0039100002 — 0.0015) — ““mm“ a! c2 gear 0.005 ~ 0.039 (0.0002 — 0.0015) — '53:; Fork claw thickness 5.93 — 6.00 (0.233 — 0.236) 5.9010232) shaft Fovk ID. 12000 - 12.021 (0.4724 _ 0.4733) 12.030 (04736) 511011 0.0. 11.957 —11.950(0.47o7 — 0.4712) 119510.470) GENERAL INFORMATION — CVLINDER/PISTONICRANKSHAFT I l ””“i "‘m ""’ 1* > ITEM V ., STANDARD SERVICE LIMIT Cylinder 1.0. . ,. 7 65.000 — 65.015125591 — 2.55961 65.10 (2.553) Taper — . , ‘ 0.10 (0.004) Oul of round , ,f—. 0.10 (0.000 VWarpaga _ VAN" — 0.1010004) Piston, Piston mark direction "IN“ mark facing to the Intake side — 5:32:32 Piston cm. W 7 64.970 — 64.950 (2.50779 - 255011 at 64.90 (2.555) pin 11 (0.4) Irom bonom 015:1 Piston pin hole ID. 17002 — (7.008 (0.6694 - 0.6396) 17.02 (0.670) Cylinder»!o-piston clearance _ 0.010 - 0.045 (0.0004 - 0.0018) 0.10 (0.004) Flston pin O.D. 16.994 —17.000(0.6690 - 0.6693) 16.98 (0.669) _I_°iston-lo-pislon pln clearance r 0,002 — 0.014 (0.0001 — 0.0006) 0.04 (0.0018) Cannecting rodrmrpiswn pin cleaIance 0.016 — 0.040 (0.0006 — 0.0016) 0.06 (0.0024) Piswn ring-(wring gmove Top 0025:3060 (0.0010 - 0.0024) 0.08 (0.003) cleavane Second ‘ 0.015 — 0.050 (0.0006 — 0.00201 0.08 (0.003) Piston ring and gap Top 0.20 - 0.35 (0.008 — 0.014) 0.5 (0.02) Second 0.35 — 0.50 (0.014 — 0.020) 0.7 (0.03] 73070510: fall) 0.2 , 0.7(0017 0.031 1.0 (0.04) Pistim ring mark Top fl 7 - "T" or 'R" mark facing up _ — Second 7 “T" or 'RN" mark facing up ‘ — Crankshah, ”VIZ-ouneming rod small and ID. 7 7717.016 — 17.034 (0.6699 — 0.67061_ 17.04 (0.671) signalling Connecting rod big and side clearane 0.10 — 0.2; (0.004 7 0.01) 0.30 (0.012) Crankshafl runoul - W I — 0.05 (0.002) Crankpin oil clevance 7 H 0.028 - 0.052 (0.0011 — 0.0020) 0.06 (0.002) l Main journlijgl-clearance ‘ 0.020 —70.045 (0.0008 - 0.0010) 0.05 (0.002) GENERAL INFORMATION [— mom WHEEL/SUSPENSION/STEERING ”m“ "‘"‘ “"’ ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 1.5 ((106) Cold tire pressure UP to 90 kg (200 lb) load 36 ml (2.50 kglcrn’, 250 kPa) — Up to maximum weight capacity 36 psi (2.60 kalcm'. 260 kFa) ~— Axle runout — 0.2 (0.01) Wheel rim runou! Radial —- 2.0 (0.08) Axial — 2.0 (0.08) Wheel balance weight — 609 (2.1 01) max. Fork spring Iree length 317.9 (12.0) 311.5 (123) Fork spring direction With tightly wound coil lacing down — Fork lube runout — 2.0 (0.08) Recommended (ork fluid Pro Honda Suspension fluid 53-8 Fork fluid level 117 (0.61) — Fork fluid capacity ‘63 0: (15.7 US 01. 16.3 Imp oz) —— Spring ere-load adjuster standard position 3rd groove — Rebound adjuster standard position 7 clicks out from lull in Steering stem bearing ore-load 0.15—0.20 kgItl Frame/Body Panels/Ethan“ Syn-m : Exhaust pipe joint nut 6 7 20 (2.0, 14) Exhaust pipe band bolt 2 8 21 (2.1, 15) J Muffler mounting bolt 1 a 27 (2.7, 20) ' Side stand pivot bolt 1 10 10 (1.0. 7) a stand pivot lock nut 1 10 30 (3.0, 22) ' Side stand bracket bolt 2 10 55 (5‘5, 40) Side stand switch bolt 1 8 10 (1.0. 7) Upper fairing stay bolt 2 8 27 (2‘7. 20) Footpeg holder bolt 5 ‘ 8 2712.7, 20) Engine Mount : Engine hanger plate bolt 2 10 45(15, 33) Front engine mounting boltlnut 2 1O 65 (6.5, 47) Rear engine mounting nut 1 1D 45 (4.5, 33) Rear lower engine mounting bolt 1 1O 45 (4.5, 33) Engine mounting adjust bolt 1 20 15 (1.5, 11) 9 Engine mounting lock nut 1 20 65 (6.5, 47) ' ‘ Drive sprocket bolt 1 10 55 (5.5, 40) Gearshilt pedal pinch belt (pedal side) 1 8 ”(21.20) (arm side) 1 B 2012.0, 14) From Whnl/SmpnnelonlS‘eerlng : ‘ Ignition switch bolt 2 8 25 (2.5, 18) ‘ Handlebar pinch bolt 2 8 2712.7, 20) Fork cap bolt 2 37 23 (2.3, 17) Fork socket bolt 2 8 20 (2.0, 14) NOTE 2 Steering Item nut 1 24 105 (10.5, 76) 1-14_ GENERAL INFORMA'HON ”a. — FRAME (com‘d) "- TORQUE A 1. ITEM my 0211:: nsmmxs 4““ ' N-m lkgm, lib-III Steering adjustment nut 1 26 25 (2.5, 18) NOTE 6 See page 12-25. Fork pinch bolt (upper) 2 8 23123.17) (lower) 2 10 4014.0. 29) Front axle bolt 1 14 60 (6.0, ‘3) Front axle pinch bolt 1 8 22 (2.2. 16) Front brake disc bolt 12 6 20 (2.0, 14) NOTE 2 Rear Wheel/Re" Suspenslon : Drive chain adjuster lock nut 2 8 22 (2.2. 16) Rear axle nut 1 18 9519.5. 69) Shock absorber mounting nut 2 10 4514.5. 33) Shock link nut Ifrarne side) 1 10 4514.5. 33) Shock link nut (shock arm side) 1 10 45 (4.5. 33) Shock arm bolt 1 10 45 (4.5.33) Swingarm pivot nut 1 14 110 (11.0. 80) Drive chain alidar screw 2 6 5,310.53, 3.8) Rear brake disc bolt 4 8 ‘3 (4.3. 31) Driven sprocket nut A 12 90 (9.0. 85) Brllto System : Rear master cylinder push rod lock nut 1 3 18 (1.8, 13) Rear master cylinder mounting bolt 2 8 910.9, 7) Rear brake master cylinder reservoir bolt 1 6 12 (1.2, 9) Front brake caliper bracket bolt 4 8 31 [3.1, 22) NOTE 2 Brake hose bolt 5 10 35 (3.5, 25) Front master cylinder holder bolt 2 8 12 (1.2. 9) Front brake llght swltch screw 1 I 1.2 (0.12. 0.9) Front reservoir cover screw 2 4 1.5 (0.15. 1.1) Brake lever plvot bolt 1 8 1 (0.1, 0.7) Brake lever plvot nut 1 8 610.6, 4.3) Breed valve 3 8 610.6. ‘3) Brake pipe three way joint bolt 1 6 12 (1.2. 9) Front brake hose clempar bolt 1 6 12 (1.2. 9) Front brake pipe stay bolt 2 6 12 (1.2. 9) Brake pad pin 3 8 18113.13) Brake pad pin plug 3 8 1510.25.13) Brake pipe flare nut 2 10 17 (1.7, 12) Front caliper bracket pin bolt 2 5 1311.3, 9) NOYE 2 Front brake caliper pin bolt 2 8 2312.3, 17) NOYE 2 Rear brake caliper bracket bolt 1 E 23 (2.3, 17) Rear brake caliper pin bolt 1 I0 28 (2.8. 20) 1-15 GENERAL INFORMATION TOOLS DESCRIPTION TOOL NUMBER APPLICABILITV REFER T0 SECTIONISI Drive chain cutter Link plate holder Oil lilter wrench Oil pressure gauge Oil pressure gauge attachment Float level gauge Pilot screw wrench Pilot elbow wrench Pilot screw wrench Valve spring compressor Valve compressor attachment Tappet hole protector Valve guide driver, 4 mm Valve guide reamer. 4.008 mm Valve seat cutter 24.5 mm (EX 45‘) Valve seat cutter 27.5 mm (IN 45‘) Valve seat cutter 24 mm (EX 32‘) Valve seat cutter 27 mm (IN 32') Valve seat cutter 22 mm (EX 60') Valve seat cutter 26 mm (IN 60‘) Cutter holder. 40 mm Valve guide driver Compression gauge attachment Driver Clutch center holder Pilot, 12mm Pilot, 35mm Attachment, 37 x 40 mm Attachment, ‘2 x 47 mm Attachment, 28 x 30 mm Inner driver Attachment, 25 mm ID. Attachment, 30 mm ID. Bearing remover shalt Bearing remover head, 20 mm Attachment, 42 x 47 mm Attachment 52 x 55 mm Pilot, 20 mm Fork seal driver Fork seal driver attachment Steering stem socket Ball race remover -driver attachment -drlver handle Bell race remover Steering stern driver Pilot. 22 mm Attachment, 24 x 26 mm Attachment. 32 x 35 mm Film. 17 mm Pilot. 25 mm Driver ahlft Bearing remover attachment Pin drlver 07HMM-MR10102 —(l—cr 07HMH-MR10103 07NMH-MW00110—(Ivor 07NMH—MW001 1A 07HAA-PJ70100 07506-3000000 :l——or equivalent com- 07510-4220100 07401 —0010000 mercially available in U.S.A 07KMA«M560101:[--or 07MMA—MT3010A 07PMA-M2201 10 079004220201 07757-001 0000 07959-KM30101 with 07PMA—M2201 ‘IA o7HMG-MR70002 ——or equivalent [a- 9999011) 07GMDvKT70100 07MMH»MV90100 ——nr 07MMH-MV9010A 07700-001 01 00 07700-001 0200 07780-001 2500 07780-00 I 3300 07780-0014202 07780-0014500 0778 1 -00 10500 07743-0020000 -or equivalent com- mercially available in U.S,A. 07R MJ-MV60100 ——-or equivalent commercial- 07749-0010000 Iv evailabla in USA 07JMB-MN50300—— or 07HGBOO1000A 07746-0040200 07740-004080!) 07746-001 0200 07740001 0300 07946—18701 00 07746—00301 00 077460030200 077460030300 07746-0050100 :|—- or equivalent corn» 07746-0050600 07748001 0300 077 46-001 0400 077 46-0040500 07947 - KA501 00 marcially available in USA. 07947-KF00100 07916-3710101——> or 0791641710100 07953-MJ10000 - Attachmml07953MJ10mA 07953-MJ10100 07953-MJ10200 07946—37 10500 07946—M800000 077 46—004 1 000 077 46-00 1 0700 07746-0040400 07746-0040600 07746-00 1 01 00 07946-MJ00100 07 LMCAKVJOZOO or 07935-MJ100NE)V Drlver (079493710001) and Attachment. 37 x 40 mm (07746010200) 07GMD-KT00100 —-Not available in USA. Driver (07949- 3710001) and Pilot, 22 mm (077460041000) .1213 aerewreoro mammmmwmwmmmommmmm uuuww 12 12 13 13 13 13 13 13 13 1-16 GENERAL INFORMATION — Icont‘d) ' DESCRIPTION TOOL NUMBER APPIJCAIIIJTV IEFETI) mm Ramovor hlndle 079306710100 13 During remover 079364710300 13 Remover weigh! 07741-0010201 —— or 0793641710200 13 Snap ring pllars (IN) 07914-3230001 1‘ Difiilll muhlmater (KOWA) 074110020000 KS-AHM-3Z-003 15. 18, I7. 18 (U.S.A. only) Analog mulximolar (SANWA) 07308-0020001 15, 16, 17, 10 All-log multimotar (KOWAI TH-SH 16, 1E, 17, 10 Polk voltage adaptor 07HGJ-0020100 —— of Imrio diagno-tic 16 taster (modal 025) Impaction adaptor 07GMJ-ML80100 16 Flywheel holder O7925—ME90000 ——-- 0! Nui‘lllhm 00m "W" 17 SISIIIAIVIIIING In Rotor pullar 017330020001 079334100000 17 (USA. only) flywheel holder 077250040000 1" Tovx biI (T 30) 077030010200 3" 9! “WW-PI“ ogmmer- 17 Torx bk (T 40) 077010010100 flgx'mhb" '" 18 1-17 GENERAL INFORMATION LUBRICATION & SEAL POINTS -— ENGINE LOCATION MATERIAL REMARKS Cylinder head semicircular cut—out crankcase mating surface Liquid aaelant Wipe the excess of sealant Camshaft lobes/journals Valve lifter sliding surfaces Valve stem (valve guide sliding surface) Connecting rod small and inner surface Main journal bearings Connecting rod bearings Male. C5. CG gear shift fork grooves Cylinder head bolt threads and seating surface Crankshaft thrust surfaces Clutch outer sliding surfaces Starter idle gear shaft sliding surfaces Molybdenum disulfide oil is 50/50 mixture of engine oil and molybdenum disul- flde grease) Oil pressure switch threads Lower crankcase sealing bolt threds Cylinder head sealing bolt threads Alternator grommet Ignition pulse generator grommet Ignition pulse generator rotor cover bolt threads (Marked by 'A" mark) Thermoeensor threads Sealant Cylinder heed cover breather plate bolt threads Cam sprocket bolt threads Oil pump driven sprocket bolt threads Shift drum bearing aet plate bolt threads Starter clutch outer bolt threads oil cooler sealing belt threads Shift drum center bolt threads Gearshift spindle oil seal set plate bolt threads Meinshaft bearing set plate bolt threads Oil filter boss threads Locking agent Clean and apply to the threads Clutch center lock nut threads Starter clutch sliding surface Piston sliding surface. piston ring grooves. pin bore Piston pin surface Piston rings Lower crankcase bolt threads and seating surface lmein journal tightening) Connecting red cap nut threads and seating surface Camshaft holder belt threads and seating surface Flywheel bolt threads Cam chain tensioner collar sliding surface Cam chain tensiuner and slipper surface Gear teeth and rotating surface Oil seal lip (without dust lip) Clutch disks OAringe Bearings Engine oil Clutch lifter piece Ignition pulse generator cover can threads Oil seal lip (with dust lip) Multipurpose grease 1-18 GENERAL INFORMATION FRAME r wanton MATERIAL Side stand pivot bolt sliding surface Gearshift pedal pivot Brake pedal pivot Wheel dust eaal Iipa Rear wheel; driven lrenge aliding area Beer wheel aide collar inner surface Steering stern bearing Steering stem dust seal lip Throttle cable and Throttle grip sliding surface, flange groove Swingarm pivot duet seal lips Swing-rm pivot needle bearing Shock arm pivot duet seal lips Shock arm pivot needle bearing Shock link pivot duet seal Iipa Shock link pivot needle bearing Rear shock absorber lower mount duet seal lips Rear ahock absorber lower mount needle bearing Main mnd pivot aliding surface Multipurpose grease Steering edjuatma nt nut threads Engine oil Handlebar grip rubber inner aurlece Honda Hand Grip Cement lU.S.A. only) Brake reservoir Meat-r piston/piston seals Caliper piston Caliper piston seals 001’ 4 brake fluid Brake caliper boote inside Meater cylinder rubber boots inside Rear muter cylinder puah red top Rear brake caliper pin bolt sliding audace From maner cylinder piston; lever contact area Caliper duet seals Silicone grease Caliper pin bolt/bracket pin bolt threads Ferlt socket bolt threads Looking agent Clean and apply to the threads Fork oil seal lips Pro Honda Suapeneion fluid SS-B Air cleaner housing inlet tube joint Sealant 1-19 GENERAL INFORMATION CABLE & HARNESS ROUTING (9) ENGINE STOP SWITCH WIRE CONNECTOR IIP MINI/RED) I8) COMBINATION METER WIRE CONNECTOR I7) FUSE BOX I5) TURN SIGNAL I18) RIGHT HANDLEBAR SWITCH WIRE (1) LEFT HANDLEBAR SWITCH I10) RIGHT HANDLEBAR SWITCH WIRE CONNECTOR I2) COMBINATION METER WIRE CONNECTOR (9p MIN/BLACK, WIRE CONNECTOR I3) IGNITION SWITCH WIRE CONNECTOR I3P WHITE) (4) AIR VENT SOLENOID VALVE RELAY /. RELAY (5) LEFT HANDLEBAR SWITCH WIRE CONNECTOR IZP MINI/BLACK) (17) THROTTLE (12) LEFI' HANDLEBAR CABLES I11) CLUTCH SWITCH WIRE CABLE (13) CHOKE CABLE RONT BRAKE (15) F HOSE IN) IGNITION SWITCH WIRE 1 -20 GENERAL INFORMA'HON (1) CLUTCH CABLE (2) LEFT HANDLE BAH SWITCH WIRE fl (3)CHOKECABLE a ( 1“?» >§ “I IGNITION SWITCH WIRE (5) FROM; BRAKE (5) FAN MOTOR SWITCH] FAN MOTOfi WIRE 1-21 GENERAL INFORMATION (1) THROTTLE CABLES (11) SPEED SENSOR 3P CONNECTOR (2) RIGHT HANDLEBAR SWITCH WIRE (IO) RADIATOR SIPHON TUBE I (9) RESERVE TANK BREATHER TUBE I CL (BI MAIN me- ‘ )CAEEEH HARNESS (7) OIL PRESSURE SWITCH (5) PULSE SECONDARY AIR INJECTION WIRE (PAIR) CONTROL VALVE TUBE (CALIFORNIA TVPE ONLV) (6) PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE AIR INTAKE HOSE (CALIFORNIA TYPE ONLV) 1 -22 GENERAL INFORMATION (1) BRAKE] TAILLIGHT WIRE I2) GROUND WIRE (3) REAR BRAKE LIGHT SWIYCH WIRE “I SHOCK ABSORBER RESERVOIR HOSE (6) RIGHT REAR TURN SIGNAL WIRE I3) LEFT REAR YURN SIGNAL WIRE "I'm I" w. ' \ "93/ (7) LICENSE PLATE LIGHT WIRE 1 -23 GENERAL INFORMATION (1) ALTERNATOR 3P (WHITE) CONNECTOR 12) SIDE STAND SWITCH 3P(GREEN) CONNECTOR (8) GROUND I I \ “#3,, IZHGNITION ‘ PULSE IGENERATOR , \ 29mm) \“ x__ {QONNECTOR m‘anomE POSITION . .‘ " 5 , x) ssnsoawms ‘ ' I6) ALTERNATOR -_ ‘ WIRE (4) REAR BRAKE LIGHT SWITCH 2P CONNECTOR I I9) VENT FILTER ‘ DRAIN TUBE (12) FUEL TANK DRAIN TUBE I11] RESERVE TANK BREATER TUBE (10) CARBURETOR DRAIN TUBES ‘I -24 GENERAL INFORMATION l 7 D: i I A I ' 1" m-ga—r‘. 5V V I _ . ' I," ‘3‘: ' M‘ fig‘fi W M ' , (z) GROUND CABLE l A .5 {I o 4 ”J V mwmen HOSES N ‘ "I“ ' LIN / I -' S l! \I‘A IN ( (3) STARTER MOTOR CABLE | ‘ ‘ -/ (6) CARBURETOR DRAIN TUBES 1/ '1 [N7]? 3‘75 (4) SPEED SENSOR WIRE (5) FUEL TUBES 1 -25 GENERAL INFORMATION CALIFORNIA WPE ONLY: (1) CYLINDER HEAD w coven BREATHER TUBE / , i u“ ,a (7) No‘ 6 tusss Q Q , ° 0 0 \ \\ (6) No. 5 TUBE (5) No. 11 TUBE Q “@o W " , \ “g (2) PULSE SECONDARY AIR INJECTION (FAIR) CONTROL VALVE AIR INTAKE HOSE — g (3) FUEL TUBES (4) No. 4 TUBE ,1-26 GENERAL INFORMATION (1) No. GTUBES I2) No. 1 TUBE (TO FUEL TANK) (CI) EVAPORATIVE EMISSION PURGE CONTROL VALVE I!) No. S TUBE (8) No. 11 TUBE (7) No. B TUBE (a) No. a was F \, \ ..|' (5) Na 2 TUBE (4] No. 4 TUBE 1 I12) PULSE SECONDARY AIR INJECTION CONTROL VALVE AIR INTAKE HOSE [TO AIR CLEANER) "1m PULSE seconmnv AIR INJECTION I ' ” - eon-ram VALVE was ' - ‘ no) miscarlsg’fgggggbm no No. a cvunnen INTAKE ' VALVE MANIFOLD) 1-27 GENERAL INFORMA'HON EMISSION CONTROL SYSTEMS (U.S.A. only) The US. Enviromental Protection Agency and California Air Resources Board (CARE) require manufactures to certify that their motorcycles comply with applicable exhaust emissions standards during their uselul lite, when operated and main» tained according to the instructions provided, and that motorcycles built alter January 1, 1983 comply with applicable noise emission standards tor 1 year or 6,000 kilometers ( 3,730 miles) alter the time of sale to the ultimate purchaser, when operated and maintained according to the illustrations provided. Compliance with the terms of the Distributer‘s Warranties for Honda Motorcycle Emission Control Systems is necessary in order I!) keep the emissions system warranty in ellect, SOURCES OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons, Control of hydrocarbons is very important because, under certain conditions, they react to term photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way, but I s toxic. Honda Motor Cor, Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocar- bone. CRANKCASE EMISSION CONTROL SVSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emmisions into the almospher, Blowby gas is returned to the combustion chamber through the air cleaner and carburetor, (1) AIR CLEANER 12) CARBURETOR (3) <): :FHESH Am (4) « :BLOW-EY GAS 1 -28 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SVSTEM (California type only) This vehicle complies with the California Air Resources Board evaporative emission regulations. Fuel vapor from the fuel tank end carburetors is routed into the eveporetive emission cenieter where it is absorbed and stored whllethe engine is stopped. When the engine is running and the evaporative emission purge control valve is open luel vapor in the mporative emission canister is drawn into the engine through the carburetor. At the same time, the evaporative emission . Murmur air vent solenoid valve is open and air is drawn into the carburetor through the valve. I1) — — — — Evsrorunvr _____ EMISSION PURGE CONTROL VALVE (3i EVAPORATIVE (“fist EMISSION CAN ISTER <21 m FRESH AIR 51 (7) EVAPORATIVE <:| : l5) FRESH AIR EMISSION CAREURETOR AIR VENT SOLENOID VALVES « I I6) FUEL VAPOR ‘7 WISE EMISSION CONTROL SYSTEM 'IIMPERING WITH THE NOISE CONTROL SVSTEM IS PROHIBITED: Federal Iew prohibits the following am or the causing Moot (1)The removal or rendering inoperative by any person, other than lor purpose 0' maintenance, repair o repleoe— 5mm. of any device or element at design incorporated into any new vehicle for purpose of noise control prior to It ele or “delivery“: the ultimate purcheser or while it is in use; or (2) the use ol the vehicle alter such device or element ol design "he. been removed or rendered inoperetive by any person AMONG THESE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: _’ 1. Removal of. or puncturing the muffler baffles, header pipes or any other component which conducu exhaust gases. 2. Removal of. or puncturing at any perts ol the intake system, VI. Led! of proper maintenance. ‘. Replacing my movlng parts of the vehicle. or parts ol the exhaust or intake system, with perts other than those speci’ fled by the manufacturer. 1 -29 GENERAL INFORMATION EXHAUST EMISSION CONTROL SVSTEM The exhaust emission control system is composed ol lean carburetor setting and no adjustment should be made except idle speed adjustment with the throttle stop screw. PULSE SECONDARY AIR INJECTION SYSTEM (California type only) The exhaust emission control system consists 0! a pulse secondary air injection (PAIR) synem which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge 01 lresh air promotes burning ol the unburned exhaust gases and changes a considerable amount at hydro- carbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. This model has the pulse secondary air injection control valve; it consists 0' PAIR check valve built into the pulse second- ary eir injection control valve. A PAIR check valve prevents reverse air flow through the system. The pulse secondary air injection control valve reacts to high intake manifold vacuum and will cut oft the supply of fresh air during engine decelerration, thereby preventing sherburn in the exhaust system, No adjustment to the pulse secondary air injection system should be made. although periodic inspection of the compo- nents is recommended. (I) INTAKE PORT (2) PULSE SECONDARV AIR INJECTION (PAIR) CONTROL VALVE \v b L L E _ ll) CARBURETOR I5) EXHAUST PORT (3) PAIR CHECK VALVES Q: (6): FRESH AIR ‘— (7): VACUUM PRESSURE 1 -30 ~EMIISSION CONTROL INFORMATION , LABELS (U.S.A. only] M Emiulon Control Informalion Label is located on the In a under the left side cover as shown. It gives basic _. no~up specifications. The Iefl side cover must be Is- mud to road in Mono page 2—2 lor left side cover removal VHELE EMISSION CONTROL INFORMATION .WDATE LABEL filter maklnu a high allitude carburetor adjuflmonl, attach ll updlle label to [he Irame under the left side cover us than . »W In page 2-2 907 Ian side cover removal. I ICUUM HOSE ROUTING DIAGRAM LABEL II type only) Vlcuum Hose Routing Diagram Label is on the air not case cover a: sh ownl IuII tank must be removed to read it. In pigs 2-4 for fuel tank removal. I1) VACUUM HOSE ROUTING LABEL GENERAL INFORMAflON I1) EMISSION CONTROL INFORMATION LABEL VACUUM HOSE RUUIINB DIAGRAM ENGINE FAHILVe EVAPORAHVE FAMILV- CALIFURNIA VEHICLE mp yum "m a, m comma. u/ c a k, 1-31 2. FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION 2-1 TROUBLESHOOTING 2-1 SIDE COVER 2-2 SEAT 2-2 TAIL COWL 2-3 MAINTENANCE COVER 2-3 SIDE FAIRING FUEL TANK UPPER FAIRING REAR FENDER A REAR FENDER B EXHAUST SYSTEM 2-3 2-4 2-4 I 2-9 2-10 SERVICE INFORMATION GENERAL - Work in a well ventilated area. Smokin cause a fire or explosion. seat properly. TORQUE VALUES Exhaust pipe joint nut 20 N'm (2.0 kg-m,14 lb—ft) Exhaust pipe band bolt 21 N-m (1.1 kg-m,15 Ib-ft) Muffler mounting bolt 27 N-m (2.7 kgvm, 20 lIHt) Footpeg holder bolt 27 N-m (2.7 kg-m, 20 "3—11) Upper fairing stay bolt 27 N-m (2.7 Item, 20 Ib—ftl TROUBLESHOOTING Exoessfve exhaust noise - Broken exhaust system - Exhaust gas leak Poor performance - Deformed exhaust system - Exhaust gas leak - Clogged muffler - This section covers removal and installation of the frame body panels, . Always replace the exhsust pipe gaskets when removing the exhaust - When installing the exhaust pipe, install the exhaust s - Always inspect the exhaust system for leaks after installation. - Gasoline is extremely flammable and Is explosive under oerteln conditions KEEP OUT OF REACH CHILDREN. - Serious burns may result If the exhaust system is not allowed to cool before components are removed or serviced. fuel tank and exhaust system. pipe from the engine. vstem and all fasteners loosely. Always tighten the exhaust clamps first, then tighten the mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not g or allowing flames or sparks in the working erea or where gasoline is stored can i - Be careful not to bro-Ii the pins, tabs end slot: in tho FRAME/BODV PANELS/EXHAUST SVSTEM SIDE COVER i 1 REMOVAL ‘ ( HJUICK RELEASE FASTENER Unlock the quick release lasteners by aiigning the long slot With the punch mark ‘ r F i i ° 0 er 11> i 12) UNLOCKED l3) LOCKE CAUTION (Z) BOSSES side cover Ind tail cowl when removing the side cover. ‘ Remove the Slde cover by releasing the 3 bosses on the cover lrom the grommets and carelully pulling the cover lree from the tabs and pin in the back. (1i QUICK FASTENER INSTALLATION Install the Side cover aligning its bosses with the grommets and engage ihe tabs with the slots, and pins with the hole securely as shown. Lock the clip by aligning the 'A" mark with the punch mark. Do the same on the other side SEAT (1) BOLTS REMOVAL] INSTALLATION Remove the Slde covers Remove the seat by removing the 2 bolts and sliding the seat back. Install the sea! In the reverse order of removal, the install the side covers. ‘ 2-2 FRAME/BODY PANELS] EXHAUST SVSTEM TAIL COWL REMOVAL] INSTALLATION Remove the seat (page 2-2)l Remove the 2 bolts and the tail cowl (one boss). Imtall the tail cowl in the reverse order or removal. MAINTENANCE COVER REMOVAL/INSTALLATION Remove the two screws and remove the maintenance cover backward. ‘ Install the maintenance cover in the reverse order (”49* moval. NOTE - Align the {fight the maintenance cover with the grooves of the upper and side iairmg securely. SIDE FAIRING REMOVAL] INSTALLATION Remove the maintenance cover (page 273) and side cover (page 2-2). Turn the quick fastener countenclockwise and loosen itl Remove the bottom screw from the inner cover. Release the trim clips by pulling the center pin, Remove the seven bolts. Release the tabs from upper fairing and remove the side ialr- ing, Installation is in the reverse order 01 removal, Install the bolt with the high shoulder as shown. (2) TAIL COWL I3) 8085 [r r (1) SCREWS / (2i MAINTENANCE COVER I5) BOLT WITH HIGH SHOULDER COVER I!) QUICK FASTENER (3i BOTTOM SCREW 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK REMOVAL] INSTALLATION - Gasoline is extremlv llammahl:e;1d is up dar 00min condition; KEEP OUT OF REACH OF CHIL DREN. Remove the seat {page 2-2). Turn the luel valve OFFr Remove the 6 mm bolt and collar H) FUEL VALVE ( Remove the 8 mm bolt and collar, Lift the fuel tank up. Disconnect the fuel tube, breather tube and dram tube from the fuel tank, then remove the fuel tank‘ Installation is in the reverse order of removal. Before installing the fuel tank, make sure the breather tube and drain tube are through the guide as shown Alter inste||alion, turn the fuel valve 0N and check the Vuel line for leakage l1) GUIDE UPPER FAIRING REMOVAL Remove the screws and rearview mirror mner covers‘ (Zl BOLTS/COLLAHS (2) INNER COVERS (1) SCREWS FRAMEIBODV PANELS/EXHAUST SYSTEM Remove [he man/law mirror plvol bout (1) BOLI’S Remove the folluwlng' - Bolts - Reerview mirror - Seat rubber plate - Seal rubber Remove the upper fairing lower cover {page 187M Remove the screws and arr guides. Remove the upper fairing mounring bolls. Ramove the screw and fuse box cever (page18-18). Slightly open both srdas 01 the upper fairing rear ends, men pull the fairing forward. Diwonnem me turn signal connectors. Release the retaining tabs and remove me headlight socket Remove the upper fairing assembly and Windscreen. FRAME/BODV PANELS/EXHAUST SVSTEM DISASS EMBLYIASS EMBLV Remove the screws and headlight (2) HEADLIGHT Remove the screws and d‘sassemble Ihe upper fairing, Pull our ")0 mm slgnal wire from the wire guide groove. Remove "\e ‘um signal unit mouming nu! and setting plme. Remove me screws and Inner cowl. Assembly is in the veverse order 0' dlsassemblv. (“NUT FRAME/BODY PANELS/EXHAUST SVSTEM |NSTALLATION l2) BOSSES/GROMMETS Install the windscreen ‘ Connect the [urn signal connectors and headlighi sockel, Install the upper (airing, aligning Ils basses with [he grom- mm. Engage the windscreen iabs With (he upper lairlng s|ols se» cursly as Shown. lnsiall the upper lainng assembly and windscreen, ll) TABS/SLOTS Install the upper fairing mounting bolts. lnnall the screw and luse box cover (page 1871B). lnnall the air guides and screws Insiall the upper (airing lower cover (page 18-5). FRAME/BODY PANELS/EXHAUST SYSTEM Install the left seat rubber With the mark "MT4-L" lacing uut, Install the left sear rubber plate with the marked side in and each arrow mark pointing lurward and down Install the rlght seat rubber with the mark 'MTLR" lacing out. Install the right seat rubber plate with the marked side out and each arrow mark painting torward and down (1) SEAT RUBBER Install the rearvrew mirror and tighten the bolts‘ Install the rearview mirror prOl boot. Install the rearview mirror inner covers aligning its tabs with the slots. Install and tighten the screws. in ARROW MARKS I (1) BOLTS (2) INNER COVERS”) ALIGN ’ \ FRAME/BODY PANELS] EXHAUST SYSTEM REAR FENDER A ‘1’ CONNECTORS (3) REAR FENDER A REMOVAL] INSTALLATION Remove the tail cowl (Page 23) Disconnem the turn signal, brake/tail ltght and |icanse light connectors. Remove the bolts] nuts and rear lender A. lrmallatian is in the reverse order of removal. NOTE - At turn gnal unit and licence light unir installation, I route the wures as shown J REAR FENDER B REMOVAL] INSTALLATION unmove the suds cover (page 272). Remove the bolls and left rear footpeg holder. Rumove the bolts, nut and la“ reflector. Remove the screws Relaase the rear brake truss from clamps on rear lender B. Remove the screws. FRAME/BODV PANELS/EXHAUST SYSTEM Remove the rear fender B backward to the left. m,— lnstelletlon is tn the reverse order oi removal. Torque: LESS THAN ; 7 . , » .2 - Reufootpeg holder bolt 2 N m (2 7 kg m 0 Ib '0 mm (023 in, NOTE - After clamping the brake hose with rear clamp on the rear fender 8, make sure the clamp opemng is less than 7 mm (0.23 In), EXHAUST SYSTEM - Do not undo. the exhaust system while MUFFLER REMOVAL] INSTALLATION Remove the side feirlng (page 2-3l. Loosen the two exhaust pipe band bolts, Remove the muffler mounting bolt. nut and muffler. (3) MUFFLER Remove the muffler packlng. (1) BAND BOLTS Muffler installation is In the reverse order of removal. (“WASHER (2) FLANGE COLLAR Torque: Muffler mounting bolt: 27 N-m (2.1 kg-m, 20 lb-fl) Exhlust pipe blnd bolt: 21 N-m (2.1 kg—m, l5 lb-ft] NOTE - Always replace the muffler packing with a new one Lrfi ,h— EXHAUST PIPE REMOVAL/INSTALLATION Remove the upper fairing [page 2-4) Pew MB] (3) MUFFLER CAUTION [ - Be nreful not to damage the radi-tor tins. I Remove the radiator mounting bolts and release Ine grom- met on the radiator top from the bracket boss. Move the radiator iorward and secure it (page 35). Remove the muffler, Remove the exhaust pipe iolnt nuts Remove the exhaust pipe mountmg boll, nut, exhaust pipe and gaskets. (2) BOLT/NUT (3! EXHAUST PIPE l1) NUTS 2-10 FRAME/BODV PANELS] EXHAUST SYSTEM Exhaust pipe installation is in the reverse order 0! removal. NOTE - Tighten all exhaust pipe joint nuts and clamp bolts Ioosaly. Always lighten the exhaust pipe joint nuts first. then the clamp bolt, . Tighten the joint nuts in order as shown. 'm nut: 20 N-m (2.0 kn‘m. ‘II "’41) Exhaust pipe band bolt: 21 N-m (2.1 Ila-m. 15 lb-lt) 2-1 1 3. MAINTENANCE SERVICE INFORMATION 3-1 EVAPORATIVE EMISSION CONTROL MAINTENANCE SCHEDULE 3_3 SVSTEM (California type only) 3~15 HJEL LINE 34 DRWE CHAIN 3-16 THROTTLE OPEflA'nON 34 3““ "-U'D 3'19 maunEron CHOKE 3-5 ME MD WEAR 3'2” AIR CLEANER 35 BRAKE SYSTEM 3-21 SPARK PLUG 3-8 BRAKE UGHT SWITCH 3-21 VALVE CLEARANCE 3:, HEADLIGHT AIM 3-21 ENGINE OIL/OIL FILTER 3-11 CLUTCH SYSTEM “'2‘ CARBURETOR SYNCHRONIZATION 3-12 3'“ STAND 3'22 ENGINE IDLE SPEED 3-14 SUS'ENS'O" 3‘23 RADIATOR COOLANT 3-14 NUTS, BOLTS, FASTENERS 3-23 COOUNG SVSTEM 345 WHEELS/T IRES 3-24 SECONDARV AIR supva SYSTEM 5mm“ "EA” ”flames 3‘” (California type only) 3-15 SERVICE INFORMATION ' SPECIFICATION ITEM SPECIFICATIONS Throttle grip free play 2 — 6 mm (1/12 — 1/4 in) Spark plug Standard NGK NIPPONDENSO CRSEHS U27FER9 Spark plug gap 0.8 — 0.9 mm (0.031 - 0.085 in) Valve clearance IN 0.18 1 0.03 mm (0.006 :t 0.001 in) EX 0.22 :I: 0.03 mm (0.009 t 0.001 in) Engine oil capacity at draining 3.4 l (3.8 US qt, 3.0 Imp qt) at diuesembly 4.2 l (‘4 US qt, 3.7 Imp qt) at oil filter change 3.7 l [3.9 US qt, 3.3 Imp qt) Carburetor vacuum diflerence . Within 30 mmHg (1.2 iani Baae carburetor1N03 Carburetor idle speed ‘9 state, Canada type 1.200 t 100 rpm California type 1,100 2 100 rpm Drive chain slack 15 — 25 mm (5/8 - 'I In) Drive chain silo/link ax ‘ axsoMFO/wa DID DID50V‘I108 3-1 MAINTENANCE ITEM SPECIFICATIONS Ecrmcn lever (ree play 10 ~ 20 mm (3/3 — 3a in) Cold tire pressure Up to 00 kg (200 lb) Front E 36 psi (2.50 kg/cm‘. 250 kPa) m“ 7 Rear ‘ 42 psi (2.90 kg/cm’, 290 kPa) Up to maximum Front 36 psi (2.50 kg/crn‘. 250 kPa) [weigh' apathy fares: 42 psi (2.90 kg/cm'. 290 kPa) Minimum tire tread depth Front 15 mm (0.06 in) .. Rear 20 mm (0.08 in) Tire site Front 120/60 ZR 17 Rear 160/60 ZR 17 fire brand 7 Bridgeslone Front BT50F RADIAL (3 Rear BTSDR RADIAL J Michelin Front MACADAM 90X [Rear MACADAM 90x TORQUE VALUES Spark plug Cylinder head cover bolt Camshaft holder bolt Ignition pulse generator cover can Oil drain bolt OII filter cartridge Drive chain adjuster luck nut Raar axle nut Side stand pivot bolt . Side stand pivot lock nut ' Side stand bracket bolt TOOLS Oil filter wrench Drive chain cutter Link plate holder 12 N-m (1.2 kgrm, 9 lb-(t) 10 N-m (1.0 kg-rn, 7 lb-(t) 12 N-m (1.2 kg-m, 9 Ila-ft) 18 N-m (1.8 kg—m, 13lb-1t) 30 NW! (3.0 kgAm,22lb~1tl 10 NH“ (1.0 kgAm, 7 Ib—ft) 22 N-rn (2.2 kg-m, l6 Ib~itl 95 MM (95 kgAm, 691b-ft) 10 N-m (1.0 kg-m. 7 IIHtl 30 MM (30 kg-m, 22 lb-(t) 55 N~m (5.5 kg-m.401b—ft) 07HAA — PJ70100 Apply oil to the threads. Apply grease to the threads. 07HMH — MR10102 or 07HMH — MR10105(U.S.A.onIyl 07NMH - MWOOIIO or 07NMH — MW0011A (USA. only) MAINTENANCE ' MAINTENANCE SCHEDULE hrform the PRE-RIDE INSPECTION in the Owner's Manual at each scheduled maintenance period. I: Inspect and clean, Adjust, Lubricata, or Replace if necessary. I: Replace. C: Clean, L: Lubricata, A: Adjust The following items require some mechanical knowledge. Certain items [particularly those marked ' and "i may require metechnicel intermation and tools. Consult an authorized Honda dealer, FREQUENCY NOTE ODOMETER REAOING INOTE 1) Mar m G X1,000mi 0.6 4 a 12 16 20 24 mg. ITEM X1,000km 1 s 12 Is 24 so as . FUEL LINE I | | u - THROTTLE OPERATION i W I I I M . CARBURETOR CHOKE V I I I 3-5 AIR CLEANER NOTE 2 R R 3-5 SPARK PLUG I R I R I R 3-3 E VALVE CLEARANCE I 3-7 ENGINE OIL R R R R 3-11 fl ENGINE OIL FILTER R R R R 3-11 B «- CARBURETOR I I I 3-12 SVNCHRONIZATION . ENGINEIDLE SPEED I I I I I I I 3-14 RADIATOR COOLANT NOTE 3 | I R 3.13 - COOLING SVSTEM I I I 3-15 . SECONDARY AIR suPPLv NOTE A . I I I 3-15 SVSTEM . EVAPORATIVE EMISSION NOTE A I I 3-15 CONTROL SYSTEM - DRIVE CHAIN 3-16 BRAKE FLUID NOTE 3 3-19 BRAKE PAD WEAR 3-20 BRAKE SVSTEM 3-21 - BRAKE UGHT SWITCH 3-21 . HEADLIGHT AIM 3-21 CLUTCH SYSTEM 3-21 SIDE STAND 3-22 . - SUSPENSION _ , _ V - I , 3-23 . NUTS, BOLTS, FASTENERS « ' n v , ,' m ‘ j , ; ’ 3-23 on WHEELS/TIRES ‘ , *- * m5. .. y, , I 3.22 n STEERING HEAD BEARINGS - ‘ ; Hug: g I ' _ 1 I ,-: , 3-24 . At higher odometer readings, repeat at the Irequancv interval established here. 1. Service more frequently when riding in unusually we: or dusty area. 3. Re lace every 2 years, or at indicated odometer interval, whichever comes first, Replacement requires me- chamcal skill. b. California type only. MAINTENANCE FUEL LINE (1) FUEL LINES ‘l INSPECTION Remove the side cover (page 22). Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary. Forthe tube routing, see page 1720. THRO'I'I'LE OPERATION Check for any deterioration or damage to the throttle cables. Check the throttle grip Ior smooth operation. Check that the throttle grip returns from the toll open to the lull closed pOSI- tion smoothly and automatically in all steering positions. It the throttle grip does not return properly, lubricate the throttle cable. overhaul and lubricate the throttle grip housr mg. For cable lubrication: Disconnect the throttle cable: at their upper ends lpage 12-3). Thoroughly lubricate the cables and their pivot points with a commercially available cable lubrir cent or a llght weight OII. It the throttle grip still does not return properly, replace the throttle cables. l1) FREE PLAY 2»S mm tion and may lead to 3 Ian at throttle control while ridlng. With the engine idling, turn the handlebar all the way to the rrght and left to ensure that idle speed does not change. If idle speed increases, check the throttle grip free play and the throttle cable connection. Measure the throttle grip free play at the throttle grip Ilanga, Filo ploy: Z - 6 mm (1/12 - 1/. in) Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster. Loosen the lock nut and turn the adjuster to obtain the tree play. Tlghten the lock nut and reposition the adjuster boot prop- erly alter the adjustment has been made. 3-4 Major adjustments are made with Ihe lower adjuster. Remove the air cleaner base (page 5-4). Loosen the lock nuts and turn the adjuster to obtain the tree play. Tighten the lock nuts after the adjustment has been made. Rochock the throttle grip tree play. CARBURETOR CHOKE STARTING ENRICHMENT (SE) VALVE The choke system uses a fuel enrichenlng circuit controlled by an SE valve. The SE valve opens the enrichening circuit via a cable when the choke lever on the handlebar ls moved back Chock tor smooth operation of the choke lever. lithe operation :5 not smooth. lubricate the choke cable. overhaul and lubricate the Choke lever. For cable lubrication: Disconnect the choke cable at the up- per and (page 12-6). Thoroughly lubricate the cable and its pivot point with a commercially available cable lubricant or a lightweight oil, Remove the air cleaner base (page 54). Move the choke lever all the way back to the fully open posir tlon. Make sure the SE valve is open by trying to move the choke lever on the carburetor. there should be no tree play. Adjust the tree play by loosening the choke cable clamp on the carburetor and moving the choke cable casing so the choke lever is fully open, Tighten the clamp, Push the choke lever lully closed. Make sure the SE valve is hilly closed by checking lor free play In the cable between the lever on the carburetor and cable casing. Install the removed parts in the reverse order of removal. AIR CLEANER NOTE - The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. - ll‘ the motorcycle is used in wet or dusty areas, more frequent inI actions are required, ~ Replace the air cleaner and sub air cleaner as a set. lemon the luel tank (page 2-4), Remove end loosen the air cleaner housing cover screws. Remove the air cleaner housing cover. (ll CHOKE LEVER MAINTENANCE MAINTENANCE Remove the air cleaner and sub air cleaner. Replace the air cleaner according to the maintenance schedule (see page 3-3). Install the removed parts in the reverse order of removal. SPARK PLUG Remove the left and right maintenance covers [page 2-3). Remove the spark plug caps and clean around the spark plug bases. NOTE ~ Clean around the spark plug bases with compressed air before removing, and be sure that no debris is allowed to enter the combustion camber. Remove the spark plugs using the spark plug wrench. In- spect or replace as described in the maintenance schedule (page 33). INSPECTION Check the following and replace il necessary (recommended spark plugs: page 3-1). - insulator for damage ' electrodes for wear - burning condition,coloretion - v dark to light brown indicates good condition. - excessive lightness indicates mallunctioning ignition sys- tem or lean mixture. - wet or black sooty deposit indicates over-rich mixture. (2) SUB AIR CLEANER l1) INSULATOR 2) SIDE ELECTRODE (3) CENTER ELECTRODE 3-6 MAINTENANCE REUSING A SPARK PLUG Clo-n the spark plug electrodes with a Wire brush or spark plug cleaner. Check the gap between the center and side electrodes with a wire-type feeler gauge. If necessary, adiust the gap by bendA In the side electrode carefullyt Iplk plug gap: 0.8 - 03 mm [01131 — 01335 In] CAUTION _ 7 ~ To prevent damning the cylinder head, hend-tigten the spark plug before using a wrench to tighten to the WM torque. Reinstall the spark plug in the cylinder head and hand~ tlghten, than torque to specification Torque: 12 N-m ILZ lrg-m, 9 Ib-ftl REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type feeler gauge (see above). tau-non _ - Do not ovnnlghten the spark plug, I MII and tigten the new spark plug, then tighten it about 1/4 of turn alter sealing washer contacts the seat of the plug hole. VALVE CLEARANCE NOTE - Inspect and adjust the vulva clearance while the enginej II cold (below SSW/95°F), fiemove the cylinder heed cover (page 8-5), “SPECTION Remove the ignition pulse generator rotor cover cep. ‘8 — 0.9 mm 0 031—0.!135in); v. “”9““? I‘ll IGNITION PULSE GENERATOR ROTOR COVER CAP 3-7 MAINTENANCE Turn the crankshaft clockwise, and align the T mark (notch mark) with the index mark on the ignition pulse generator rotor cover. Make sure that the timing merks ('IN' and 'EX') on the cam- shaft sprockets are aligned with the cylinder head upper sur» lace and lacing opposite each other as shown. It thetiming marks (‘IN' und 'EX') on the camshah sprockets lace each other, turn the crankshaft clockwise one full turn (360') and realign the T mark (notch mark) with the index mark. Remove the cam chain tensioner litter sealing bolt and seal» ing washer. Turn the tenaioner shaft lully in (clockwise) and secure it us- ing the stopper tool. This tool can easily be made from a thin (1 mm thickness) piece 01 steel using the dimensions shown below. 15 mm 19 mm 3mm 15 mm 35 mm MATERIAL THICKNESS: 1.0 mm *5 mm Check the valve clearance (or the No.1 and N03 cylinder in take values using a feeler gauge. Insert the leelar gauge between the valve litter and the cam lobe. Valve clearance: IN: 0.16 : 0.03 mm (0.005 1 0.001 In) NOTE - Record the clearance for each valve in case shim selec» tion is required tor adjustment. Turn the crankshaft clockwise 1/2 turn (180°) and make sure the index line on the ignition pulse generator rotor is facing straight up as shown (not aligned with the index mark). Check the valve clearance for the N01 and No.4 cylinder ex- haust valves using a teeler gauge. v-m clearance: EX: 0.22 x 0.03 mm (0.009 i 0.001 In) (1)T MARK (2) INDEX MARK (3) TIMING MARKS (2) STOPPER TOOL <7?” m SEALING aom * c WASHER: (3) TENSIONER SHAFT MAINTENANCE Turn the crankehah clockwise 1/2 turn (180°) and make sure T M theT mark (notch mark) on the ignition pulse generator rotor (1) IIAHK/ 5 (2) INDEX MARK allgne wlth the index mark. Check the valve clearance tor the No.2 and No.‘ cylinder in» Mevalvae using a laeler gauge. Viva deer-nee: IN: 0.16 i 0.03 mm (0.006 t 0.001 in) Tum the crankshaft clockwise 1/? turn (180°) and make sure the Index line on the ignition pulse generator rotor is lacing Irelght up as shown (not aligned with the index mark). Check the valve clearance for the No.1 and N03 cylinder ex- haust valves using a leeler gauge. Vila delete“: EX: on 1 0.03 mm (0.009 t 01101 In) ADJU$TMENT We the cemehafts (page 8-5). We the valve lifters and shims. m (1) VALVE LIFTER - shims may stick to the inside of the valve Iilter. Do not allow the shims to fall into the crankcase. ' Mark all valve lifters and shims to ensure correct reassembly in their original locations. - The valve lifter can be easily removed with a valve lap ping tool or magnet. - The ahlma can be easily removed with tweezers or a magnet. Claen the valve shim contact area in the valve litter with com~ -' araeaed air. Measure the Ihirn thickness and record it. (1) SHIM NOTE - Sixty-five dlflerent ehim thicknesses are available: from 1.200 mm to 2.800 mm in intervals of 0.025 mm. ‘, Mule" the new shim thickness using the equation below. w “I W Weafiefiu~ heeded valve deer-nee W valve eleennee _ Weflmthlekneea MAINTENANCE Example: Recorded valve slur-nu: 0.16 mm Old [him thickneu 1.725 mm Specified valve clu I'I nee: 0.20 mm A : 0.16 - 0.20 o 1.75 A: 1.685 NOTE Verify the new shim thickness by measuring it with a micrometer. Relece the valve sent if a carbon deposit results in a cal- culared dimension at over 2.300 mm. It the valve seat must be releced, re»ceIculete the shim thickness AFTER refacing, Install the new shim on the valve retainer. Apply molybdenum disulfide oil to the valve lifters. Install the valve litter in the valve lifter holes. NOTE - Install unchanged shims and valve litter: in their (vigil nel locations, Install the cernshal‘t and camshaft holders (page 8-21). Rotate the camshahs by rotating the crankshaft clockwise several times, Recheck the valve clearance. Remove the stopper tool. Install the new sealing washer and cam chain teneioner sea|~ ing bolt. Tighten the bolt securely. Install the removed parts in the reverse order of removal, Check that the O-ring is In good condItion, replace it neces- sary. Apply grease to the ignition pulse generator cover cap threads. install and tighten the cap. Torque: 18 N-m [1.8 kg—m. 13 Ib-fl) (3) BOLT (1) CAM CHAIN TENSIONER " ’fl «1) IGNITION PULSE GENERATOR '6‘ Home COVER CAP (2) 0+1an 3-10 ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION a It the engine must be "Amino; do mine work, inele owe the one I: well-ventileted. Nev-t um the engine In en enclosed eree. 7 Start the engine and let it idle lor 2 . 3 minutes, Stop the engine and wait 3 minutes. Remove the dipstick and wipe the owl lrorn the dipstick with a clean cloth. With the motorcycle upright on level ground, Insert the dip- Itick into the slick hole without wrewlng it in‘ Remove the dipstick and check the oil level, llthe level is below or near the lower level mark. remove the oil filler cap and add the recommended oil up to the upper level mark. Immended engine oil: Hond- 6N4 O-etroke oil at equivalent motor oil certified to meet AH service Glennie-lion sF or $6 Vleoaeltv: SAE 10W~40 NOTE - Other viscosities shown in the chart mayrberused when the average temperature in your riding area is within the indicated range. Reinstall the dipstick. For engine DII change, see below. ENGINE OIL AND FILTER CHANGE NOTE - Change engine oil with the engine warm and the motor cycle on its side stand to assure complete end rapid draining. ~ Englne eust eye-tam pert: become vevy hot in! rem-in hot for some time eitev the engine is run lneuleted groves or weit until the engine end exheufl Iyetem heve cooled before handling these parts, Remove the dipstick. Mean oil drain pen under the engine to catch the oil, then remove the drain bolt, MAINTENANCE ll) DlPSTICK V (l) UPPER LEVEL (2) LOWER LEVEL OIL VISCOSITIES (I) DRAIN BOLT 3-11 MAINTENANCE Remove the side (airings (page 2-3). Remove the oil filter using the oil filter wrench. Tool: oil filter wrench 07H“ — PJ70100 Check that the sealing wesher on the drain bolt is in good condition. replace it if necessary. Install end tighten the drain bolt to the specified torque. Torque: 10 Nail (3,0 kg-m. 22 lb-fll Apply oil to the new oil filter O-ring. Install the new oil filter and tighten to the specified torque. Torque: to Mom (La mm, 7 Ira-m Fill the crankcase with the recommended oil (page 3-11). Capacity: 3.1 l (3.6 US at, 3.0 Imp qt) at d g 3.1 l (3.9 US qt, 13 Imp qt) It oil filter change Install the dipstick. Stan the engine and recheck the oil level (page 3-11). Make sure that there are no oil leaks. CARBURETOR SYNCHRONIZA'HON _ a (1) OIL FILTER ’7. (1)0~RING - It the engine must be running to (firm. work, meIre sure the area ie well—vemlleted. Never run the enplne In an enclosed eree. NOTE - I’erform this maintenance with theisngine at normal on eraling temperature and transmission in neutral. Place the motorcycle on a level surlece. Remove the tuel tank (page 2-4). Remove the left and right engine hanger plates. No.1 CVLINDER: Remove the plug and washer (rom the cylinder head intake port. - Remove the rubber up by pinching the one of the cap. Do not pinch the up body or it will be demeged. No.2. I CVLINDER: Remove the rubber caps from the vacuum joint on cylinder head intake port. No.3 CYLINDER: - 48 STATE. CANADA TYPE: Remove the rubber cap (mm the vacuum joint on cylinder head intake port. l‘llPLUG (2) RUBBER CAPS (3) CALIFORNIA TYPE (ll RUBBER CAP 3-12 - “Um“ TYPE: Oleeonnect the No.3 cylinder vacuum tube from the pulse “condery air injection (PAIR) control valve. , Screw the adaptor in the No.1 intake port vacuum hole and connect the vacuum gauge tube to the adaptor, Connect the vacuum gauge tubes to the No.2, 3, A vacuum lolme. WM TYPE ONLV: Oomect the vacuum gauge tube to the No.3 vacuum tube. lint-ll the fuel tank and connect the fuel tube but do nut in» ' fill the luel tank mounting bolts. ' ‘l.Turn the iuel valve ON. Start the engine and adjust the idle need to the specification. ‘fllwzmehnedetype: 1.200 t IDOrpm Calllornle type: 1.400 t 100 rpm a 1 Check the diflaranca in vacuum between each carburetor. ‘metwvewum Menace: Wlthln 30 mm Hg 11.2 in Ha) "NOTE - No.3 carburetor is the base carburetor. ] LSynchreniza to specification by turning the adjusting ecrewe with the phillips screwdriver as shown. ‘ Be cure that the synchronization is stable by snapping the throttle grip several times. Snap the throttle grip several times and recheck the idle epeed and difference in vacuum between each carburetor. met the vacuum gauge and install the removed parts, argue: hanger plate 10 mm bolt : 46 NM- “.5 [94“, 33 39-“) MAINTENANCE (1) SCREW DRIVER MAINTENANCE ENGINE IDLE SPEED NOTE - Inspect and adjust idle speed after all other engine ad- justments are within specifications, - Engine must be warm tor accurate adjustment. Ten minutes of stop-and-go riding is suflicient. Warm up the engine. Support the motorcycle on a level surtace and shift the trans- mission into neutral. Check the idle speed and adjust by turning the throttle stop screw it necessary. Idle speed : ‘9 State, Cert-d- type: 1,200 A 100 rpm Cnlflovnla type: 1,400 1 100 rpm RADIATOR COOLANT LEVEL CHECK Check the coolant level at the reserve tank with the engine running at normal operating temperature. The level should be between the 'UPPEFI' and 'LOWER' level lines with the motorcycle in a vertical positron on a flat, level surface, If necessary, remove the reserve tank cap and till to the "UP- PER" level line wlth a 50-50 mixture of distilled water and entilreeze (coolant mixture preparation: page 674). CAUTION - Be air; to use the proper mixture at until: r to protect the engine. ed wlter. Tap water may come the englne to Check to see it there are any coolant leaks it the coolant level decreases very rapidly. It the reserve tank becomes completely empty, there is a possibility of air getting into the cooling system. Be sure to remove all air Item the cooling system as described on page 6-4. . l1 THROTTLE STOP SCREW 3-14 MAINTENANCE OOOLING SYSTEM , ' _ V, ””5; Cheat the radiator air passages Ior clogging or damage, heighten bent fins With a smell, flat blade screwdriver and mva insects, mud or other obstructions with compressed all or low pressure water. Heleca the radiator it the air flow is restricted over more than 20% of the radiating surtece. For radiator replacement. refer to page 6-8. Chock for any coolant leakage Irom the water pump, water hope and hose joints. . Make sure the hoses are in good condition; they should not mew any signs of deterioration, Replace eny hose that shows any sign of deterioration. Check that all hose clamps are tight. 7 SECONDARY AIR SUPPLY SYSTEM ICaliIornia type only) » Check the air supply hoses between the reed valve end ln- ” pipes for deterioration, damage or loose connoclions, Hallo lure the hoses are not kinked or pinched. ME 7 7 - . lithe hoses show any signs 01 heat damage, remove the ‘ nod valve: and inspect tor damage (page 5738i 4] ’ Mtho vacuum hose between the intake pan and valve bramrloration. damage or loose connections. Min Iurotho hose is not klnked or pinched. - WAPORATIVE EMISSION CONTROL SYSTEM (California type only) [mm tutm between the tuel tank, EVAP canister, EVAP [m control valve, EVAF CAV solenoid valve and carbure- _m fordetorioration, damage or loose connections, WIN EVAF canister for cracks or other damage, Ninth. Vacuum Hose Routing Diagram label and Cable at MIAMI (page 1-20) Ior tube connections. (1) EVAP CAV SOLENOID VALVES (2) EVAP PURGE CONTROL VALVE 3-15 MAINTENANCE DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION - Never inspect and ediuat (It—e drl h n whl engine is running. Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission into neutral. Check the slack In the drive chain lower run midway between the sprockets. Drive chain slack: 15 - 25 mm [5/8 — I In) Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically lor use O-ring chains. Wipe off the exess chain lube. ADJUSTMENT Loosen the axle nut, Loosen both lock nuts and turn both adjusting nuts until the correct drive chain slack is obtained. Make sure the index marks on the both adjusters are aligned with the rear edges oI the axle slots in the swungerm. Tighten both lock nuts. Torque: 22 N-m (2.2 Ito-m. 16 lh-ft) Tighten the rear axle nutv Torque: 96 N-m (9.5 kg-m, 69 lb-It) Recheck chain slack and tree wheel rotation. Lubricate the drive chain with Pro Honda Chain Lube or equivalent chain lubricant designed specifically lor use an O-ring chains. Wipe off the exees chain lube. Check the chain wear label. It the arrow mark 0' the chain adjuster reaches the red zone on the label, replace the drive chain with a new one. Replacement chain: HKSOMFO DIDSOV‘ CLEANING, INSPECTION AND LUBRICATION CHAIN Clean the chain with non-flammable or high flash point sol- vent and wipe It dry. Be sure the chain has dried completely belora lubricating. Inspect the drive chain for possible damage or wear, Replace any chain that he: damaged rollers. loose lining links, or other wise appears unearv-cable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprockets as necessary. (3) ARROW (2) AXLE NUT (2) RED zouat l3) NON-FLAMMABLE OH HIGH FLASH POINT SOLVENT (I) CLEAN v9 (2) WIPE AND DRY ‘ (A as“: 3-16 ,‘7 .Lubricete the drive chain with Pro Honda Chain Lube or Quivelent chain lubricant designed specifically Ior use on O— ‘M nhelna‘ Wipe of! ihe exau chain lube. . v iha drive and driven sprocket teeth for damage or . Replace il necessary. we a new drive chain on worn sprockets. Both chain - aprockeu mun be in good condition, ur the new replace— chain wili wear rapidly. , the attachment boil and nuts on the drive end driven .H » if any are looae, torque them. mmle um I drive chain wi1h a staked master link. III. drive chain (page 3-16], the special tool In shown. 07HMH - MHIMM or 07mm — MR101OB (U‘SJ. onivi ‘hhm MAINTENANCE (1i LUBRICATE (2) PRO HONDA CHAIN LUBE OR EQUIVALENT i1)WEAR- \ (2 NORM (3i DAMAG I ) AL m DRIVE CHAIN CUTTER 3-17 MAINTENANCE Locate the crimped pin ends of the master link lrom the out- side ol the chain, and remove the link with the drive chain CUHSI'. Tool: Drive chein center 07HMN - MR10102 ov 07HMH - MR10105 IU.S.A. only) Remove the drive chain. Remove the excess drive chain links lram the new drive chain with the drive chain cutter. NOTE - Include the master link when you count the drive chain links. Sllndlrd link: 108 llnks Replacement chein: RKEoMFO DIDEOV4 CAUTlON . Never reuu the old drive chain, mentor Ilnk, rnnter Ilnlr plete end o-ringa. Install the new drive chein. Auemble the new master link, O-rings and plate. CAUTION - Insert the mar link lrom the inside of the drive chain, Ind lnetell the plete with the Identification m-rk lacing (1) MASTER LINK E1111 1‘4 DRIVE CHAIN CUTTER (3) MASTER LINK HILINK the amide. Assemble and set the drive chain cutter. Tools: Drive cheln cutter 07HMH _- MRIMOZ er DTHMH - MRID‘IOB IU.s.A. nnly) Llnk pllll holder UTNMH - MWW‘I In or OTNMH — MWN‘I‘IA (U.S.A. only] Make sure that the master link pins are installed properly. Measure the master link pin length projected lrom the plate. Sand-rd length: RK : 1.2 — 1.4 mm (0.06 - 0.06 In) DID: 1.15 - 1.55 mm (0.06 - 0.08 In) Stake the master link pins. in DRIVE CHAIN CUTTER l1) STANDARD LENGTH 3-18 MAINTENANCE ' Mature lhanha pins are makad properly by measuring the humor afth- staked are: using a slide caliper. Mflflflmkodln' > -w -E.$ mm [0.219 — 0.180 In) * . I.” - 5.” mm [0.217 - 0.223 In] M109. chuck the staked area 0' the master link for It any cracking. replace the masler link, O-rings and in. ell-In with I clip-typo mun: link mun m In mm the 0mm or up unlou 1h- rourvolr is " mm my 19'" om. It "In M In»: of lluld, as lhuy on not com- ' vmh «eh other. fink-union mmllll to cum tho Ivstull whnn ‘0. muvolr. fin. fluid on polnud. picnic or mhbor part. I. mm mm whonovor the system in ur- IM fluid leval II low; chuck the brake pads luv bolowi. A law fluid level may be due to wear ‘ pads. II (he brake pads are worn, the caliper ' ‘ bullied out, and this account: tor a low resur- ‘ pm In not worn and (he fluid level is low. all. lav-l float lmm the reservoir whan huh fluld. (1) SLIDE CALIPER MAINTENANCE FRONT BRAKE Turn the handlebar to the Is“ side so thal the reservoir is level and check the front brake reservolr level through the sight glass. It the level (float edge) l5 near the lower level mark, remove the cover, set plate and diaphragm and fl“ the reservoir to the casting ledge with DOT 4 brake llurd from a sealed container‘ REAR BRAKE Place the motorcycle on a level surface, and support it upright. Check the rear brake fluid reservoir level through the sight hole. llthe level is near the lower level mark, remove the side cover and cap (page 2-2) and fill the reservoir to the upper level mark with DOT 4 brake lluid from a sealed container. Reler to page 14-4 for brake fluid replacement/bleeding pro cedures. BRAKE PAD WEAR Check the brake pad for wear, Replace the brake pads if either pad lS worn to the bottom 0' Wear lirmt groove. Relev to page 14-6 [or brake pad replacement. (2) LEDGE 3-20 ‘ BRAKE SYSTEM firmly apply the brake lever or pedal, and check that no air he entered the system. It the lever or pedal feels soft or eponw when operated, bleed eir trom the system. hiepect the brelte hoses and iiitings for deterioration, cracks lid Ilene of leakage. Tighten any loose fittings. Replace ' Finn and fittings as required. Mar to page 14-4 for brake bleeding procedures. : BRAKE LIGHT SWITCH NOTE - The front brake light switch does not require edlust: merit. Adlult the rear brake light switch so that the brake light Wtiimiu on just prior to the brake actually being engaged, ll ‘thl light fIIIs to come on, adjust the swtich so that the light m0" at the proper time. Hold the switch body and turn .liutfluetlng nut. Do not turn the switch body. MDUGHT AIM ; - Ari WV min-mi iiLe'iiJm my blind art-oom- h' fiver-a. or It may tell to light the road tor e “to dis- tame. UTE - Adiiut the headlight beam as specified by local laws Ind regulations, the motorcycle on a level surface. the headlight beam horizontally by turning the hori- lldjusting knob. Turn the adjusting knob clockwise to the beam down. out the headlight beam vertically by turning the vertical no knob‘ Turn the adjusting knob clockwise to direct bum toward the right side at the rider. UTOI'I SYSTEM me the clutch free play at the and of the clutch lever. play: lo- 20 mm (3/8 - 3/4 in) MAINTENANCE l1) BRAKE Hoses‘ l0 7 20 mm 13/8 — 3” in) \ MAINTENANCE Adjust es lollows: Minor adjustments are made at the adjuster near the lever Loosen the lock nut and turn the adjuster. Tighten the lock nLIL CAUTION , 7 , , The ustor may be damaged it it is positioned toe fur out vlng minimal thmd engagement. IV the adjuster is threaded out near its limtt and the correct lree play cannot be obtained. turn the adjuster all the way in and beck out one turn. Tighten the lock nut end make a major adjustment as described helow. Major adjustment ls perlormed at the clutch arm Remove the left side leiring (page 273), Loosen the lack nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening the lock nut. ll proper free play cannot be obtained, or the clutch slips dur- ing the test ride, disassemble and inspect the clutch (see seer tion 9). Install the left side (airing in the reverse order 0! removal. SIDE STAND Support the motorcycle on e level surlece. Check the side stand spring lor damage or loss at tension. Check the side stand assembly tor freedom of movement and lubricate the side stand pivot if necessary. Make sure that the side stand is not bent. Check the side stand ignition cut-off system: - Sit astride the motorcycle and raise the side stand. - Start the engine with the transmi sion in neutral, then shift the transmission into gear, with the clutch lever squeezed - Move the side stand lully down, - The engine should stop as the side stand is lowered. It there is a problem with the system, check the side stand switch (sectionts). l1) LOCK NUT l2) ADJUSTER 3-22 'sSUSPENSION torcyelo nobility and control. Hop-Ir or ropllc. ny mood component: Moro riding, Riding a motor ”do with iaulty suspension increase- your risk oi an m and possible Injury. 'HONT mute action of the forks by operating the front brakes “compressing the lront suspension several times. Mthe onlire iorlr assembly for signs of leaks, damage or ‘ houlutaners. Replace damaged components which cannot be repaired. - Tlglmn all nuts and bolts. erto union 12 for lront lork sen/Ice. ISM upper! the motorcycle securely and raise the rear wheel off Ihl ground. Chick for worn swingarm bearings by grabbing the rear final and attempting to move the wheel side to side. ”bathe bearings ii any Iooseness is noted (section 13D - the action at the shock absorbers by compressing ~ the am a shock absorber assembly for signs ul leaks, or loose fasteners. >- damaged components which cannot be repaired. all nuts and bolts. In nation 13 for shock absorber sen/Ice. , BOLTS, FASTENERS » thIl all chassis nuts and bolts are tightened to their ~ torque valuu (page 1713). am all collar pins, safety clips, hose clamps and cable III In place and properly secured. MAINTENANCE MAINTENANCE WHEELS/TIRES NOTE - Tlre preseure should be checked when tiree are COLD‘ Recommended tlre pressure and (Ire an: unIL psl (kg/c311, kPal Front Rear Cold upmso'x'g 36(2.5o, 250) “(290,290) tire tZolelloed pres- Uptomaximum 36(2.50,250) “(130,290) sure weightcapecity Tire svirzer 120/60 ZR17 160/80 ZR 17 Check the tires Ior cuts, embedded nails, or other damage. Check the front and rear wheels lor trueness (reler to sec tions 12 and 13). Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the folluwing limits. Minimum trend depth: From: 1.5 mm (006 In) Rnr. 2.0 mm (0.08 inI STEERING HEAD BEARINGS N OTE - Check that the control cables do not interfere with henr dleber rotation. Support the motorcycle securely and raise the front wheel off ground. Check that the handlebar moves freely from side [0 side. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (section 12L (1) STEERING HEAD BEARINGS LUBRICATION SYSTEM I2) EXHAUST CAMSHAFT [‘I) INTAKE CAMSHAFT (Id) PISTON (13) CONNECTING (3) OIL PRESSURE ROD SWITCH I‘lZI CRANKSHAFT _ (11) MAINSHAFT (10) OIL COOLER (4) OIL ORIFICE "I (5) COUNTERSHAFT (6) OIL PUMP (9) OIL FILTER F URE R F (8) HESS ELIE VALVE (7I OIL STRAINEFI SCREEN 4. LUBRICATION sverM " SERVICE INFORMATION e1 OIL PAN 4-4 TROUBLESHOOTING 4-2 on. PUMP +5 .on. PRESSURE CHECK 4-3 on. COOLER 4.10 t INFORMATION line ermine must be running to do some work, make sure the area I: well ventilated. "not run the anpine In an I mad tea. The exhaust cent-Ina pniaonoua carbon menexida gas that can cauu lose oi consciouan-a nd may had” death. Run the an no In an open area or with an exhaust evacuation ayatern In an enclosed a " 'lI-Ilenflne oil may cause skin cancer if repeatedly Mt in contact with the skin ior prolonged perioda. Although thin -‘ Inflow unless you handle and oil on a daily bull, It la otill advisable to thoroughly wash your hand: with soap um u soon I! possible that handling used all. KEEP OUT OF REACH OF CHILDREN. aarvlee procedures in this section can be performed with the engine in the frame. moving and installing the oil cooler and oil pump. use care not to allow dust or dirt to enter the engine. = any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. ' rthe oil pump has been installed, check that there are no oil leaks and that the oil pressure is correct. . ell prauura indicator inspection, refer to section 13 of this manual. - TIONS Unit: mm (in) ITEM ST ANDAHD SERVICE LIMIT .5 prenure at oil pressure switch (80'CI176'F) 050.4 kPe (5.0 kg/cm', 71 psi) at 6,000 rpm — tip clearance 0.15 (0.006) 0.20 (0.008) body clearance 0.15 - 0.22 (0.006 — 0.009) 0.35 (0.014) and clearance 0.02 — 0.07 (0.001 — 0.003) 0.10 (0.004) I pump drive sprocket collar 0.0. 31050 - 34.075 (1.3405 — 1.3415) 31.03 (1.35) I m driva sprocket ID. 35025 — 35.075 (1.3789 - 1.3809) 35.10 (1.33) 18 N-m (1.8 kp-m. 13 Ib—itl Apply locking agent to the threads. 15 N-m (1.5 kg-m, 11 lbfl) Apply locking agent to the threads. 12 N~rn (1.2 kg-m, 9 lb-h) Apply sealant to the threads. 8 N-m (0.8 kg-m, 5.8 Ib-ft) 50 N-m (5.0 kg-m, 36 lb-itl Apply locking agent to the threads. 07506 — 3000000? or equivalent commercially available in U.S.A. rI gauge attachment 07510 — 4220100 LUBRICATION SYSTEM TROUBLESHOOTING Oll level low ' Oilconsumprion - External oil leaks - Worn pismn ring or incorrect piston ring installation - Warn valve guide or seal on cantaminetlou - From coolant mixing with oil - Faulty water pump mechanical seal - Faulty cylinder head gasket - Water leak in crankcase No ell prlllurl ' Oil level too low ‘ Oil pump drive chain or drive sprocket broken - Oil pump damaged [pump shaft) - Internal oil leak Low oll pressure - Pressure reliel valve stuck open . Clogged 0| lilter and strainer screen - Oil pump worn or damaged - Internal oil leak - Incorrect all being used ' Oil Ieveltoo low High eil presume - Pressure relief valve stuck closed - Plugged oil filter, gallery. or metering orilice - Incorrect oil being used Selzed engine - No or low oil pressure - Clogged oil orifice/passage - Internal oil leaks - Non-recommended oil used OIL PRESSURE CHECK Remove the side leiring (page 2-3). NOTE - "the engine is cold, the pressure reading will be abnor- mally high. Warm up the engine to normal operating temperature before starting this test. Slop the engine. Remove the switch cover and disconnect the oil pressure switch wire by removing the screw. Move the oil pressure switch and connect an oil pressure gauge attachment and gauge to the pressure switch hole. Todl: ca peeaun gauge attachment 07510 - 0220100 on paeeura gauge 07506 — 3000000 Heath-lent commercially available In USA. Check the oil level and add the recommended oil ii neces» any (page 3-11). M the engine and check the oil pressure at 6,000 rpm. uni-nun mur. (at) tum, 71 pell at 6,000 rpm (we/11am low the engine. aealant to the pressure switch threads as shown and 1! Wm [11 kg—lll, 9 b-ft) the all preeeure switch wire and install the switch the englne. the! the oil pressure indicator goes out after one or mm. ll the oil pressure indicator stays on, stop the Immedietely and determine the cause (p393 13.10). LU BRICAHON SYSTEM ‘ 1) COVER ‘ (2) SCREW (2) OIL PRESSURE GAUGE Do not apply to the thread head. 3 - ‘ mm C— (0.1 — 0.2 in) LUBRICATION SVSTEM OIL PAN REMOVAL Remove the exhaust pipe (page 2-10). Drain the engine oil (page 11!). Remove the oil pan bolts. Remove the oil pan and gasket. Remove the pressure relief valve. Remove the oil simmer and packing Check the oil strainer {or damage or clogging. Clean the oil strainer. RELIEF VALVE CHECK Check the operation of the pressure reliel valve by pushing on the piston. Remove (he relief valve snap ring and disassemble the relief valve Check the piston for wear, sticking or damage Check the spring and piston lor wear or damage, Check the valve lor clogging or damage. Clean the remaining parts and assemble the rails! valve in the reverse order of disassembly, (“BOLTS 7/ (3) GASKET (1) PACKING . (l) PRESSURE RELIEF VALVE (3) VALVE (2) SNAP RING (1) PISTON (2) SPRING LUBRICATION SYSTEM NSTALLATION Apply oil to the new O-ring and install the pressure relief valve groove, and install the relief valve to the crankcase (2) PRESSURE RELIEF VALVE Conn new pecking With the engine oil and Install into me erlnlrnu. lllltlll the oil strainer by aligning the crankcase slot and drain-r uh. (3D ALIGN mum: new gasket and oil pan (1) gGASKET l2) OIL FAN mum- bolts. Tighten the bolts in a gradual, crisscross pal- m. xlIauIt pipe (page 2-10). ”In mine with oil (page 3-12). thlt than are no oil leaks and that oil pressure is corv LUBRICATION SVSTEM ‘l DRIVE SPROCKET OIL PUMP H REMOVAL Drain the engine oil (page 3»11)i t Remove the clutch (page 973)‘ Remove the oil pump driven sprocket bolt/washer. Remove the oil pump drive and driven sprocket and chain as a set. Remove the oil pump drive sprocket collar. Remove the three mounting bolts and the oil pump. (2) OIL PUMP DISASSEMBLY i1) BOLT Remove the oil pump cover bolt and cover. Remove the dowel pin. Disassemble the oil pump and clean the removed pans‘ (2) COVER INSPECTION ROTOR TIP CLEARANCE: PUMP aopv CLEARANCE: ll any portion of the oil pump is worn beyond the service limit, replace the oil pump as an assembly, Measure the rotor tip clearance. Service llmh: 0.20 mm [0.008 In) Measure the pump body clearance. Service limit: 0.35 mm (0‘01! In) 4-6 LUBRICATION SYSTEM Measure the oil pump and claarance END CLEARANCE: Savio- Iimi‘: 0.10 mm (0.0!” in) Manure the oil pump drive sprockel collar. “Me. limit: 0b.: 34.03 mm (1.35 In) ’4qu" the oil pump dnva sprocket. ”who Ilmlt: I.D.: 35.10 mm (138 in] (2) PU NCH MARK (10) OUTER ROTOR (9) INNER ROTOR (6) BOLT (8) DRIVE PIN (7) SPACER LUBRICATION SVSTEM Before assembly, clean all disassembled parts thoroughly wnh clean engine oil, Install the outer and inner rotors into the pump body with the outer rotor punch mark Iacmg the pump covert Insert the rotor shaft and "1518” the drive pin by aligning the slots in the inner rotor. Place the spacer into the inner rotor groove. Install the dowel pin in the oil pump body. Install the oil pump cover. Install and tighten the oil pump cover boll, Torque: B N-m (0‘8 liq-m, 6.8 lb—ft] 11) PUNCH MARK [2) OUTER ROTOR (4) PUMP BODV 3 II) ALIGN I2) DOWEL PIN I1) BOLT I3) INNER ROTOR I‘ll ROTOR SHAFT l2) SPACER 0 I3) DRIVE PIN l1) PUMP COVER INSTALLAHON Align the rotor shaft lug with the water pump shaft groove Ind install the oil pump into the crankcase. Inn-ll and tighten the oil pump mounting bolts‘ junll the drive sprocket collar over the mainshaht Ithe oil pump drive and driven sprocket and chain as an bly with the 'OUT' mark on the driven sprecket lecing the flat surfaces of the driven sprocket hole and oil Ihlfl end. LUBRICATION SVSTEM (2) OIL PUMP 4-9 LU BRICATION SYSTEM Apply lacking agent to the driven sprocket bolt threads. and install the bolt with the washer and tighten it securely. Torque: 15 Ntm (1.5 kg-m. 11 lb-n) Install lne clutch (page 9-11). Fill the engine with oil (page 3—12). Check that there are no oil leaks and that oil pressure Is cor- rect. OlL COOLER REMOVAL Remove the exhaust pipe (page 2-10). Drain the engine on (page 3-11). Drain the coolant (page 6‘), Remove the oil filter (page 3-12). i Remove the pulse secondary air iniection (PAIR) control valve (California type only: page 5-38). Remove the water hose. Remove the oil cooler mounting bolts Remove the oil cooler assembly and O~ring. » 1 (1) OIL COOLER Remove the O—rings and joint collars (rem theacrankcase. - 1 / I , (3i 0»RINGS/JOI NT COLLARS ‘ (2i o-nws 4-10 LU BRICATION SYSTEM '. I 'MASSEMBLV ("CASE * 5- ‘ mm: oil cooler case bolts and sealing washer. .' anolhc oil cooler case and O-ring‘ "' - (3) O-RING II) BOLT/ SEALING WASHER the bolt: and washers, (1) BOLTS/WASHERS the oil cooler. Rh. Grinas and joint collars from the oil cooler I2) OIL COOLER / (3) O-RlNGS/JOINT COLLARS I2) OIL COOLER I3) WASHER I0 BOLT (5) OVRING (6) BOLT (10) JOINT COLLAR (sx'o-HING ', m) SEALING WASHER ‘ (8) OIL COOLER CASE (7) SEALING WASHER LUBRICATION SYSTEM Install the 10an collars‘ Apply oil lo tha new O-nngs and ins‘all into the oil cooler base. Install the oil cooler with the direction arrow facing down. g FIOARINGS/JOINT COLLAns Install and lighln the bolts and washers (3) DIRECTION ARROW (2) OIL COOLER‘ (1)0 7. O-RING Apply oil lathe new 0an and lush)" into me all cuoler case. (2) CASE lnstall the all cooler case‘ ‘1’ BOLT lnstall the OII cooler case bolts and sealing washerv Tagmen the bolts. ..I>'1;‘..mn (2) BOLT/ SEALING WASHER INSTALLATION Apply oil to the new O-ringa and install onto me ioim collarsv Install the joint collar: to tha crankcase as shown‘ 4-12 LUBRICATION SYSTEM Apply all (0 ma new O-ving and inuali into me oil cool-r hm. III." tho 0“ cool-r ummblyfl ‘ C'HWMIMM oil ooolur mounting bohsv Conn-u in Mr hm to (he I cooler. hill" the oil filler (page 3-12). Inmll (M cxhlun pipe (page 2-10). - Flll "II main. with oil (page 3-12). HI! Ind blood the cooling system (page 6-5)‘ MIMI than: are no oil leaks and that on pressure is cor- nu. FUEL SYSTEM m m 3 3 m 9 k 5 U .m N 5 4 5. FUEL SYSTEM 5‘1 PILOT SCREW ADJUSTMENT 5-22 5-3 HIGH ALTITUDE ADJUSTMENT IU.S.A. only) 5-23 DIRECT AIR INTAKE (D.A.I.I SYSTEM 5-25 5-5 SECONDARV AIR SUPPLY SVSTEM (Calllornla type onlyl 5-38 _ 5-13 EVAPORATIVE EMISSION CONTROL a» .4. SYSTEM (Celflornie type only) 5-39 uhwmmmmmwmwmwn IhmMMmhnhWMmM-nfimhm Mum-mmmoddegudtatn-yoetuele-oitheeonadeuenmand ”hmhnwnwm an uhauetevaeueflonaymn lnan «reload area. mammmrmemmwmaumm uhleto atlelr or bind, hhedv‘leleeontnl. Iva-I “but! am. Smoking or allowing flames or aperlu in the work area or where gasoline is stored can hear W. u Mme the WI More cleaning alr end IueI passage: with compreeud air. The diaphragm be damaged. . ,yehlde II no he noted Ior more then one month. drain the float bowls. Fuel IeIt in the float bowie may cause . In multlng In hard naning or poor driveabillity. - BM: we and inatallation, refer to Section 2. ‘ pump Inapection. reIer to Section 18. Mnbllng the carburetor, place an approved iuel container under the carburetor drain tube, loosen the - drain ecrew end drain the carburetor, I “en-bung the fuel eyatem parts, note the locations at the O-rings, Replace them with new one: on reassem- ‘ retrieving the carburetor, wrap the intake ports of a engine with a shop towel or cover them with a piece oi tape to monnlgn material Irom dropping into the engine. Be sure to remove the cover when reinstalling the carbure- ‘ Mug the direct air intake system, follow the steps in the troubleshooting flow chart (page 5-26]. “‘ need In the direct intake system are numbered (or identification When connecting one of these hoses, the hm number wrt the Hose Routing Diagram Label on page 533, for its proper routing. used in the aecondary air supply and eveporative emission control system (California type only) are numbered r A ~ on. When connecting one of these hoses, compare the hose number with the Vacuum Hose Routing Label on the air cleaner housing cover or page 1-31, for its proper routingt FUEL SVSTEM SPECIFICATIONS ITEM SPECIFICATIONS Carburetor type V Constant velocity 2;;buretorIITnztae bore 36 mm (1‘4 in) Carburetor identification 49 star; type fl 7 7w 1 VP61A "“mb‘" California type l VPszA Wéa¥nada type VPBOA Main jet 49 state, Canada type No, 1/4 carburetor: 0135. No.2/3 carburetor: #138 California type #135 Slow jet 7 V 7 H 0 no Filot screw initial/final opening See page 522 Ti‘gh altitude adjustment See page 5723 Float level 137 mm (0.54 in) Idle 5.3;; 7 fi 49 states, Canada type 1.200 1 100 rpm California type 1.“)0 : 100 rpm TOOLS Carburetor Iloet level gauge Vacuum/Pressure pump Vacuum pump Pressure pump Pilot screw wrench Pilot elbow wrench Pilot screw wrench or U.S.A. only Pilot screw wrench Adjustable guide 07‘01 — 0010000 A937X — 0‘1 — XXXXX or ST— AH—ZGO — MC7 (U.$.A‘ only) ST— AH — 255 — MC7 (U.S.A. only) 07KMA — MSGO101 with 49 state, Calilurnia type 07PMA — M22011!) J 07508 — 4220101 Canada type D7MMA — MT30|0A WIII‘I D7PMA - MZZDHA TROUBLESHOOTING NOTE Engfne earth but won't etart - No fuel in tank - No fuel to carburetor - Fuel filter clogged - Fuel line clogged - Fuel level fanlty - Fuel tank breather tube restricted, 49 state/Canada Wool - Evaporative emission tube No.1 restricted (California wee) - Too much fuel getting to the engine - Air cleaner clogged - Flooded carburetor , - Intake air leak ‘ - Fuel contaminated/deteriorated -l¢l close-d I llnpfoper starting enrichment valve operation Mn: enrichment valve circuit clogged Inpmpar throttle operation . Newark at plug (ignition system faulty) we ml evetern feutty (California type only) ‘ the efhlaeion control system faulty Iv mom faulty (California type only) - purge control valve faulty oomrol eyetem faulty F When checking the direct air intake system. follow the steps in the procedure on page 5-26. FUEL SVSTEM Engine etalla, hard to start, rough Idling - Fuel line restricted ~ Fuel mixture too lean/rich Fuel contaminated/deteriorated - iets clogged Intake air leak Idle speed misadiusted Float level misedjusted Fuel tank breather tuba restricted (l9 state/Canada W99) Evaporative emission tube No.1 restricted (California type) ‘ Pilot screw misadjustad Starting enrichment valve circuit clogged Thermo valve stuck open Thermo valve stuck closed Ignition system malfunction Emission control system faulty (California type only) - Evaporative emission purge control valve faulty - Hose of the emission control system faulty Afterburn when engine braking le ueed - Lean mixture in slow circuit - Air cut-off valve malfunction . ICM stops ignition intermittently to prevent over rev- olution (rev limiter functioning) Backflring or rn'rafirlng during acceleration - Ignition system malfunction - Fuel mixture too lean - ICM stops ignition intermittently to prevent over rev- olution (rev limiter functioning) Poor performance (drive-blllfty) and poor fuel economy - Fuel system clogged ' Ignition system malfunction - Emission control system faulty (California type only) - Hose of the emission control system faulty FUEL svsrsm AIR CLEANER HOUSING/ DIRECT AIR INTAKE (D.A.|.) DUCT REMOVAL/INSTALLATION Remove the arr cleaner housing cover and arr cleaner (page 3-5), Remove the screws. Disconnect the cylinder head cover breather lube and ter (1) TUBE move the air cleaner base , » Drsconnect the sub~arr cleaner lube and air vent lube horn the direct air intake (D.A.l.) duct. Remove the trim CIIDSV Remove the radiator mounting bolts and D.A.Ii duct mountr mg screws Disconnect the fan motor connector. Remove the upper iairrng (page 24). a (2) FAN MOTOR CONNECTOR FUEL SVSTEM Release the grommet on the left side radiator top from the (1) FILLER NECK bou. Mm the hook on the filler neck irom the hook. Month: radiator down and secure it With pieces ol strings WG—5)- Meve the D.A.I. duct. Mlellon is in the reverse order of removal. (2) mm. oucr ‘ICPECTION (1) DAL DUCT Wm. D.A.|. duct and air inlake tract lor signs of deterioV mm or Iir passage clogging, Winems, mud or other obstructions with Compressed * or lmv pressure water (2) AIR INTAKE TRACT RETOR REMOVAL In CLEANER TUBE the llr cleaner base (page 51) the No.15tube (California type only) lrom the air 7. math. sub-eir cleaner tube lrom the sub-air cleaner‘ the No.8 tube from the tube ioiut‘ IN fuel lube from the tube joint. FUEL SYSTEM Loosen the cable clamp screw and disconnect the choke cable "am the carburetor. Remove the throttle stop screw from the clamp 7\ Disconnect the No.5 and Not" tubes from the EVAP purge ' control valve (Celilomie type onlylt Disconnect the throttle position sensor connector. (1) THROTTLE 510}: (2) No.5 TUBE CV” _ / , :i w r ‘1‘ i (A) THROTTLE SENSOR CONNECTOR 13) No.11 TUBE Disconnect the carburetor healer tube tram the water pump. Disconnect the carburetor heater tube from the thermostat (1) CARBURETOH HEATER TUBE velvet 5-6 FUEL SYSTEM the bolts, right angina hanger plate and collar. (1) BOLTS (2) COLLAR 13! RIGHT ENGINE HANGER PLATE Inch inuulntur band screw at cylinder head side as (1) BAND SCREWS (CVLNDER HEAD SIDE) 0|. 'mlulatou fvom the cylinder head while carefully Inc-murmur assembly. flu chroma cables from the throttle drum and re- uibumor assembly, FUEL SYSTEM CARBURETOR DISASSEMBLY “’ SCREWS ‘2’ Locfinms NOTE ' vacuum chambers, float chambers and pilot screws can be serviced wnhout separetmg the carburetors. - Keep each carburetor's parts separate trom the other's so you can Install the pens In their ongmal positlons. ‘ Bend up the lock plate tabs and remove the screws Remove the air chamber and air tunnel assembly. Remove the Owings. (3) AIR CHAMBER/FUNNEL/OVRING Disconnect the sub~alr cleaner tube and alr vent tubes ham (2) AIR VENT TUBES the carburetor. DISCDHHECI the No.5 tube loint (Calllornla type only) from the vacuum tubes. (3) No.5 TUBE JOINT (1) SUE-AIR CLEANER TUBE Remove the carburetor heater tube, fuel tube and drain (llCARBURETOR HEATER TUBE H) No.11 TUBE tubes. Remove the No.1! tube (California type only), (3) FUEL TUBE 42) DRAIN TUBES Loosen the Insulator bend screws and remove the Insulators. (1) SE VALVE ARM (2) SCREW Remove the lollowmg: . SE valve arm screws . Plastic washers . SE valve arrn - Plastic collars - Spring (A) COLLAR/WASHER (3) SPRING 5-8 FU EL SYSTEM -_ Lao-In the carburetor connecting nuts gradually and alter l1) CABLE HOLDER "My the nuts and choke cable holder. \ (2) NUTS the connecting bolts and separate the carburetors. [1) CONNECTING BOLTS 4 I Do not lose the three synchronixation adjusting springs ltd two thrust springs, I Do not damage the tuel and air joint pipes. the vacuum tubes (California type onlyl and throttle . (“VACUUM TUBE ‘ WtNoB carburetor only). ‘ (Z) THROTTLE STOP SCREW the three screws and vacuum chamber covert (1) SCREWS FUEL SYSTEM Remove the diaphragm spring. diaphragm/vacuum piston. (1l SPRING Check the piston [or smooth operation up and down in the carburetor body. (2) DIAPHRAGM/VACUUM PISTON Screw a proper 4 mm thread screw in the jet needle holder as [1) 4 mm SCREW shown and pull out the jet needle holder with e pliers. NOTE V - Be cerelul not damage the diaphragm, i - Do not remove the jet needle holder by pushing on the L jet needle‘ 12) JET; NEEDLE HOLDER Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. Check the diaphragm for damage, pin holes, wrinkles or hands Replace these parts il necessary (1) DIAPHRAGMNACUUM PISTON Air will leak out 0' the vacuum chamber if the diaphragm is damaged in any wavveven a pin hole, ‘\ (2i JET NEEDLE Remove the three screws and the float chamber. (2) FLOAT CHAMBER l1) SCREWS FUEL SYSTEM the float pin, flout end float valve. (l) FLOAT f2) FLOAT VALVE I - thefloctfor damage, deterioretlon or fuel in the float, ' , the float valve and valve seat for scoring, scratches, fl) FLOAT VALVE ~ Old-mace. _ thetip cf the float valve where it contacts the valve ‘ ht mapped weer or contamination, or contaminated valve does not sent properly and . lvflood the carburetor. “ (ll SLOW JET f3l PILOT SCREW I m with care. They can easily be scored or ' jet, needle jet holder end slew jet. - mm are factory ore-set and should not be - mine the carburetors ere overhauled. J (2) MAIN JET/NEEDLE JET HOLDER I I. pllm let-w sen will occur If the pilot 4 5w walnut the "It, mew in and carefully count the number of .iefi lightly. Make e note of m: to use as e refer- ‘ tent-lung the pilot screw. elm Icnwa and inspect tham. "M an worn or damaged. h for wear or damage. with non-flammable or high flash solvent and . convened airt FUEL SYSTEM Remove the SE valve nul, spring and valve. (r) VALVE (2) VALVE NUT Check the valve and dust seal for wear or damage, Check the spring lor damage or lalrgue (4) SPRING (3) DUST SEAL Disconnect lhe vacuum lube. Remove the screw, alr culrofl valve assembly, Orrings and (I) VACUUM TUBE (2) AIR CUT~OFF VALVE air jet, u (31) SCREW Visually check me following: (1) AIR JET - the air jet for clogging or restriction - the O-rings for damage, ( i O (2) 0~R|NGS fAUYIQN Y m FUEL STRAINER - cl ninn the air and luel puugu wnh - place of wire / g L will darn-go the carburetor body, ’ , I Blow open all air and luel passages in the carburetor body With compressed airs Clean the fuel strainer In the float valve using compressed air from the "on valve seat side. 5-12 FUEL SYSTEM I MURETOR ASSEMBLY I21) N03 CARBURETOR (20) No.4 CARBURETOR [2) SUB-AIR CLEANER TUBE I .119) SYNCHRONIZATION SPRINGS (1) AIR VENT TUBES (3) LOCK PLATE 6 (4) AIR FUNNEL can ,/6 4,. (5) DOWEL PINS 7 , - O ' I -. 7- ‘ ’ \‘.\ - u ’ P PE " ‘xfl. HEATER JOINT PIPES flUBES/O-FIINGS (11) FUEL JOINT PIPE (12) THRUST SPRING (13) No.2 CARBURETOR . I9) THROTTLE POSITION CONNECTING BOLTS SENSOR! JOINT (10) No.1 CAHBURETOR O-flW, IMO! and air cut-off valve assembly (I) g O-RINGS I2) VACUUM TUBE I and oonnm the vacuum tube. (3) SCREW 15) AIR JET FUEL SYSTEM Install the SE valves and springs. valve nuts to the 11)VALVE (ZlVALVE NUT carburetor body. \ 111 {441% ”5:9: (4) SPRING l3) DUST SEAL Install the pilot screws and return them to their original posir ' ' (3’ PILOT SCREW hon as noted during removall Perturm prlot screw adjustment it new pilot screws are inr stalled Install the needle jet holder, main jel and slow jeL Hang the float valve onto the float arm lip. (1) FLOAT Install the float valve with tloat in the carburetor body, then install the fleet pin through the body and float. FLOAT LEVEL NOTE - Check the float level after checking the float valve, valve seat and float. - Set the float level gauge so that It is perpendicular to the float chamber lace and in line with the main jet, Set the carburetor so that the (loet valve just contacts the float arm lip. Be sure that the float valve ans securely in contact with the valve seat, Make sure the float level with the (last level gauge. Tool: Carburetor that level gauge 07m - 9010000 Float Ievelz 13,7 mm (0.5‘ in) FUEL SVSTEM Install the new O-rlng into the float chamber groove. (1) SCREWS a 2 O-RIN Install the float chemberand tlghtan the three screws. ‘ ’v G (3) FLOAT CHAMBER Chuck the 0~ring on the jet needle holder for damage and (1} DIAPHRAGMNACUUM PISTON "film if necessary. (2) JET NEEDLE Inn-II the washer onto the jet needle and set the jet needle Im the vacuum piston. 3 WA mllthe spring onto the needle holder. ( ’ SHE“ - ~le oil to the O-ring inn-the jet needle holder into the vacuum piston until you I click indicating the O-ring is seated Into the groove in // mum 9"” (6) SPRING (5) JET NEEDLE HOLDER (4) O- RING th! dilphrnum/vacuum piston Into the carburetor .1) DIAPHRAGMNACUUM PISTON (3, ALIGN by allgnlng the tab of the diaphragm with the cavrty. v; bottom altha piston with your finger to set the die- ‘ llp In the groove in the carburetor body. lnot to pinch the phmgm and to keep the might when instellmg the chamber cover by luring and chamber cover while the piston re» jinn. Socurl the cover with screws before releas- plmn. t (2) SPRING I" limo chlmbor cover screws. (1) SCREWS (2) VACUUM CHAMBER COVER FUEL SYSTE M Install the vacuum tubes (Calitovma type only) and throttle stop screw (No.3 carburetor onlyl. Coat new O-rlngs wrth oil and Install them on the arr vent Iolnt pipe. Coat new O-nngs with oil and Install them on the Iuel joint pipe. Coat new O-vings with all and install them on the carburetor heeter joint pipe, Install the air vent, tuel and carburetor heater joint pipes to the carburetor. Install the air joint rubber pipe and dowel pins to the carburar tor. Assemble the No.1 and No.2 carburetors together with the joints and thrust spring. Install the synchronization spring. Assemble N03 and No.4 carburetors in the same way Coat new Orrings wrth oil and install them on the air joint pipe. Install the airjoint pipe, collared dowel pin and dowel pin to the carburetor. Assemble the No.1/2 nnd No.3/4 carburetors together With the joint, mm” the synchronization spring. (1) VACUUM TUBE (2) THROTTLE STOP SCREW (6) DOWEL PINS l2l CARBURETOR HEATER JOINT PIPE (7) AIR JOINT RUBBER W m (7) DOWEL PINS (ZICARBURETOR HEATER JOI (SI AIR JOINT RUBBER I‘le‘l\ \ m l5) FUEL JOINT PIPE l4) SVNCHR wk \ (17 AIR VENT JOINT PIPE l3) THRUST SPRING (5) FUEL JOINT PIPE (I) SVNCHRONIZATION SPRING NT PIPE v (1) AIR VENT JOINT PIPE (3) THRUST SPRING ONIZATION SPRING (3) DOWEL PIN (2) COLLARED DOWEL PIN - —» I ~‘ (4) SYNCHRONIZATION SPRING (1) AIR JOINT PIPE 5-16 Be sure there is no clearance at the loints ol the carburetors. Install the carburetor connecting boltsv install the choke cable holderv Install and tighten the connecting nuts gradually and alter notelv, be sure the bolt thread projections are equally high, Mold the nut and tighten the nut on other side Operate the throttle cable drum and check its operation lor drag. "you remove the throttle posllan senser. install the throttle pomion sensor jolnt to the throttle position sensor. lhmll the throttle position sensor to the carburetor while dignlng the throttle position sensor joint with the throttle M end—groove. Int-II and tighten the three screws. NOTE - When installing route the throttle position sensor wire In :hown. hit-Intro spring onto the No 2 carburetor body. mum plutic collars onto the N02 and Nova carburetor ‘ Mu. ”the SE valve arm, aligning its cutout with the SE valve yuan. FUEL SYSTEM l1) CONNECTING BOLTS l1) CHOKE CABLE HOLDER l2) NUTS l2) JOINT l1) THROWLE SENSOR (3i ALIGN (A) SCREWS l1) SE VALVE ARM FUEL SVSTEM Install the DIBSHC washers and SE valve arm screws onto the No.2 and No.4 carburetor body. Operate the SE valve arm and check its operatron to ensure there is no drag. Check and adjust the carburetor synchronization visually as follows: Tum the throttle stop screw to align the No.3 carburetor throttle valve with the edge of the bypass hole. Align each throttle valve with the bypass hole edge by turn mg the synchronization adjusting screw. NOTE - Check carburetor sync rennet-on (page 3712) after m7 ' stalling the carburetor assembly. Install the carburetor Insulators with the "CARB" mark facing toward the carburetor and Wlth the "UP" mark leclng up Tighten each insulator band screw Connect the luel tube to the tuel lube iomts. Connect new carburetor heater tube to the heater tube Joints. Connect the drain tubes to the carburetor lloat chambers Connect the No.” tube to the No.2 carburetor lCalitornia type only). [Zl ALIGN (I) 'UP" MARK (2) 'CARB" MARK (ll SCREW (3DFUEL TUBE {ZlDRAlN TUBES 5-18 FUEL SYSTEM -_ , Mm Rh! sub-air cleaner tube to the carburetoro mm the III vonl tubes to (he lube joims. mmm. No.51ube joint to the vacuum tubes (California '31” only). l3) No.5 TUBE JOINT l1) SUB»AIR CLEANER TUBE mo liriunnsls and new lock planes to the air chamber » IMO-ring (or damage and replace il necessary, .7 mo O-rings inlo the carburetor body grooves‘ » mum on! on me sir funnel wuh «he groove in me carr r body, then install (he air chamber and air funnel asr (1) AIR CHAMBER/FUNNEULOCK PALTE ‘ ndh'ghlan the screws graduauy and alternately. In lb. onhe lock plate, ‘ Mind tubes properly (page 1-20 ,- [firm cable Ind! to (he rhronle drum and in- » . “Mu into the cable holder. FUEL SYSTEM Install the carburetor assembly onto the cylinder head. Tighten each insulator band screw alternately. Install the right engine hanger plate and collar, Install and tighten the hanger plate bolts. Torque: 10 mm bolt: A5 N-m (4.5 kg-m, 33 lb To LOWER SECTION OF THE VACUUM PISTON ‘I. . (I) d BELOW 12 mph ( 20 km/h ) AIR VENT (OUTER VENT) ‘5) m ABOVE 12 mph I 20 km/h ) AIR VENT (INNER VENT) W (5) AIR VENT SOLENOID VALVE (7) EVA? CAV SOLENOID VALVE I8) EVAF PURGE CONTROL VALVE I I. EVAP CANISTER 5-25 FUEL SYSTEM TROUBLESHOOTING Engine hard to nan - Air vent tube clogged or restricted - Air vent filter clogged - EVAP CAV solenord valve laultv (California type only, page 5*28l Engine do” not idle - Air vent tube clogged or restricted - Air vent lilter clogged - EVAP CAV solenoid valve faulty (California type only, page 5‘28). Engine stalk. rough idling at warm engine - Air vent lilter clogged - Air vent solenoid valve faulty (see next page) - Incorrect air vent tube connections Engine nulls, rough Idling In a strung wlnd - Outer air vent lube out of connection Poor drivnbillty at law speed . Air vent filter clogged - Sub-air cleaner clogged or restricted - Air vent tube clogged or restricted - Sub-air cleaner tube not connected, clogged or restricted Poor drivelblllty at high ape-d - Air vent filter clogged - Sub-air cleaner clogged or restricted . Air vent tuba clogged or restricted . Sub-air cleaner tube not connected clogged or restricted ~ Air vent solenoid valve leultv (see next page) Incorrect air vent tube connections Poor ”dormanc- It high speed . D.A.I. duct not connected on the air cleaner housing I With the nition switch 0N, check the air vent Iollnoid valve (pageS-SZ). Normal Mav- the drive sprocket from the counter M. . rt the engine then shift the transmission gear. I the speedometer above 12 mph (20 km/h). the air vent solenoid valve (page 5-32)‘ Abnormal Normal - Air vent solenoid valve (D.A.l. system) is Nor- mal theuppertairing (page 2-4). bl loose or poor contact of the combina- ‘ 8P connectors. "ttu-poodometer below 12 mph (20 km/h). ‘ bl continuity between the bottom speed- minals. m hIIlhl: No continuity It above 12 mph (20 inn/hi, between the bottom speed- -Onanllleek Imllli: Continuity Abnormal Normal ;. 1 , Ihetollowing page) FUEL SYSTEM Ab vent wicnoid valve inspection (49 state. Canada type) With the ignition switch 0N, measure the volt- age between the connector terminals at the air vent solenoid valve connectortpage 5—33). Connection: Orange/Black (o) - Grnn l-l Standard: Battery voltage Voltage i - Faulty air vent solenoid valve No voltage With the ignition switch 0N, measure the volt- age between the connector terminals at the air vent solenoid valve relay connector (page 5- 33). Connection: Orange/Black (oi - ground i-i standard: Battery van-go I No voltage Voltage - Open circuit Orange/ Black wire With the ignition switch ON, measure the volt- age between the connector terminals at the air vent solenoid valve relay connector (page 5 33). Connection: Black 1 (cl - ground H 2 Black 2 M - ground (—1 Standard: Battery voltage Voltage 1 - Open circuit Black wire ' Faulty air vent solenoid valve relay No voltage Abnormal ~ Faulty speed sensor or speedometer (page 18—3) (1) PINK WEL SYSTEM (From the previous page) With the ignition switch OFF, check (or continu- ity between the Pink wire oi the air vent sole- noid valve relay and Pink terminal of the speed» ometer. Connoctlon: Pink - Pink Standerd: Continuity Abnormal - Open circuit Pink wire Abnormal With the ignition switch ON, measure the volt- age between the cunnector terminals at the air vent eolenoid valve relay connector (page 5- 33). Connection: Buck I lo) - ground (-1 : Black 1 to) - ground (-I Standard: Buttery voltage No voltage Voltage - Open circuit Black wire ' Faulty air vent solenoid valve relay FUEL SYSTEM Air vent eoleneld valvoIEVAP CAV solenoid valve lnepectlon (Calllomla type) With the ignition switch ON, check the EVA? Abnorma| With the ignition switch ON, measure the volt- CAV solenoid valve (page 5-331 age between the connector terminals at the EVA? CAV solenoid valve connector (page 5—34). connection: Bled: (4-I - Green l-I Standard: Battery voltage Normal No voltage Voltage 1 - Open circuit Black wire . Faulty EVAP CAV solenoid valve " Remove the drive sprocket lrorn the counter M " Start the engine then shift the transmission he seen ‘ . the Ipsodomatev above 12 mph (20 Itrnlhlv ‘ . m. V3,“ solenoid valve (page 5.3“ v Normal ’- r Air vent solenoid valve (D.A.l. system) in normal Abonormel l the upper hiring (page 2-0. for looee or poor contact of the combinaA ‘ Mr 8? connectors. themedometer below 12 mph (20 km/hl, let continultv between the bottom ‘ i urmlnels. i — Abnormal —§ - Faulty speed sensor or speedometer (page 1&3) (1) PINK built): No oomlnulty above 12 mph (20 km/h). lty between the bottom (2) GREEN/BLACK FUEL SYSTEM (From the previous page) 1 With the ignition switch OFF, check tor continu- ity between the Pink wire at the air vent sole- noid valve relay and Pink terminal at the speed- ometer, Connectlon: Pink - Pink stand-rd: Continuity Normal Connect the air vent solenoid valve relay. Check lor loose or poor contact 01 the air vent solenoid valve connector. Start the engine then shift the transmission into gear. With the speedometer below 12 mph (20 km/hlv measure the voltage between the connector terminals atthe air vent solenoid valve connec— tor. Lid n Connection: Orange/Black (o) - Gnon (—l Stand-rd: Below 12 mph (20 kin/h): No voltage measure the voltage between the connector terminal; at the air vent solenoid valve connec- tor. Connection: Orange/Block lol - Green l-) sanctum: Above ‘2 mph (20 kmlhl: Buttery voltage With the speedometer above 12 mph (20 km/h), Normnl (Continue the following page) 5-30 Abnormal Abnormal - Open circuit Pink wire - Faulty air vent solenoid valve FU E L SYSTEM (From the previous page) 1 the engine men shift the transmission , “modems!" below 12 mph (20 km/h). re the voltage between the connector 8! the air vent solenoid valve relay , Milled: lo) — ground 1-) I” kmlh): Ne voltage I yabove 18 mph (20 Ian/ll)v when between the connector air vent solenoid valve relay Block («I - ground H ~ hnlhl: Balm voltage ‘ Abnormal m 0N and measure the ‘ MMOI’ terminals at the Mlvconnecmr (page 5- k) - round (-1 Voltage appeared Normal ‘ , - Open circuit Orange/Black Wire - Faulty air vent solenoid valve relay FUEL SVSTEM SUB-AIR CLEANER/TUBE INSPECTION Remove the Iuel tank (page 24). Check the tubes between the D.A‘|. duct, sub-air cleaner and carburetors for deterioration, damage or loose connections Remove the sulrair cleaner and check it Ior clogging. INNER AIR VENT CLEANER/TUBE INSPECTION Remove the Iuel tank (page 24). Check the tubes between the D.A I. duct, air vent cleaner and air vent solenord valve Ior deterioration, damage or loose connections. Remove the air vent cleaner and check it for clogging OUTER AIR VENT CLEANER/TUBE INSPECTION Remove the upper fairing (page 24). Check the tubes between the outer air vent duct, air vent cleaner and air vent solenoid valve for deterioration, damage or loose connections. Remove the air vent cleaner and check it Ior clogging. (1) INNER AIR VENT CLEANER FUEL SYSTEM D.A.|. DUCT (1) AIR INTAKE TRACT . .. u MOTION Ramm the fuel tank (page 2-4)i Cluck "is air intake "act between (he D.A.I. duct and air cleaner housing cover lor signs ol dateriomion, damage or hoot connmionsv (1) HOSE ROUTING No“ Routing Diagram Label (49 stale, Canada type) is D'AGRAM LABEL hair cleaner housing cover. 1' unum Hose Routing Diagram Label (California type) is Ill' cleaner housing cover (see page 1-31 and page 5- ‘_ ”tuning diagram for the hose connections. ‘9 state. Canada type: /—'—f/—‘—Tfi'.—W’ " HOSE RUUiiNb 01mm V kw} 5-33 FUEL SYSTEM AIR VENT SOLENOID VALVE [49 state, Canada ‘YPGI OPERATION CHECK Disconnect the No.4. 6, 7 tubes from the air vent solenoid valve. Connect the pressure pump to the No.‘ tube fining. Yool: Prawn pump ST -AH - 255 — Mc‘l (U.S.A. only) CAUI’ION - Damage to the air ventialonoid valve may result Iroin uu el high pressure air source. Uu a hand oper-ted alr pump only. With the ignition switch OFF, pump airthrough the No.6 tube lining. Connect the pressure pump to the No.7 tube fitting. With the Ignition switch ON, pump air through the No.6 tube fitting. Remove the drive sprocket from the countershaft (page 7-3), pm whllo irrive sprocket I: installed. I Connect the pressure pump to the No.‘ tube Iitting. Stan the engine then shill the transmission into gear. With the speedometer above 12 mph l20 km/hI, pump air through the No.6 tube fitting. IGNITION SWITCH 1 N0. 6 TUBE Fli'l'l OFF: ( ) NG (2) No. A was FITTING (a) PRESSURE PUMP} IGNITION SWITCH ON: (1) NO. 7TUBE FITI‘ING (3) N0. 6 TUBE FI‘ITING [1) NO. STUBE FIWIN? (3) NO. 4 TUBE FITTING (2) PRESSURE PUMP 5-34 AIR VENT SOLENOID VALVE VOLTAGE Disconnect the air vent solenoid valve connector. Check for loose or poor connection oi the connectol. Turn the Ignition switch ON and measure the voltage bar tween the connector terminals ol the WIra harness. Connection: Orange/Bleak l+l — Green l-I Sunderd' Buttery voltage AIR VENT SOLENOID VALVE RELAV (49 state, Canada type) AIR VENT SOLENOID VALVE RELAV VOLTAGE Remove the upper fairing (page 24L Check for loose or pool connection oi the connector, Turn the ignition SWIlCh ON and measure the voltage be- tween the connector terminals at the air vent solenoid valve relay connectoL Connection: cringe/Block lo) - ground (-I sane-m; Bettery volnge Connection: Bleck 1 lo) - ground i-i Sand-rd: Buttery volt-go Connection: BI-ck 2 M — ground [-I Stand-rd: Battery volt-9e ' EVAP CAV SOLENOID VALVE (California type) WERA‘HON CHECK Disconnect the No.4, 8 tubes horn the EVAF CAV solenoid ' veil/e. ‘ Connect the pressure pump to the No.4 tube lining goes to EVAPcenister. Tool: Plenum pump ST — AH — 255 — MC‘HUSA. only) ' CAUTION “ - Dunne to the II: vent solenoid we 0 may result front nee at high preuure e eoumes Uu I end opereted lir Wino only FUEL SVSTEM (1) AIR VENT SOLENOID CONNECTOR (1) AIR vshti SOLENOID VALVE RELAY (1) AIR VENT SOLENOID VALVE RELAY iérlunow SWITCH OFF. H) No‘ ‘ TUBE Fin-me (2) s VDDL' PRESSURE PUMP FUEL SVSTEM With the ignition switch OFF, pump air through the No.4 tube Iltting goes to air vent solenoid valve. Connect the pressure pump to the Not}! tube fitting With the ignition switch 0N, pump air through the No.4 tube fining goes to air vent solenoid valve. EVAP CAV SOLENOID VALVE VOLTAGE Disconnect the air vent solenoid valve connector. Turn the ignition switch 0N and measure the voltage be tween the connector terminals of the wire harness. Connection: Bleak Iol - Green (-I Standard: Buttery volt-no AIR VENT SOLENOID VALVE (California type) OPERATION CHECK Remove the drive sprocket lrom the counterstaft (page 7-3). Disconnet the N04; 6, 7 tubes Irom the air vent solenoid valve. Connect the pressure pump to the No.‘ tube fitting. Tool: Prneure pump ST - AH — 255 - NIC7 IU,S.A. onIvI CAUTION - Dem-g- te the Air vent Iolonoid valve may mult Irom uu eI high preewre air eource. Uue hend operlted air pump only. Connect the pressure pump to the No! tube fitting Start the engine then shilt the transmission into gear. With the speedometer below I2 mph (20 km/h), pump an through the No.6 tube fitting, IGNITION SWITCH ON: (1) NO. 4 TUBE FITTING (2) PRESSURE PUMP (1) EVAP CAV SOLENOID VALVE CONNECTOR III No,6 TUBE FITTING 5-36 Connect the pressure pump to the No.7 tube fitting Sun me engine then shift the transmission into gear, with the speedometer above 12 mph (20 km/h), pump air mrounh the No.8 tuba fitting. VENT SOLENOID VALVE RELAY (Celilomla m MEMO“) VALVE RELAV VOLTAGE ‘ an upper fairing (page 24). int bone or poor connection a! the connemol. - [on switch ON and measure the voltage be- ~ alarminals a! the air vent solenoid vere 1 lo) - round (-I W . “6-de FUEL SYSTEM ABOVE 12 mph (20 krnlh): (1) N01 TUBE FITTING (1) AIR VENT SOLENOID VALVE 7/ RELAV /" ' FUEL SVSTEM SECONDARY AIR SUPPLY SYSTEM (California type only) NOTE ‘ - Refer to tubing diagram on peg-T131 lor the lube conr noctions. l PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE REMOVAL/INSTALLATION Remove the exhaust pipe (page 240). Disconnect the PAIR control valve control tube and No.15 hose from the PAIR control valve. Disconnect the air injection hoses lrorn the PAIR control valve. Remove the three bolts and FAIR control valve. Remove the (our nuts and air injection pipes, Remove the air injection pipe gasket. Installation is in the reversal order of removal. ll) PAIR CONTROL VALVE / J INSPECTION Start the engine and warm It to operating temperature. Stop the engine and remove the air cleaner (page 35!. {1) PAIR CONTROL Check the No.15 hose ports are clean and free of carbon de- posits. Check the PAIR check valves In the secondary/air passage ii the pens are carbon fouled. (A) EXHAUST PORT (2) N0. 15 HOSE //(3) SECONDARY AIR INTAKE PORT FUEL SYSTEM » nnoct the air cleaner to-PAIR control valve No.15 hose tho air clunar housing. math. PAIR control valve control tube from the PAIR Ivnlvo; install a plug to keep air from entering. , maths vacuum pump to the PAIR control valve. pump sr-AH-zeo-Mc7 (USA. only) ‘ th- naine and open the throttle slightly to be certain Ilrl united in through the No.15 hose, llnot drawn in, check the No.15 hose for clogging. tho engine running. gradually apply vacuum to the antral valve. . thlt the air intake port stops drawing air, and that the does not bleed. . voeuum: 40 mmHg l1.8 Ianl I dawn in, or if the specified vacuum is not maintained. , I nlw PAIR control valve. - m occurs on deceleration. even when the second WPP'Y IyItem is normal. check the air cutrofl valve. htubinu diagram on page 1-31 lor the tube con» WE EMISSION (EVAP) CANISTER » ALLATlON It. ald- lniring lpaga 2-3). I“ No.2, No.1 and No.4 tube from this EVAF cam my bolt: and EVAP canister. . hlnthn reverse order of removal. TNE EMISSION [EVAPl PUHGE VALVE MMTION WA? purge control valve lrom the frame stay. 4 "I Null. No.5 and No.‘ tube from their con- . blame mom order of removal. (1) PAIR l2) N0. l5 HOSE CONTROL (4) ’ VACUUM PUMP (3) PAIR CONTROL VALVE CONTROL TUBE l1) BOLTS l5) EVAF CANISTER (0 No.2 TUBE (3) N0. 1 TUBE (2) EVAP PUHGE (1) NO. 5 TUBE CONTROL VALVE (4) N0. 11 TUBE (3) N0. 4 TUBE 5-39 FUEL SVSTEM INSPECTION NOTE - The EVAP purge control valve should be inspected it not mean is difficult. Remove the EVAP purge control valve (see above). Connect e vacuum pump to the No.5 tube fitting (output port) that goes to the carburetors. Apply the specified vacu- um to the EVAP purge control valve. Tool: Vacuum/Presure pump Vacuum pump Marx — ou— xxxxx or ST - an -zoo - mcr iu.s.a. only) Specified vacuum: 250 mmNg [9.8 lan) The specified vacuum should be maintained. Replace the EVAP purge control valve it vacuum is not main- tained. Remove the vacuum pump and connect it to the No.11 tube fitting (vacuum port) which goes to the rear carburetor. Apply the specified vacuum to the EVAP purge control valve. Specified vecuum: 250 mmHg 19.! lan) The specified vacuum should be maintained. Replace the EVA? purge control valve it vacuum is not mainr teined. Connect e pressure pump to the No.4 tube fitting (input port) which goes to EVAP canister. Tool: Vacuum/Pressure pump AMTX - 041- XXXXX or Preeeure pump ST -AR - 255 - M07 (U.S.A. only) CAUTION (1) TO EVAF CANISTER (Input port) (2) TO CARBURETOR (Vacuum port) (3) VACUUM PUMP \ (4) TO CARBURETOR (Output port) ~ Damage to the EVAP purge control velve may reeult lrom use at a high preeeure elr source. Use a hand operated air pump only. While applying the specified vacuum to the EVA? purge con- trol valve vacuum port, pump air through the input port. Specified vewum: 250 mmHg (8.! Ian) Air should tlow through the EVA? purge control valve and out the output port that goes to the cerburatois. Replace the EVAP purge control valve if air does not flow out. Remove the pumps and install the EVAP purge control valve In the reverse order of removal (page 5-36). 5-40 OOOIJNG SYSTEM 13 N-m (1.3 kg-m, 9 lb-fl) 6-0 6. COOLING SYSTEM SERVICE INFORMATION TROUBLESHOOTING SYSTEM TESTING OOOLANT REPLACEMENT THERMOSTAT THERMO VALVE 6-7 RADIATOR/COOLING FAN 6-8 WATER PUMP RADIATOR RESERVE TANK l ro may cause serious scalding. up it away lrom eyes, mouth, skln and clothes. ' -leny eoolant get: in your ey . rinse them with water and consult a doctor lmmedlahty. - leny coolant is awallowed. induce vomltlng. uarglc Ind consult a phyflelan lmmedlahty. - law coolant not: on your sun or clothes. rlnu thoroughly wlth plenty of weter. ‘. IEP out or REACH or CHILDREN. "I. only distilled water and ethylene glycol in the cooling system. A 50-50 mixture is recommended (or maximum 'oorroolen protection. Do not use alcohol-based antiIreeze or an antiIreeze with 5911 sealing properties. coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. All coollng system services can be done with the engine in the frame. - spilling coolant on painted surIaces. aervicing the system, check (or leaks with a cooling system tester. to Section 18 for (an motor switch and tharmc sensor inspection. -TION ITE M SPECIFICATIONS capacity radiator and engine 2.4 l (0.83 US gal, 0.53 Imp gal) rese rve ta nk 0.35 I (0.09 US gal. 0.08 Imp gal) u up raliel pressure 108 -137 kPa (1.1 — 1.4 kg/cm’. 15.6—19.9 pal) begins to open 80— 84'C(176-183'Fl tully open 95‘C (203'F) valve lift 8.0 mm (0.31 in) minimum 73— 77‘C (183— 171'F) 13 NM (13 kg-m, 9 lb-(t) CT bolt. 10 Nm (1.0 kg-m, 7 Ib-(l) Apply aaalant to the threads. 10 N'rn (1.0 kg-m, 7 Ib-(ll Apply sealant to the threads. (Do not apply sealant to the sensor head.) ‘ pump ST—AH-255—MC7 lU.S.A. onlyl COOLING SVSTEM TROUBLESHOOTING Englne temperature too hlgh ~ Faulty temperature meter or thermosensor - Faulty radiator cap - Insufficient coolant - Passages blocked in radiator, hoses or water jacket ' Air in system - Faulty water pump - Thermostat stuck closed - Faulty cooling lan motor - Faulty fan motor switch Engine temperature too low - Faulty temperature meter or thermoeenso' - Yhermostat stuck open - Faulty cooling fan motor switch Coolant leak: - Faulty water pump mechanical seal ' Dateriorated O-rings ~ Damaged or deteriorated gasket ~ Loose hose connection or clamp . Damaged or deteriorated hoses SYSTEM TESTING coowu'r [HVDROMETER TEST) Remove the side fairing (page 273). Ilmave the reserve cap. Chock the coolant gravrty usmg a hydrometer (refer to Sec- ion 5 0| the Common Service Manual for "Coolant gravity dart”. For maximum corrosion prulacliun. a 50507:. solu- fiou oi ethylene glycol and distilled water is recommended (peg. 6-4). Looklor contamination and replace the coolanl if necessary. I I TOR CAP/SYSTEM PRESSURE . 3 ' CTION , Tho-ml". must be cool halo emoving rho radiator m or more scalding may result - the upper {airing (page 2-4). - the radiator cap. ‘ More innelling the cap in [he tester. we! the sealing .Iurfaeaa. roles! the radiator cap. Replace the radiator map If u not hold pressure, or i! reliel pressure is too high or (no it mun hold specified pressure {or at least 6 seconds . up relief prnwro: I31 IP- l1.1 - 1.4 kglcm’, 15.6 — 19.9 psi) he radiator, engine and hoses. and check for leaks. pressure can damage (he cooling twin; u. Do not exceed 137 RP. [11 kg/cm', 19.8 ' or replace components inhe system win not hold - pressure (or at least 6 seconds. COOLING SYSTEM (1) RESERVE CAP [1) COOLING SYSTEM TESTER COMMERCIALLV AVAILABLE COOLING SYSTEM COOLANT REPLACEMENT ANTIFREEZE PREPARATION . SOLUTION ‘ M (ETHVLENE (1) ifi 7“ ‘ GLVCOL BASE r coolant is toxlc. Keep It nway lrom eyes, SOLUTION} (2,2)?” MINERAL mouth skin and clothes. - If any cool-rut get: in your eyes rinse them with wutor and comult I doctor immodlnoly. - if any coolent I: swallowed. induce vomiting, gerglo Ind cenxult n physiciln immediately. - ll eny coolant gets on your ohm or clothu, rinse thor- oughly with plenty or wear, . KEEP OUT OF REACH OF CHILDREN ‘ DISTILLED WATER L (3) COOLANT *7 \J NOTE . The effectiveness of coolant decreases With the accumu~ 1 lation of rust or if there is a change In the mixing propor- IIon during usage. Therefore, for best periormance change the coolant regularly as specified in the mainte- nance schedule. - MIX only distilled, low mineral water with the antllveeze. Recommended mixture: 50-50 lDlstillod water and coollnt) REPLACEMENT/AIR BLEEDING - The engine mult be cool before servicing the coollng system, or ”were scolding mly result. NOTE - When filling the system or reserve tank With a coolant I (checking the coolant level), place the motorcycle in a | vertical position on a (let. level surlace. J Remove the upper fairing (page 2-4). Remove the radiator cap. Remove the drain bolt on the water pump and drain the sys- tem coolant. ' Reinstall the drain bolt with a new sealing washer. Place a suitable container under the srphon tube Joint ol the mews tank. Dileonnect the siphon tube from the reserve tank and drain the reserve coolant Empty the caolant and rinse the inside al the reserve tank with water, Reconnect the siphon tube. Flllthe system with the recommended coolant through the Ill" opening up to filler neck. Move the resarve cap and fill the reserve tank to the upper llvol line, Ilud air from the system as lollows: £1. Shllt thotransmission into neutral. Start the engine and let it idle (or 2 — 3 minutes. Snuptha throttle 3 — 4 times to bleed Bl! lrom the system. stop the engine and add coolant up to the proper level if necessary. Reinstall the radiator cap. (link the level of coolant in the reserve tank and till to the upper level It it is low. COOLING SYSTEM (l) RESERVE TANK l2) SIPHON TUBE COOLING SVSTEM THERMOSTAT m HOSE BAND REMOVAL Drain the coolant (page 6-4). Remove the hose band. Remove the three cover bolts and thermostat housing cover. Remove the O-ring from the cover groove. Remove the thermostat Irom the housing. (ZlTHERMOSTAT INSPECTION - Vile-r ineuleted gloves and edequete eye protectlen. - Keep flammable ma r als away lrom the electrk heat- ing element. Visually inspect the thermostat for damage. Heat the water with an electric heating element to operating temperature for 5 minutes. Suspend the thermostat in heated water to check Its opera- tion. NOTE ‘ - Do not let the thermostat or thermometer touch the pan, or you will get false readings, ' (1) THERMOSTAT Replace the thermostat it the valve stays open at room tem- perature. or if it responds at temperatures other than those specified, Thermostet begin: to open: so - INC (176 - 18:?) valve lift: 3 mm (031 in) mlnllllum It 95'0 (203?) (2) THERMOMETER COOLING SVSTEM fluthormostat into the housing with its hole facing up. the lhormosm flange with the groove or the housing marines. Make sure the thermostat is securely installed I new O-ring in the thermostat housing cover groove. Wthormostat housing cover and tighten the bolts. lilo hone bandt blud the cooling system {page Grslt VALVE .NJlNSTALLATION Mint (page 64), | MI tank (page 2-4). tho water hoses from the thermo valve. boll Ind thermo valve. h in tho reverse order a! removal. lho thermo valve with in-port (golden color 6 the water hose which goes to the cylinder "I. cooling system (page 6-5). (1) HOLE (ZlTHERMOSTAT /\12) some (2) THERMO VALVE It) GOLDEN SIDE COOLING SVSTEM INSPECTION - Wear insulated glove: and adequate eye protection. - Keep flammable ma III away lvom the electrlc heat- ing element. Visually inspect the thermo valve tor damage, Connect a suitable tube to the thermo valve in-pon (golden color side). Connect a pressure pump to the tube as shown. Tool: Pressure pump: ST-AH-zss—MC7 (U.S.A. only) Suspend the thermo valve completely in heated water, Be sure the thermo valve does not touch the bottom or Sides of the containert Any Contact can produce false readings. Apply a light pressure to the thermo valve. Valve Item to clou: 13 -77'c (163 - 111‘F) Replace the thermo valve Ifthe passage is blocked at a tem- perature lower then those listed above, or it there is no re- striction at a temperature higherthan those listed. RADIATOR/COOLING FAN CAUYION - Be careful not to damage the radiator line while servic- lng the radiator and tin. REMOVAL/ INSTALLATION Drain the coolant (page 64). Remove the upper (airing (page 24L Disconnect the fan motor switch connector. Disconnect the upper and lower water hoses from the redia» tor, Remove the radiator mounting bolts and cells}: then remove the radiator by releasing the upper mounting grommet from the frame stay. Install the radiator in the reverse order of removal, Fill and bleed the cooling system (page 55). l1) THERMOMETER (3) GOLDEN 7%05 ,7/t n (ll THERMO VALVE (:4) RADIA i COOLING SVSTEM DISASSEMBLV m FAN moron SWITCH (2) sons CONNECTOR ‘ I Disconnect the Ian mmor switch connector and remove the will [mm the clamp. llmove the Ian momr assembly by removmg the three bolts lid the ground terminal. (4) CLAMP (3) FAN MOTOR Move the nuk and me cooling Ian. Movelha Ian moror connecxor from me shmud. _ Movelhe nuts and Ian moton (2) NUTS waun motor swuch inIotmation, refer la page 18713) (AI COOLING FAN (3b FAN MOTOR (2) SHROUD 41) COOLING FAN (3) FAN MOTOR (6) RADIATOR (5’ O~R|NG (I) FAN MOTOR SWITCH COOLING SYSTEM Install the Ian motor onto the shroud wrth the breather facing (1) NUTS down Install and lighten the nuts. Install the fan motor connector to the shroud (2) FAN MOTOR CONNECTOR (5) FAN MOTOR (4] BREATHER 13) SHROUD Install the cooling Ian onto the motor shaft by allgnmg the [1) COOLING FAN (lat surfaces. Tighten the nut. \ (Zl NUT Install the Ian motor assembly onto the radiator and tighten (I) GROUND TERMINAL (2) RADIATOR the mountlng bolts with the ground termlnel. Route the wrres properly, clamp the wires and connect the switch connector. (4) CLAMP ' . - ' (3I BOLTS WATER PUMP l1) MECHANICAL SEAL INSPECTION ‘ l WATER PUMP ' (ZI TELLTALE HOLE ‘ Vn‘ ‘ V -_ l lye/f, Remove the side Iairing (page 23) Inspect the telltale hole for signs of coolant leakage II there is leakage, the mechanical seal is deleclwe and the water pump assembly must be replaced. Inspect here 6-10 COOLING SYSTEM EMOVAL Dnin the coolant (page 6-0. Diloonnect the water hoses and tubes from the water pump. flomove the bolts and water pump cover. Remove the Orving and water pump Irom the crankcase. INSTALLATION Apply engine oil to a new O-rlng and install n onto the mapped portion 0! the water pump, Install the water pump into the crankcase while allgning the mar pump shaft groove with the (NI pump shaft and. Align the mounting bolt holes in the water pump and crank ms and make sure the water pump is securely installed Inltull a new Owing into gvaove In the water pump. WIZ) WATER TUBES ‘ , ll (2) WATER PUMP H) g O~RING (1| ALIGN l2) OIL PUMP SHAFT END (”WATER PUMP COOLING SYSTEM Install the water pump cover and tighten the bolts. Torque: CT bolt: 13 Min ".3 Ito-m. 3 lb-ltl Install the water hoses and tubes to the water pump. Fill and bleed the cooling system (page 6-5). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the shock absorber (page 13-8). Drain the coolant from the reserve tank (page 85). Remove the bolt and rear master cylinder reservoir. Disconnect the breather tube and siphon tube. Remove the mounting bolt and release the hook on the ra- serve tank from the oval hole in the lrama by pivoting the tank rearward. Install the removed pans in the reverse order of removal. Fill the tank with coolant {page 6-5). (1D WATER HOSE ‘. E (2i WATERTUBES (3l BOLTS (2i SIPHON TUBE ( 1l BREATHER TUBE (8) REAR MASTER CYLINDER RESERVOIR (3) RESERVE TANK (l) HOOK (5i BOLT ENGINE REMOVAL/INSTALLATION ‘5 N-m (4.5 kgrm, 33 lb-fl) 65 N-m (6.5 kgvm, ‘7 RH!) 15 N-m (1.5 kg-m, 11 lb-R) 65 N-m (6.5 kg-m, t7 lb-fl) 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-1 ENGINE INSTALLATION 7-4 I ENGINE REMOVAL 7-2 ' , l SERVICE INFORMATION GENERAL - Afloor jack or other adiustabla support is required to support and maneuver the angine. WION - Do not support the engine using the oil oooler. 1 I When removing/installing the engine, tape the frame around the engine beforehand (or frame protection. The following components require engine removal (or service. . -Crenkcaea/Transmiaeion (Section 10) I -Crenkahaft/cylinder/Piston (Section 11) Thetollowing components can be serviced with the engine installed in the lrame. . -Oll pump (Saction 4) -Carhuretor (Section 5) -Weter pump (Section 6) ' - Cylinder haad/camshaft/velvee (Section 8) - Clutch/gearshift linkage (Section 9) ~50th drum/shirt fork (Section 10) -Alternetor/Ilywheel (Section 15) - Ignition pulse generator (Section 16) -Stnrter motor/starter clutch (Section 17) ITEM SPECIFICATIONS Engine dry weight I 49 state, Canada type 61.9 kg (136.4 lb) 62.8 ((9 (138.4 lb) 4.2 l (4.4 US qt, 1.7 Imp Q!) 24 I (0.63 US gal, 0.53 Imp gal) California type Engine oil capacity at disassembly Coolant capacity (radiator and engine) UE VALUES tengine mounting nut 65 N-m (6.5 kg-m, 47 Ib-ft) upper engine mounting nut lower engine mounting nut no mounting adjust bolt no mounting lock nut rte hangar plate bolt (10 mm) sprocket bolt ‘5 N-m (4.5 kg~m, 33 |b~ft) l5 N-m (1.5 kg-m. 33 lb—(tl 15 N-m (1.5 kg-m, II Ill-III 85 NM (6.5 kg-m. 47 Ib-fti 45 N'm (4.5 kg-m, 33 Ib-M 55 N-m (5.5 kg-m, 4O lb-I‘t) ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil image 3711) and coolant (page 6-“ Turn the ignition switch OFF and disconnect the battery ground cable. Remove the followrng: - Exhaust system (Section 2i - Carburetor (Section 5i - Spark plug caps (page 3-6) Disconnect the lollowing: -Allernator 3P connector - Ignition pulse generator 2? connector - Oil pressure switch/neutral switch/thermosensor 3P con- nector Remove the wires irom the clamps Disconnect the speed sensor 3P connector and remove the wire from the clamp. Disconnect the clutch cable and remove the cable holder bolts and holder. Remove the bolt and nut and disconnect the starter motor and ground cables. - l I) CLAMPS (i 12) CONNECTORS (ll 3P CONNECTOR l4) CLAMP l3) CABLE HOLDER (2) CLUTCH CABLE f, l1) STARTER MOTOR CABLE ENGINE REMOVAL/INSTALLATION finmove the water hoses from the water pump and thaer M WVB'. Remove lha bull and gearsmn pedal link from [he shill Iplndle. fiemuve the drive sprocket cover bolls, cover and drive chain guide. . m GEARSHIFT «3) DRIVE PEDAL LINK SPROCKET covsnl. ~ Loosen the drive sprocket bolt while applying the rear brake (1) DRIVE SPROCKET BOLT (Z) WASHER with the rear wheel on the ground. 1 ‘- Romove the drive sprocket boll and washer, Loon" the drive chain then remove the dl’IVB sprockel. Supper! the mulorcycle securely using a salary stand or hoist. Plus a lloor jack or other adiusrable suppon under the NOE - Thu jack height must be continually adjusted m relieve | um: lor ease of bolt removal. , aswklng palm. ’7 j ENGINE REMOVAL/INSTALLATION Remove the left engine hanger plate bolts, hanger plate and collar. Remove the left front mounting nut. bolt and collar. Remove the rear upper engine mounting nut, bolt and collar. Hold the adjust bolt and loosen the lock nut. Remove the right front mounting nuts, bolts and collars. Remove the rear lower mounting nut and bolt. CAUTION - During engine anombly removal, hold the angina u~ our-Iv and be unlul not to damege the from. and on- nine. Remove the engine from the frame. ENGINE INSTALLATION CAUTION - Carolully llinn mounting point- with tho lock to pre- vent damage to engine, heme, wlru and cables. ‘ r A c ‘7 1 , ‘a (an LOWER MOUNTING Ml) (2) FRONT MOUNTING NUT/BOLT/COLLAR Use a lloor jack or other adjustable support to carefully ma- neuver the engine into place. Carefully align the bolt holes in the frame and engine than insert the rear lower mounting bolt from the left side. Loosely install the rear lower mounting nut. Install the collar (short) and right lront mounting bolt. Loosely install the right iron! mounting nut. Install the collar and rear upper mounting bolt. . w v iv! 7—)! , 1 (3) LOWER MOUNTING; ‘/ j 12) FRONT MOUNTING NUT/BOLT BOLT/COLLAR ENGINE REMOVAL/INSTALLATION lnltlll the collar and left hanger plate. Lnouly install the left hanger plate mounting bolts. hall the collar (long) and lelt lront mounting bolt. Looulv install the left front mounting nut, Push the rear upper engine mounting bolt so that you can tlghtan the adjust bolt With a hexagonal wrench. Tighten the adjust bolt to the specified torque. TWIII: 15 N-m (1.5 kg-m, 11 Ib-ft) hull tho lock nut. Tlgltton the lock nut while holding the adjust bolt WIIh a hex- Igonll wrench. Two: 05 MM [55 ltg-m, 47 lb»hl l2) ADJUST BOLT ' -M the rear upper engine mounting bolt lully and tighten ll) UPPER ENGlNE MOUNTING BOLT/NUT "nut. ‘ V T ' ' Tm: l5 N-m (4.5 ltg-m. 33 lb-kl tuning the roar upper mounting nut, tighten the angina mounting nuts to the specified torque. 65 N-m l8,5 Itfl~m, 47 lb-ft) g nut: 45 Nvm “.5 Itg-m, 33 Ila-fl) hunger plm bolt (10 mm): ‘5 N-m “.5 kg»m, 33 lh-nl II the ramovod parts at engine removal in the revarse nl removal, (Zl WASHER yacht bolt: 55 N-m (5‘5 ltg-rn, ‘0 lb-Rl pod-I pinch bolt: 20 N-m l2.0 kg-m, M Ib-lt] Ilhl lallowing: Exhaun mnem (Section 2) tMurotor (Section 5) lurk plug caps (Section 3) cunkcua with the engine oil (page 3-12). blood the cooling system (page 6-5), the battery ground cable. I [3) DRIVE SPROCKET CVLINDER HEAD/VALVES 12 N-m (1.2 kg-m, 9 llHfl 20 N-m (2‘0 kg-m, u lb-fl) 12 N-m (1.2 kg-m, 9 lb-ft) 10 N-m (1.0 kg-m, 7 lb-m 8-0 8. CYLINDER HEAD/VALVES SERVICE INFORMATION 8-1 VALVE GUIDE REPLACEMENT 8-14 TROUBLESHOOTING 33 VALVE SEAT INSPECTION/REFACING 8-15 CYLINDER COMPRESSION 8-4 CVUNDER HEAD ASSEMBLV 8-18 CAMSHAFI' REMOVAL 8-5 CYLINDER HEAD INSTALLATION 8-19 CYLINDER HEAD REMOVAL 8-9 CAMSHAI-‘l' INSTALLATION 8-21 CYLINDER HEAD DISASSEMBLV 8-11 J SERVICE INFORMATION mEflAL I 1'Irla eection covers service of the cylinder head. valves, camshaft. These parts can be serviced with the engine installed 1 lntha frame. - When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original been tiona. - Clean all disassembled parts with clean solvent and dry them using compressed air belera inspection. I‘- Camlhalt lubricating oil is fed through oil passages in the cylinder head. Clean the oil passage: before assembling the - cylinder head. - Pour clean engine oil into the oil pockets in the cylinder head during assembly to lubricatie lhe camshaft lobes. ‘.,I Be caraml not to damage the mating surfaces when removing the head cover and cylinder head. Incrncrmous Unit: mm (in) ITEM STANDARD SERVICE LIMIT _ qllndar compression 1,275 — 1,314 kFa (13.0 713.4 kg/cm', — . 185 — 191 psi) " Valve clearance IN 0.16 1 0.0310006 :- 0.001) — ' Ex 0.22 : 0.0310009 : 0,001) — Cyllndar head werpage # 0.1010004) ‘ Clmthak ‘ Cam lobe 49 state, Canada type 36.140 , 30.380 (1.4223 — 1.1323) 38.11 (1.422) ’ “is” N California type 34.5w — 34100113593 - 1.3698) 34.51 (1.359) K EX 49 state, Canada type 35.300 — 35.550 (1.3898— 1.3992) 35.27 (1.389) i California type 33.580 - 33.820 (1.3220 — 1.3315) 33.55 (1.32" Runout — 0.05 (0.002) 1 Oil clearance 0.02 - 0.062 (0.0008 - 0.0024) 0.1 (1100‘) Journal OD. 23.959 — 23.980 (0.933 — 0.9!") 2.965 (0.9825) CImahafl holder LD. . 24.000 - 24.021 (0.9449 - 0.9‘57) — 8-1 CYLINDER HEAD] VALVES Unit: mm (in) )— (cont’dl ITEM STANDARD SERVICE LIMIT Valve and valve guide Valve stem OD. 3.975 — 3.990 (0.1565 — 0.1571) 3.965 — 3.980(01561— 0.1567) 3.965 (0.1561) 3.955 (0.1557) Valve guide I.D. 4000—4012(01575—01580) 4.04(0.159) 4.000 — 4.012 (0.1575 — 0.1530) 4.04 (0.155) Stem-to-guide clearance 0.010 — 0.037 (0.0004 - 0.0015) 0.020 — 0.047 (0.0008 - 0.0019) 0.075 (0.0029) 0.085 (0.0033) above cylinder head Valve guide projection 13.1 — 13.3 (0.516— 0.524) 11.3 — 11.5 (0.445 ~0.453) Seat width 0.9 — 1.1 (0.035 — 0.043) 1.5 (0.06) Valve spring Free length 31.92 (1.257) 35.36 (1.392) 30.62 (1.206) 33.86 (1.333) Valve lifter 0.D. 25.978 — 25.993 (1.0228 — 1.0233) 25.97 (1.022) Bore |.D. 26.010 — 26.026 (1.0240 — 1.0246) 26.04 (1.025) TOROUE VALUES Cylinder head bolt Spark plug Cylinder head cover bolt Camshaft holder bolt Cylinder head cover breather plate bolt Cylinder head stud bolt Cam sprocket bolt Cylinder head sealing bolt Water hose joint Vacuum ioint Cam chain tensioner slider cap nut TOOLS Valve spring compressor Valve spring cdmpraesor attachment Tappet hole prerector Valve guide driver, 4 mm Valve guide reamer, 4.008 mm Valve guide driver Valve seat cutter. 24.5 mm (EX 45') 27.5 mm (IN 45'] 24 mm (EX 32'l 27 mm (IN 32‘) 22 mm (EX 60') 26 mm (IN 60‘) Cutter hnlder, 4.0 mm Compression gauge attachment 48 N-m (4.8 kg-rn. 35 leit) Apply molybdenum disulfide oil to the threads. 12 NH“ (1.2 kg-m. 9|b41) 10 N-m (1.0 kg-m. 7 (Daft) 12 N-m (1.2 kg-m. 9 1541) Apply oil (0 the threads. 12 N-m (1.2 kg-m, 9 lb-ft) Apply locking agent to the threads. 26 N-m (2.5 kg-m,19|brfl) 20 N'm (2.0 kg-m, 14 lb“) Apply locking agent to the threads. 33 N-m (3.3 kg-m. 24 lb—(t) Apply sealant to the threads. 25 N-m (2.5 kg-m,18 |b~ft) 2.5 N-m (0.25 kg-m, 1.8 Ib-ft) 12 N-m (1.2 kg-m, 9 lbrft) 07757 — 0010000 07959 - KM30101 07HMG — MR70002 or equivalent see page 8-11. 075MB - KT70100 07MMH - MV90100 or 07MMH — MV9010A 07743 - 0020000 07780 — 0010100 07780 — 0010200 07780 — 0012500 07780 — 0013300 07780 — 0014202 07780 — 0014500 07781 — 0010500 07HMJ — MV50100 or equivalent commercially available in U.S.A. Equivalent commercially available in USA. CVLINDER HEAD] VALVES Engine top-end problems usually eflect engine performance These can be diagnosed by a compression test, or by tracing noises to the top-end with a sounding rod or stethoscope. lithe pariormance is poor at low speeds, check [or white smoke in the crankcase breather tube. If the tube is smoky, ,dmeck for e seized piston ring. Ion too low, herd starting or poor pMOm-flcl at land Velvet - Incorrect valve adiuetment -!umld or bent valves -lneerrect valve timing - Broken valve spring - Uneven valve seating Cylinder head .- Leaking or damaged cylinder head gasket - Werped or cracked cylinder head - Louie spark plug Ion too high Excessive carbon buildup in cylinder head or on top of plnon vesmolte Worn valve stem or velve guide Damaged stem seal Flunycvlinder or piston (Section 11) nelu orrect valve adjustment . lclting valve or broken valve spring Worn or damaged camshaft ‘worn or damaged cem chain Worn or damaged cem chain tensioner Worn cam sprocket teeth ulty cylinder or piston (Section 11) w cylinder compression CVIJNDER HEAD/VALVES CYLINDER COMPRESSION Warm up the engine to normal operating temperature. Stop the engine. disconnect the spark plug caps and remove one spark plug at a time. NOTE i - To measure the cylinder compression oi each cylinder, remove only one plug at a tln’le. l—i — . A Shift the transmission into neutral and turn the engine stop switch ON, Insen the compression gauge. Open the throttle all the way and crank the engine with the starter motor. Crank the en- gine UMII the gauge reading stops rising. The maximum reading IS usually reached within 4‘ 7 seconds. Yool: Companion g-uge meet-merit o7RMJ — MV50100 Compruu‘on mu": 1175-1311 KPI‘13.0-13.‘ kglcm’, 185 - 191ml! Ii compression is high, it indicates that carbon deposlts have accumulated on the combustion chamber and/or the piston crown. ll compression is low, pour 3 — 5 cc (0.1 , 0.2 or) a! clean engine oil Into the cylinder through the spark plug hole and recheck the compression. If the compression increases [mm the previous value, check the cylinder, piston and pislon rings. If compression is the same as the previous value, check the valves lor leakage. (1i 1 L COMPRESSION GAUGE ATTACflMENT CYLINDER HEAD/VALVES (3) GHOMMET SHAFI’ REMOVAL ova the upper [airing (page 2-4). nnact the Ian motor connector. v. the radiator mounting bolts. 3 the grommet on the let! side radiator top from the (1) FILLER NECK lathe hook on the filler neck from [he hook. the radiator down without disconnecring the hoses «cure it with pieces of strings ON I II ardul no! to dam-fie m: rudinor fins 11) RADIATOR J (2) SPARK PLUG CAP meet the spark plug caps and breather tuba, «the cylinder head cover mounting bolts and cylinder cover. (4) HEAD COVER new»... the «m... “\\\\\\\\‘\%\h\\§ I ‘ D :Klllilllltl \KK\\Q\E\\\\\\K\Q§.W\”«:\R&3 m mm mm m at . \'\) CHNN COVE“. 12) BOLTS- Removetha right engine hanger plate bolts, caller and plate. (3, HANGER PLATE , (‘ll BOLTS | Remove the cam chain tensioner lifter sealing bolt and seal- " ing washer. Turn the tensioner shaft iully in (clockwise) and secure It us» my the stopper tool. This tool can easily be made from a thin (l mm thickness) P piece 01 steel using the dimensions shown below. 15mm 19 mm (H SEALING BOLT/ WASHER 3mm ‘5 "‘m 3'5 "V" (a) TENSIONER MATERIAL THICKNESS: 10 mm "5 mm NOTE . Be careful not to let the cam sprocket bolts and cam sprockets fall into the crankcase. V t . After removing the cam chain from the sprockets, 5145- v ‘ pend the cam chain with a piece 01 wire Remove the cam sprocket bolts. . Rotate the crankshaft clockwise one turn (360') and remove the other cam sprocket bolts and cam sprockets. w (2) SPROCKETS CYLINDER HEAD/VALVES Loosen and remove the cam shah holder bolts. CAUTION - From the nunida to th I. loosen the bola n .- crisscross pa cm In aver-I steps or the cumsh-h holder mlgM hulk. 1‘ llmovelhe camshaft holders and Camshafts ' manor: ”SHAFT JOURNAL ' the camshafl IDLIH’IEI surfaces for SCOllng or evidence . Immficiem Iubvicafion. both ends of the camshafl with V-blocks and check ll! runoul with a dlal indicator. f we mos mm (0.002 In) (1) CAMSHAFY CAM LOBE HEIGHT: 36.1! mm [1,422 In) (“‘51 mm (1,359 In) 35.27 mm (1.389in) 33.55 mm (1,321 In) CYLINDER HEAD/ VALVES CAMSHAFT JOURNAL 0. De JOURNAL O.D.: Measure the 0D, 0' each camshaft journal. Service limit: 24.955 mm (03825 In) CAMSHAFI' OIL CLEARANCE Clean off any oil [mm the journals 0' the camshaft holders, (1) CAMSHAFT head and Camshafts. Put the camshaft onto the cylinder head and lay a strip 01 plestlgauge lengthwme on top of each camshaft laurnal, NOTE . Do not block any all holes with the plastlgeuge. ' Do not rotate the camshaft during inspection, (2) PLASTIGAUGE Apply engine oil to the camshaft holder bolts threads. Install the camshaft holdevs carefully and tighten the bolts (page 8-22lr Torque: 12 N-m (1.2 kg-m, 9 Ib-l't] Remove the camshaft holders and measure the width at each plestigeuge. ~ The widest thickness determines the oil clearance, Service limit: 0.1 mm (04004 in) When the service limit is exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holders it the clear ence still exceeds the service limit. 8-8 HM CHAIN COVER Cluck the cam chain cover fior wear or damage; il it has ex- olllive wear, replace it. NDER HEAD REMOVAL - "ha exhaust system (page 2-10). v. the carburetor (page 5-5). '. . we‘ll: radiator (page 6-8). we the thermos“! (page 6-6). vothe PAIR control valve (California typa only: pugs , atho cylinder head 6 mm bolts, «be up nut and sealing washer. tho cam chain tensioner slider. (1) 6 mm BOLTS (1) TENSIONER SLIDER CYLINDER HEAD/VALVES (l) CAM CHAIN COVER CYLINDER HEAD/VALVES Disconnect the water hoses to the cylinder head. ‘ (1) CONNECTOR Disconnect the thermusensor connector. Disconnect the PAIR control valve hose irom the cylinder head (California type only). Loosen the cylinder head bolts from the outside to the inside in a crisscross pattern in several steps Remove the cylinder head bolts, Remove the cylinder head assembly. Suspend the cam chain with a piece of wire to prevent the chain from falling Into the crankcase. Remove the cylinder head gasket and dowel pins. 8-10 DER HEAD DISASSEMBLY Mark all parts during disassembiy so that they can be I ‘ placed back in their original locations for installation. the valve lilters and shims. v Im— tappet hole protector into the valve lifter sliding huh protlctor D7HMG — MH70002 ‘uuivalent tool can easily be made from a plastic 35 mm _ container by using the measurements as shown. valve spring compressor onto the valve and cnmr _anlva spring. - nq tha velva springs mera than necessary ‘ all». lol- of valv pring tension, the valve cutters. 07959 - KMJOIM 07757 — 0010000 - mares-or attachrnant . cantor-nor the valve spring compressor. then remove the re- aming; and valves _ “mm seals, inner spring seats and enter spring . M u I removed stem seal. CYLINDER HEAD/VALVES m TAPPET HOLE PROTECTOR rorvmw E ismm 25mmOD mm campramdi (I) VALVE SPRING COMPRESSOR (4] VALVE l5) INNER SPRING SEAT (6) STEM SEAL 8-11 CVLINDEFI HEAD/VALVES INSPECTION CAUTION l‘ wold dam-glng the g . I Remove the carbon deposits Irorn the combustion chamber and clean of! the head gasket surfaces, CVLINDER HEAD Check the spark plug hole and valve areas for cracks. Check the cylinder head Iarwarpage with a straight edge and Ieeier gauge, Sorvi it: 0.1 mm (0.00! in] VALVE SPRING I1) OUTER SPRING (2) INNER SPRING Measure the Iree length of the inner and outer valve springs. Service limits: Inn": 30.82 mm (1.206 in] Outer: 33.86 mm (1.333 in) VALVE S‘lEMJO-GUIDE CLEARANCE (1) VALVE Inspect each velve Ior bending, burning. scratches or abnorv mal wear. Insert the valves in their original positions in the cylinder head. Check that each valve moves up and down smoothly, without binding. Measure the each valve stem OD. and record it. Service limits: IN: 3.95 mm [0.1561 In] EX: 3.855 mm [0.1551 In) Ream the valve guide to remove any carbon buildup before (1, VALVE GUIDE REAMER measuring the guide. ‘ . Insert the reemer lrom the camshaft side at the head and al~ ways rotate the reemer clockwise. .5 tool: Valve gnld. rum-r, (DOB mm 07MMH - MV90100 or OTMMH - MVSOIOA IU.S.A. only) CVLINDER HEAD] VALVES Measure each valve guide LD, and record it. Mir:- limits: IN: 1.0! mm IDJSS in) EX: 4.04 mm (0.159 In] Subtract each valve stem CD. from the corresponding guide ID. to obtain the stemrtorguide clearance. Mice limits: IN: 0.075 mm (0.0029 in) EX: 0.085 mm [0.0033 in] "muom-to-guide clearance exceeds the service limit, d9, mlne if a new guide With standard dimensions would notho clearance within tolerance. , In, replace any guides as necessary and ream to lit _ In. mm-to»guide clearance exceeds the service limit with ‘ guide. also replace the valve. Ill-poet and refece the valve seats whenever the valve Idle are replaced (page 8-14). TENSION“ suns“ (1) TENSIONER SLIDER um chain tensioner slider tor wear or damage. manor blnding during movement. - I wear or hard movement, replace it. (I) VALVE LIFTER . e lilter for scratches or abnormal wear. _ Viv. lifter 0,0,. mm (1.022 in) lifter for scratches or abnormal wear. Ilkar bore I.D.. lln [1.025 In) CYLINDER HEAD/VALVES VALVE GUIDE REPLACEMENT Chill the valve guides in the freezer section 0' a relrigerator for about an hourr Heat the cylinder head to 13°C — 1‘0'C (275"F — 290?) with a hot plate or oven. Do not heat the cylinder head beyond ‘50": (300'Fl' Use temperature indicator sticks, available lrnm welding supply stores, to be sure the cyllnder head IS heated to the proper temperature. CAUTION " VALVE GUIDE DRIVER ~ Using I torch to heal the cylinder head may cause warping. Support the cylinder head and drive out the old guides from the combustion chamber side of the cylinder head. Tool: VIIVO guide driver, I mm 07GMD — KT70100 CAUTION @- Adjust the valve guide driver to the valve guide height. mega the cylinder head. I r1) VALVE GUIDE DRIVER Tool: Valve guide driver 07743 - 0020000 Valve guide projection above cylinder head: IN: 13.1 - 13.3 mm 10.516 - 0,524 in) EX: 11,3 - 11.5 "111111.45 - 0.453 in) Drive the new guide: in from the camshaft side oi the cvlin» (2) VALVE GUIDE der head while the cylinder head Is still heated > I PROJECTION: 8-14 CYLINDER HEAD/VALVES the cylinder head cool to room temperature, then ream (1, [sigh] VALVE cums REAMER new valve guides \‘t guid- rumur, 4.006 mm 07MMH — MV90100 or 07MMH — MVSOWA 1U.$.A. only) Take care not to tilt or lean the reamer in the QUIde while turning. Otherwise, lhe valve is installed slanted, that arises oil leaks lrorn the stern seal and improper valve “contact and results in the valve seal reiacing not Ibleto be performed Insert the rumor from the combustion chamber side of the head and always rotate the reamer clockwise, ‘ the cylinder head thoroughly to remove any metal parr alter roaming and relacing the valve seat ' VE SEAT INSPECTION/REFACING C'I'ION all make and exhaust valves thoroughly to remove deposits. I light coating ol Prussian Blue to each valve lace. “valve against the valve seat several times usmg a ping teal, without rotating the valve, lo make a clear the valve and inspect the valve seat facet vllve cannot be gromce is gulned ‘bldly worn or it it contacts the seal unevenly, replace the valve seat face for: , "ll WW“ m DAMAGED FACE (2) UNEVEN SEAT or collapsed valve stem; WIDTH the valve and relace the valve seat. fees: the valve and relace the valve seat. I'll [too high or too low area): i unvalve seal. (1) TOO LOW i2lTOO HIGH 8-15 CYLINDER HEAD/ VALVES Inspect the Width of valve seat. The valve seat Contact should be wilhin the specified widlh and even all around the circumference. Sllndard: 0.9— 1.1 mm (0.035 - 0.043 in} Service limit: 1.5 mm (0.06 In) N the valve seat width is not within specification, reIace the valve seat, VALVE SEAT RE FACING NOTE Follow the tool manufacturer’s operating iflSInIC-IIOHS Be careful not in grind the seat more than necessary. lithe contact area is too high on "18 valve, the seat must be lowered using a 32‘ flat cutier, lithe contact area is loo low on the valve, the seat must be raised using a 60‘ inner cutter. Refinish the seat to specifica- tions, using a 45" finish cutter. Using a 45' cutter. remove any roughness or irraguiarines Irorn the seat. Tools: VIIV. not cutter, 27.5 mm [‘5' IN) 07780 — 0010200 VIIV. scat cutter. 24.5 mm [‘5‘ EX) 07780 — 0010100 anvo sen cutter holder. 4.0 mm - 07781 — 0010500 or equivalent commercially available in U.S.A. (1) CONTACT T00 HiGH ‘2) OLD SEAT WIDTH Q 32' (2) OLD SEAT WIDTH (3) CONTACT TOO LOW - 11D ROUGHNESS CYLINDER HEAD/VALVES n ”2' cutter, remove 1/4 ol the existing valve seat mater I I.“ cm. 27 mm (32‘ IN) 07780 - 0011100 (1) OLD SEAT WIDTH "I1 «mar, 24 mm ISZ'EXI 07780 - 0012500 an elm-r hold", [.0 mm 07781 - 0010500 1 comm-mlallv Iv-iI-bla in U.S.A. uso‘ cutter, vemove the bottom 1/4 of the old seat. (1) OLD SEAT WIDTH V “unlit, 26 mm (60' IN] 07730-00I‘500 Humor, 22 mm (60' EX] D7780 - 0014202 In out!" hold-r. 4.0 mm 07781 — 0010500 unmmotclllly avuillhla in U.S.A, L ; fi'cuttor, cut the ssatta the proper width. lhltall min d' a Iar'l'es em a. p gan In an ll aver ave 0.90—1.10mm (0.035 , 0.043 in) lqplng pnnur- may dolomt or dam-g: tho ‘ the law of lapping tool lroquctttlv to puvnnt mild Ian cnuu dim-ac ll it ant-rs ba- VIIVI sum and an , ' mount. apply lapping compodnd to the valve «My-Ive using light pressure. wash any residual compound off the cylinder contact after lapping. CYLINDER HEAD/VALVES CYLINDER HEAD ASSEMBLY (12) VALVE SHlM ll) SPARK PLUG Q {11) VALVE LIFTER\‘O 113) VALVE CUTTER $9 a W! (10) VALVE RETAI NEH M , 1. . l9) INNER VALVE SPRING 7': r A r. - »\ K (2) VALVE GUIDE l8) OUTER VALVE SPRING (7i STEM SEAL [6) INNER SPRING SEAT I I3 EX (5) OUTER SPRING SEAT x/ ’ ”“157 VALVE \ l4) INTAKE VALVE lnslall the ouler spring sears, inner spring seats and new 519m seals. Install the (apps! hole protector into the valve Iiher sliding surlace, Tool: Tlppfl hob prmanor 07HMG — MR70002 or equivalent, no plan 8-11 Lubricate each valve stem with mulyhdenum oil solution and insan the valves into the Valve guides. To avoid damage to the sham seal, turn the valve slowly when installing. Install the valve springs and retainers. The sprIngs' lightly (1) VALVE SPRINGS wound coils should face reward the combustion chamber. 8-18 CYLINDER HEAD/VALVES ‘ lnnall the valve spring compressor onto the valve and comr (2) r5.» VALVE SPRING COMPRESSOR pm: the valve springs ‘ uunou - Commuting the valva springs more than necessary will cause loss ol valve spring t-naion ' not: ‘ To ease installation nfthe cutters, grease them first, | Null the valve cotters. "in Updng comprouor attachment 07959 - KM30101 Ipvlng compressor 07757 - 0010000 > Suppen the cylinder head so that the valve heads Will ‘ notwntact anythingthat causes damage. ‘ [he cutters firmly using two soft hammers as shown one hammer on the valve stem and genlly lap in With other hammer. DER HEAD INSTALLATION Invqaskat material from the cylinder mating surfaces the dowel pins and new gasket. fill. cylinder head onto the cylinder. molybdenum oil solution to lhe cylinder head bolt and amine surface. tighten the cylinder head bulls in a crisscross pat >3 mpt , Iflvm [1.8 kg-m. 35 Ila-ft) CVLINDER HEAD/VALVES Connect the thermosensor connector. Connect the water hoses to the cylinder head. Install the cam chain tensionev slider. Install the sealing washer and cap nut, Torque: 12 N-m (1,2 kg-m, 5 Ih-ltl Install the cylinder head 6 mm bolls Install the PAIR control valve (California type only: page 5 34L Install the thermostat (page 6-7). Install the radiator (page 6-5). Install the carburetor (page 5-19). Install the exhaust system (page 2-10). (I) CONNECTOR ' (2) WATER HOSES CYLINDER HEAD [VALVES :CAMSHAFF INSTALLATION poly molybdenum disulfrde oil to the valve liners. hullthe shims and valve litters, the T mark (notch mark) with the index mark on the on pulse generator rotor cover by turning the crank clockwise. molybdenum disullids oil (a 50/50 mixture of engine molybdenum disulfids greasel lo the camsheh jour- 01th- cylinder head and camshaft holders. the clmshal‘ts onto the cylinder heed with the cam lollha No,‘ cylinder facing up as shown I each camshaft into the correct side 5:}. camr his an identification mark; "IN' is lor the intake and 'EX' is for the exhaust sidev malybdonurn dieulfida oil to the cam lobes and jourr l1) BVALVE LIFTER it. (2l-SHIM ‘ 13) EXHAUST CAMSHAFT [2) IDENTIFICA- TION MARKS leWi Jr-Lri 1rd 8-21 CYLINDER HEAD / VALVES install the camshaft holders onto the Camshafts. Apply engine oil to the camshaft holder bolts threads. Install the longer bolts into the outer bolt holes and the shorter ones into the inner, and tighten the camshaft holder bolt: in the numerical order casted on the camshaft holders in a miss-cross patterm in 2 or 3 steps. Torque: 12 MM (1.2 Ito-m, 9 "Mil CAUTION Do not tighten ft holder bolts III at one t Tightening th armha holder bolts on only one- do I might cause I camshaft holder to brult . Make sure that the T mark (notch markl aligns with the index mark on the ignition pulse generator rotor cover. Install the cam chain over the cam sprockets. Install the cam sprockets onto the cam shaft flange with the timing marks on the cam sprockets aligning With the cylinder head upper surface. facing opposite each other NOTE - Install each cam sprocket to the correct camshaft. Each cam sprocket has an identification mark‘ "IN" is for the Intake 5 e and "EX" is for the exhaust s e. Before tightening the bolts, clean the old locking agent off the bolt threads and the bolt holes in the cam sprockets. Apply a locking agent to the threads of the cam sprocket bolts and tighten the two bolts loosely. Turn the crankshaft clockwise 1/2 turn (180‘) and tighten the first two bolts to the specified torque. Torqul: 20 N-m (2.0 Ito-m, 14 Ib-ftl Turn the crankshaft clockwise 1 /2 turn (180') and tighten the first two bolts to the specified torque. install the cam chain cover and secure it with the bolts. ‘7 (1) CAMSHAFT HOLDERS I21 eon—7' .. [_ f1lTMARK leNDEX ( MAFlK (SlTIMING MARKS COVER f2) BOLTS I010 stopper tool, ltho new sealing washer and cam chain 1enslonev sealr bolt. the bolt securely. run the timing marks on the camshaft sprockets are Iwith the cylinder head upper edge lltho right engine hangar plate and collar. Ilnd tighten the hanger plate bolts. 10 mm bolt : ‘5 N-m (t5 kg-m, 33 Ila-k) remove the head cover breather plate, replace the gas I "M 0'18. locking agent to the threads, and lighten the breather bolt: .12 Ntm [1.2 kg-m, 9 um) Honda Bond A or equivalent to the cvllnder head cover then install the packing into the groove CVLINDER HEAD/VALVES (3) BOLT W/m 9 SEALING WASHER l1] CAM CHAIN TENSIONER l1) BOLTS l3) RLGHT ENGINE HANGER. PLATE l2) 9! GASKET mflaons (1) PACKING (2) HEAD COVER 8-23 CYLINDER HEAD] VALVES Apply sealant to the semicircular cut-out on the cvllndel head as shown (1) Jam: CUT—OUT Install the cylinder head cover onto the cylinder head. NOTE ‘ Be sure that the gasket is seated properly, especially around the spark plug holes. Install the new washer with its 'UP" mark facing up. (1) 'UP" MARK Install and tighten the head cover belts in 2 — 3 steps. ( )BREATHER TUBE (2} SPARK PLUG CAP NOTE . Tighten the -A" marked side balls first I Torque: 10 Mom (1.0 llg-m. 7 IIHtl Connect the spark plug caps and breather tube. Install the ignition pulse generator rotor cover cap (page 3~ 10). f . - \ . _ (‘1 HEAD COVER ‘~. (3) "A' MARKS 8-24 CLUTCH/GEARSHIFT LINKAGE 20 N-m (ZO/kg-m. 14 mm 110 N-m [11.0 kg-m, 80 lb-fll 12 N-m (1.2 kg-m, 9 lb-fl) 23 NW! (2.3 k9>m, 17 lb-h) 9. CLUTCH/GEARSHIFI' LINKAGE l SERVICE INFORMATION 9-1 GEARSHIFT LINKAGE 9-8 TROUBLESHOOTING 9-2 CLUTCH INSTALLATION 9-11 CLUTCH REMOVAL 9-3 ‘ IIVICE INFORMATION The clutch and gearshift linkage pans can be servi d with the engine installed in the lrarne. Engine ail 'scosity and level, and the use of oil ed ves have an effect on clutch disengagement. Oil additives 01 any llnd are not recommended. When the clutch does not ssngege or the motorcycle creeps with the clutch disengaged, lnlpnct the engine oil viscosity and level betore servicing the clutch system. TI!- crankcese must be separated when the transmission requires service (section 10). Unit: mm (in) STANDARD SERVICE LIMIT 10,20(3/3,3/4) — 49.7 (1.96) W 433 (1.90) 2.92 — 3.08 (0.115 A 0.121) 2.60 (0,102) ‘ w plate warpage 7 — 0.30 [0.012) ‘ 4 )1 outer gulda . . "7 34,975 - 34.391 (1.3770 —1.3776) (“.985 (1.3766) 21.954 — 22.007 (0.3659 — 0.8664) 22.017 (0.8688) , all CD. at clutch outer guide 21.980 — 21.993 (0.3654 — 0.8659) 21.95 (0.864) . E VALUES contorlock nut ‘IIO N~m (I‘LD kg-m, EO lb~ftl Apply oil to the thleads. Stake. nplndle return spring pin 23 N~m (2.3 kg-m, 17 lb»ft) _ . center bolt 23 N'm (2.3 kg-m, 17 lb-ftl Apply a locking agent to the threads. muse cover bolt 12 N-rn (1.2 kg-m, 9 lb-ft) pedal pirch bolt 20 N-m (2.0 kg-m, 14 Ib-It) wring bolt 12 N-m (1.2 kg-m, 9 Ib-ft) topper arm bolt 12 N-m (1.2 kg-m, 9 Ila-ft) 07JMB -‘MN50300 or 07HGB — 001000AlU.5.A.onlv) 077‘6 — 00‘0200 077‘6 — 0010200 077‘6 — 0010300 07716 — 00‘0800 07916 — 1870100 CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch love! too hard - Damaged, kinked or dirty clutch cable ' Improperly routed clutch cable - Damaged clutch lifter mechanism . Faulty clutch lifter plate bearing Clutch will not dlungagc or motorcycle creeps with dutch disengaged - Too much clutch lever free play - Warped plate - Loose clutch lock nut - Engine oil level too high, improper oil viscosity or oil addi- tlve used Clutch elips - Clutch lifter sticking - Worn clutch discs - Weak clutch springs - No clutch lever free play ~ Engine oil level too low or oil additive used Hard to shift - Improper clutch operation - Incorrect engine oil viscosity - Incorrect clutch adjustment - Bent or damaged gearshift spindle - Damaged shift drum cam grooves - Bent shift forks or fork shaft (section 10) Transmission lumps out of our . Broken shift drum stopper arm - Broken shift linkage return springs - Damaged shift drum cam grooves - Bent shift fork shaft (section 10) - Worn or bent shift forks (section 10) - Worn gear dogs or slots (section 10) CLUTCH REMOVAL ”hove the side (airings (page 23), Drum the engine oil (page 341). Va the clutch cable holder bolt and disconnect the II cable from the clutch arm. “he oil filler cap/dip stick. the bolts and right crankcase cover, the gasket and dowel pins. , the clutch lifter plate balls in a crisscross pattern in 2 the bolts, lifter plate, sprlngs and lifter real not deluge the melnsh-k thro- tlnclutch center lock nut. , CLUTCH/GEARSHIFI’ LINKAGE (3) HOLDER (5) K ‘ l o w l r r FILLER CAP/DIP sncx w RIGHT CRANKCASE coven (2) GASKET ('ll BOLTS CLUTCH/GEARSHIFT LINKAGE Hold the pressure plate with the clutch center holder and loosen the clutch center lack nut. Tool : Clutch center holder DUMB — MN50300 or 07HGB — MIWDA IU.S.A. only! Remove the clutch center lock nut. Remove the lock washer, thrust washer, clutch center, judder spring and spring seat, Remove the nine clutch discs and eight clutch plates. Remove the clutch pressure plate and thrust washerl Insert a 5 mm pin (or suitable tuol) into the holes in the prir mery driven gears to align the gear teeth. Pull the clutch outer guide out by pinching the ribs on the clutch outer guide and sliding the guide fomard. (1) aim CLUTCH CENTER HOLDER z (1| DISCS/PLATES , 13) Juooen SPRING (SlCLUTCH CENTER (llSPRlNGSEAT' ‘ ' 9- (1) PRESSURE PLATE (3) 5 mm PIN Align the projecflons ol the crankcase with the teeth of the primary driven gears and remove the clutch outer from the Human. CTION LIFTER PIECE/ARM v. the clutch lifter pieced wthaclutch liner arm, washer and return spring. the apring for latigue or damage. Iha Iiflor piece and lifter arm lor damage or bending. the needle bearings for wear, damage or loose (iL the oil seal for fatigue or damage. (2) OIL SEAL HATE BEARING r (1) HEARING at lifm plate bearing for damage. . . bearing inner race with your finger. The bearing lmoothly and quietly without play. am the bearing outer race litslighfly in the piatei III baring i! necessary. CLUTCH/GEARSHIFT LINKAGE (1) PROJECTIONS CLUTCH/GEARSHIFT LINKAGE CLUTCH SPRING Measure the spring free length. Servlc' Ilmit: 48.3 mm ".90 in) NOTE ' Replace the clutch springs as a set. ‘ (1) SPRING CLUTCH DISC (HDISC Check the clutch discs lur signs 0' scoring or discoloration. Measure the thickness 0! the discs. Servic- Iimh: 2.60 mm l0.l02 inI NOTE 1 - Replace the discs and plates as a set. I CLUTCH PLATE Check the plate for excessive warpage or discoloration. Check the plate warpage on a surface plale using a Iaeler gauge. Sorvica limit: 0.30 mm (0.012 in] CLUTCH CENTER Check the clutch center for nicks, indentations or abnormal wear made by the clutch plates. (1) CLUTCH CENTER EUTCN OUTER Check the clutch outer ior nicks, rndemalions or abnormal ‘wr made by the cluich discs, Check the serrated ieem of the primary driven gear for wear :ordamege. Chockme needle bearing lnr wear or damage. SPRING/SPRING SEAT the spring seat and juddar spring for distortion, wear dlmage. OUTER GUIDE Im! the clutch outer guide, III“: 0.0 34.985 mm (1.3766 In) I.D. H.017 mm (0.8658 In) in. mainshah 0.0. at the clutch outer guide. m 21.95 mm (0,854 In) CLUTCH/GEARSHIFT LINKAGE (1) CLUTCH OUTER (1) SPRING SEAT (2) JUDDER SPRING (1) OUTER GUIDE <1)MAIN$HAF1‘ CLUTCH/GEARSHIFI’ LINKAGE CLUTCH LIFTER HOD Check (he clutch lifter rod for wear or damage, CLUTCH OUTER NEEDLE BEARING REPLACEMENT Press lhe needle bearing out of the cluxch outer. Tool: Driver 07749 - 0010000 Afllchmonl. 37 x 40 mm 07746 - 0010200 Pila‘, 35 mm 07746 - 0040600 Press 5 new needle bearing Into the clutch outer so that the edges ohhe needle bearing and clutch outer are flush. Tool: Driver 07749 - 0010000 Afllchmom, 42 x 47 mm 07746 - 0010300 Pilot. 35 mm 07746 - 0040800 GEARSHIFTLINKAGE REMOVAL Remove Ihe gearshift pedal pinch bolt and pedal link‘ Remove the clutch outer (page 9-3). (1) LIFI’ER ROD (1) 1min] DRIVER (ll E’:}'°°’ DRIVER (2) PEDAL LINK r Mn the gaarshifi spindle assembly and washer. the shift drum center boll. shin drum center and pin. [by «upper arm boll, sloppev arm, washer and (4) STOPPER ARM nhlfi spindle for wear or damage‘ mspring for fatigue or damage, CLUTCH/GEARSHIFT LINKAGE ‘ I' I (3) WASHER (I) GEARSHIFT SPINDLE CLUTCH/GEARSHIFT LINKAGE Check the needle bearing for wear or damage. Check the oil seal lor tatlgua or damage. '1‘} \\ '(2) OIL SEAL INSTALLATION (1lBOLT"" - (2) SPRING .1 ‘ _ I ‘; Install the return spring. washer and stopper arm and tighten the stopper arm bolt, Torque: 12 Man (12 klfln, 9 Ib—n) Check the stopper arm for proper operation. Install the dowel pin into [he shift drum Move the stopper arm out at the way using a screw driver. Align the shift drum center hole with the dowel pin and slip it in to place. (3) STOPPER ARM M /\ Apply a locking agent to the shin drum center bolt threads. (1) m BOLT Install and tighten the shift drum center bolt. 1‘ . Yorque: 23 Min (23 kwm, 17 Ib—Rl 9-10 CLUTCH/GEARSHIFI' LINKAGE mull the gearshift spindle and washerv (1) GEARSHIFT SPINDLE , , v A u Irltlll the gearshift pedal link by aligning the punch mark withthe slit in the link. Install and tighten the gearshift pedal pinch bolt. Torque: 20 mm (2‘0 kg-m, 14 “741) ‘ Move the gearshift pedal and check the shift mechanism for proper, smooth operation, Imll the clutch (see belowlv CLUTCH INSTALLATION , {same Apply molybdenum ml solution to the clutch outer needle During. hullthe clutch outer onto the mainshah by positioning the projections oi the crankcase between the teeth 0' the pri ,mlrv driven goers. <2) CLUTCH OUTER \ up the gear teeth of the primary driven gears with e 5 (1i CLUTCH OUTER ' pin (or suitable tool). . GUIDE (2) 5mm PIN y molybdenum oil solution to the clutch outer guide. lithe clutch outer guide with the ribbed side lacing out Ithe clutch outer, aligning the clutch outer holes with all pump driven sprocket while pushing in on the clutch llghtly. Ir installing the clutch outer guide, remove the 5 mm pin the primary driven genre. CLUTCH/GEARSHIFT LINKAGE I t II the her onto the m ' shaft "5 a was em (1’ WASHER Coat the clutch discs with clean engine oil, NOTE ‘ . Do not confine the 'A" and 'B' clutch discsr The 'A" disc is black and the "8' discs are brown. [2) SPRING‘ SEAT Install the spring seet, iudder spring and clutch disc A on the clutch center. NOTE 5 P T L ' Note the direction of the 3 seat, judder spring and disc A. ‘ ) LA ES (3) JUDDER SPRING install the B clutch discs and clutch plates on the clutch center. '- i1) CLUTCH CENTER Install the pressure plate to the clutch center aligning the punch marks on the clutch center and pressure plate, (1) PRESSURE PLATE (2) CLUTCH CENTER Minn m puna. mm. Install them in the clutch outer as an assembly. N DTE - When installing the A disc, align the end graove in ta clutch outer with the tabs of disc, I install the thrust washer on the mainshelt. Install the lock washer on the mainsheft with "OUTSIDE" mark facing the outside. Apply oil to the new clutch center lock nut threads. Install and tighten the new clutch center lock nut. (3i THRUST AND LOCK WASHERS, 9-12 lite pressure plate with the clutch center holder and In the lock nut. center fielder 07JMB - MNSOOOO or OTHGB - 001000A (USA. only) . 110 Mm! (11.0 kg-m. so lb-fl) the lock nut into the meinshah groove. hull the springs onto the bosses of the pressure plate. Aucmble the clutch lifter rod and clutch lifter plate, and in» all the assembly to the clutch pressure plate. Secure the litter plate by tightening the belts In a crisscross mm in several steps. ovum: 12 N4" [12 kg-m, 9 Ibm I more . lithe clutch lifter rod comes out while’lightening the clutch lifter plate bolts, push the rod all the way in to prevent the rod from being bent or damaged. CLUTCH/GEARSHIFT LINKAGE m CLUTCH_CENTER HOLDER CLUTCH/GEARSHIF‘I’ LINKAGE Note the return spring direction and install lhe lifter arm wnh [he sprmg and washer, Apply grease lo me clulch liner place and install it. Install the dowel pins and new gasket. Install the right crankcase cover and bolts. Yorque: 12 MM (12 Ira-m, 9 HM!) Connect the clutch cable to the clutch arm and install the cable holder, After Khe clutch system has been serviced, fill the crankcase wirh the recommended engine oil (page 3-12) and perform the clutch adjustmenr (page 3721), (1) RETURN SPRING \g (2) WASHER \ ( ) FILLER CAP/DIP STICK COVER CflANKCASE/ TRANSMISSION 40 N-m (w kg—m, 29 Ib-ft) 2“ M“ ‘2" “9’“ ‘9 "”0 a 26 N-m [2.6 kgm, 19 lb—fl) 12 N-m «1.2 kg-m‘ 9 mm 12 Mn (1.: kg-m, 9 Ib-m [ fi( » 7,,“ 'V/ 7 ‘ ~ A ‘ w . 1 ~ . . 6‘» gm. 9 IN!) 12 N-m (1.2 k (-2» la N I I: 12 Mom (12 kg-m, 9 lbrh) / f 12 NW (1-2 Ram 9 Ib-m 2‘ N-m12‘4 kg-m, 17 lb-h) 10. CRANKCASE/TRANSMISSION SERVICE INFORMATION 10-1 TRANSMISSION 10-4 l TROUBLESHOOTING 10-2 CRANKCASE ASSEMBLY 1012 anNKcASE SEPARATION 10-3 SERVICE INFORMATION GENERAL 'The crankcase halves must be separated to service the crankshaft, p)ston, cylinder and transmission (Including the shift fork and shrft drum). To service these parts, the engine must be removed from the heme (sactien 7), -Tha following pans must be removed belore separating the crankcase: < Oil pan, oil pump and oil cooler (Section 0) (Water pump (Section 6) ~Cylindev head (Section 8) ~Clutch and gearshift linkage (Section 9] r LeIt cramkcase cover (Section 15l . Ignition pulse generator cover and rotor (Section 16) ~ Fly wheel (Section 17) - Starter motor and starter clutch (Section 17) - Be carelul net to damage the crankcase mating surface and crankshaft mam journal bearings when servicing. 1 Prior to assembllng the crankcase halves, apply sealant to thalr mating surtaces. WIpe off excess sealant thoroughly. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Tm“ Gear |.D. M5, M6 29.000 - 29.021 (1.1024 — 1.1032) T104) mission 02764 31.000 - 31.072.5(12205 — 1.2215) 31.04 (1.222) "(gear 005111300. M5, M6 27.959 — 27.990 (1.1007 — 1.1016) 21.94 (1.100) ' c2 30.959:30.990 (1,2199 - 1.2197) 30.94 (1213) C3, c4 30.950 - 30.975 (1.2195 — 1.2195) 30.93 (1.218) Gear bushlng 1.1;). M5 24.995 — 25.006 (0.9937 — 0.9045) 25.015 (0.9849) ' c2 7 27.905-2900601019- 1.1026) 29.021 (1.1032) Gear-turbushing clearance at M5, M6 gear 0.020 — 0 062 (0.0008 — 0.0024) I — ”3062, C3, (:4 gear 0.050070 (0.0009 — 0.0029) — Malnshaft 0.0. at M5 gear bushing 24.967 — 24990019930 — 0.9935) 24.960 (0.9927) at clutch outer guide 21.990 - 21.993 (0.8654 — 0.8655) 21.95 (0.0694) :Ountershah 0.0. at (:2 gear bushing 27967—27900 (1.1011 — 1.1016] 27.95 (1.101) ‘ Gear bushing-to-shaft M5 gear I I "0.005 — 0.039 (0.0002 - 0.0015) — “mm“ at c2 gear 0.005 — 0.039 (0.0002 — 0.0015) — Shilt Fork claw thickness 5.93 - 6.00 (0.233 2 0.236) 5.90 (0.232) III-I111 Fork (.0. iWW I 7 . 12.000 - 12.021 (0.4724 "91,793 12.030 (0.4736) Shaft 00. 11.957 ~ 11.969 (0.4707 — 0.4712) 11.95 (0.470) 10-1 cRANKCASE/TRANSMISSION TORQUE VALUES . Main inunal bolt 25 N-m (2.6 kmm. 19 Ib-ft) Apply oil to the threads. Crankcusn boll (6 mm) 12 NW! (1.2 kg»m. 9 lb-ft) (8 mm) 24 MM (14 kg-m, l7 lb-fl) : (10 mm)!!! N-m (t0 kg»m, 29 Ib-h) Sealing bolt (20 mm)30 N-m (3.0 kg—m, 22 Ib-fY) Apply saahm to the threads. (14 mmDZE N-m (2.5 kg-m, 18lb-f1)App(v seal-m 10th. thread; TOOLS Inner driver. 07746 - 0030100 Anachmem, 25 mm ID. 07746 - 0030200 TROUBLESHOOTING Hard ‘0 mm . Improper clutch adjustment ' Incorrect engine oil viscosity - Improper clutch operation ‘ - Bani shift fnrks - Banl shiff fork shaft - Bent shift fork claw - Damaged shift drum cam grooves - Bent shift spindle Trmsmlsdon lumps out 01 your - Worn gear dogs or slms - Bent fork shah - Broken sniff drum stopper - Worn or bent shift forks - Broken shift linkage rarurn spring - Damaged shift drum cam grouves ‘ 10-2 CRANKCASEITHANSMISSION NKCASE SEPARATION 7 In Service Information [page 1071i for removal ol erv pans befora disassembling (he crankcase vs the boil, collar and cam chain guide. vs the cam chain and cam chain drive aprockm. the screw and oil pressure switch ierminalr nnoct the nemrel switch connecturr the bolts and speed sensor. vs the speed sensor before sop-retina (he usnk- . Do not sap-run or III-"lb" "I. annual. with ups-d sensor Installed. "he upper crankcase bolts and sealing washers ‘(2) CHAIN n A (2) CONNECTOR (1) BOLTS » / ,. ' r-l (2) BOLTS/SEALI NG WASHERS l CRANKCASE/TRANSMISSION Turn (he engine upside down Loosen the lower crankcase bolt: in a crisscross pattern from the outside to inside In sever“ steps. Remove the bolts and sealing washers. Remove the lower crankcase lrom the upper crankcase. Note the direction 0' the oil orifices. Remove the dowel pins and oil orifices. TRANSMISSION REMOVAL Remove the countershaft assembly. Note the iocaiion oi the pin and bearing ring. Remove the bolts and mainshaft sat plate. i1) BOLTS 2iBOLTS/SEALING " WASHERS Move me mainshan assembly, V move the bolts and shift drum set plates. 0 the shifl lork shah and shift 'orks, tha shih drum bearing and shift drum. CRANKCASE/TRANSMISSION TRANSMISSION DISASSEMBLV Disassemble the mainshak and countershah. Check the mainshafl and caumershah needle hearings (or damage or excessive wear. INSPECTION GEARS Check the gear dogs. dog holders and teeth for damage or excessive wear. Measure the ID. of each gear, Servle- lIqu: M5, M8: 28.0! mm (1.104 in) C2, ca. (:4: 31.0. mm (1.222 in) ausumss ‘ Check me bushings for damage or excessive wear, Measure the OD, of each bushing. Service IImlts; M5, M6: 27.54 mm (1.100 in) C3, C4: 30.93 mm (1.213 in) CZ: 30.94 mm (1.218 in) Measuve the ID, of each bushing. Sandc- Ilmlts: M5: 5.016 mm (038481") “128.021 mm (1.1032(") 11) MAINSHAFT 4“” (2) COUNTERSHAFT (1| BEARING (2) BEARING CASE 6” 10-6 CRANKCASEITRANSMISSION ISHAFHCDUNTEFISHAFI l1) MAINSHAFT > krhe spline grooves and sliding surfaces for damage or nrmal wear, nurs the 0.0. 0' the mainshaft and countershaft m the land bushing sliding areas. llmih: M“ It M5 gear but In 24.960 mm [0,9827 inl lhlft ll CZ guy buih 27.96 mm (1.101 inl (Zr COUNTERSHAFT DRUM (H BEARING pen the shift dlum end for scoring, scratches or evidence imufficienl lubrication wk the shift drum grooves [or abnormal wear or damage. {2) SHIFT DRUM Fl’ FORK ck Ior abnormal wear or delurmalion, sure the shift lurk LD, and claw thickness, Ilmlts: . 12.030 mm (01736 inl thlcknou: 5.90 mm [0.0232 in) FORK SHAFT Ho! abnormal wear or damage‘ ure the shift lork 0D. I:- limin: ".95 mm (0.470 In) CRANKCASEITRANSMISSION TRANSMISSION ASSEMBLY Clean all parts in solvent. Apply molybdenum ail solution to the gear and bushing sliding surlace and shift lork grooves to ensure initial lubrication. Assemble all parts into their original positions. N OTE - Check the gears for freedom of movement or rotation on the shaft, - Install the washers and snap rings with the chamlered edges facing the thrust load side. Do not reuse worn snap rings which could easily spin in the groove. - Check that the snap rings are seated in the grooves in CORRECT (2) INCORRECT Align their and gaps with the grooves ol the spline. MAINSHAFI’ (1) MAINSHAFT (2) THRUST WASHER (33 x 25 x 11 ‘3’ 5“” ”MG (3) M5 GEAR (ZUT) M) SPLINE WASHER ‘ s 15) M3/M4 GEAR (17/191) ' (Bl SNAP RING /@ (7) Me SPLINE BUSHING , I17) M5 BUSHING / , (a) SPLINE WASHER » (Isl SNAP RING (9) M2 GEAR I1 _,_.-@ IIoI NEE WASHER AND SNAP RING DIRECTION: ”5’ SW“ WASHER a: 114) M6 GEAR (23T) @ (13) LOCK WASHER (12) THRUST WASHER (31 x 20 x 0.9) zen-mum eIdI Wemmhrfingu (11) BEARING 10-8 CRANKCASEITHANSMISSION TERSHAFI' 120) BEARING CASE (17D THRUST WASHER (3I x 20 x 0.9) (I) COUNTER SHAFT (15) SNAP RING I (13) c: GEAR SPLINE ‘ 0 (19) NEEDLE » BUSHING BEARING m) LOCK WASHER (18) C1 GEAR (HT) \' ‘ (9} C3 GEAR BUSHING (16) C5 GEAR (ZIT) (7) SPLINE WASHER (1‘) SPLINE WASHER , I5) SNAP RING 112) C3 GEAR (28T) (3) C2 GEAR BUSHING (10I SPLINE WASHER (8) CA GEAR IZGTI (6) cs GEAR (251) 0 (4) SPLINE WASHER (2) C2 GEAR (331') WASHER AND SNAP RING DIRECTION: : Gut and buahing flldlng sud-col and Ihlk fork groovn CRANKCASE [TRANSMISSION MAINSHAF‘I BEARING REPLACEMENT (ll MAINSHAFT (Z) BEARING NOTE ‘ - Do not remove the countershafi bearing. If bearing I replacemam is required, replaca the countershafl assembly. Remove lhe mainshafl bearing by pressing the mainshsfl as shown. Press (he new bearing onto the mainshafl using the special mm; m DRIVER Tools: Innlr drivlr 077w - 0030100 Anlchmlnt, 25 mm ID 07746 - 0030200 N OTE . Install the bearing wilh ils marking lacing out. (ll MAINSHAFT INSTALLATION Install the shift drum and bearing into (he lower crankcase. Each shin Iork has an identification mark; 'Fl“ is for the right u) 'L' MARK (2) "5- MARK (3} "R' MARK ’ shin lork, 'L‘ is Ior the left shift dark and "C' is for the center ~ shifi fork. I4) SHIFT FORKS ltho shift forks, aligning the shin drum pins With the ‘ dmm grooves‘ Be sure that the identification marks are nettle right side ofthe engine. ly clean engine oil to the shift tork shall and install it ugh the shift torks. II the shift drum bearing set plates with the "OUT‘ mark out as shown. ly locking agent to the threads of the set plate bolt. Iland tighten the set plate boltst II the mainshaft in the upper crankcase II the mainshah bearing set plate with the 'OUTSIDE“ facing out. ‘ locking agent to the threads of the set plate bolt. II and tighten the set plate bolts. CRANKCASE [TRANSMISSION (1)"7.SHIFT FORK SHAFT 10-11 CHANKCASE/TRANSMISSION lnstall the countershel‘t assembly. NOTE I . Align the hole in the countershaft needle bearing case th the pin in the upper crankcase. - Align the groove in the countarsheft bearing with the stopper and pin on the bearing with the groove in the crankcase. After installing, check for smooth transmission operation. CRANKCASE ASSEMBLY Clean the upper and lower crankcase mating surlaces thoroughly, being careiul not damage them. Apply a light but thorough coating of sealant to all crankcase mating surfaces except the main bearing journal bolt (8 mm lower crankcase bolt) areas and the oil passage area as shown. CAUTION l - Do not apply mlorrt around the all passage am "3' L maln bearing leurnal aa. Install the oil orifices to the upper crankcase. NOTE ' Install the oil orifices. aligning the cutout on the orifice with the upper crankcase hole. CRANKCASEITRANSMISSION v II the dowel pins imo the upper crankcase. bla the crankcase haIves, aligning the shift fork claws u I"! . [has I av gear grooves [2) CENTER SHIFT (1) LEFT SHIFT FORK , for smooth ‘ransmission operation FORK (3) RIGHT SHIFT FORK \/ (5p M314 GEAR < (5) C6 GEAR CRANKCASE/TRANSMISSION Apply oil to the main jounel bolt threads and seating sur» face, Install the lower crankcase bolts and washers. From the inside to the outside, tighten the lower crankcase 8 mm belts in a crisscross pattern in several steps, Torque: rmIrt journal bolt: 26 N-m (2.6 kg-m. 1s lb-ltl Install the remaining crankcase bolts and sealing washers as shown. NOTE V - Install the sealing washers to the bolt holes indicated by ‘ ‘ the "A' marksr Tighten the crankcase bolts in a gradual crisscross pattern, beginning with the larger diameter bolts first. Torque: 6 mm bolt: 12 MM (1‘2 kn-m, 9 “rm 8 mm bolt: 2‘ N-m (2.4 Itg-m, 17 RH!) 10 mm bolt: 40 N-m [4.0 kg-m, 29 Ib-ltl Clean the speed sensor and install a new O-ring. Install the speed sensor to the upper crankcase and tighten the bolts. Connect the oil pressure switch terminal and neutral switch connector. - (1) MAIN JOUNAL BOLT (2) 6mmBOLT 10-14 ORANKCASEITRANSMISSION V II the cam chain drive sprockat aligning the groom with wide teeth. Install the cam chains through the cmnkcase. II the cam chain guide, cells: and bolt, nmllme removed parts (page 10-1). /, J- I} (5) CHAIN GUIDE CVLINDEHIPISTONICRANKSHAFT 26 N~m (2.6 Kg-m, IS lb—fi) 11. CYLINDER/PlSTON/CRANKSHAFT SERVICE INFORMATION 11-1 TROUBLESHOOTING 11-2 CRANKSHAFT 11-3 CVLINDERIPISTON[CONNECTING ROD 11-7 etankcase must be separated to service the crankshafl, piston, cylinder. urelul not to damage the crankshaft main journal bearings while removing or installing the crankshalt. arMuI not to damage the cylinder have white ramovmg or installing the piston/connecting rod. nnecting rod and crankshaft bearing inserts are Selecl fitted and are identilied by color code. Select replacement rings uslng the selection tables. Alter installing new bearings, recheck them with plastigauge to verify correct 78'1“. n disassembling. mark and store the disassembled parts to ensure that they are reinstalled in than original locations. y molybdenum dtsullide oil to the main journals and crankpins during assembly n removing the piston, clean carbon and sludge from the top at the cylinder. CIFICATIONS Unit: mm (in) STANDARD SERVICE LIMIT I.D. W 65.000 — 65.015 (2.5591 - 2.5596) 65.10 (2563) up; 7 0.10 (0.004) W 0.10 (0.004) a. 10 (0.00:) 0ut-of»round Warpage ‘ Piston mark direction 'IN“ mark facing to the intake side Piston 0.0, 61.970 - 60.990 (2.5579 — 2.5587) 31 11 (0.4) from bottom olskirt 6‘30 (2.555) Piston pin hole I.D. 17.002 — 17 008 (0.6654 — 0.6696) 17.02 (0.670) CyllndeFIO’pislun clearance 0.010 r 0.045 (0.0004 - 0.0018) 0.10 (0.004) Piston pin OD. 16.994 7 17.000 (0.6690 — 0.6693) 16.98 (0.669) Pistonrto-piston pin clearance 0.002 — 0.014 (0.0001 - 0.0006) . 0.04 (0.0016) Connecting rod-to-piston pin clearance 0.016 — 0.0‘0 (00006 ~ 0.0016) 0 06 (0.0024) Piston ring-to-ring Top 0.025 — 0 060 (00010 ~ 0.0024) 0.08 (0.003) wove clearan ' 9 ca Second 0.015 — 0.050 (0.0006 — 0.0020) 0.08 (0.003) Piston ring end gap Top 020 — 0.35 (0.008 — 0.014) 0.5 (0.02) Second 0.35 v 0.50 (0.016 — 0.020) 0.7 (0.03) Oil (side rail) 0.2 — 0.7 (0.01 — 0.03) 1.0 (0.04) Piston ring mark Top ”T" on?" mark facing up Second "T" or 'RN" mark facing up CVUNDERIPISTON/CRANKSHAFI' Unit: mm [I lcont’dl ITEM STANDARD SERVICE LIMIT Crankshaft. Connecting rod small and ID. 17.016 - 17.034 lam —- 0.6708) 17.0‘ (0.871) connoctin rod 9 Connecting rod big and side clearance 0.10 - 0.25 (0.004 — 0.01) 0.30 (0.012) Crankshaft runout — 0.05 (0.002) L Clankpin oil clearance 0.028 — 0.052 (0.0011 - 0.0020) 0.06 (0.002} ! Main journal oil Clearance 0020 — 0.045 (0.0008 — 0.0018) 0.05 (0.002) TORQUE VALUES Connecting rod bearing cap nut 26 N-m (2.8 kg-m. 19 Ib-ft) Apply oil to the threads and seating surface. TOOL Inner driver 077.6 — 0030100 Attachment, 30 mm ID. 07746 — 0030300 TROUBLESHOOHNG Cylinder compression I- too low, or engine I: bird to our! - Blown cylinder head gasket ~ Worn, stuck or broken piston ring - Worn or damaged cylinder or piston Cylinder compression in too high, or engine ovum-m or knocks - Carbon deposits on the cylinder head and/or piston Noise - Worn cylindar, piston end/or piston ring - Worn piston pin hole and piston pin - Worn connecting rod small and Excessive smoke - Worn, stuck or broken piston ring - Improper installation 0! piston rings Exceuivo nolu - Worn connecting rod big-and bearing - Bent connecting rod . Worn cranluhalt main bearing - Worn transmission bearing Engine vlbrnlon - Excessive crankshalt runout 11-2 CVLINDER/PlSTON/CHANKSHAFT Ineln journal or connecting rod belring Insane. puma the nrankcase (page 10-3). on removing the crankshaft, check the big end side "0139‘ V wire the clearance by insenlng the feeler gauge between crankshaft and connecting rod big end, mit: 0.30 mm (0.0l2 In) ovethe connecting rod bearing cap nuts and the bearing Mark the bearing caps and bearings as you remove ' them to indicate the correct cylinder and position on [he mnkpins lor reassembly. ‘ Tap the side of the cap lightly it the bearing cap is hard toremuve. we the crankshaft from the upper crankcase I1) FEELER GAUGE ' CTION ‘ KSHAFT RUNOUT .» - the crankshaft on a stand or Vrblocks. the indicator on the main journal. othe crankshaft two revolutions and read the runout. » IImlt: 0.05 mm (0.002 inl MURNAL BEARING INSPECTION [2) DAMAGE tthe bearing inserts Ior unusual wear, damage or lug and replace it necessary. (2i FEELING (1) MAIN JOURNAL BEARING 11-3 CYLINDERIPISTON/CRANKSHAFT OIL CLEARANCE INSPECTION Clean off any oil lrom the bearing inserts and journals Put a strip 01 plastigauge lengthwise on each journal avoiding the oil hole. (1) PLASTIGAUGE NOTE l - Do not relate the crankshaft during inspection. I Assemble the crankcase halves (page 10-12). Apply oil to the threads and seating surlaces of the main jounal bolts‘ Tighten the upper and lower crankcase bolts to the specified torque (page 10714), Remove the lower crankcase and measure the compressed plastigeuge 81 its widest point on each journal to determine the oil clearance. Servlc- limll; 0.05 mm (0.002 in! If the clearance exceeds the service limit, select the carrect replacement bearings as lollows, MAIN JOURNAL BEARING SELECTION Record the crankcase LD. code letters stamped on the left side of the upper crankcase. NOTE I - Letters (A, B or C) on the left side of upper crankcase are L the codes lorthe rnain journal LDls lrorn left to right. I 11-4 Iocord the corresponding mam journal 0.0. code numbers from the crank weight. NOTE - Numbers (1 or 2) on the crank weight are the codes lor the main journal 0.D.s from the left to right. Crow rolarance the case and journal codes to determine the tlpllcament bearing color code. 1 Crankcase A [ B ‘ C “3- 0°“ 36.000- 36.007- 36.0117 1 _ 36.007 rnrn 36.014 mm 36.021 mm W" Journal 11.41737 [1.4176- (1.4179- 00 code 14176 in) 1.4179111) 1.t181inl 1 32.993 7 33.000 mm o c a ll.2989~ 1.2992 in) (Pink) (Yellowl (Green) -2 32.986 — 32.993 mm c a A (1.2986 —1,2assin) (Yellow) (Green) (Brown) _:Erown: 1.507 — 1.511 mm (0.0593 — 0.0595 in) :Groen: 1.503 — 1.507 mm (0.0592 — 0.0593 In) :Vallow: 1.499 —1.503 mm (0.0590 — 0.0592 in) :Pink: 1.495 —1.499 mm (0.0589 — 0.0590 in) MTER CLUTCH NEEDLE BEARING LACEMENT vs the needle bearing with a commercially available rul bearing puller. 'palor slum, cover the mlinshal‘t journal prop-rlv; lam th- :r-nluhuft m-in Journnl Irom tho burn“ in main Journal bearing: an its-bl. u mat-non. . a naw neédlo bearing onto the crankshaft. Mar 0m. 30 mm ID. 07746 - 0030100 077w - 0030300 CVLINDEH/PISTON/CRANKS HAFI' ' (1) MAIN JOURNAL O.D. CODE (1D MAIN JOURNAL BEARING #1 (2) MAIN JOURNAL BEARINGS (1) NEEDLE BEARING (1) DRIVER AND ATTACHMENT (2) NEEDLE BEARING 11-5,.- CYLINDER/PISTONICRANKSHAFI' INSTALLATION Install the main journal bearings into the upper and Inwer crankcase. CAUTION ~ “no bearing lulu Ihnuld be Illgn-d whh the grown in the can. Apply molybdenum oil to the upper and Inwer main journal bearing surface. Belore installing the crankshaft, position all the pistons at Top Dead Center (TDC) to prevent the crankpin tram being damaged by the connecting rod bolts. Install the crankshaft into the upper crankcase. Apply molybdenum oil to the crankshaft main journals and crankpln journals. Apply molybdenum oil to the connecting rod bearing surluce. Install the connecting rod bearing caps to their original position. Apply oil to the cpnnscting rod bearing cap nut threads and seating surlaca. Install and tighten the nut in 2 - 3 steps. Torque: 28 MM (2.6 liq-m. 1S Ib-RI Assemble the crankcase (page 10- Ill '7' umurs "' ' 11-6 INDER/PISTONICONNECTING ROD Winn luv' ‘ng the piston nnd connecting rod, b0 cam ’ I! not to dlmugl tho main imam-I or connecting rod balm illllnse ’1: OVAL ‘ . vtha cranksheh (page 11~3). the connecting rods and piston out through the top of _ cylinder bores. E l V ‘ mm to remove tnezonn-cfing rod/p ton uum~ ‘ lrom the bottom of mo cvllnd he Immbly I locked so that the all ring expands in the yup be- m cylinder llnu Ind the upper cr-nkc-u. the bearing caps and bearings as you remuve lo indicate the correct cylinder and position on the nl Ior roessemblvr v vlhe piston pin clips, push the piston pin out and lhepiston. the piston plus to ensure the or' 'nal reassembl i: ION the piston rings and mark them to indicate the cor- - rand piston position piston crown, removing all carbon deposits. till piston ior cracks or other damage. Inspect the ior excessrvs wear and carbon build~up. CVLINDER/PISTONlCRANKSHAFT firm, (1) comm}; RODS/PISTONS (1) PISTON PIN CLIP (3| PISTON 12) PISTON PIN (1i PISTON RING (2) PISTON 11-7 CVLINDERIPISTON/CRAN KSHAFI' Measure the piston ring-to-grouvs clearance. (U PISTON Servlce Iim‘nzTopleeoond: 0.09 mm (0.003 In) (2) PISTON RING Using a piston, push (he ring securely into (he cylinder and \ PISTON RING mounts the and gap, .. Service llmlt: Tap: 0.5 mm (0.02 in) Second: 0.7 mm (0.03 in) Oil ring (side nil): 1.0 mm (0.04 In) Measure each piston 0.D.. NOTE ( - Take measuremems 11 mm (0.4 in) from the bonom, ‘ and 90°10 the piston pin hole. Sen/loo limit: 64.90 mm (2.555 in) Measure each bimon pin hole n.0,. Sowice IimK: 17.02 mm (0.610 In) (2) PISTON RING [Push (n) (1) PISTON 11-8 CYLINDER [PISTON/CHANKSHAFI' m0" PIN Insure each piston pin O.D.. w llmlt: 6.95 mm (0.669 in) Maine the piston pin-to-piston clearance. lee Ilmlt: 0.00 mm (0.0016 in) EC‘I'ING ROD lure each connecting rod small end I.D.. imit: 17.04 mm (0.671 in) late the connecting rod-to-piston pin clearance. — llmlt: 0.06 mm (0.0024 In) LNDER - the cylinder walls lar scratches and wear. are and record the cylinder ID, at three levels in both X and Y axes. Take the maximum reacting to determine cylinder wear. A limit: 65.10 mm [2.583 in) late the pietan-to—cylinder clearance. Take the maxir In reading to determine the clearance. ea limit: .10 mm 10.00“") eure the cylinder tor out 01 round at three levels in an X -Vaxis Take the maximum reading to determine the out round. a II .10 mm (0.00! l we the cylinder for taper at three levels in an X and V Take the maximum reading to determine the taper. - limit: 0.10 mm (0.000 in! (it PISTON PIN l1) CONNECTING ROD (1) TOP (2) ' 77 77,‘ MIDDLE “ I . (3) . BOTTOM . CVLlNDER/PlSTON/CRANKSHAFT Check the cylinder tor warpage by placing a straight edge and a leeler gauget Scrvioo limit: 0.10 mm (0.004 in) CONNECYING ROD BEARING INSPECY ION Inspect the baaring insans for unusual waar, damage or peeling and replace it necessary. OIL CLEARANCE INSPECTION Clean a“ any oil Irom the hearing inserts and crankplns‘ Put a strip at plastigauge lengthwise on each crankpin avoiding the oil halet NOTE - Do not rotate the crankshaft during inspection J Apply oil to the threads and sealing surteces of the connecting rod cap nuts. Install the connecting rod caps and rods on the correct crenkpins, and tighten the nuts to the specified torque (page 11-6). (3) DAMAGE (2) FEELING (1) CONNECTING ROD BEARING (1) PLASTIGAUGE m (2) BEAIN AP CVLINDER/PlSTON/CRANKSHAFT we the connecting red cap and measure the com- plestigeuge at its widest point on each crankpin to ine the oil clearance. limit: 0106 mm (01002 in) \ clearance exceeds the service limit select the correct . I ment bearings as Vollows . NECTING ROD BEARING SELECTION (1) CONNECTING ROD LD. CODE lithe connecting rod LD. code numbers on the rods. umbers (1 or 2) an the connecting rods are the codes ' E hrthe connecting rod I.D.s. the crenkpin OtD. code letters 1mm the crank werght. (ll CRANK PIN OD. CODE rs [A or E) on the left side of the crank weight are codes tor the crankpm 0.05 from leh to right, reference the crankpin and rod codes to determine the ement bearing color code Connecting I 1 2 LD‘ ”“9 34.000- 34.008- 34.008 mm 34.016 mm in (1 3385- (13339- node 1.3339 in) 1 3392 in) JIM—31.500 mm C B (1) CONNECTING ROD BEARING (mas -1.2992 in) (Yellow) (Green) 434 — 31 492 mm a A 1.2985 —1.2989 in) (Green) (Brown) : 1.20—1.24?! mm (0.0489 — 0.0491 in), II: 1210—1244 mm (0.0d88 - 0.0489 on) : 1236—1240 rnrn (0.0486 » 0.0483 m) 11-11 CV LINDER/PISTONICRANKSHAFI’ INSTALLAT10N CAU110N - In artful Inn '0 dam-g- Iho pinan Ind ring: during numb”. Clean the piston heads, ring lands and skirts. Carefully install the piston rings onto the piston wilh me markings facing up. NOTE - Do not conluse ms lap and second rings. - To install the oil ring, install the spacer first. then insrsll the side rails. - Slugger the ring and gaps 180“ as shown. After installing the rings. check that may rotate freely without sticking. > /— (2)70? mm; ’_ l3) SECOND RING \ ‘ W. (1) PlSTQN RING l2) PIS (1) MARK (2) TOP RING (3) SECOND RING (4) SIDE RAIL (5) SPACER } (4) SIDE RAIL CVUNDER/PISTON/CRANKSHAFT [the connecting rod bearing. Align the oil holes in the (1) CONNECTING ROD (2) BEARING 'ng and connecting rod, and align the bearing tabs with grooves in the connecting rod and bearing cap. the connecting rod small and and bearings with dunurn oil. (4) ALGN (3) BEARIN CAP oilto the piston pin outer sufiace- gin PISTON PIN CLIP (2) PISTON PlN his the pistons and connecting rods with the oil hole connecting rod facing the intake side ('IN“ mark side). pilton pin through the piston and connecting rod. new piston pin cllpst Malta sure that the piston pin clips are seated properly uldtheir and gaps are not aligned with the cutouts in the piltun. Apply engine all to the cylinder wall, piston and piston ring ‘3’ ”5T0” (4) "N" MARK 45) OIL HOLE other su rfecesl Mall lhe connecting rod/piston assemblies into the cylinder in)!" the top of the crankcase, Be sure each assembly is [9* turned to its original position as noted during removal. HUTION - Be «Mun not to dam-V '." the piston rings and cylindu in To prevent damaging the cylinder well, 5“]! short I m of rubber be“ owr the rod butts baton Inst-I- lotion Compress the piston rings with a nng compressor and insert lilo connecting rod/piston assembly into the cylinder with m piston 'IN" mark facing the intake side. Mike sure the piston "IN' marks are facing the intake side. (661397-312 m can CYLINDERIPISTON/CRANKSHAFT Inscall the crankshaft (page 11»6) and lower crankcase (page [1) CRANKSHAFT 10-12). FRONT WHEEL/SUSPE NSION/STEERING 27 N-m (2‘7 kg-m. 20 III-V!) 105 N-m (10.5 kg-m, 76 lb-fl) 23 N-m (2.3 kg-m,17lbrh) w N-m [4.0 kgrm. 29 mm 12 N-m (12 ngn. 9 lb-fl) 22 N-m12.2 kg-m, 16 lb-m SERVICE INFORMATION TROUBLESHOOTING HANDLEBARS 12. FRONT WHEEL/SUSPENSION/STEERING 12-1 12-2 12-3 FRONT WHEEL FORK STEERING STEM 12-3 12-14 12-22 I SERVICE INFORMATION GENERAL . A contaminated hrnlro disc or pad reduce: Hopping power. Discard contaminated path and clean comeminated use. with a high quality brlka dograesing agent. 110M . Do not lupport the motorovcle uling the oil cooler. When sarvrcing the front wheel, support the motorcycle uslng a safety stand or hoist. Marta Section 1410: brake system informatlon, . Tubeless tire removal, repair, and remounting procedures are covarad in Section 16 01 the Common Service Manual. Uu only tires marked "TUBELESS" and lubeless valves on rims marked "TUBELESS TIRE APPLICABLE". Unit: mm (m) STANDARD SERVICE LIMIT 1.5 (0.06) Up to 90 kg (200 lb) load Up to maximum welght capacity ‘ 36 psi 1250 kg/cm', 250 We) 36 psi (2.50 kg/cm', 250 kPa) Wheel rim runout Radial 0.2 (0.01) 2.010118) Axial 2,0 (008) Ibnlancs weight spring free length 317.9 (12.5) . 60 9 (2.1 oz) max. 311.5 (12.3) upring direction wuh tightly wound coil lacing down 0.2 (0.008) mmanded fork fluid Pro Honda Suspension fluid 5878 Iluid level 117 (4.61) lluid capacity 463 cc (15.7 US oz, 16.3 Imp oz) no prarioad adjuster standard position und adiuster standard position 3rd groove 7 clicks out Irom full in ring starn bearing preload 0.15 , 0.20 kg-m(1.1—1.Ub-M FRONT WHEEL/SUSPENSIONISTEERING TOROUE VALUES Handlebar pinch bolt Fork cap bolt Fork socket bolt Steering stem nut Steering adjustment nut Fork pinch bolt (upper) (lower) Front axle pinch bolt Front axle bolt Front brake disc bolt From brake hose clamper bolt Front brake pipe stay bolt TOOLS Bearing remover shaft Bearing remover head, 20 mm Attachment, 42 x 47 mm Attachment, 52 x 55 mm Pilot, 20 mm Fork eeel driver Fork seel driver attachment Steering stem socket Bell rece remover » driver attachment - driver handle Ball race remover Steering stem driver TROUBLESHOOTING Herd steering ' Faulty steering head bearings ' Damaged steering head bearings ‘ Insufficient tire pressure . Steering head bearing adjustment nut is too tight - Faulty tire 27 N-m (2.7 kg»rn. 20lb-1tl 23 N'm (2.3 kgrm, 17 lb-ltl 20 N'm (2.0 kg»m, 14 lb-ltl Apply locking agent to the threads‘ 105 N-m [10.5 kg-m, 76 lh-fl) 25 N-m (2.5 kg»m, 18 Ib-ltl Apply oil to the threads 23 N-m (2.3 kg»m. 17 lb-ltl 40 N-m (4.0 kg»m. 29 lb-ltl 22 N'ITI (2.2 kgfll. 16 lb4tl 60 N-m (6.0 kgfll. 43 lb-ltl 20 N-m (2.0 kg»m. 14 lb-ltl l 12N-m (1‘2 kg-m. 9 Ib—fl) 12N-m (1‘2 kn-m, 9 Ib—fl) 07746 - 0050100 :l— or equivalent commercially available in USA 07746 - 0050600 07746 - 0010300 07746 — 0010400 07746 - 0040500 07947 — KA50100 07947 — KF00100 , 07916 — 3710101 7 or 07916 — 3710100 07953 — MJ10000 or Attachment (07953 — MJ‘lODOA or 07935 — MJ10005), 07953 - MJ10100 Driver (07949 ~ 3710001) and 07953 _ MJ10200 Attachment, 37 x 40 mm (07946 - 0010200) 07946 — 3710500 07946 — M300000 Wheel turns herd - Faulty wheel bearings - Sent front axle Soft suspension - Improper spring pro-load adjustment - Weak springs - Low fluid level in fork - Low tire pressure Steers to one side or does not tuck straight - Bent lork Bent front axle Wheel installed incorrectly Bent lreme Worn wheel bearings Front wheel wobbles - Bent rims - Worn wheel bearings - Feulty tire - Unbalanced tire and wheel Faulty steeringlteed bearings Worn swingarm pivot components - High tire pressure unevenly adjusted damping and pre- load' In each lork leg “I'd IIIIPIIII‘OII ~ Improper spring pre—Iosd adjustment ~ lncorrectlluid weight - High fluid level in fork - Bent fork sliders - Clogged fluid peaaege Front map-mien neley - Insutficient fluid in tork - Loose tork laeteners FRONT WHEEL] SUSPENSION] STEERING HANDLEBARS (2) MASTER CYLINDER MHT HANDLEBAR REMOVALS Disconnect the ham brake sw-tch connectors NOTE "fl - Keep the masts! cylinder uprléht to p7evertt air lrom entering the hydraulic system Imovs the two bolts, master cylinder holder and master wlindat ltom the handlebar. \ l1) BOLTS ave the two attaching screws and the nght handlebar ‘ h housing from the handlebar‘ ‘ onnect the throttle cables lrom throttle grip flange, 41) THROTTLE CABLES vs the sctew, handle-bay weight and throttle grip» (3) THROTTLE GRIP (2) WEIGHT (1) SCREW 12-3 FRONT WHEEL/SUSPENSIONISTEERING Remove the stopper ring. (3) HANDLEEAR. - Loosen the handlebar pinch bolt and remove the handlebar, l1) STOPPER RING (2) BOLT RIGHT HANDLEBAR INSTALLATION (1, HANDLES“ (3, we" Install the right handlebar aligning the stopper on the \ handlebar with the groove In the lop bridge‘ ‘ (2) TOP Ell! Tighlen the handlebar pinch bolt. Torque: 27 Man (2.7 kg-m. 20 lb-fll Install the stopper ring into the fork groove. (1) BOLT . » Apply grease to the throttle grip inner surlace and flange (”THROTTLE GH 9m ,6. Install the throttle grip. FRONT WHEEL/SUSPENSION/STEERING Install the handlebar weight aligning Its boss with the handlebar. Clean and apply a locking agent to the screw threads. Tighten the screw, (1) WEIGHT (ZlALIGN Connect the throttle cables to the throttle grip flange. Install the handlebar swttch housing onto the handlebar, aligning the locating pin With the hole in the handlebar. l2) SWITCH HOUSING a" 3" 11) THROTTLE CABLES 4" . t l3) ALIGN... hull the attaching screws and tighten the front screw first, then tighten the rear screw. ll) SCREWS hall the master cylinder and holder with the "UP“ mark 12) PUNCH MARK lll MASTER CYLINDER being up. Align the and o! the master cylinder with the punch mark on thehandlebar and tighten the upper bolt first, then llghlen the lower bolt. Tame: I2 N-m (1.2 kg-m. 9 Ithl Connect the front brake switch connectors. Chums throttle grip free play (page 34). I (3) "UP' MAR _ m eons 12-5 FRONT WHEEL/SUSPENSION/STEERING LEFT HANDLEBAR REMOVAL (3) CLUTCH LEVER BRACKET (1) CONNECTORS Disconnect the clutch swilch connectors Remove the two bolts, clutch lever bracket holder and clutch lever bracket lrorn the handlebar. (2) BOLTS Remove the two attaching screws and the left handlebar switch housing from the handlebar Disconnect the choke cable lrom Ihe choke lever. - (1) SCREWS Remove the screw and handlebar weight, (2| HANDLEBAH GRIP (3) CHOKE LEVER Remove the left handlebar grip and choke lever from the handlebar, Remove the stopper ring. l1) WEIGHT (4) STOPPER RING Loosen the handlebar pinch bolt and remove the handlebar. ‘ (z) HANDLEBAR ,(1) eon FRONT WHEELISUSPENSIONISTEERING LEFT HANDLEBAR INSTALLAflON (1) HANDLEBAH (2i ALlGN Install the left handlebar aligning the stopper on the handle» bar with the groove in the top bridge. Tighten the handlebar pinch bolt, (5) WEIGHT (3) CHOKE LEVER ‘ Tuque: 21 MM (2.7 Ila-m. 20 Ib-ftl htlll the stopper ring into the fork groove. hltlll the choke lever onto the handlebar ‘ Gun the Inside surface ol the left handlebar grip and the outside surface of the left handlebar. .Applv Honda Band A or Honda Grip Cement (U SA. onlyi l0 31.! inside surface at the left handlebar grip and the OUKSIde marine of the left handlebar. Wait 3 - 5 minutes and install the grip. We the grlp lot even application of the adhesive NOTE ' Allow the adhesive to dry for an hour before using. lull the handlebar welght allgning its boss with the lobar. an and apply a locking agent to the screw threads. Man the screw tract the choke cable to the choke lever. II the handlebar switch housing onto the handlebar, ning the locating pin with the hole in the handlebar. II the attaching screws and tighten the front screw first, tighten the rear screw, FRONT WHEEL/SUSPENSIONISTEERING Install the clutch lever bracket and holder with the "UP“ mark laclng upl Align the end of the clutch lever bracket Wllh the punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt. Connect the clutch switch connectors. FRONT WHEEL REMOVAL Raise and support the motorcycle usmg a hoist. Loosen the right axle pinch bolts Remove the axle bolt. Remove the left brake caliper bracket bolts and the left caliper. CAUTION - Do not suspend therbulte caliper Item the br- - he". Do not twitt the buli- hos-t NOTE i ' Do not operate the front brake lever alter removing the > caliper and trout wheell To do so will cause difficulty In fining the brake disc between the brake pads. J Loosen the left axle plnch bolts. Pull the axle out. Remove the front wheel CAU110N ‘ - Whoa removln; um whut, and. the right huh callpor .‘ out so that the wheel rim clears. ‘ l2) PUNCH MARK (2) AXLE BOLT (3] BOLTS l1) FRONT WHEEL (ll CONNECTORS NSFECTION AXLE Place the axle in V-blocks and measure (he runoul. Actual runout is 1/21he total indicator reading. Ilvlco Ilmk: 0.20 mm (0.00! In) WHEEL Check the rim runoul by placing the wheel in a lruing standi Spin lha wheel slowly and read the runout using a dial hilcator. Actual runout is 1/2 the lolel indicalor reading. m limlll: Rldi I‘ Z 0 mm [0. 08 in) Axlal: 2.0 mm ll) 08 inl L BEARING um the inner rece ol each bearing with your finger. The rigs should lurn smoothly and quietly. Also check lhut bearing outer race fils lightly in (he hub, we and discard the bearings if the races do not turn hly and quietly, or if they lit loosely in the hub‘ Replace the wheel hearings in pairs, FRONT WHEEL/SUSPENSION/STEERING (1) WHEEL BEARING FRONT WHEEL/SUSPENSIONISTEERING DISASSEMBLV 43) BRAKE DISC Remove the side collar from the wheel. Remove the socket bolts and brake disc. Remove the dust seal / / l4) DUST SEAL ‘(Zl SOCKET BOLTS Remove the srde collar lrom the wheel Remove the socket bolts and brake disc. Remove the dust seal (2) SOCKET BOLT (4) DUST SEAL Install the bearing remover head into the bearing. From the opposite side install the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other hearing. Yools: Baring remover shaft 07746- 0050100 or ‘ nt eommeroially la in U.S.A. Burlnn remover hand. 20 mm 077.6 - 0050600 or equi IIIM commercially Ivaillble in USA. NOTE (“:15 m REMOVER HEAD (ll-REMOVER SHAFT - If the bearings are removed, they must be replaced with new ones‘ FRONT WH EEL/SU SPENSION/STEE RING ASSEMBLY (2i BRAKE DISC (31 FRONT WHEEL m SOCKET BOLT (4) DISTANCE COLLAR 15) BRAKE DISC (8) BEARING (9) BEARING (7) DUST SEAL (6) SOCKET BOLT in a new right bearing squarely Wilh the marking lacing - - v , -, = . (1) 313m DRIVER umil ll is fully sealed. II the distance collar. in a new lsfl bearing squarely With the marking facing until it is lully seawd. 077‘s - 0010000 07746 - 0010300 07746 - nowsoo i2>@AWACHMENT AND PILOT Iv grease to the new dus‘ seal lip and install the dust seal , ~ “(5) COLLAR the left wheel hub, ' . Do not an am“ on tho brake disc or napping va-r . wll be minced. Ilhe leh blaka disc with [he direclion arrow bointing in direction 0| mimic". land lighlan the new socket bolls. . 20 N-m [2.0 kn-m, 14 lb“! II the left side collar. FRONT WHEELISUSPENSION/STEERING Apply grease to a new dust seal lip and install the dust seal into the right wheel hub. - Do not get green on the brake disc or stopping power will be reduced, Install the right brake disc with the direction arrow pointing in the direction 01 rotation, Install and tighten the new socket bolts, Torque: 20 N-m (2.0 kg-m. 14 'b-ltl Install the side coller. WHEEL BALANCE NOTE _ , - The w 38 mounted, - For optimum balance, the tire balance mark (a paint dot on the side well) must be located next to the valve stem. Remount the tire it necessary ‘ alance must be checked when the tire is re I - Wheel balance tectly lflecte the nobility, hendlinn end over-II seletv of the motorcycle. Cerelullv check lance belo Installing the wheel Mount the wheel, tire and brake disc assembly on an inspecr lion stand, Spin the wheel, allow it to stop, and mark the lowest (heavi- est) part of the wheel with chalk. Do this two or three tlmes to verify the heaviest area, If the wheel is balanced, it will not stop consistently in the same position. To balance the wheel, install balance weights on the lightest side ol the nm. the side opposite the chalk marks, Add just enough weight so the wheel will no longer stop in the same position when It is spun. Do not add more than 60 grams (2,1 02) to the hunt wheel. INSTALLATION CAUTION - When installing the wheel. olide the right brake caliper out so Chet the wheel rim ale-re. Install the front wheel between the lork legs so that the brake disc is positioned between the pads, being carelul not to damage the pads (Z) BRAKE DISC 7 ,7 , l5) COLLAR i l1) INSPECTlON STAND i1) FRONT WHEEL . t a thin layer of grease to the front axle surface. II the front axle. ll the left brake caliper and new bracket bolts. :31 MM (3.1 kg-m, 22 Ila-ft) ll and tighten the axle bolt. In: 50 N-m (6.0 kg-m, ‘3 “)4“ n the right axle pinch bolts. m: 22 N.m (2.2 kg-m. 18 Ila-ft) the front brake applied, pump the front suspension up dewn several times to seat the axle and check front ta operation. tell the clearance between each surface of [he left brake and left caliper bracket. a clearance should be at least 0.7 mm (0.03 in) when sured With a (eeler gauge. the gauge Inserts easily, tighten the left front axle pinch I). :22 N-m (2.2 kg-m, 16 Ila-m the (color gauge cannot be installed easily, pull the left fork or push it in until the gauge can be inserted. mitten the left front axle pinch bolls. mm: 22 N~m (2.2 Ila-m. ts Ib-m installing the wheel. apply the brake several times, then heck both discs (or caliper bracket-to-disc clearance. FRONT WHEEL] SUSPENSION] STEERING l1) AXLE BOLT (1i BRAKE DISC I 0.7 mm (0.03 in) 12-13 .. FRONT WHEEL/SUSPENSION/STEE RING REMOVAL Remove the front wheel (page 1278). Remove the {our bolts and the front lender. CAUTION” , ,, l - Do not hang the brake ulipu from tho huh plpl. (1) FRONT FENDER Remove the stopper ring. [1)STOPPER RING Loosen the handlebar pinch bolt and remove the handlebar. Loosen the top bridge pinch boll. When the fork is ready to be disassembled, loosen the fork cap. but do not remove it. Loosen the bottom bridge Dlnch bolt and remove the fork. (UPINCH BOLT FRONT WHEEL/SUSPENSIONISTEERING (3) PARTING LINE ' I. careful not to much the tour slider or damage the {5) GROOVE In all. u'll need two screwdrivers to remove the (ark tube - ector. lmert a screwdriver between the fork tube and protector ‘ It a point where one of the three retaining pewle exists. then carefully pry up on the screwdriver placed against the groove 01 the iork slider. ' Without disturbing the above setup; insert another screw- (2) FORK PROTECTOR driver at any one of the two remaining pawl: and pry up (4) RETAINING on the protector in the same manner. PAWL Repeat the above procedure to remove the other protec- Ior irom the other iork slider, (1) SCREW DRIVERS we the [ark cap from the fork tube. (1) FORK CAP ‘ The fork cop II under Iprlng preuure. Use ceutlon when removing it, we the font cap from the damper rod. FRONT WHEEL/SUSPENSIONISTEERING Remove the seat stopper, upper spring see! and spacer (2) SPRING SEAT (1) SEAT STOPPER Remove the lower spring seat and fork spring, Four out the fork Iluid by pumping the fork tube up and clown several times. (2) SPfllNG SEAT 7,, CAUTION . Do not ever tighten the bucket. Hold the brake caliper bracket of the fork slider in e vise with a piece 0! wood or sell jaws to avoid damage. Loosen and remove the (ark socket bolt and sealing washer. If the fork damper turns with the socket bolt. temporarily in- stall the lork spring, spacer and lork can Remove the lork damper from the (ark tube. (1) FORK SOCKET BOLT Remove the dust seal and stopper ring. (ll DUST SEAT (2) STOPPEH RING CAUTION L- Be careful not to watch the lerk tube. ‘| 12-16 , 1 FRONT WHEE LlSUSPENSION/STEERING 1- Check that ihe fork lube moves smdofiulviin the lork slider. ll it does not, check the lurk lube lor bending or damage, and the bushings for wear or damage. successive motions, pull the lork lube out at the move the oil lock piece 1mm the fork slider. (uronxruss ' 'l2lFO Ksunsm ve the oil seal, back-up ring and slider bushing from (H Oil. SEAL (3) SLIDER BUSHING lorkiubo. E f Do not remove ihe lurk lube bushing unless it is neces- sary to replace it with a new one. [2) BACKvUP RING urerhe fork spring free length, Ilmk: 311.5 mm [11.3 In) TUIEISLlDER/DAMPER (1) FORK TUBE , _ (5) REBOUND SPRING Ir the fork tube, lork slider, oil luck piece and lork rfor score marks. and excessive or abnermal wear. Ihe rebound spring ler fatigue or damage. the compone m il necessary. FRONT WHEEL/SUSPENSIONISTEERING Place the fork tube in V-blocks and measure the runout. Actual runout is 112the total indicator reading. Sande. limit: 0.10 mm [0.008 In) FORK TUBE BUSHING Visually inspect the slider and fork tube bushings. Replace the bushings iI there is excessive scoring or scratch ing, or ii the teflon is worn so that the copper surIace appears on more than 3/4 ol the entire surface. Check the backup ring; replace it if there is any distortion at the points shown. ASSEMBLV Beiere assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely I5) FORK DAMPER (4i REBOUND SPRING (3) FORK TUBE PROTECTOR (2) FORK SLIDER I“) SOCKET BOLT (20) OIL LOCK PIECE l6) SLIDER BUSHING (1) DIAL INDICATOR I2) FORK TUBE (I) BUSHING (2) BACK-UP RING (3) CHECK POINTS (6) COPPER SUR FACES I7I DUST SEAL (a) srorpsn ems ‘1 1’ Fm" ‘ (H) UPPER“ I15) SPACER SEAT (13) SPRING 0:“ fig srowen i (16) LOWER SPRING i (18) FORK TUBE 117) FORK SPRI ‘ (19) FORK TUBE BUSHING 12-18 Install a new lork tube bushing ii the bushing has been re- moved. Install the slider bushing and back-up ring onto the iork tuhet NOTE . Remove the burrs from the bushing mating surface, being careful not to peel off the coating. - Coat the slider bushing and guide bushing with the recommended fork fluid, Install the lork damper into the [ark tuber Install the oil lock piece onto the lork damper and. Install the lork tube into the iork slider. CAUTIqN - Do not over tlgM-n the bucket Hold the Drake caliper bracket in a visa with a piece 0' wood or soft jaws. Apply locking agent to the lork socket bolt threads and install the socket bolt and new sealing washer into the lurk damper. Tlghten the fork socket boll. Town: 20 N-rn 12.0 ug-m, u lb-fll "the fork damper turns with the socket bolt, temporarily install the fork spring. spacer and dork cap. Drive the slider bushing into the outer tube with the back-up rlng. Teen: M seal driver M loll driver mechment 079‘7 - KASMOO 07947 - KFOO‘IOO Wrap vinyl tape around the top of and of the lurk tube to 'd damaging the oil seal lip. II a new oil seal with fork fluid and install it over the fork with the marked side lacing upr ethe oil seal until the stop ring groove is visible. Cell: seal driver seal driver mochrn-nt 01947 - KA50100 07947 - KF00100 II the stopper ring into the groove in the tork slider‘ Iy fork fluid to the lip of a new dust seal and install the seal. FRONT WHEEL/SUSPENSIONISTEERING ingroaxruaa usu a (5) OIL LOCK ‘ EIECE l3) BACK-UP RlNG (2) SLlDER BUSHING Ch FORK socxar BOLT m [sfioLJFoaK SEAL DRIVER AND ATTACHMENT (2) DUST SEAL l3) STOPPER RINGI we! OIL SEAL SLIDER BUSHING (Z) DUST DEAL . , (ll STOPPER RING FRONT WHEEL/SUSPENSION/STEERING Pour helfthe required amount at the recommended fork fluid in the fork tubal Recommended lork Iluid: Pro Honda Suspension Fluld ss-a Oil capacity: 453 or: (15.7 us oz. 163 Imp 0:] Slowly pump the fork tube and damper rod several times to remove trapped air. Pour additional all up to the specified capacity and repeat the above step. Compress the lurk leg and damper rod Iullv. Measure the oil level lrurn the top 0! the lork tubal Oil laval: 117 mm (4.61 In] Pull the damper rod up and while holding it, install the Iork spring with the lightly wound and lacing downr Install the lower spring seat and spacer, Install the upper spring seat and seat stopper. Install a new Owing into the lurk cap gruavo. Install the lork cap onto the lurk damper rod. , Install the fork cap into the {ark tube. NOTE - Tighten the fork cap alter installing the fork tube into the lurk bridges. - I‘ll OIL LEVEL (1) FACING DOWN 4- (1) UPPER SPRING SEAT l2) SEAT STOPPEI'I Install the fork lube protector over the fork Slldel wnh the ”WI: aligned wrth (he slldel grooves as shown, NSTALLATION lnllall the fork lube Into the bottom and top brldgev Temporarily ngmen me bottom bridge pinch bolt and nghxen tho lork cap to the specified mrque. Torqun: Z3 N-m [2.3 kg-m, 11 Ib-m 'Looun [he bouom bridge pinch boll. Mall [he handlebav (page 12- 7) Allan the groove m the fork lube with the upper surlace ol '- hundlebar. “Men the lop bridge pinch bolt : 23 N-m (2.3 kg-m, 17 Ib-h) an the handlebar pinch boll : 27 mm (2.7 kg-m. 20 lb-R) N the slopper ring to the fork lube groove‘ In the bonbm bridge plnch bolt. .40 N~m (to lug-m. 29 “H" FRONT WHEEL] SUSPENSION] STEERING . l2) ALIGN [2) FORK CAP (1) FORK TUBE ‘(2l STOPPER RING (1) HANDLEBAR ‘ (3) PlNCH BOLT (1) BOTTOM BRIDGE PINCH 30le « FRONT WHEEL/SUSPENSION/STEERING Install the tram fender and pipe stay. Trghten the bolts se- curely. Torque: Brake pipe any butt: 12 N-m (1.2 hg-rn, 5 lb-ltl lnstellthelrontwheel[page1Z-12). With the lront brake applied, compress the fork several umes to check [or proper tork operation. Set the praiload adjuster to standard position. Standard position: 3rd groove STEERING STEM REMOVAL Disconnect the Ignition swrtch connector and remove the wire from the clamps (page 18-12). Remove the steering stem nut and washer. Remove the tollawmg: . upper fairing (page 2-4), v Vront wheel (page 12-8). - handlebar (page 12-3]. - fork legs (page 12-14). Remove the top bridge. Remove the D.A.| duct (page 54). Remove the brake hose clamp from the steering stem. l (2) BOLTS H) IGNITION SWITCH CONNECT' " 4 - (ZlT'OP BRIDGE (2) BRAKE HOSE CLAMP “A (1) D.A.I. DUCT FRONT WHEEL/SUSPENSION/STEERING Waigmen [he lock washer tabs, and remove the lock nut and washer‘ (2) LOCK NUT I 1' n the sleermg bearing adjustment nm by holding me (1» a: STEERING STEM SOCKET ring stem and remove tha adjustment nuL ng slam wukn 07918 - 3710101 or 07916-3710100 w: the dust seal, uppet ll’ll’lE' race and steering slam (1) DUST SEAL [3) STEERING STEM . wathe upper and lower steering bearings. - the steering bearings, Inner and outer races (or wear ;' mags‘ (2) UPPER INNER RACE (5) STEERING BEARING mi?! BALL RACE REMOVER l s replace the bearings and races as a set the upper bearing uuler race. 07953 - MJ1oooa or 01953 - wumooA or 01953 — Monoa FRONT WHEELISUSPENSION/STEERING Remove the lower bearing outer race. , ‘(1) s tom |BALL RACE REMOVE“ I / Yool: Ball moo vomovu 07946 - 37I0500 Install the stern nut onto the stem to prevent the threads lvom being damaged when remuwng the lower beanng Inner race from the stem Removstha lower bearing inner race WIth a chisel or equwalent 1 tool, being carelul not to damage the stern‘ A ‘ Ramnve the dust seaI. ‘ II II [2) LOWER BEARING INNER RACE INSTALLATION (‘ll s'm’m STEERING STEM DRIVER I Apply grease to a new dust seal hp and install it over the steering stem, Install a new lows: beanng Inner race using a hydvaulIc press. Tool: Steering stem driver 079‘s - MBOOOOO Drive a new lower bearing outer rate into the steering head pIpe. Tools: deu 07949 - 0010000 Amchmont 52 x 55 mm 07746 - 0010400 - (1) 5mm] DRIVER FRONT WHEEL/SUSPENSION/STEERING a new upper bearing outar race mm the steman head . (1l 5 umIDFHVER 07949 - 0010000 mom 42 x 47 mm 07746 - 0010300 grunge to each new steering bearing. Ilhe lower sleering healing onto the stem. grease to new upper dust seal lip‘ all to the steering bearing adjus‘ment nut threads. the slam into the sleering head pipe and inslall the flaming bearing, Inner race and new dusk seal. oillo [he sleering adjustmenl nul threads, (ha steering adjustment nut and lighlen it to [he Inmal 079l6- 3710“)! or 079|6 — 3710100 ‘umuc: 25 um [25 kg-m, 1a lb-hl moving slam Iock-to-lock a: least fwe times "In adjustmenl nut to the final torque. .31 MM I11 Ila-m, H Ibhl m STEERING STEM 12-25 l l l l l. I FRONT WHEEL/SUSPENSION/STEERING Install a new lack washer, aligning its bent tabs mm the grooves in the adjustment nut. Install and finger tlghtan the lock nut. Hold the bearing adjustment nut and lunher tlghten the lock nut. withln 90 degrees, to align its grooves with the tabs of the lock washer. Bend upthe lock washer tabs into the grooves ofthe lock nut, Install the top bridge. washer and steering stem nut Temporarily install the {ark legs and handlebars. Tighten the steering stem nut. Torque: 105 Mm l10.5 kg-m, 76 lb-tt) Make sure that the steering stern moves smoothly without play or bindlng. Install the brake hose clamp to the bottom bridge. Torquefll N-m (1.2 Org-m, 9 lb—ft) Install the followlng: - D.A.l. duct (page 55). - fork legs (page 12721). ~ handlabars (page 12-7l, » front wheel (page 1242). Connect the ignition switch connector (page 18712). i1) STEERING STEM NUT/WAS (1) BRAKE HOSE C - (2) D.A.I, DUCT (1) IGNITION SWITCH CONNEC ' A — \ RING BEARING PRELOAD lee the tram wheel on the ground, itien the steering stem to the straight ahead pusitlon‘ eke spring scale to the fork tube between the fork top and cm bridges. ke sure that there is no cable or era harness interference. Ithe spring scale keeping the scale at a right angle to the ring stem. the scale at the point where the steering slem just starts move. 'ng bearing proload: 0.15 - 0,20 Its-m (1.1 —1th-ft) the readmgs do not tell within the limits, readjust the steer» bearing adjustment nut. II the removed parts in the reverse order of removal, TE ' Route the hose, cables, and wire harnesses properlv“ (page l-ZO), FRONT WHEEL/SUSPENSION/STEERING REAR WHE ELI SUSPENSION 55 N-m (5‘5 kg-m. 40 lb-k) 21 N-m (2‘7 kg-m. 20 mm f\ 12 N-m (1‘2 kg-m. 9lb-fl) no N-m(11.0 kg-m,eoltrm' A5 N-m (4.5 kg-m, 33 lb-R) 45 N-m14.5 kg-m, 33 lb-M 95 N-m (9.5 kg-m, GS Ib-ft) 13. REAR WHEEL/SUSPENSION SERVICE INFORMATION 13-1 SHOCK ABSORBER 13~8 TROUBLESHOOTING 13-2 SUSPENSION LINKAGE 13-11 REAR WHEEL 13-3 SWINGARM 13-18 SERVICE INFORMATION GENERAL - A contaminated brake disc or pad reduces stopping power. Discard contaminated pods and clean a contornlnahd . din: with a high quality brake depressing agent. ‘ - The shock absorber contains nitrogen under high pressure. Do not bring the shock absorber nur fire or host. - adore disposing of the shock absorber, role-u the nitrogen by pressing the valve core, than remove the valve Irern the shock absorber. - When servicing the rear suspension linkage, swingarm or shock absorber, suppon the motorcycle using a safety stand or hoist, ~ Refer to Section 1A for brake system information. - Tubeless tire removal, repair. and remounting procedures are covered in Section 16 oltne Common Service Manual. - Balancing procedures are covered in Section 16 of the Common Servme Manuel. Do not add more than 60 grams (2.1 oz) to the wheel balance weight. I Use only tires marked ‘TUBELESS" and tubeless valves on rims marked "TUBELESS TIRE APPLICABLE'. . Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. ‘ SPECIFICATIONS Urnit: mm (in) ITEM STANDARD i SERVICE LIMIT Minimum tire (read depth , i 2.0 (0.08) Gold tire pressure i Up to 90 kg (200 lb) load 7 42 psirl2.90 kg/cm', 290 kPal — i Up to maximumweighr capacity ‘2 psi (2.90 kg/cm‘, 290 kPal — Axle runout , — 0.2 (ODI) Wheel balance weight Radial 7 — 2.0 (0.08) Axial 7 —— 7 2.0 (0.08) Wheel balance weight , f 609 (2.1 ox) max. Drive chain slack 15 — 25 (5/3 — 1) — Drive chain size/link RK ’ 7 RKSOMFO/lOS W — DID DIDSOVA/IOB — Drive chaln slider lhicknsss , — To the indicator Damper gas pressrue/compressed gas in kg/cm‘ (980 kPel/Nitrogen — Spring pre-Ioed adjuster standard position 2nd — Rebound adjuster standard position 1 turn out from full in — Compression adjuster standard position l rurn out from lull in — REAR WHEEL/SUSPENSION TORQUE VALUES r Drive chain adjuster lock nut 22 MM (21 kg»m, 16 Ibvlt) 4 Rear axle nut 95 N~m (9.5 kg-m, 69 1040 *1 Shock absorber mounting nut 45 Nrm (4.5 kg-m. 33 lbrft) ‘1‘ Shock link nut llrame side) 45 N-m (4‘5 kg-m, 33 Ib-ft) “ Shock link nut (shock arm side) 45 N-m (4‘5 kg-m, 33 IbAlt) . Shock arm bolt 45 N-m (4.5 kg-m, 3311:3411 i Swingarm pivot nut no N-m (r 1,0 kg-m, so Ibrltl ‘ Rear brake disc bolt 43 NM! (4.3 kg-m. 31 lb-lt) Driven sprocket nut 90 N-m (9‘0 kg-m, 65 Ib—lt) ‘ TOOLS 1' Hearing remover shalt 07746 — 0050100 :1 or equivalent commercially available in U.S,A. Bearing remover head. 20 mm 07746 — 0050600 Attachment. 32 x 35 mm 07746 — 0010100 ‘ Anachmenl, 28 x 30 mm 07948 — 1870100 ‘ Attachment, 42 x 47 mm 0774:; — 0010300 Pilot, 25 mm 07746 — 0040600 Pilot, 20 mm 07746 — 0040500 Attachment. 26 x 24 mm 07746 — 0010700 Pilot, 17 mm 07746 — 0040400 Driver shalt 07946 — MJOOlOO Bearing remover attachment 07LMC—KV30200— or driver (07949 — 37100011 and pilot. 22 mm (07749- ‘ 0041000) (USA) 1 Pin driver 07GMD — Kraoma f Bearing remover 07936 - 3710300 ' Remover handle 07936- 3710100 .‘ Remover sliding weight 07741- 0010201 "7 — or 07936— 3710200 TROUBLESHOOTING Rear wheel wobbles Salt suspenaion - Bent rim - Improper spring pro-load adjustment 1 - Improper compression damping adjustment ‘ - Weak spring - Oil and gas leakage from damper unit - Low tire pressure Worn rear wheel bearings Bent rear axle Faulty tire Unbalanced tire and wheel Low tire pressure Faulty swingerm pivot bearing: Hard suspension - Damaged shock absorber mount bearing Rear suapanalon noiav - Bent damper rod - Faulty rear shock absorber - Damaged swingarm pivot bearings - Worn or damaged suspension linkage pivot bearing: - Bent swingarm pivot ' Loose fasteners - Incorrectly adjusted suspension ' Hightire pressure REAR WHEE LI SUSPENSION 13) BRAKE HOSE *I in the rear wheel oil the ground and support the rcycle using a hoist. twathe axle nut and washer. ova the rear brake caliper bracket bolt. mthe brake hose from the clamp on lhfi rear tender B move the brake caliper upward. n the drive chain lock nuts and adjusting nuts. N (2) BOLT Do not sulpond tho brill. cullpar from the brain hon. l no “MM“ a.- b" . hos- l2) DRIVEN SPROCKET (3) DRIVE CHAIN Do not operate the brake pedal alter rernoving the cal?‘ pnr and rear wheel. To do so will cause difficulty in fit- ting the brake disc between the brake pads. h the rear wheel forward and remove the drive chain the driven sprocket. ovetha rear axle and rear wheel assembly. l1) DRIVE CHAIN LOCK NUT‘IADJUSTING NUT CTION ’ r the axle in V-blocks and measure [he runout. runout is 1/2 the total indicator reading. Ilmlt: 0.20 mm (0.01 in) the rim runout by placing the whael in a truing stand. the wheel slowly and read the runout using a dial r. runoul is 1/2 the total indicator reading. llmlt: final-l: 2.0 mm (DDS in) All! . 2,0 mm (0.08 in) REAR WHEEL/SUSPENSION WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or If they lit loosely In the hub. N OTE wfliep’la‘ce the wheel bearings in pairs, A DRIVEN SPROCKET Check the condition of the driven sprocket teeth. Replace the sprocket if worn or distorted. NOTE » - The drive chain and drive sprocket must be inspected II the driven sprocket Is worn or damaged. Never install a new drive chain on Worn sprockets or is worn chain on new sprockets. Both chain and sprocket must be in good condition or the new replacement chain or sprockets will wear rapidly. DISASSEMBLV Remove the side collar from the wheel. Remove the socket bolts and brake disc. Remove the dust seal. Remove the side collar from the wheel. Remove the dust seal. l1) WHEEL BEARING (1) GOOD [2) REPLACE / ,, ,7 _ *vrs\ 77,,.r/—\ (2) SOCKET BOLTS [1) SIDE CI . . (3i BRAKE DISC » (4) DUST I'll SIDE COLLAR (2i DU n ave the driven sprocket and driven flange together. place the rear wheel dampers lf they are damaged or Irioraled. Ickthe O-rmg for weer or damage Replace l' necessaryr eve the rear wheel dampers vethe driven flange collar "am the drwen flange. am the flange bearing. II the bearing remover head Into the bearing, the opposite side Install the bearing remover shah and the bearing out of the wheel hub‘ the distance collar and drive out the other bearing. 077$ - 0050100 or 041 'vllom cummorcillly IV Ibla in USA 07745 - 0050600 or Iq 'vllam commcrcially lvlillhl' in U.S.A. no remover Ihlfl remover had. 20 mm ”the beanngs are removed, they must be replaced Wilh m ones. REAR WHEEL/SUSPENSION (1) DRIVEN SPROCKET AND DRIVEN FLANGE l2) DRIVEN FLAGE l2) l‘mIBEARING HEMOVER HEAD ‘ m r:] REMOVER SHAFT REAR WHEEL/SUSPENSION ASSEMBLY (1) SOCKET BOLT 0a . , (”REAR WHEEL DAMPEFIS Q (5) DRIVEN FLANGE COLLAR (13) RIGHT BEARING ‘ (6) DRIVEN FLANGE BEARI [2) DUST SEAL (3) REAR WHEEL (7) DUST SEAL (8) SPROCKET NU I12) O-RING I11) LEFT BEARING (10) DRIVEN FLANGE (9) DRIVEN SPROCKET Drive in a new right bearing squarely with the marking lacing up until it is lullv seated Install the distance collar‘ Drive in a new loft bearing squarely with the marking Incing up until it is sealed. YooIs: Dflvor 07149 - 0010000 Aflldlmnm, 42 x 47 mm 07746 - 00‘0300 Pilot. 20 mm 077“ — 0000500 (2) AWACHMENT Drive the driVen flange caliar into a new driven flange bear- ingv Tools: Mar 077.9 - 0010000 AMMQM. 28 l 30 mm 07946 - 1870100 REAR WHEEL/SUSPENSION Drive the bearing into the driven flange. l:‘l¢;m|(1) DRIVER 07745 — 0010000 chm-n1, ‘2 x 47 mm 07746 — 0010300 Iy grease to the Orring and groove in the wheel huh. I?) DRlVEN SPROCKET '" "‘9 0"“19 AND DRIVEN FLANGE llthe rear wheel dampers. _ v I_ * II the driven flange assembly, 11) O-RING (3) REAR WHEEL DAMPERS greasetolhedusrsaallipand installlhe dust seal onto (3, DRIVEN SPROCKET '61 (1) SIDE COLLAR lhnb. \ y grease to the inside cl rhe Side collar and install the “ Iidu collar as shown. driven sprocket is removed, install the sprocket wuth pod side facing out. the driven sprocket nuts to the specified torque. on N-m (9.0 mm. 55 lb-m (4) SPROCKET NUTS h. (2) DUST SEAL lutoths dust seal hp and install the dust seal onto (2) BRAKE Disc ,6 u) slog COLLAR Ihub, \ on umu on the huh disc or stopping power I. reduced. brake disc with the stamped side lacing out, tighten the new disc bolts to the specified torque, a ”Wu “.3 kg-m. 31 lb-kl . a cl 0 l v (3) DISC BOLTS (1) DUST SEAL 13-7 lo the inside 0! the side collar and install the REAR WHEEL/SUSPENSION WHEEL BALANCE Refer to page 12-12. INSTALLATIO N Install the rear wheel, aligning the callper bracket Wlth the slide rell on the swmgarm Install the drlve chaln over the drive sprocket. Install the drlve chain adjusters with the Index mark side faclng out, Apply a thin layer or grease to the axle. Install the rear axle from the left slde. Install the washer and axle nut. Install the rear brake callper, flttlng the brake dlsc cararully between the brake pads. Install and tlghten the callper bracket bolt. Torque: 22 N-m (2.3 kg-m, l7 lh-ftl Adjust the drive sham tpage 346). Tighten the rear axle nut. Torque: 95 MM (9.5 kg-m, 69 Ila-rt) SHOCK ABSORBER REMOVAL Raise the rear wheel oil the ground and support the motor cycle uslng e hoist. Remove the {uel tank (page 2-4). Remove lhe rear lender 8 (page 279). Remove the reservoir holder and reservon from the stay. Remove the hose bands from the frame. Remove the shock absorber upper mountlng bolt and nut (3) REAR AXLE (‘ll DRIVE CHAIN (2) REAR CALIPER , g lalnoseemns . ’ _ J _ ‘V. l2) RESERVOIR HOSE (I) UPPER MOUNTING BOLT/NUT REAR WHEEL/SUSPENSION ‘ Remove the lower moummg bull and nut lrom the shock (1) SHOCK ABSORBER absorber. l Romove «he shock absorber, NSFECTION Remove the dust seals and collar and check (hem for wear, damage or fatigue, lime needle bearing IS loose or damaged, replace It l2) COLLAR 13) NEEDLE BEARING NEEDLE BEARING REPLACEMENT (11 @FIN DRIVER Move the dust seals and collar lrom the lower ,oim Hold the lower join! with a suitable tool. Puts the needle bearing out of the lower jaunt. 07GMD- KTaDlDo Mn new neerile hearing will: grease. [1) 3 vooxlDRIVER Pm: the hearing me the lower jolnl until the bearing “l NEEDLE BEARING wrloce is llush with we join! surface as shown. ,6. Tall: NM: 07749 - 0010000 fl Much-nun. 24 x 20 mm 0774s - 0010700 mm. 17 mm 0774a - 0040400 =J \(3) W PILOT (2, 1:15 m ATTACHMENT REAR WHEEL/SUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the center ol the shock absorber reservoir cap to merit the drilling point. Wrap the shock absorber reservoir inside a plastic bag. Support the shock absorber reservoir in a vise as shown. Through the open end of the bag, insert a drill motor with a sharp 2—3 mm (5/54'1/8 In) drill bit - Do not us. I dull drill bit which could cause I build-up of extensive hut Ind prouu ro inside the dump-r, lud- Ing to oxplooion and oov o pononll injury. Tho Ihoelt nluorbor can! no nitrogen fins and oil under high prawn. Do not drill tho damper case pressure tlnlt body, or you my drill into the oil ch-mbor: oll os- coplng undo: high pressure my cause urlous person-I Injury. Always wur eye protection to avoid getting metal ‘ shavings in your eyes when on amount in IOIOI ad The ploutic bag I: only Imondod to a old you Item I «coping on. Hold the bag around the drill motor and briefly run the drill motor inside the beg; this will inflate the bag with air from the motor and help keep the beg lrom getting caught in the bit when you start, Remove the joint hose Item the damper INSTALLATION Install the shock absorber to the frame, Install the shock absorber upper mounllng bolt and nut. Tighten the nut. Torque: 45 Mom [45 kn-m, 33 lb-fll Install the shock absorber lower mounting bolt and nut. Tighten the nut. Torque: 45 Ntm (4.5 ltg-m, 33 lb-lt) (2) RESERVOIR CAP (II LOWER MOUNTING BOLT/NUT Install the reservoir tank aligning the hose and with the cut ell ol the stay‘ Install the reservoir holder and hose bandr Install the reservoir hose to the clamp. Install the luel tank (page 24) Install rear fender 8 (page 279). SUSPENSION LINKAGE REMOVAL Raise the rear wheel a" the ground and support the motor- cycle using a hoist. Remove rear fender 3 (page 2-9), Remove the shock link bolt and nut (frame side), Retrieve the lower shock absorber mounting bull and nut. Remove the shock arm bolt and nut (swingerm side). move the sho‘ck IInk/shock arm assembly. REAR WHEEL/SUSPENSION (1) RESERVOIR TANK \ > (3) HOSE BANDS “ m SHOCK ARM BOLT/NUT Y (1) SHOCK LINK/ARM ASSEMBLY v" REAR WHEEL/SUSPENSION DISASSEMBLV/ INSPECTION ”l SHOCK LINK (3) SHOCK ARM Remove the shock erm-te-eheck link bolt, nut and separate lhe shock Imk from shock arm. (Zl BOLT/NUT Remove the dusx seals and collars and check them lor wear. damage or letique. Check the needle bearings of the shock arm {or damage or loose fit. If lhe needle bearings are loose or damaged. replace them. l3) BEARINGS (1) DUST SEALS. \ (Zl COLLARS Remove lhe dun seals and collar from the shock arm and (3) DUST SEALS check them lor wear, damage or feligue. Check the needle bearings ol the shock arm for damage or loose fit. II the needle bearings are loose or damaged, replace them. (ll COLLAR (2) BEARI I NEEDLE BEARING REPLACEMENT (1) PIN DRI snocx Am ' Press the needle bearing out of the shock arm. Tool: H" the: 076MB - KTWIOD or or»: 01748 - 0010000 "0'. 22 Ill!" 07748 - 0041000 13-12 REAR WHEEL/SUSPENSION Press a new needle bearing into the shock arm 50 that the needle bearing outer surlace is 6.5 mm (026 ml below the outer edge or the shock arm pival bearing cavityl Tools: MO! 01743 - 0010000 Annulment, 20 l 26 mm 01116 - 0010700 Hot. 17 mm 07746 - 0040“” NOTE . Press the needle bearing in with the sramped side lacing out. LINK “he needle bearing out oi the shock link. can: M «Ivor 076MB - “80100 or I 07749 - 0010000 22 mm 07746 - 0041000 3 new needle bearing into the shock link to so ihat the le bearing outer surface is 57 mm (0.22 in) below the "edge of lhe shock link pivot bearing cavity. D: 07719 - 0010000 07746 — 0010700 07740 - 0040‘00 chm-m, 2‘ x 28 mm 17 mm Press the needle bearing in WIth the slampad side facing om. (4) NEEDLE BEARINGS 6.5 mm [028 in) s (1) DRIVER V- s “m (2) ATI’ACHMENT l3) PILOT 5 '00»! (1) PIN DRIVER 5 mm] (1) DRIVER 4) NEEDLE BEARING 13v- REAR WHEEL/SUSPENSION ASSEMBLY m SHOCK ARM COLLAR m suocx ARM .6: (3) NEEDLE BEARING (4) DUST SEA (3) SHOCK LINK L (7) DUST SEAL .6 l6) NEEDLE BEAR'NG (5) SHOCK LlNK COLLAR Apply grease (0 [he needle bearings, collars and dust seal (1) NEEDLE BEARINGS l3) DUST SEALS lips) ‘ lnmll the callers and dun seals into the shock link. (2) COLLARs'fi. Apply grease to the needle bearings, caller and dust seal lips. l2) NEEDLE BEARINGS Install the collar and dust seals into the shock arm. (3) DUST SEALS (1) COLLAR '54 REAR WHEEL/SUSPENSION II the shock link to the shock arm. lnstall the shock arm» (1) SHOCK LlNK (z) NUT (3) SHOCK ARM Ink bolt and nut. tighten the nut. l l I I : 45 Nvm [4.5 kgvm, 33 um) hurt the shock arm-lo»shock link bolt from the ”0- FR ‘ MAL' mark side ol the shock arm. l5) BOLT/NUT (4) 'O-FR MAL' MARK TALLATION V”) m SHOCK LlNK/ARM ASSEMBLY ; l ; II the shock link/shock arm assembly with the "th ' malk facing the left side. (2) ” ‘- FR MAL" MARK “the lower shock absorber mounting bolt lrom the It!“ (1) LOWER SHOCK ABSORBER MOUNTING BOLT/NUT Ind tighten the nut. . V, : 45 MM (‘5 ltg-m. 33 llrh) lthe shock arm bolt lrurn the left side and tighten lhe .45 N-m (4,5 kg-m, 33 III-fl) the shock link bolt from the left side and tighten the . ‘6 MM “.5 kn—m. 33 Ib-fl) I nor lander 8 (page 28). REAR WHEEL/SUSPENSION SWINGARM REMOVAL Rarse the rear wheel 0" the ground and support the moton cycle using I: hoistt Remove the rear wheel (page 13-3), Remove rear lender B {page 2-9L CAUTION - Do not suspend the brake caliper lrom the brake hose, I rDo nut twist the brake hose. . >- Do not ooerate the fgnl brake pedal after removing the caliper and rear wheel . To do so will cause difficulty in fitting the brake disc between the brake pads. Remove the shock arm bolt and nut (swingarm stde). Remove the shock link bolt and nut [frame side). CALIFORNIA YVPE ONLY: Disconnect the No.1 and No.4 tubes horn the EVAP canlslev. Remove the 'swingarm pivot caps, Remove the swingarm pivot nut and bolt. Remove the swingerm. (1'! HEAR FENDER e (2] SHOCK LINK BOLT/NUT V I“ (1DNo.1TUBE" ‘ /. J, '§ (H PIVOTC REAR WHEEL/SUSPENSION SEMBLV/INSPECTION eve the screws and drive chain slider lrom the ngavm. the drive chain slider fol excessive wear. . Ice the drive chein slide! il it is worn to the wear indica- ove the dust seal, lelt pivot collar and distance COIIGL ove the dust seal and right pivot collar. .. the dust seals and collars for damage or letigue. to make sure the ball bearings turn smoothly and y and lit tightly in the swing arm . the needle bearing for damage or loose fit‘ beating is loose or damaged, replace it. T BEARING REPLACEMENT - ethe snap ring‘ - e the right pivot bearings (radial ball bearings} lrom ulnaerme 07930 - 3710300 07930 - 3710100 07741 - 0010201 or 07930 - 3710200 - remover handle elidlng weight new radiei ball bearings "110 the right swingerm pivot ' e timel 07749 - 0010000 "1.32:135 mm 07748-0010100 ‘7 mm 07740 - 0040400 , , II the beer as w h the stamped e lacing out. the snap ring with [he chamfered side facing in. -- 1'1) SCREWS (2) DRIVE CHAIN SLIDER (1) COLLAR (2) DUST SEALS (I) DISTANCE COLLAR (3) COLLAR i1) SNAP RING REMOVER (11- DRIVER AND PILOT REAR WHEEL/SUSPENSION <1) DRIVER SHAFT Press the needle bearing out of the left swingurm pivm, (2) NEEDLE BEARING Tooll: ,’ luring nmovnr attach mom 01LMC - KVSOZOD Drlvuv than onus - M50010!) m@ BEARING REMOVED! ATTACHMENT Prnss a new needle bearing with (he stumped side facing out. (3) NEEDLE BEARING 01749 - 0010000 An-chm-m, 32 l 35 mm 07948 - 0010100 Pllot, 25 mm 07746 - 0040000 N OTE I - Th9 bearing surlace should be flush with the pivot inside surface as shown. A} W“ . ‘ ATTACHMENT AND PILOT ASSEMBLY (I) SIDE COLLAR (2) SNAP RING (3) BALL BEARINGS (A) DISTANCE COLLAR I10) DUST SEAL (9) NEEDLE BEARING? (a) DUST SEAL (7) SIDE COLLAR (5) SCREWS (6) DRIVE CHAIN SLIDER (8) REAR WHEEL/SUSPENSION Apply grease to the dust seal lip and install the dust seal in h swingerm pivot. II the right collar. Iv grease to the needle bearing. II the distance collar. ply grease to the dust seal lip and install the dust see! in mingarm pivot. III the left collar. y a locking agent to the drive chain slider screw threads. lthe drive chain slider to the swingarm and tighten the . 5.3 N~m (0.53 kg-m, 3‘8 lb-fl) ALLATION the swingarm to the frame. mos-wingarm pivot bolt and nut, tighten the nut. 110 Mm 111.0 kg-m. 80 lb-fl) the awingerm pivot caps. TYPE ONLY: the Nani and No.4 tubes to the EVAP canister. (1) RIGHT COLLAR - 7\ (4) DISTANCE COLLAR 7o (3) LEFT COLLAR (1) SCREWS . l3)EVAP Emma 13-19 REAR WHEEL/SUSPENSION Install the shock arm boll lrom lhe left side and lighten the nut, Torquo: 45 Man “.5 Ila-m, 33 lh-RI Install the shock link bolt from ma left side and tighten lha nut, Torquu: 45 N-m (4.5 Ito-m, 33 Ill-h) Install rear fender 8 (page 2-9). Install the rear wheel (page l3~8). 13-20 HYDRAULIC DISC BRAKE 12 N-m11.2 kg»m. S Ib-h) 1 N-m (0.1 kg-m, 0.7 lb-ft) 35 N'"‘ ‘3'5 “9"" 25 ""m 6 Min (0.6 kg-m, 4.3 lb-h) 31 N-m (3.1 kg-m, 22 lb-fl) 6 N-m (0‘s kg-m, 4,3 IIHI) 2.5 N-m (0.25 kg-m, 1.5 - 14. HYDRAULIC DISC BRAKE SERVICE INFORMATION 1&2 FRONT MASTER CVUNDER we ' TROUBLESHOOTING 1+3 FRONT CALIPER 14—1 1 BRAKE FLUID REPLACEMENT/ REAR MAsTER CVLINOER 14-1; A'“ BLEED'NG 1‘“ REAR CALIPER 14.19 BRAKE PAD/DISC 14-6 9 N-m (0.9 kg-m, 7 lb»!!! ‘2 N'm ”‘2 “9"“ 9 "H” 27 N-m 12,7 kgm, 20 lb-fi) 23 N-m (23 kg-m. 17 IIHI) 35 N-m (3‘5 kg-m. 25 lb-fl) HYDRAULIC DISC BRAKE SERVICE INFORMATION GENERAL - A cont-minutes] brake disc or pld reduce: flopping newer. Din-rd contaminated pede end clean the eontemlnlted disc with I high quellty brake decanting agent. CAUTION - support the bake caliper with e piece of win no that it do“ not hung hem the brake hose. Do not twist the brake hou. - Avoid epllllng brlke Iluid on painted, plesflc or rubber Mm. Place I reg or shop towel over that part: whenever the system Is serviced. ~ Be very careful whenever you remove the reservoir cap: make sure the front reservoir is horizontal first, - Once the hydraulic system has been opened. or if the brakes feel spongy. the system must be bled. - Never allow contaminants (dirt, water. sac.) to get into an open reservoir. < Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types fluid as they may not be compatible. - Always check brake operation before riding the motorcycle. SPECIFICATIONS STANDARD SERVICE LMII’ Specified brake Iluid DOT I brake fluid Brake pad wear — To the groove Broke disc thickness 3.8—4.2 (0.15—0.17) 3.5(0.14I 4.8v5.2 (0.19-0.20) 40 (0.I6) Brake disc runoul — 0.3 (0012) Master cylinder |.D. 12.700— 12.743 (0.5000‘05017) 1216(0502) H.000 — 14.043 (0.5512 — 0.5529) 14.055 (0.5533) Master piston OD. ”.675 — 12.68‘ (0.4983 — 0.4994) 12.65 (0.49!) 13.957 — 1338‘ (0.5595 — 0.5506) 13.945 (0.543” Caliper cylinder |.D. 25.400 — 25.450 (1.0000 - 1.0020) 25.46 (1.001) 38.180~ 35.230 (1.5031 — 1.5051) 38.24 (1.503) Caliper piston 0.D. 25.335 - 25.368 (0.5974 v 0.9937) 25.33 (0.99” 38.093 — 38.118 (1.4999 — 1.5019) 33.09 (1.500) TORQUE VALUES Caliper bleed valve Fed pin Pad pin plug Drake hose bolt Brake lever pivot nut lrake lever pivut bolt Front reservoir cover screw Front brake light switch screw Front brake hose clamper bait ant brake pipe stay bolt Brake pipe flare nut Brake pipa three way ioint bolt Front brake caliper bracket bolt Front brake caliper pin bolt 'Frunt caliper bracket pin bolt ront master cylinder holder bolt Rear brake caliper bracket bolt r brake caliper pin bolt LS lp ring pliers OUBLESHOOTING e lever/pedal mft or spongy .Alr in the hydraulic system Leaking hydraulic system ‘pontamlnated brake pad/disc orn caliper piston seal 'Worn brake pad/disc Contaminated caliper llper not sliding properly WM fluid level logged fluid passage . I pad/deformed brake disc ll glworn caliper piston ntaminated master cylinder t brake lever/pedal Bear master cylinder mounting bolt r master cylinder reservoir bolt r master cylinder push rod lock nut orn master cylinder piston cup Sticking/worn master cylinder piston HYDRAULIC DISC BRAKE 8 NW“ (08 ky-m. 4.3 letl 18 NM (1.8 kg-m, 13 lb-ft) 2.5 N-m (0.25 kg»m, 1.8 lb-ft) 35 Nom (3.5 kg-rn, 25 Ib-ft) 6 Wm (0.6 kg-m, 4 MM!) 1 N'm (0.1 kg-m. 0.7 lb-fil 1.5 N-m (0.15 kg»m, 1.1 lb-ltl 1.2 N‘m (DJZ kg-m, 0.9 lb-fl) 12 N-m (1.2 kg-m, 9 lb-fl) 12 N'rn (1.2 kg-m, 9 lh-ft) l7 N'rn (1.7 kg-m, 12 lb-ft) 12 N-m (1.2 kg-m, 9 lb-ft) 31 N-m (3.1 kg-m, 22 Ib-ftl 23 N-m (2.3 kg-m, 17 lb-l'tl Apply locking agent to the threads. 13 N-m (1.3 kg-rn, 9 Ib-ft) Apply locking agent to the threads. 12 N-m (1.2 kg-m, 9 lb-fl) 9 NW" (0.9 kg-m, 7 lb-M 12 NW" (12 kg-m, 9 lb-ft) 23 N'm (2.3 kg-m, 17 Ila-ft) 23 NW“ (2.8 kg-m. 20 lb-ft) 18 N-m (1.8 kg-m.13|b—ft) 01914 7 3230001 Brake lever/pedal hard Clogged/restricted brake system Sticking/worn caliper piston Caliper not sliding properly Clogged/restricted fluid passage Worn caliper piston seal Sticking/worn maeter cylinder piston Bent brake lever/pedal Brakes drag - Contaminated brake pad/disc ~ Misallgned wheel ~ Worn brake pad/disc ~ Warpad/delormad brake disc ~ Caliper not sliding properly ' Worn/broken return Ipring HYDRAULIC DISC BRAKE BRAKE FLUID REPLACEMENT] AIR BLEEDING . A brake disc or pld com-m nlted with brekl lluid I reduce: stopping power, Discard cant-minated pads Ind dun I contaminated disc with a high quality brill- L dugnning ugent, V (1) FRONT RESERVOIR 74 CAUTION - Do not IIIOW loreign materiel to enter the system when Illllng the reservoir. 9 Iluid on painted. plastic or rubber parts. lg over the" pens whenever the system is Mr» (ll REAR RESERVOIR . \ BRAKE FLUID DRAINING Fur the lront brake, turn the handlebar to the left until the reservoir is level before removing the reservoir cap. For the rear brake, remove the side cover (page 2-2), Remove the reservoir cap, set plate and diaphragm. Connect e bleed hose to the bleed valve. Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/BLEEDING Fill the reservoir with DOT A brake fluid from a sealed conv tamer. CAUTION ‘l1l8LEED VALVE - Uu only DOT A bull. fluid lrum a lulled cont-Ina. t Do not mlx dilloront types at fluid. They no not com- ll) BLEED VALVE ‘ (2) BRAKE BLEEDEH pltib ) Connect a commercrally available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve Add brake Ilurd when the fluid level In the rsservoi a low NOTE - Check the fluid level often while bleeding the brake to“ prevent air Irom being pumped into the system. - When using a brake bleeding roul, lellow the menutacturer's operating instructions. I 1 4-4 HVDRAULIC DISC BRAKE ltepeat the above procedures until air bubbles do not appear in the plastic hose. la entering the bleeder from around the bleed valve threads] seal the threads With tellon taper Chase the bleed valve and operate the brake lever or pedal. "it still reels spongy, bleed the system again, Ila brake bleeder is not available, use the following proceV flute: Pump up the system pressure with the brake lever or pedal until lever or pedal reslstance Is laltv Connect a bleed hose to the bleed valve and bleed the svsr turn as follows LSqueeze the brake lever or depress the brake pedal‘ Open the bleed valve 1/2 turn and then close it NOTE - Do not release the brake lever until the bleed valve has been closed. L— , ,7, “Release the brake lever slowly and wait several seconds alter it stops moving. Meat steps 1 and 2 until air bubbles do not appear in the d h'oset luhten the bleed valve, aqua: a N~m iota kg-m, 4.3 lb-ttl Ithe reservoir to the upper level mark Wllh DOT 4 brake dlrom a sealed container Ill the diaphragm set plate and reservoir cap‘ the lront brake: tighten the reservoir cap screws. In: 1.5 N-m (0.15 Itg-m. 1,1 lb-tt) the rear brake, install the side cover [page 2-2), (I) BLEED VALVE (Z) BRAKE BLEEDEFI HYDRAULIC DISC BRAKE BRAKE PAD/ DISC FRONT BRAKE PAD REPLACEMENT NOTE - Always replace the brake pads in pairs to ensure even disc pressure. Push the caliper pistons all the way in by pushing the caliper body inward to provide clearance (or the new pads. Remove the pad pin plug and loosen the pad pint Remove the pad pin and the brake pads. Make sure that the pad spring is installed in position. Install new pads so that their ends rest on the pad retainer en the bracket properly‘ lnstell the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper. Tighten the pad pin, Torque: 18 NM! [1.3 ku-m, 13 Ib-ft) Install and tighten the pad pin plug. Torque: 2.5 Mm (015 ku-m, 1.8 lb—h) Operate the brake lever to seat the caliper pistons against the pads REAR BRAKE PAD REPLACEMENT NOTE r- Always replace the brake pads is pairs to ensure even disc pressure. Push the caliper piston all the way in by pushing the caliper body inward to provide clearance for the new peas. 1 4-6 HYDRAULIC DISC BRAKE Remove the pad pin plug and pad pin. (1) PAD PIN PLUG Remove the caliper bracket belt. Pivot the caliper up and remove the pads. lnnall new pads so that their ends rasl properly on the pad retainer on the bracket. 7‘ (2) RETAINER lnwer the caliper and install the pad prn while pushing the pd: against the pad spring. Mall and tighten the caliper bracket bolt. TWO: 23 N’m [2.3 kg-m, 17 Ib-h] ighttm the pad pin plug. “-10:18 N-m l1.8 lip-m. 13 lb-m II and tighten the pad pin plug. mute: 2.5 N-m l0.25 kg-m. 1.8 lbvhl less the brake pedal to seat the caliper piston against the E DISC INSPECTION ually inspect the disc for damage 0! cracks. Iure the brake disc thickness at several points. "In": Front 3.5 mm [0.1. in] Rear: 4.0mmlD.16inl Ice the brake disc iI the smallest measurement is less nthe service limil. HVDRAULIC DISC BRAKE Check the brake disc for werpege. Service limit: 0.30 mm [0‘012 in) Check the wheel bearings ler excessive play, it the warpage exceeds the service limit. Replace the brake disc ifthe wheel bearings are normal. FRONT MASTER CYLINDER DISASSEMBLY DIaIn the brake fluid "am the front hydraulic system (page ”-3). Disconnect the lront brake light switch connectors‘ Remove the pivot nut, bolt and brake lever, CAUTION - Avoid tpllling bake fluid on painted. plastic or tube: plfll. Place I reg or shop towel over the“ pom when- ever the Intern is being Iervieed‘ - When removing the all hell, cover the end of the hole to pvevem contamination . Disconnect the brake hose lrom the master cylinder by removing the oil bolt and sealing washers, Remove the master cylinder holder bolts, holder and the master cylinder. Remove the screw and the front brake light switch, Remove the piston boot from the master piston and cylinder. [7i SEALING WASHERS 11) OIL BOLT (6) MASTER CYLINDER i ~ (‘ll SCREW (3i PISTON BOOT (2) BRAKE LIGHT S 14-8 HYDRAULIC DISC BRAKE Remove (he snap ring. (I) SNAP RING Tool: Snap vlng plifll 0791‘ - 3230001 Ramave the masiev piston and spring. Clean the master cylinder, reservoir and master piston with clean brake fluid. (2). SNAP RING PLIERs' INSPECT'ON (1) MASTER CYLINDER Check me piston cups Ior wear. deterioration or damage Check the masier cyIindor and piswn for scoring or damage. Measure the master cylinder LD. (2) CUPS Smile. limit: 12,75 mm (0502 In) Measure The master piston O,D. lorvleo limit: 12.65 mm I049! In) (3) PISTON ASSEMBLY (2) SNAP RING (1i BOOT (SI RESERVOIR CAP (6) SET PLATE (7) DIAPHRAGM (B) MASTER CYLINDER BODV ‘0 \‘:%\ (9) BRAKE LIGHT SWITCH (10) SCREW 1 4-9 HVDRAULIC DISC BRAKE Coat the master piston and piston cups with clean DOT A brake fluid. Install the piston spring onto the piston end‘ Install the piston spring and piston Into the master cylinder. CAUTION yr - Do not allow the piston cup line to turn Insldu out: Install the snap nng into the groove in the master cylinder. Tool: Snap ring alias 07914 - 3230001 CAUTION [:39 the "I... r g I: llvmly s the groov Install the piston Door into the master cylinder and the graove in the master piston, Apply SIIICOHe grease to the brake lever contacting surface of the master cylinder. Install the front brake light swuch and tighten the screw‘ Torque: 1.2 N-m (0.12 kg-m, 0.9 Ila-ft) Install the master cylinder and the holder with the 'UP" mark lacing up. Ailgn the end at the master cylinder with the punch mark on the handlebar, and tighten the upper bolt first, then tighten the lower bolt, Torque: ‘2 Man (12 kn-m. 9 III-RI (1) MASTER CYLINDER (2) SPRING é I3) f PISTON AND PlSTON CUPS I [2% g (5) SNAP RING “j. (A) PISTON BOOT l1) SNAP RING L SNAP RING PLIER 13) PISTON BOOT (1) SCREW ’61 (2) BRAKE LIGHT SWITCH I1) MASTER CVLINDER [2) MASTER CVLIN HOLDER (I) "UP‘ ' k (5) PUNCH MARK 14-10 HVDRAULIC DISC BRAKE noct the brake hose to the master cylinder with the Oil m MASTER ”UNDER mass/mm WASHERS lurid sealing washers and tighten the bolt. . ., ue; 35 N-m (3.5 kg-m, 25 lb") '4 l l ctthe brake light switch connectors Iv silicone grease to the brake level pivot. III the brake lever and pivot bolt. and tighten the bolt. :1 N-m (0.1 ltg-m. 0.7 lh - Faulty regulator/rectifier. - Shorted wire harness. - Poorly connected connector. Check the alternator charging coil (page 15« Incorrect Correct - Poorly connected alterna- tor connectorr - Faulty charging coil. CHARGING SVSTEM/ALTERNATOR Z. Buttery overcharging [Regulated voltl 0 too high). Measure the charging voltage th the battery fully charged and in good condman (page 15- l a). Regulated voltage greatly exceeds the stan- dard value. i Check the continuity between the ground Ilne : and frame ol the regulator/rectifier connector [ (page 15-9). Correct Correct . Faulty battery, Incorrect _ . _ , - Open clrcmt In wrre harness. - Poorly connected connector. ‘————'—’ ' Faulty regulator/rectifier. ' Poorly connected connector. CHARGING SYSTEM/ALTERNATOR BATTERY (1i BOLTS REMOVAL] INSTALLATION Ramuve the seal (page ZAZL NOTE — , ‘ - Always turn the Ignition switch OFF belore removing Ol ‘ installing the battery. Remove the battery cave! bolts and cover. Remove the battery positive cable cover. Disconnect the battery negative cable Iirsl, then the pasutwe cable from the battery Flemcve the tool kit and the battery. (2i POSITIVE CABLE Installation is In the reverse order of removal, NOTE - Apply clean grease to the battery termmals. - Pull the cover away the posltive terminal. ' l VOLTAGE INSPECTION (1) NEGATIVE CABLE Measure the battery voltage using a digital multimeter, Volt-go: Fully chug-d: Over 13.0 V Undar charged: Below 123 V Tool: Dlgltnl munimstu Comm-rcillly Ivlilablo BATTERV CHARGING - The buttery gives 0" axploaivo gn ; hep :plvkl, II-mas, and cigarettes lle. Provide Idoqulta vontlll- lion whan churging. ~Tho battery contains sulfuric ucid lulmvolytt). Contact with skin or eyes may cause nvan burns. Wear protec- tive clothing and a he. Ihiold. - ll electrolyte gets on you: skint Ilush with water. - II oloctvolyto got: on your oven, Ilush with w-tev Ior It Inst 15 minutes and all phvgici-nt - Eloctlolyto is poitonuus. II Iwallowod. drink llrgo qulntitin at watu or milk and Iollow with milk of mag- nuil or veg-table oil and cull I phvlicinn. - Tum pow-v ONIOFF It the chum-r. not It the buttery I tannin-Is. 1 5-5 CHARGING SVSTEM/ALTERNATOR Remove the battery. Connect the charger positive to) cable to the battery positive l+) terminal, Connect the charger negative (—I cable to the battery nega- tive 1—) terminal. '\ Standard 7 Quick j Charging current 0.9 A 4.0 A Charging time 5 hours I 1 hour J CAUTION - Quick-charging eheuld only he done in an emergency: i alow charging is preferred. - For battery charging. do not exceed the charging ‘ current and time Ipecltled on the battery. Uaing exceuive current or extending the charging time may damage the battery. CHARGING SYSTEM INSPECTION NOTE I - Measuring circuits with a large capacity that exceegi the capacity of the tester may cause damage to the tester. Belore starting each test, set the tester at the high capacity range first. then gradually down to low capacity ranges in order to ensure that you have the correct range and do not damage the tester. ~ When measuring small capacity circuits. keep the ignition switch 0". I.’ the switch is suddenly turned on during a test, the tester Iuse may blow. REGULATED VOLTAGE INSPECTION (1) DIGITAL MULTITESTER 7 ‘,\ - II the engine must be running to do aome work. make am- the area In well-ventlleted. Never run the engine In an encloaed area. - The exhauat contains polaonoua carbon monoxide gee that may cause lose at coneoioueneea and may lead to death. Install a lully charged battery. Start the engine and warm it up to the operating tempera- ture: stop the engine Connect the multimeter between the poaitive and negative terminals of the battery. CAUTION - To prevent ehort. make absolutely certain which are the poaltlve and negetlve terminal: or cable. - Do not dlaconnect the battery or any cable In the cherglng ayatem wlthout Ilrat awltching all the lgnltlon switch. Failure to Iollow thla precaution can damage the teeter or electrical components. | 15-6 With the headlight ON (Lo beam), restart the angine. Measure voltage on the multiteeter when the angina runs at 5,000 rpm. legal-ted voltage: 13.0 - 155 V at 5,000 rpm lhe battery is normal it voltage reads the regulated voltage . the tester. TE . The speed at which voltage starts to rise cannot II: checked as it varies with the temperature and loads or ‘ the generator. lrequentlv discharged battery is an indication that it IS . v riorated even ll it proves normal in the regulated voltage pection. . echarging circuit may be abnormal it any of the following moms is encountered: - Voltage not raiaed to regulated voltage (page 15-3l ‘ Open or shorted circuit in the charging system wire harness or poorly connected connector Open or shorted oi the alternator Faulty regulator/rectifier Regulated voltage too high (page 154) Poorly grounded voltage regulator/rectifier Faulty battery Faulty regulator/rectifier ' RENT LEAKAGE TEST we the battery cover (page 155). n of the ignition switch, and disconnect the ground i—l . irom the battery. . the ammatar H) probe to the ground cable and the eter 1—) probe to the battery l—l terminal. . the ignition switch ofl, check lor current leakage. r i CHARGING SYSTEM/ALTERNATOR ‘ m NORMAL CHARGING ' VOLTAGE l (2) REGULATED T e VOLTAGE v u : (a) BATTERV O l VOLTAGE % - I A I G _ l E l (Vl—'—r—I—'—t—l—t—“—l ENGINE SPEED —> (rpm) (1) ABNORMAL CHARGING VOLTAGE ". (1) AMMETER (2) GROUND CABLE When measuring current using a tester, set it to e higt range, and then bring the range down to an appropriate level, Current llow higher than the range selected may blew out the luaa in the teeter. While measuring current, do not turn the Ignition on. A hidden surge oi current may blow out the fuse in the later. ed ourrent leakage: 1.2 MA max. mnt leakage exceeds the specified value, a shorted , ia likely. H the short by disconnecting connections one by one measuring the current. CHARGING SYSTEM/A LTERNATOR REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the right slde cover lpage 27h Disconnect the regulator/rectifier connector eAnenv LINE Make sure the battery voltage between RedNVhite (4) and Green l—l. If there are no voltage, measure the Iollowings: Item Terminals Specification Battery Red/White l4») and Banery voltage charging line ground (—l should register Ground line Green and ground Continuity exists. CHARGING LINE Measure the resistance between the connector terminals (Vellow and Vellow). Sundlrd: 01-11) H IZD-CISB’FI Check for continuity between the Vellow wrra terminals and ground. There should be no continuity. ALTERNATOR NOTE - It is not necessary to remove the stator coil to complete this test. Remove the fuel tank (page 2-4) and disconnect the shame tor 3? (White) connectorv Measure the resistance between the connector terminals (Yellow and Yellow), Standard: 0.1-1.0 Q (Zo‘c/W‘F) Check Ior continuity between the yellow Wire terminals and around. There should be no continuityt l1) REGULATOR/RECTIFIER LEFT CRANKCASE COVER REMOVAL Remove the side tairing (page 2-3l. Disconnect the alternator 3P connector. Remove the Ian crankcase cover bolts and left crankcase cover. Remove the gasket and dowel pin STATOR REMOVAL/INSTALLATION NOTE ~ 7 . For flywheel removal and installation, refer to page 17 L \0 "FLYWHEEL/STARTER CLUTCH". , REMOVAL Remove the clamp bolt and clamp. Remove the stator bolts and the wure grommets then remove the stator from the left crankcase cover INSTALLATION Place the stator In the left crankcase cover. Apply liquid sealant to the wtre grommets seating surface and install the grommets into grooves in the crankcase cover. CHARGING SYSTEM/ALTERNATOR t1) ALTERNATOR l 3? CONNECTOR (‘ll BOLTS (1) GROMMETS fie (2) WIRE CLAMP (3) BOLTS.~ (ll GROMMETS JG!!! 12) ALIGN CHARGING SYSTEM/ALTERNATOR Ruute the wire properly and Install the wire clamp with the bolt. [2) BOLTS Torque: 10 N-m (1.0 lrg-m. 7 RH!) Install and tighten the stator bolts. Yorqun: 12 N~m (1.2 Ira-m, 9 lb-l'tl (1) WIRE CLAMP . LEFT CRANKASE COVER INSTALLATION (1) DOWEL PIN . n \ a“ 1" Install the dowel pm and new gasket onto the crankcase. \ Install the left crankcase cover and tighten the caver bolts. (2) BOLTS \ Rome the alternator wire through the trams properly (03991- 20). Connect the alternator 3P cannector securely. ll) ALTERNATOR 3P CONNECTOR Install the side hiring and fuel tank (page 2-3, A). 15-10 CHARGING SYSTEM/ALTERNATOR BATTERY CASE (1) STARTER RELAY SWITCH 'y" REMOVAL/INSTALLATION Remove the fuel tank (page 24L Remove (he Slde Iarnng (page 273) Remove the banew1 “name: 5 '7: ? 5i! i 7 (xalmnm ans mm. m ("'1 m , 1 Hum ms: mano- ‘ sum Ion mm woman 14 “275mm Inns ,3. g I, (I; _I_I_I_L J. BI BLACK :1 m — T T v mm It ‘ MT: —_ Iu M: u LM mac n v ~ mash 16-1 IGNITION SYSTEM SERVICE INFORMATION GENERAL - itch n no mun In running to do some work. make sure the area is well-ventilated. Never run the engine in on oncloud o - The exhaust contains poisonous carbon monoxide go: th-t mly cause In" at consciousness and rn-y loud to death. CAUTION - Sonic electrical components may be damaged it term I or connectors are connected or disconnected while the ignition switch is ON and I current I: present. When checking the ignition system, always follow the steps in the troubleshooting (page 16-3”. The ignition control module (ICM) may be damaged it dropped. Also. if the connector is disconnected when currentla (lowing, the resulting excessive voltage may damage the unit. Always turn off the ignition switch before servicing. Ignition timing cannot be adjusted since the ignition control module is non-adjustable. ll ignition timing is incorrect. check the system components and replace any isulty parts. A laulty ignition system is often related to poorly connected or corroded connectors. Check those connections belorl proceeding. Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plugs. Use spark plugs oI the correct host range. Using a spark plug at an incorrect heat range can damage the engine. For neutral switch and side stand switch inspection and removal/installation see Section 18. For engine stop switch and ignition switch inspection and removal/installation see Section 18. SPECIFICATIONS ITEM SPECIFICATIONS Spark plug Standard NGK NIPPONDENSO CHBEHS UZ7FER9 Spark plug gap 0.8 —0.9 mm (0.031 — 0.035 in) Ignition coil primary peak voltage 100V minimum Ignition pulse generator peak voltage 0.7 V minimum Ignition coil resistance Primary 2.5 — 3.1 II (At 20°C/68‘FI Secondary: with plug cap 21 A 25 kn Secondary: without plug wire 11 — 15 kn Ignition pulse generator resistance (At 20°C/68°FI 460 — 5801) Ignition timing "F" mark 49 state, Canada type 10’ BTDC at 1,200 2 100 rpm California type 5" BTDC at1,u)0 : 100 rpm TORQUE VALUES Ig on pulse generator rotor cover cap 18 N-m (1.8 kgsm, 13 lb-ft) Apply grease the threads. Ignition pulse generator rotor cover bolt 12 N'm (1.2 kg-m, 9 Ib-ft) Ignition pulse generator rotor bolt 60 N~m (6.0 kg-m, A3 Ib-lt) TOOLS Imrie diagnostic tester (model 025) or Peak voltage adaptor 07HGJ — 020100 with Commercially available digital multimeter (impedance 10Mn/DCV minimum) Inspection adaptor 07GMJ — ML80100 1 6-2 TROUBLESHOOTING - Inspect the iollowing before diagnosing the system. — Faulty spark plug. no SPARK AT ALL SPARK PLUGS é! IGNITION SYSTEM — Loose spark plug cap or spark plug wire connections. —Water got into the spark plug cap (Leaking to the ignition coil secondary voltage). - II there is no spark at either cylinders, temporarily exchange the ignition coil with the other good one and perform the spark test. It there is a spark, the exchanged ignition coil is faulty. - 'Inltial voltage‘ of the ignition primary coil is the battery voltage with the ignition switch ON and engine stop switch at RUN. (I’ha engine is not cranked by the starter motor.) Unusual Condition Probale Cause (Check in numerical order) No initial voltage with igni- tion and engine stop switch- es ON. (Other electrical com- ponents are normal.) Ignition coil primary voltage be we Faulty engine stop switch, An open circuit In BI/ W wire between the Ignition coil and en- gine stop switch. .Loosa primary terminal or an open circuit in primary coil. .Faulty ignition control module (ICM): in cases when the initial voltage is normal while disconnecting ICM connectors. Initial voltage Is normal, but it drops down to 2 — 4 V while cranking the engine. 9’9? 9H9 we 30 Incorrect peak voltage adaptor connections, Underchargad battery. No voltage at the power source wire between Bl/W M and ground (—i of the Ignition control module (ICM) connector or loosen ICM connection. An open circuit or loose connection in G wire oI the ICM. Open circuits or loose connections in Bu/Y and V/Bu wires be- tween the ignition coils end ICM. Short circuit in ignition primary coil, Faulty side stand switch or neutral switch. An open circuit or loose connection in No.1 related circuit wires. - Side stand switch line: GM and G wire - Neutral switch line: Lg and Lg/R wlre Faulty ICM (in cases when above No. ‘I —B are normal). Initial voltage is normal. but no peak voltage while crank- ing the engine. Incorrect peak voltage adaptor connections. Faulty peak voltage adaptor. Faulty ICM (in cases when above No. 1, 2 are normal). Initial voltage is normal, but peak voltage is lower than standard value. PN.‘ :- The multimeter impedance in too low; below 10Mn/DCV. Cranking speed is too slow (battery is underchargedl. The sample timing 0' the tester and _meaaured pulae were not synchronize (Synern ls normal it measured voltage is over the standard voltage at least once). Faulty ICM (In cases that above No. ‘l - 3 are normal). Initial and peak voltage are normal, but does not spark. .N-' Faulty spark plug or leaking Ignition coil secondary current am- pare. Faulty Ignition coils. Ignition pulse puerator Peak voltage ls lower than standard value. A PN.‘ ‘l’he multimeter impedance is too low; below 10 Mil/DCV. Cranking speed Ia too slow (battery is underohargad). The sample timing of the tester and measured ignition pulse were not synchronize (System is normal it measured voltage is over the standard voltage at least oncel. .Faulty ICM (in cases when above No. I — 3 are normal). No peak voltage. u- . Faulty peak voltage adaptor. . Faulty ignition pulse generator. IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE - Ii there is no spark at either plug. check all connections ior loose or poor contact before measuring each peak voltage. ' Use the recommended digital multimeter or commercially available digital multimeter with an impedance ol 10 Mnl DCV minimum - The display value diners depending upon the internal impedance oi the multimeter. - It using an lmne diagnostic taster imodel 625), follow the manufacturer‘s instructions (2) PEAK VOLTAGE ADAPTOR Connect the peak voltage adaptor to the digital multimeter. or use the Imrie diagnostic tester. Tools: Imrle diagnostic tut-r imodel 625) or Punk voltage I Iptor 07HGJ - 0020100 with Commercially available digital multimeter limped-nee 10MDIDCV m um) IGNITION PRIMARY VOLTAGE INSPECTION NOTE - Check all system connections heiore the inspection. II the system is disconnected, an incorrect peak voltage will register. - Check cylinder compression at each cylinder and check that the spark plugs are installed correctly in each cylin- der. Remove the maintenance cover (page Z-ait Disconnect the spark plug caps from the spark plugs on the cylinder heads Connect a good known spark plug to each spark plug cap and ground the spark plugs to the cylinder as done in a spark teat, (I) SPAR K PLUG Remove the air cleaner base (page 5-4). Connect the peak voltage adaptor or lmrie tester to the ignition coil. NOTE - Do not disconnect the ignition coil primary wires. ‘l Tools: Irnrie diagnostic teeter (model GZSI or Peel voltage edeptor 07HGJ - 0020100 with Commerclelly eveilebIe di el rnuItimeter (Impedence 10MD/DCV minimum) Connection: No. 1. 4 Ignition coil: V/Bu terminal (bl - Body ground H No. 2, 3 lgnitlon coil: BuIV terminel (oi - Body ground l-i Turn the ignition switch 'ON' and engine stop switch to 'RUN'. Check for initial battery voltage ii battery voltage is not present, Iollow the checks described In the troubleshooting chart on page 16-3. Shift the transmission into neutral. Crenk the engine with the starter motor and read each igni- IIon coil primary voltage Peek voitege: 100 V minimum Avoid touching t spark plugs end teeter probee to prevent electric ehoelt. NOTE - Although measured values are different for each igni- tion coil, they are normal as long as the voltage is higher than the standard value. 'lithe peak voltage is lower than the standard value, iollow theehecks described in the troubleshooting chart on page 163. IGNITION SYSTEM (1i 4 i a PEAKVOLTAGEADAPTOR . IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE INSPECTION NOTE V - Measure the peak voltage with the cylinder compres- sion applied. Leave the spark plug in the cylinder head. Remove the side cover (page 2-2). Disconnect the ignition control module 16F connector. Connect the peak voltage adaptor to the wire harness side connector. Toele: lrnrie agnostic teeter lModel 625) or Peek voltage adopter D1HGJ — 0020100 with Commer lly I able d tel multlmetet (impede nee 10MB] DCV mlnlmurnl Connection: White/Vellow lol - Vellew l-l Measure the ignition pulse generator peak voltage while cranking the engine with the starter motor. Peek voltage: 0.7 V minimum If the peak voltage is lower than standard value. perform the Iollowing procedure. Disconnect the ignition pulse generator 2? (Red) connector. Measure the peak voltage at the ignition pulse generator 2? (Red) connector and record it. Connection: White/Yellow M - Yellow l-l Peek voltage: 0.7 V minimum Compare their values at the ignition control module 16F con- nector and the ignition pulse generator 2? (Red) connector. II the value at the ignition pulse generator is normal. but abnormal at the ignition control module: - Open the circuit in the ignition pulse generator wires - Loosen connection in the ignition pulse generator connec- (01 If both values are abnormal: ~ The ignition pulse generator is likely to be laulty. Check and perform troubleshooting per the overt on page 1&3, (2) PEAK VOLTAGE ADAPTOR m ICM m— (2) 2? (RED) CONNECT IGNITION COIL nsracnou Remove the maintenance cover (page 13), lemove the air cleaner base (page 5-H. Measure the primary coil resistance at each terminal, hand-rd : 2.5 — 3‘1 9 [20”0/38' FI Diwonnect the spark plug caps lrom Ihe plugs and measure the secondary coil resistance between the spark plug caps, Itandlrd : 21 - 25 k1) IZD‘CISB' Fl Illhe resistance us out of range, remove the spark plug wrre Irorn the ignition coil and measure the resistance as shown. Bundard : 11 — 15 ks! I20'C/B8'Fl REMOVAL] INSTALLATION Move the m enance cover (page 2-3), 'bmove the air cleaner base (page 5-0. Remove the spark plug cape lrom the spark plug (page 3-8). Remove the ignition coil mnunting bolts. IGNITION SVSTEM IGNlflON SYSTEM Disconnect the ignition coil primary connectors. Remove the ignition coil. Installation is in the reverse order of removal. NOTE - Connect the primary Wire terminals properly. No 1, A coil' Black terminal ~ Black/White wire Green terminal , Yellow/Blue wire No 2, 3 CDII' Black terminal 7 Black/White wire Green terminal 7 alue/Vellow wire INSPECTION NOTE - It Is not necessary to remove the ignition pulse genera- tor Irom the engine. Remove the Iuel tank (page 24) Disconnect the ignilion control module 16F connector. Measure the reSistance oi the Ignition pulse generator at the Ignition control module 16F connector. Connection: White/Vellow - Yellow Sundlrd: 460 — 580 Q (ZO'CISB'FI lithe measurement is out of specified range, perform the Iollowmg procedures: Disconnect the ignition pulse generator 2P (Red) connector. Measure the resistance of the ignition pulse generator at the ignition pulse generator 2F (Red) connector. Standard: 480 - 580 Q (ZO'CISB‘FI (Z) IGNITION COIL 16-8 IGNITION SVS‘i‘IM Compare their values at the ignition control module 16? con- nector end the ignition pulse generator 2F (Red) connector. lithe value at the Ignition pulse generator is normal. but abnormal at the ignition control module: - Open circuit in the White/Vellow wire - Open circuit in the Yellow wire r Loosen connection in the Ignition pulse generator 2P (Red) connector. "the value at the ignition pulse generator is abnormal: - Replace the ignition pulse generator REMOVAL (1) IGNITION PULSE Remove the side fairing (page 2-3). GENERATOR CONNECTOR Remove the iuel tank (page Z-A). Disconnect the ignition pulse generator 2? (Red) connector. Remove the ignition pulse generator rotor cover bolts and Ignition pulse generator rotor cover. Remove the gasket and dowel pins. (1) BOLTS (2i COVER ove the wire grornrnete from the cover. (3, (GNITION PULSE GENERATOR on the mounting bolts and the ignition pulse generator. ‘ - (I) GROMMETS 1 6-9 0N SVSTEM Shift the transmission into 6th gear and apply the rear brake. then loosen the ignition pulse generator rotor bolt. NOTE - II the engine IS removed Item the frame, remove the left crankcase cover (page 15-9) and loosen the bolt while holding the flywheel wlth a flywheel holder 107925- 1 MESOEQO) or equivalent commercially available in USA. Remove the bolt. washer and ignition pulse generator rotorv INSTALLATION Install the ignition pulse generator rotor. aligning the groove with the wide teeth of the Crankshaft. Install the washer and rotor bolt. Shift the transmisswn into 6th gear and apply the rear brake, then tighten the ignition pulse generator rotor bolt. Torque: so N~m (5.0 kg-m. 43 um) - If the en BIS removed from me Irame hten (rte bolt while no ding the flywheel with a "Ythe holder (07925 , MEBOOOOI or equivalent commercially available in USA. Place the ignition pulse generator. Apply liquid sealant to the wrre grommet seating surlace and install the grommet into the groove in the ignition pulse geri- erator rotor cover. Install and tighten the mounting bolts‘ l‘ll BOLTNVASHER l2) ROTOH (1i ALIGN / l2) BOL'T (1) IGNITION PULSE GENERATOR (3) G n .‘ it \ 16-10 Install the dowel pins and new gasket to the crankcase Apply liquid sealant to the threads of the bolts indicated by "A" marks. Install the ignition pulse generator rotor cover and tighten the cover bolts. Torque: 12 N-m (1.2 liq-m. 9 Ib-fl) Connect the ignition pulse generator 2F (Red) connector Install the side fairing (page 2-3). Install the fuel tank (page Z-lir THROTTLE POSITION SENSOR INSPECTION Remove the side leiring (page 2-3). Disconnect the throttle position sensor 3? connector, Check the connector for loose or corroded terminals, Connect the inspection adaptor between the throttle position sensor connectors. Tool: Intention od-ptor 016W - MLflHM IGNITION SVSTEM I1) DOWEL PINS (5) " A' MARKS (SI COVER (1i IGNITION PULSE GENERATOR CONNECTOR INSPECTION ADAPTOR IGNITION SYSTEM INPUT VOLTAGE Turn the ignition switch 0N. Measure and record the input voltage at the inspection adaptor terminals using a digital multimeterl Connection: Red clip to) - Green clip l-l Standard: 4.5 - 5.5 V ll the measurement is out of the specification, check the Iollowing: - Looen connection ignition control module 18F connector. - An open circuit in wire harness. Output voltage Measure and record the output voltage at the inspection adaptor terminals using a digital multimeter. Connection: White clip to) - Green clip 1-) Measuring conditions: At full throttle open At Iull throttl- close (with throttle stop screw Iuliy turned out) Compare the measurement to the result oI the Iollowing calculation. At Iull throttle open: Va X 0,824 - V0 Where Va: Input voltage measured Vc: Result of calculation The sensor is normal iIthe value measured is V0 1 10%. At Iull throttle close: Va X 0.1 - Vt: Wh era Va: Input voltage measured Vc: Result oi calculation The sensor is normal it the value measured is V: :i: 10%. Using an analog meter. check that the needle of the Volt meter swings slowly when the throttle is opened gradually, CONTINUITV CHECK Disconnect the ignition control module 16F connector and the throttle position sensor 3P connector. Check the contin itv between the throttle position sensor 3P connector and the ignition control module 16F connector ol the wire harness. Connection: Yellow/Red — Yellow/Red fled/Yellow - Red/Yellow Blue/Green — BlueIGreen Mord: Continuity ifthera is no continuity, replace the wire harness, IGNITION SYSTEM (“INSPECTION ADAPTOR e > L] { (3) GREEN CLIP (2) RED CLIP (1) msrscnon ADAPTOR \ l3) GREEN CLIP (2) WHITE CLIP I1) THROTTLE SENSOR CONNECTOR I (2) lCM CONN 16-12 IGNITION SVSTEM IGNITION TIMING Warm up the engine. Stop the engine and connect e timing light to the spark plug wire, NOTE ' Read the manulacturer’a instructions Ior the timing light 1 below operating, J Remove the following : - Right side Iairing (page 2-3l - ignition pulse generator rotor cover cap. Start the engine and let it idle, “STATE AND CANADA TYPE: The timing is correct if the F mark (three punch marks) ali n ”STATE AND CANADA CALIFORNIA g (1) INDEX MARK (2) INDEX MARK with the index mark on the ignition pulse generator rotor WVOI‘. Increase the engine speed by rotating the throttle stop screw And make sure the F mark begins to move counterclockwise at approximately 1,500 rpm CALIFORNIA TYPE: The timing is correct it the F mark (two punch marks) align with the index mark on the ignition pulse generator rotor 00 . V” (4) THREE PUNCH MARKS (3) TWO PUNCH MARKS Increase the engine speed by rotating the throttle stop screw n It th k ' I Irw' e d me a sure e F mar begins to move counter: no use ,1 (2) "l It approximately 1,500 rpm, Check the ignition pulse generator rotor cover cap O—ring for damage or deterioration Replace it with a new one iI neces- llrv, Apply grease to the ignition pulse generator cover cap Ihreada and tighten itt Torque: 18 N-m IlJItg-m, 13 It-lb) Innall the right side Iairing (page 2-3). ELECTRIC STARTER/STARTER CLUTCH III IGNITION SWITCH (2) ENGINE STOP SWITCH (3) STARTER SWITCH It) CLUTCH SWITCH DIODE I5) MAIN FUSE 30A (6) BAT—IE RV I11) FUSES 10 A, 15A (10) STARTER MOTOR (9) N E UTRAL SWITCH (8) SIDE STAND SWITCH I7) STARTER RELAY SWITCH (TIIG NITION m STARTER SWITCH (e) BATTERV RELAY SWITCH S’\‘? A o R/ Bl R V fl I __ fi (10> STARTER (11) FUSE T 151 MAIN ”07°“ 15A (IIIFUSE FUSE V/‘R Io A 30 A T E 1/ Br 81 G/ R NEUTRAL I LII/o— Bl/ H—O/RTER (2) ENGINE STOP (3) STA (‘2) CLUTCH INDICATOR squcu swrrcn swncn Lg/ R : e/ R G/ R 4/0] (9) u) CLUTCH NEUTRAL SWITCH G/ U SIDE STAND SW'TC” _L,_g D'ODE SWITCH = INDICATOR 17.ELECTRIC STARTER/STARTER CLUTCH SERVICE INFORMATION 17-1 STARTER RELAY SWITCH 17-9 I TROUBLESHOOTING 17-2 CLUTCH DIODE 17-10 ‘ STARTER MOTOR 17-4 FLYWHEEL] STARTER CLUTCH 17-10 I SERVICE INFORMATION GENERAL - Alw ya turn the Ignition twitch OFF before urvlclng the starter motor. ll not the motor could suddenly nart. causing I nrioul iniury. 4 - A weak battery may be unable to turn the starter motor quickly enough. or supply adequate ignition current, - II current continues to flow through the starter motor while the engine is not cranking over, the starter motor may be damaged. - Always turn ofl the ignition switch belore disconnecting any electrical components. - For ignition, starter and clutch switch inspection, see Section 18. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE UMIT Starter drivan gear 0.0. 5717.699 — 51.718 (2.0351 — 2.0361) 51.68‘ (20343) Starter motor brush length 12.0 — 13 0 (017 7 0.51) 4.5 (0.18) TORQUE VALUES Flywheel bolt 105 N-rn (10.5 kg-m, 76 lb-ftl Apply oil to the threads. Starter clutch bolt 16 N-m (1.6 kg-m, 12 IbrhI Apply a locking agent to the threads, TOOLS Flywheel holder 07925 - ME90000 or equivalent commercially available In USA. Rotor puller 07733 — OOZOOOI or 07933-2160000 (USA. only) Flywheel holder 07725 — 040000 or equivalent commercially available in USA. Torx bit IT30I 07703 — 0010200 or equivalent commercially available in USA. ELECTRIC STARTER/STARTER CLUTCH TROUBLESHOOTING Starter motor will not turn r Check for a blown main or sub fuse beiore servicing. ‘ Make sure the battery is fully charged and in good condition. terminals, and opened or shorted battery cable Check for loose or poorly connected battery M. - Poorly connected battery terminals - Open or short circuit in battery cable I Normal Check for loose or poorly connected starter relay switch terminals and JP connector. A . w - Poorly connected terminals or IP connector T Normal Check for loose or poorly connected starter motor cable, or opened cablet I Normal With the ignition switch ONA push the starter switch and check for a 'cliclt" sound irom the starter relay switcht Abnormal - Poorly connected motor cable - Open circuit in motor cable _ Connect the starter motor terminal directly to Clicks the battery positive terminal. (Because a large amount of current flows' do not use thin No click Wires). | l Starter motor Starter does not turn motor L turns - Faulty starter motor - Loose or disconnected starter motor cable - Faulty starter relay switch Check the relay coil ground wire lines (page 177 9). w. - Faulty neutral switch - Faulty clutch switch diode Continuity ' Faulty clutch switch - Faulty side stand switch ' Loose or poor contact oi connector ' Open circult in wire harness Check the starter relay voltage at the starter relay switch connector (page ”-9). ML» ~ Faulty ignitlon switch ~ Faulty starter switch T Voltage appearea - Blown out main or sub fuses - Loose or poor contact or connector - Open circuit in wire harness Check the starter relay switch operation (page 17-9). Am. - Looaa or poor contact oi the starter relay switdl» connector | Abno rmal |—————' - Faulty starter relay switch 17-2 ELECTRIC STARTER/STARTER CLUTCH The starter motor turns when the transmission is in neutral, but does not turn wlth the transmission in any position except neutral. The aide stand is up and the clutch lever is pulled in. Check that the side stand indicator operates Abnormal . . , . . r , - Faulty uncle “and awttch properly With the Ignition xwrtch ONt _ Burnt bulb Normal ‘ Open circuit in wire harness Check the clutch switch operatin (page 13-11). Abnormal - Faulty clutch swltch Normal Check the aide stand switch lpage 18-17). Abnormal - Faulty side stand switch Normal - Open circurt In wura harness - Loose or poor contact at connector Start-r motor turn: slowty - Low specific gravity in battery (or dead battery) - Poorly connected battery terminal cable - Poorly connected starter motor cable - Faulty starter motor - Poorly connected battery ground cable Startor motor turns, but engine does not turn - Starter motor is running backwards - Case assembled improperly - Terminals connected improperly Faulty starter clutch Damaged or laulty starter motor gears Starter relay switch “clicks", but engine does not turn over - Crankshaft does not turn due to engine problems - Excessive starter motor gear friction ELECTRIC STARTER/STARTER CLUTCH STARTER MOTOR REMOVAL Willi gnltlon :wltch OFF, remove the non-tin cable l It the b ttuy before nrvicing the Inner motor. Remove the fuel tank (page 2-”, Remove the lelt engine hanger plate (page 7-“ Disconnect the starter motor cable. Remove the motor mounting bolts and ground cable. Remove the starter motor. DISASSEMBLV L- Record the location and number of shims. -‘ Remove the following components: - motor case bolts - front and rear covers - armature INS PECTION Check for continuity between the cable terminal and case‘ There should be no continuity. Check [or continuity between the cable terminal and brush. There should be continuity (2) COVERS (2) GROUND CABLE: (ll BOLTS lZl BHUSH ELECTRIC STARTER/STARTER CLUTCH Check 10! continuity between (+1 and (v) terminals 0! the mush holds“ 9 TERMINAL 9 TERMINAL There should be no continuity, 9) TERMINAL 6 TERMINAL # Measure each brush length. SONIC. limit: 4.5 mm (0.18 In] |nspect the commutator bays for discolmation. Bars discol- (I) COMMUTATOR BAH orsd in pfllfS indicate grounded armature coil. NOTE - Do not use emery or sand paper on the commutator. l2) ARMATURE COIL Check for continuity between pairs 0! commutator bars There should be continuity. l1) COMMUTATOR BAR ELECTRIC STARTER/STARTER CLUTCH Check '07 continuity between each individual commutator bar and the armature shah, There should be no connnuily. Check the from cover oil seal for wear or fungus. Check that the bearing rotates smoothly. ASSEMBLV N l \ggogn SHIMS \ (7) CABLE TERMINAL AND BRUSHES {13) REAR COVER (12) BRUSH SPRINGS / (11) BRUSH HOLDER (10) INSULATOR (9) O-RING i1) COMMUTATOR BAR (2) ARMATURE SHAFT (“OIL SEAL ,; (Z) BEARING (a) LOCK WASHER (4) o-nmc. / (5) FRONT COVER 0 \_ (8) CASE AND FIELD COIL ELECTRIC STARTER] STARTER CLUTCH Set the brushes on the brush holder, Install the brush holder onto the motor case. N OTE ‘ Align the terminal holder plate with the motor case insuV lator. Install the insulators, washer and nut to the cable terminal. Push and hold the brush Inside the brush holder and insert the armature through the brush holder. When installing the armature into the case, hold the arma~ lure tightly to keep the magnet from pulling the armature against the case. CAUTION . The coil may be damaged it the magnet pulls the Irml- ‘ ture agelnet the case 4 Set the brush springer Install the Oring on the caae. Install the same number of rear shims in the same locations as when disassembled. Apply a thin coat of grease to the armature shalt endr Install the rear cover aligning ita groove with the brush holder tube (1) BRUSH HOLDER l2) MOTOR CASE l3) INSULATOR 7N6 l3) WASHER ‘ 9 0 ° (2) INSULATORS l4) NUT ll) ARMATURE l'l) CARING (3) ALIGN (2) SHle '61 ELECTRIC STARTER/STARTER CLUTCH Install the O-rmg on the case Install the same number of lront shims In the same locations as when disassembled, Apply grease to me seal lips and bearing Install the lockwasheron the Irontcuver, and Install the Iront cover to the case. CAUTION . When installing the novel tuke can to prevent dlmlg- I ml lip with (he 5h Align the marks on the case and Iront covert Install and tighten the slanev molol case bolts. Apply all to a new O-ling and Install it INSTALLATION Install the stanet motor onto the crankcase. Install the mounting bolts Wllh the ground terminal and thermo valve steyt Tighten the mounting bolts. Connect the starter motor cable by tightening the terminal nut and install the rubber can securely. Install the left engine hanger plats (page 7-5l, Install the fuel tank (page 2-4). (a) ,fi OIL SEAL AND BEARING 12) 0-HING (M LOCK WASHER l1) SHIMS l1) BOLTS l2) go-RING (3) MOUNTING (2) GROUND TERMINAL AND THERMO VALVE STAY (1) STARTER MOTOR CABLE a“ we. War Weumww ELECTRIC STARTER/STARTER CLUTCH STARTER RELAY SWITCH INSPECTION Remove the seat (page 2-2). Shift the transmission into neutral. Turn the ignition switch 0N and depress the starter switch button. The coil is normal ii the starlet relay switch clicks. If you don't hear the switch ‘CLICK', inspect the relay switch using the procedure below. GROUND LINE Disconnect the relay swrtch connector. Check for continuity between the Green/Red wire (ground line) and ground. If there is continuity when the transmission is in neutral or when the clutch is disengaged and the side stand switch is up, the ground circuit is normal. (In neutral, there is a slight resistance due to the diode.) STARTER RELAY VOLTAGE Connect the starter switch connector. Shin the transmission into neutral. Measure the voltage between the Yellow/Red (9) wire and ground at the starter relay switch connector. ll battery voltage appears only when the starter swrtch is pressed with the ignition switch 0N, it is normal. OPERATION CHECK Disconnect the connector and cables. Connect a Iully charged 12 V battery positive wire to the relay switch Vellow/ Red wire terminal and the negative wire to the Green/Red wire terminal. There should be continuity between the large terminals while the battery is connected, and no continuity when the battery is disconnected. (Ii STARTER RELAV SWITCH A". (1) RELAV SWITCH CONNECTOR l1) STARTER RELAY SWITCH (Ii BATTERY ELECTRlC STARTER/STARTER CLUTCH CLUTCH DIODE INSPECTION Remove the side lairing (page 2-3). Remove the tape and diode. Check for continulty between the diode terminals. Bk) Ind AH: No continuity Bl.) Ind C(-): No continuity Alt) and Bt-l: Comlnuitv Ct.) and 31-): Continuity When there IS continuity, a small resistance value w:ll registet. ll there Is abnormal, replace the dlode, FLYWHEEL/STARTER CLUTCH REMOVAL Remove the Ieh crankcase cover (page 15-9). Loosen the flywheel bolt while holding the flywheel with a flywheel holder. Tool: Flywho-l holder 07925 - ME90000 or equiv ant commercially lvl bl. In [III USA. Remove the flywheel bolt with the washevl Remove the flywheel using the rotor puller‘ Tool: Rotor puller 01733 - 0020001 or 01933 - 2150000 (USA, only) Remove the woodrufl ksv, ll) DIODE [2) FLYWHEEL ,- ELECTRIC STARTER/STARTER CLUTCH Remove the starter idle gear shah and idle gear. DISASSEMBLV Remove the starter driven gear by turning it counterclock- wise. Remove the starter clutch bolls while holding the flywheel With a flywheel holder. Tools: Flywheel hoIdor 07725 - 0040000 j of Ten: Mt (T30) 07703 - 0010200 equivalent commercially available Remove the starter clutch. After removing the starter clutch bolts, clean the locking agent resudue on the bolts. INSPECTION Assemble the one-way clutch, clutch housing and driven gear and check that the driven gear turns smoothly in one direction and locks up in the other direction. ONE-WAV CLUTCH Check the onerwuv clutch sprag for abnormal weer, damage or irregular movement. CLUTCH HOUSING Check the inner contact surlace of the clutch outer for damage. (2) IDLE GEAR \ \ l1) SHAFI’ (l) STARTER DRIVEN GEAR (ll TORX BIT (2)- FLYWHEEL HOLDER (1) ONE-WAY CLUTCH (2) CLUTCH HOUSING ELECTRIC STARTER/STARTER CLUTCH STARTER DRIVEN GEAR Check the roller contact surlace for damage, Measure the driven gear OD. Sonic. limlt: 51.634 mm (2.0348 in] Check the starter idle gear shaft. gear and shaft journal for wear or damage, ASSEMBLY Apply engine oil to the one-way clutch. Install the onavway clutch into the clutch housing with its flange side facing flywheel. Install the starter clutch onto the flywheelt Apply a locking agent to the threads ol‘ the starter clutch bolts and tighten them to the specified torque whlle holding the flywheel with a flywheel holder. Torque: 16 N-m (1.8kg-m. 12 h-lbl Install the starter driven gear to the flywheel while turning the starter driven gear counterclockwise. (Z) CLUTCH HOUSING (1» “11m STARTER CLUTCH l2l SHAFT t (1) IDLE GEAR BOLTS FLYWHEEL HOL ELECTRIC STARTER/STARTER CLUTCH Install the starter driven gear to the flywheel while turning the driven gear counterclockwise. INSTALLATION Apply Oll to the Idle gear shaft outer suflace. Install the starter Idle gear shah and idle gear. Install the woodruff key in the crankshaft. Set the flywheel over the crankshaft by elignlng lls groove With the woodruf' key and install the flywheel. Apply oil to the flywheel bolt threade‘ Install the llvwheel bolt and washer‘ Tighten the flywheel bolt while holding the flywheel with a flywheel holder‘ Tool : Flywhaol holder 07925 - MESOOOO or equiv-hm communal-IN null-bl. In U.S.At Torque: 105 Mm [10.5 kq-m, 76 III-fl) Install the hall crankcase cover (page 15-10). . a (ll STARTER DRIVEN GEA ll) IDLE GEAR (-1) I BOLI m FLYWHEEL HOLDER 5’ . LIGHTS/METERS/SWITCHS 11) TURN SIGNAL (2) IGNITION SWITCH (3) FRONT BRAKE LIGHT I14) CLUTCH SWITCH SWITCH v (I) THERMO SENSOR (6) FUEL CUTAOFF (5) FUEL PUMP (13) HORN I'IZI FAN MOTOR SWITCH I11) SPEED SENSOR (8) OIL PRESSURE SWITCH (ID) NEUTRAL SWITCH (9; SIDE STAND SWITCH (7| REAR BRAKE LIGHT SWITCH 18. LIGHTS/METERS/SWITCHS SERVICE INFORMATTON 13-1 REAR BRAKE LIGHT SWITCH 13-10 TROUBLESHOOTING 13-3 CLUTCH SWITCH 1e11 HEADLIGHT 13-5 HANDLEBAR serCH 13-11 TURN SIGNAL 13-5 IGNrrION SWITCH 13-12 TAIL/BRAKE LIGHT 13-1; FAN MOTOR SWITCH 11313 LICENSE UGHT 18-6 COOLANT TEMPERATURE GAUGE 13-14 COMBINATION METER 13-7 FUEL PUMP 13-15 ‘, SPEED SENSOR 13-9 HORN 13-13 ' OIL PRESSURE SWITCH 13-10 TURN SIGNAL RELAY 13-15 NEUTRAL SWITCH 13-10 SIDE STANO SWITCH 13-17 FRONT BRAKE LIGHT SWITCH 1cm sue FUSE 13-13 SERVICE INFORMATION GENERAL - the halogen headlight bull: becomes very hot while the headlight I: 0N and romaine hot for a while after it” Ia turnedI OFF Be sure to In I! cool down More servicing. I - Gasoline" II extremely flammable and is explosive under certain condition: KEEP OUT OF REACH OF CHILDREN. - Use an electric heating element to heat the water/coolant mixture lor the in motor switch inspection Keep all llarnrnable materiel: away horn the electric heating element Vile-r protective clothing, insulated gloves and eye protection - Note the followmg when replacing the halogen headlight bulb. - Weercleen gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to break. - If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. 1 Be sure to install the dust cover after replacing the bulb. 1 All Plastic connectors have locking too: that must be released before disconnecting, and must be aligned and engaged fully when reconnecting. 1 Always turn Oil the ignition switch before disconnecting any electrical component. 1 A continuity test can be made with switches installed on the motorcycle. - Check the better condition before performing any inspection that requires proper battery voltage. ~ The following color codes are used throughout this section. Bu - Blue G = Green Lg - Light Green H - Red BI - Black Gr = Grey 0 - Orange W = WhiIe Br - Brown Lb = Light Blue P - Pink V = Yellow 13-1 LIGHTS/METERS/SWITCHS SPECIFICATIONS ITEM SPECIFICATIONS Main 30A Sub 15AX1,10AX3 Headlight (high/low beam) , iZV—60/55W Brake/tail light 12V—32f3cp License light Front turn signal/running light leer turn signal light 12v—4cp iZy~32l3chZ 12V—32ch2 Instrument light 12V—1.7WX4 High beam indicator 12V~1.7W Turn signal indicator 12V-3WX2 Neutral indicator 12V71V7W Side stand indicator I2V—‘IJW Oil pressure warning indicator 12V-1.7W , Fuel pump flow caeacitv (min/minute) 700 cc (23.7 US oz, 24.6 imp oz) Coolant temperature sensor IGSISCanCQ EO'C/176'F 45~60 (2 120'CI248'F 10—20 (I Fan motor switch N *Start to close (ON) 98 —102‘Cl203 - Z‘lS‘F) Slop in open (OFFl 93 ~ 97'Cl199 — 207T) TORQUE VALUES Fan motor switch Thermosensor Oil pressure switch Neutral switch Ignition switch holt Side stand switch bolt 10 NM (1.0 kg-m, 7 lb-It) Apply sealant lo the threads. 10 N-m (LD kg-m, 7 lbrft) Apply sealant to the Ihreeds. 12 N-m (1,2 kg-m, 9 lb-fll Apply sealant to the threads. ‘2 N-m (1V2 kg~m, 9 Ib-ft) Apply sealant to the threads, 25 N'm (2.5 kg~m, 19 lb“) 10 N-m [1.0 kg-m, 7 lb-il) LIGHTS/METERS/SWITCHS TROUBLESHOOTING i Speed Sensor/Speedometer The odometer/trip mot-r operates normality, but the modem-tor don not operate ~ Faulty speedometer The speedometer operates norm-Hy, but the odometer/trip me r does not worn. - Faulty odometer/trip meter The speedometer oporntn abnorm-llv - Check lor the lollowrng before diagnosing: , blown main or sub luses , loose or corroded terminals on the connectors ‘ , discharged battery Remove the side leiring (pagem— Abnormal . Check lor loose or poor contact ol the speed r’—‘ Loose or ”90" cannot O' "Ilka “"“l'l'll _ sensor 3P1Whlte) connector - Open Circuit In Black/Brown or Green/Black Wires With the ignition switch ON, measure the volt- “WW" "‘9 ”mew and spend Icnmrr ago at the speed sensor connector. ‘ Connection: Green/Black and Buck/Brown Sund- Buttery volt-go Normal 7 . Abnormal ' Remove the u er lair-n l a 2 2-6]. ‘ Check tor looszpov poor (33:8: 0' me - Loose or poor contact 01 related terminals, combination meterconnenors - Open circuit in Black/Brawn or Green/Black Wllh the ignition swrlch 0N, measure the Volt “"55 ”9"”99" "‘9 ““9” 5"“ s”°""°’"°‘°’- ,- ege at the bottom of the speedometer termi- nalsi (4) PlNK/GREEN (1] PINK W, #1 Connection: Green/Blink Ind Block/Brown s dud: Battery volt-go a? 7 Normal {3) GREEN/BLACK (2) BLACK/BROWN (Continued on the following page) 18-3 LlGHTS/METERS/SWITCHS {From the prevmus page) lg l . , . » V . Abnormal Wm" the ignltion SYNC" OFF' check for continu E - Open circuit or loose connection in Pink! :ty between the PInk/Graen ere of the speed Green wire sensor and Pink/Green terminal of the speed- ‘ ' ometer Stead-rd: Contlnuity ‘ 4| fl Normal V a Abnormal Support the motorcycle using the hoist er other _ Faulty speed sensor support to raise the rear wheel of! the ground. (No input voltage) _ Loose speed sensor boltt Measure the output voltage (sensor signal) at the speedometer with the ignition switch ON while slowly turning the reer wheel with your hand. Connection: Pink/Green and Green/Sleek Stud-rd: Repeat 0 to 5 V ‘ Normal [Sensor signal registers on the speedometer) Faulty speedometer HEADLIGHT BULB REPLACEMENT l - The halogen hndllght bulb Inc-mo: very hot while the I heldllght I: 0N and remains hot lot I while liter it is turned OFF. 8. sure to let it cool down before urvicing‘ CAUTION - Wear clean gloves while repllcing the bulb. Do not put; fingerprint: on the headlight bulb. us they any crnte hot met: on the bulb Ind cause It to brulr. - If you touch the bulb with your bare hands, clnn It with a cloth moistened with Ilcohol to prevent its nrly l-il- ure V - Ba lure to incull the dust cover after replacing the bulb, Remove the upper leiring lower cover. Disconnect the headlight bulb socket and remove the dust cover. Release the bulb retainer and remove the headlight bulb. lnstell a new bulb and the removed parts in the reverse order of removal. FRONT BULB REPLACEMENT Remove the screw and turn signal unit. Remove the turn signal bulb and socket as an assembly by turning it counterclockwise. Remove the bulb by turning it counterclockwise. Replace the new bulb and Install it in the reverse order of removal. UGHTS/METERS/SWITCHS (1) SOCKET (2) DUST COVER (1) RETAINER (2) BULB l1) SCREW l2) SOCKET 18-5 LlGHTS/METERS/SWITCHS REAR BULB REPLACEMENT Remove the screw and turn signal lens. Remove the bulb by turning it counterclockwise Replace the new bulb and install It in the reverse order at removal. TAILI BRAKE LIGHT BULB REPLACEMENT Remove the \all cowl (page 2-3). Remove the tall/brake light bulb and socket as an assembly by turning it counterclockwise. Remove the bulb by turning it counterclockwise. Replace the new bulb and install it in the reverse order of removal. LICENSE LIGHT BULB REPLACEMENT Remove the bolts, nuts, number plate base lrorn the rear lender. being carelul not to damage the wire harness. Remove the lens attaching screws on the reverse side 01 the number plate base and remove the license light lens. Remove the bulb by turning it counterclockwise. Replace the new bulb and install it in the reverse order of removal. it (2) LENS (1 i SCREW (1) BOLT/NUT l'll SCREWS (2) BULB (1] SOCKET l! LlGHTS/METERS/SWITCHS COMBINATION METER NOTE - When checking the speedometer and speed sensor. fol low the steps in the troubleshooting flow chart (page 18* 3). BULB REPLACEMENT Remove the upper fairing {page 274]. Remove the bulb socket by turning it counterclockwrse. Remove the bulb and replace with a new one. Install rt in the reverse order 0! removal. REMOVAL Remove the upper leirrng lpage 24). Remove the rubber cap from the combination meter. Remove the meter mounting bells and collars. (‘llCAP Raise the combinehon meter and disconnect the connectors. Remove the meter assembly. INSTA LLATION Installation is in the reverse order 0! removalt (2) METER ASSEMBLY DISASSEMBLY (2) METER com I Remove the screws and meter cover. 18-7 LIGHTS] METERS/SWITCHS Remove the screws and bulb sockets. Remove the speedometer, tachometer and coolant tempera- ture gauge, (1 ) SOCKETS (2) SCREWS ASSE MBLV Assembly is in the reverse order of disassembly. (1) METER CASE (2) MEYER COVER {4) TACHOMETER (3) COOLANT TEMPERATURE (5) SPEEDOME‘I’ER TACHOMETER INS PECTION Remove the upper fairing (page 2-4). Check [or loose or poor contacts on the tachometer termi- nals. Connect the peak voltage adaptor to the digital multimeter, o: uuo the lmrie diagnostic taster (page 16-1). Tools: hulk dllgnonle "nor [model 825] or Polk my. Idlptov (”HES-0020100 with Commlly available dlghal multllif (Imp-am mun/Dev mlnlmum). 18-8 Connect the peak voltage adaptor to the tachometer terminal and ground, Connection: Yellow/Gm" lit) - ground l-l Start the engine and measure the tachometer input voltage Peak voltage: 105 V minimum It the value is normal, replace the tachometer. it the value is below 10.5 V, replace the ignition control mod- ule (ICM). It the value IS 0 V, perform the following procedure. Disconnect the ignition control module (ICMl l6? connector Check for continuity between the tachometer terminal end the ICM 16P connector Yellow/Green terminal. if there is no continuty, check the wire harness for an open circuit. If there is continuty, replace the ignition control module (ICMl. SPEED SENSOR NOTE - When checking the speedometer and speed sensor, lol- Iow the steps in the troubleahooting llow chart (page 18- 3). REMOVALI INSTALLAHON Remove the side leiring and fuel tank (page 2-3.1). Disconnect the speed sensor 3? connector. Remove the bolts and speed sensor. Remove the O-ring lrorn the speed sensor. NOTE L- Use care not to allow dust and dirt to enter the engine. Installation is in the reverse order of removal. LlGHTS/METERS/SWITC HS (1) s vaml PEAK VOLTAGE ADAPTOR (2) YELLOW/GREEN TERMINAL l1) YELLOW/GREEN ._ (2) ICM TERMINAL 7 (1) BOLTS 18-9 LIGHTS/METERS/SWITCHS OIL PRESSURE SWITCH Disconnect the oil pressure switch wire from the swuch by removing the terminal screw (page 4-3). Short it to ground using a lumper Wire, Turn the ignition SWItch "ON” The oil pressure warning indicator should come on. ll the light dose not come on, check the sub-(use [10 Aland wrres lot a loose connection or an open circuit Start the engine and make sure that the light 9055 out. II the ilght dose not go out, check the oil pressure (page 4 3L lithe oil pressure is normal, replace the Oil pressure swrtch (page 4A3), NEUTRAL SWITCH INSPECTION Remove the fuel tank (page 24L Disconnect the 3P connector Shlfl the transmission into neutral and check rnr continuity between the Light green Wire and ground. There should be continuity whenthe transmissmn is In neu- tral and no continuity in any other gear posltion. FRONT BRAKE LIGHT SWITCH Disconnect the front brake light switch wires and check Vor continuity There should be continuity with the Trent brake applied and no continuity with it released REAR BRAKE LIGHT SWITCH Remove the left side fairing (page 2-3» Disconnect the brake light 2? (While) connector and check for continuity at the switch Side connector terminals. There should be continuity with the brake applied and no continuity With it released. LIGHTS/METERS/SWITCHS CLUTCH SWITCH Disconnect the clutch switch wures and check [or continuily. There should be continuity with (he clutch lever applied and no continuity with it released HANDLEBAR SWITCH Check '01 conlinuity between the terminals, Continuity should exist between the color coded wiles as shown in each chan. LEFT HANDLEBAR SWITCH Remove Ihe upper fairing (page 2-4). Disconnect lhe leh handlebar connectors and single lead connectors, DIMMER SWITCH Bu/W Bl/Br T 'i‘ O .,_\_: Lg ave: Free Push (374C) RIGHT HANDLEBAR SWITCH Disconnect the right handlebar connectors and single lead EOHHBCIOL STARTER SWITCH _- V/R EIAN Eu/W Bl/R Free 07" ‘ Push Oflf—O ENGINE STOP SWITCH Bl/W O (1) CLUTCH SWITCH ‘ (2) RIGHT SWITCH CONNECTORS 11) LEFT SWITCH CONNECTORS ' 18-11 LlGHTS/METERS/SWITCHS IGNITION SWITCH INSPECTION Remove Ihe upper fairing {page 24). UiSCOnnecl the ignition switch 3P connectovi Check lor continuity between the terminals, Continuity should exrst between [he color coded wire as shown In chart R R/BI Bu/O Oniil ' L, , Lock REMOVAL/INSTALLATION Remove the upper tainng (paga 24), Disconnect the ignition switch 3P connector. Release the ignltlon swttch wrre Item the clamp, band and guide Remove Ihe bolts and Ignllinn switch. Yool: Torx bit (TWI 07703 - 0010100 or equivalent commercially available in U.S.A. Install the ignition swttch in the reverse order 01 removal. Install and tighten the new bolts. Torque: 25 N-m (2.5 kg-m, 18 lb-lt) DISASSEMBLV Remove the three screws and pull the contact base out of the cylinder. Tool: Tau bit [110“] Commercially available (1) IGNITION SWITCH CONNECTOR " gm BOLTS 12) CONTACT BASE (‘ll SCREWS 18-12 UGHTSIMETERS/SWITCHS ASSEMBLY (1) CYLINDER (2) CONTACT EASE install the contact base, aligning the hole olthe base with the shaft of the cylinder. Install and tighten the screws. Tool : Torx hit (T10Hl INSPECTION Remove the side lairing (page 2-3) Fan motor does not stop Turn the ignition switch OFF, disconnect the connector from the Ian motor sWItch and turn the ignition swnch 0N again. ll the fan motor does not stop, check lot a shorted Wire be tween the fan motor and switch. If the fan motor stops, replace the (an motor swnch. Fen motto! done not start Belore testing, warm up the engine to operating tempera- ture. Disconnect the connector lrom the fan motor switch and ground the connector to the body with a jumper wire. Turn the ignition switch ON and check the fan motor. ll the motor starts, Check the connection at the fan motor switch terminal. If it is OK. replace the fan motor switch. lltha motor does not start. check tor voltage between the fan motor sWitch connector and ground — Battery voltage: Faulty lan motor — No battery voltage: - Broken wire harness - Blown sub fuse - Faulty ignition switch - Poor connection ol the connector (between the ignition switch and fuse box) REMOVAL] INSTALLATION Remove the side fairing (page 28}. Drain the coolant (page 6-4). Disconnect the connector and remove the fan motor switchi Install the new O-ring and apply sealant to the fan motor Mitch threads. Install and tighten the swnch. Torque: 10 N-m (LO kg»m. 7 lb-fll . ' , ' [2) FAN MOTOR SWITCH (1l CONNECTOR 18-13 LlGHTS/METERS/SWITCHS COOLANT TEMPERATURE GAUGE INSPECTION (“THERMOSENSOR (2) WIRE Remove the fuel tank (page 2-1). Disconnect the connector from the thermosensor and short it to body ground, Turn the ignition switch ON. The coolant temperature gauge (1) IGNITION (2) COOLANT TEMPERA~ needle should move all the way to H . SWITCH TURE GAUGE CAUTION - Do not leave the thermeeeneur wire grounded Ior longer then e iew seconds or the temperature gauge will be dameged. If the gauge does not move, check the sub (use USA) and wires for a loose connection or an open circuit; it normal, re- place the gauge with a new one. THERMOSENSOR INSPECTION (3) NEEDLE - Wear ineuleted glovee end edequ eye protection. .‘ ' (1) THERMOSENSOR - Keep flemmebie meteriele ewey Item the electric heeting element. Drain the coolant (page 6-4). Remove the carburetor (page 5-5). Disconnect the thermosensor connector and remove the thermosensor. Suspend the thermosensor in a pan of coolant (50-50 mix- ture) over the electric heating element and measure the resis- tance through the sensor as the coolant heats up. NOTE - Soak the thermosensor in coolant up to vts threads with at least a ‘0 mm (1.57 inl gap item the bottom at the pan to the bottom of the sensor. - Keep the temperature constant tor 3 minutes betore testing, A sudden change of temperature will result in incorrect readings. Do not let the thermometer or I thermosensor touch the pen. Temperature BO'C (176T) 120'C (248‘F) Resistance #5 - 60 K) 10 — 20 Q _Replece the sensor if it is out of specifications by more than 10% at eny temperature listed. (2) THERMOSENSOR 18-14 LlGHTS/METERS/SWITCHS Apply sealant to the thermosensor threads. Do not apply sealant to the sensor head. Install the thermosensor. Torque: 10 N-m (LO kg-m, 7 Ib-ltl FUEL PUMP SVSTEM INSPECTION Turn the Ignition swrtch OFF. Remove the side cover (page 2-2) and disconnect the luel cutroit relay connector. Check for battery voltage between the Black (e) terminal and ground (r). There should be battery voltage with the ignition switch ONr If there Is no voltage, check {or an open circuit or loose con- nection in the Blue/Vellow wire, Ilthere is battery voltage, check for continuity in the Black/ Blue WIre, Check for continuity, between the Black/Blue wire and ground "there is continuity, replace the luel cutiofl relay. "there is no continuity, short the Black and Black/Blue termi» nals at the relay connector with the suitable jumper wire. l1) JUMPER WIRE Disconnect the luel pump 2P (Black) connector and check for battery voltage between the Black/Blue (+) and Green (-l ter~ mmals with the ignition switch ON llthere is battery voltage, replace the luel pump ll there is no battery voltage, check for an open circuit or loose connection in the Black and Green wires, l1) FUEL PUMP CONNECTOR 18-15 IJGHTS/METERS/SWITCHS DISCHARGE VOLUME INSPECTION l1) FUEL PUMP 12) FUEL TUBE - Guoline is extremely mrn certain conditions. Work in a well ‘ the nuino ofl. Do not smoke or ullow llama or works‘ in the work Iron or where gasoline is {tor—d. r Disconnect the luel cut-elf relay connector and short the Black and Black/Blue terminals with a suitable jumper Wire (see page 13-5). Remove the right side cover (page 2-2) and disconnect the luel tube from the tube joint. Hold a graduated beaker under the fuel tube Turn the ignition switch ON and let the lual flow into the bea- ker for 5 seconds, then turn the ignition switch OFF. Multiply the amount in the beaker by 12 to determine the lual pump (low capacity per minute. Fuel pump llow capacity: 700 or: (23.7 US oz, 2&6 Imp all mln./mlnute 4.. C \1 \‘ M, l HORN Disconnect the wrre connectors from the horn. Connect a 12 V battery to the horn terminals. The horn is normal il it sounds when the 12 V battery is con- nected across the horn terminals, (1i HORN TURN SIGNAL RELAY REPLACEMENT Remove the upper lairing (page Z-Alt Remove theturn signal relay from the trams and disconnect the connector. Remove the suspension rubber holder irom the relay. Installation is in the reverse order ol removal. 18-16 LIG HTS] METERS/SWITCHS PERFORMANCE TEST Remove the turn signal relay (see page 1846). Check for turn signal circuit connection before testing. Connect the termlnals as described below: Black/Brown: DC 12 V Positive I+) Green DC 12 v Negative 1-) Grey: Turn signal wire of one side; connect other side to ground (frame) Check lighting ON and OFF properly Ilthe turn signal relay leils this test, replace the relay With a new one. SIDE STAND SWITCH m 3P MINI CONNECTOR (GREEN? INSPECTION Remove the Iuel tank (page 2v”. Disconnect the side stand switch 3? mini connector, Check for continuity between each ofthe terminals as below. There should be continuity between the 3—0 positions on the chart below, Green/White Vellow/EIeck Green Side stand C 3 down Side stand . up 0 o l ‘ REMOVAL/INSTALLATION ' (1) BOLT Remove the fuel tank (page 2-“ Disconnect the side stand switch 3P mini connector (Green) and remove the bolt and side stand switch . (2) SIDE STAND SWITCH 18-17 LlGHTS/METERS/SWITCHS Install the ends stand switch aligning the pm on the swrtch with the hole in the side standt Secure the side stand swrlch with the bolt Torque: IO NO"! (1.0 kg-m, 7 Ib—h) Install the removed parts In the reverse order of removal. (3) HOLE (21PIN SUB FUSE REMOVAL/INSTALLATION Remove the screw and {use box cover. Open the {use box and remove the sub fuse. Installation is In the reverse order of removal (1) Sue FUSE a '95: 49 STATE. CANADA TYPE .m 'm m. mum mm mum m m unmo- _ mun um n um um» non «- m; mum- “Mun-D K'Iuw um 7n n / Im- __ mu! m3- (AN (EDT/CW (DY EV (P mm w—mm mm mm Mug». / um mi mm mnwuum minty: 7:2 mm uo-iw.numj .2 2mm m lmwu~rmu-m~uwnnmy ; rm ... Imam-Fur “”5“...“qu m. m .mwu: mm tum m ummuum mm mm WW um- I'm) an we un mmuuc y: 'n~ m um I E :45 {:01 @33- 19. WIRING DIAGRAMS nun nu Ben-v n. ‘ JqJ-Iw— 1w— w— mt mum 'n-[m .1 nu “catnip; n my mum In.“ M 1 gm ma: 3 4h m m m, 2:“ " % fl [ E mm mm mu . max-Wm gum M rum 7 w‘u . 9 m-m 6 mun mum Mm mam a—Ckn—c mmmm “—63:2— —~ ‘ —~_:: -I»- an, mm: n =6 um: ‘I _m v .3 Ir " 1“ >i l—_|.—I I 1,: mum '! 13.”, >>>u I fins, “-0“— .iOmm :3 n "w " I—Ckn—n—J mu" ' o »: "’ m... 9 mm o o om ’ - , ‘ mm ' _‘ mm! $5 u mm. £3 ad “41) “my, _ Juana-m mums-nu man: mmmnls: mm». n ma . um v m: n m- .4 u u m u a m H mm . m - .— mun-In- mmum. - mu . m \G IIVI 5' '17! NL "Y! at: run 00 '“' 00 "”"‘ 00 00301— MM. -8700 19-1 WIRING DIAGRAMS '95: CALIFORNIA TYPE A unvwxuu unava- - lulu mm. c «— mot Human a m nun-l mm s slwivomm r uvmnmmm Inuhw ml 7' xi ml 1' C D nu- ma mum: me» E ,_ mar mu... m mu: wu- In sum: wot u my M'm , gm» m: g . ,7 ».,_ r lull-Dawn“ 11min! u» mm Ilw m‘m Illu- X-Ivu m. "upturn-um} a u .u (.u~n.mm.m.mm mm '0 a M II! lmuwuprnu Iflmu~Mhlrmnv~LJ mm mm a w m |rm mu) mum M win-own»: yum um. um...» mm mm. m. m mm 3..., gm 04 1mm wt "Dura- n..." lum- nu m mv \_ w n L um I: FL V no un ‘ a nu ‘x sv an m I a m: arr rm 0 fl ‘ PM 0-0 W 0-0 "S" 0-0 19-2 a. mum ““91 ”5E: , :11 "25mm WA “'7‘" 7 #700 mu 1. vmvnvu1 u_:©1 Y a) : r a..- M “UM VWA'II‘ m _".IT-' I 7 rem—124m); ‘———v‘— _ __—m_ u a _ _—_“_@ u ———"_.__.; _. '1} avatar-amt W % _ . mm "fl g 1 mum. Tm...“ mm" 9 ° m r in? ,. nan-mu [90M ,. a I‘m-v e n h n I | g a” l ' l “I ' ‘ a»: ‘1 i 6" l :- mo II V - ’11 » , WWW . .n 2“ "I‘ll L.» "w Ew- Lw _‘; 1mm . ' _.—D<1—u |-¢ o—CK—c ”mum-u. E c—Ga=:= ‘ «— —‘“‘_g_. _._. . 1mm”: m... I Lag Ew— ‘_ .- r——|__|1 I ‘I m“... ' Fifi-E. ‘ E“ ° : Imcv n—Do—u—l Mum ”’ 3/325» _-| ’ / 4 ¢ 0 0 mm \ _ m a. '\ “j a _‘ mam \ f—wmurm'wn a - mum... .umvm , \_9’- w “Imam-c: m mewu- :- - In . m. ~ mm o m .. m n LM'III a m: u LMWI . u . m . w: 1. um mm. mm- yum mm x. nu \ sv In: m am an m 00 ""‘ 00 W 0 003UZ-MAL -770|] AFTER ’95: 49 STATE, CANADA TYPE mm mum / o a ”G \ '0 m w u. m lam/m [- ‘ : ‘-‘: n1 mmnm. m. Wham-man: .91 u Iva. nun-u mu /,m. .m mm «m a. mum”! ,in rum @1va :- fin: mum-m um 1n mun-m Ion"! Im- In W um. In mum m yw. (.0 m mun gamma-v KAI-ubmrgvuvm.‘ In \Imwnmmu-vlwmw: “m: [mum D... W a. m” W W Mm. m m m I I I L V PI FL I0 DAV! ‘\ VIII '5 I!" [6 III} if I" ”'4 a us: on err m: 6' n mu 0 arr Jun 0.0 mm L WIRING DIAGRAMS m mm 2mm w: an.“ - '7 7 "‘ n : All- ‘ I I mu m“ “. nu ma am» a. I n 'I m- .u w J—DQ— ”(autumn a G0“ Imm n_4 “—03:5— m _n -|« lunwuuwu mazmm 7 mafia“ - -—| . l- u > I a CO I! 3, mum-«v a . u . mm a: w . . p {.3 w 1I|I I ,- 3, Jump—‘1 mummy ulwvnuv mm uv'lnr'wldm o 0 mm- Va nu»: nun-mm. “ “a m, II-um mvum.:mrm WM“ : - m . m v mm a m n m u m-m mum-m c man u Luann . m; n m sr ma NL nu , ,m E m, "H 00 ”5" 0'0 00302- MAI. -92flll 20. TROUBLESHOOTING HARD TO START ENGINE LACKS POWER LDLE SPEEDS ENGINE DOES NOT START OR IS 20-1 SPEEDS POOR PERFORMANCE AT HIGH 20-4 20-2 POOR HANDLING 20-4 POOR PERFORMANCE AT LOW AND 20-3 ENGINE DOES NOT START OR IS HARD TO START ‘i. Check fuel flow to carburetor Reaching Carburetor r 2.Psr1orm a spark teal i Good spark 3. Remove and Inspect spark plug Spark iump 4. Test cylinder compression Compression normal on Engine does not fire 6. Stan With choke applied Nol Reaching Carburetor—~- - Sticking lloat valve - Clogged float valve - Clogged luet tank venl lube Week or No Spark —.‘ Wet Piug ——-.- ‘ Carburetor flooded - Carburetor choke excessively closed - Cylinder flooded - Air cleaner dirty - Faulty EVAF purge control valve Low Compression!»- - Valve stuck open - Worn cylinder and piston rings - Damaged cylinder head gasket - Seized valve - Improper valve timing - Improper valve and seat contact . Start by following normal procedure — Engine starts, then stops—>- , Carburetor pilot screw excessively closed , Air leaking past intake pipe v Improper ignition liming No Iuel in tank Go to page 1673. Fuel-air mixture loo rich (California type only) Valve clearance too small Choke excessively closed (Faulty ignition control module or ignition pulse generator) . Fuel contaminated 20-1 THOUBLESHOO‘HNG ENGINE LACKS POWER 1. Raise each wheel eff ground and spin by hand Wheel spine freely I 2. Check tire pressure Pressure Normal 3. Check clutch operation Normal 1 l. Accelerate lightly Engine speed increases 5. Checl ignition timing Correct 6. Check valve clearance Correct 7. Test cylinder compression Normal 8. Check carburetor for clogging Not Clogged l 9. Remove a spark plug Not Fouled or Discolored — Wheel does not spin t»- freely Brake ie dragging - Worn or damaged wheel bearings - Drive chain too tight - Axle nut excessively tight Pressure Low —. Punctured tire - Faulty tire valve Clutch Slips fir Faulty clutch litter system , Worn clutch disc/plate - Warped clutch disc/plate - Weak clutch spring Engine speed does not ~.—.~ increase Starting enrichment valve open ~ Clogged air cleaner . Restricted iuel flow . Clogged muffler ~ Clogged fuel tank vent tube Incorrect ———>- Faulty ignition control module - Faulty ignition pulse generator Incorrect —~ ' lmproper valve adjustment - Worn valve aeat Valve etuok open - Worn cylinder and piaton rings - Leaking head gaaket - Improper valve timing - Seized valve - Improper valve and aeat contact Clogged —.- Fouled or Diacolored —>~ Carburetor not eerviced lrequently enough Plugs not cervicad frequently enough < Use of plug with improper heat range 10. Remove oil level gauge and check — Oil Level Incorrect _>- ‘ Oil level too low ‘ Contaminated oil oil level Correct l1. Remove the cylinder head cover and — Valve train not lubricated —>' Inspect for lubrication/wear Valve train lubricated properly properly Oil level too high Clogged oil passage - Clogged oil control orilfice - Contaminated oil - Faulty oil pump 12. Check it angina overheats 13, Accelerate or run at high speed Not Overh eated Overheated ——>- TROUBLESHOO‘HNG Coolant level low - Fan motor not working (faulty lsn motor switch) ‘ Thermostat stuck closed - Excessive carbon build-up on the piston head or combustion chamber - Use of improper quality iuel ~ Clutch slipping - Fuel-air mixture too lean Engine Knocks —_., Worn piston and cylinder - Fuelvair mixture too lean - Use at improper quality tuel - Excessive carbon build-up on the piston head or combustion chamber - Ignition timing loo advanced POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. n P Check ignition timing and valve clearance Correct . Check carburetor pilot screw adj ustm ent Correct . Check if air is leaking past intake pipe Not Leaking Peflorm a spark test Incorrect (Faulty ignition control module or ignition pulse generator) - Improper valve clearance - Improper ig ition timing lncorrect——>- (Faulty ignition control module or ignition pulse generator) FuelAair mixture too lean . Fuel-air mixture too rich Leaking ._—.« Detoriorated intake pipe o-ring - Loose carburetor , Damaged intake pipe Week or Intermittent .0- Spark Faulty. carboned or wet-louled spark plug - Go to page 18-3 20-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEEDS 1. Check ignition timing and valve cla Inca r 1 Correct 2. Disconnect fuel tuba at carburetor Fuel flows ireelv 3, Remove the carburetor and check for clogged jetis) Not clogged 4. Check valve timing Correct 5. Check valve spring POOR HANDLING 1 . If steering is heavy Incorrect - Improper valve clearance - Faulty ignition control module - Faulty ignition pulse generator Fuel flow restricted —>- Lack 01 fuel in tank - Clogged lual lina - Clogged lual tank vent tuba ' Clogged luel valve » Clogged luel strainer Clogged —_~- lncorred ——+ v Damaged .—_—.- Check tire pressure Clogged jets Cam sprocket not installed properly Faulty valve spring , Bearing adjustment nut too tight - Damaged steering head haaring - Bent steering stem 2. I! either wheel is wabbling __..————-——~. Excessive wheel bearing play - Bent rim Improperly installed wheel hub or wheel - Damaged swingarm pivot bearing ' Bent axle 3 It the vehicle pulls to one side ———————>- - Front and rear wheels not aligned - Bent lork pipers) ‘ Bent awingarm ' Distorted irame Front brake caliper dragging to one side 20-4 21. INDEX Air Cleaner 35 Air Cleaner Hou ng/Dlr 54 Alternator . Battery l . Battery Case .15711 Brake Fluid , Brake Fluid Replacement/Air Bleeding Brake Light Switc Brake Pad/Diac ‘ Brake Pad Wear Brake Systam Cable 5i Harneaa Routing. Camshait Installation Camshaft Removal. Carburetor Assembly . 5-13 Choke 3~5 Disaaaemb 5-8 Installation 5-19 Removal .. 5-5 Synchronization 112 Charging System Inapection 15-6 Clutch Diode.. 17-10 Clutch Installat n 9-11 Clutch Removal. . 9-3 Clutch Switch . 18-11 Clutch System 3-21 Combination Meter . 1677 Coolant Replacement 6-4 Coolant Temperature Gauge 18-14 Cooling System 3-15 Crankcasa Assembly 10-12 Crankcase Separation . 10-3 Crankshaft 11-3 Cylinder Compression. 8-! Cylinder Head Assembly 8-18 Disassembly 5-11 Installation 8~19 Removal 8-9 Cylinder/Piston/Connect ng Ra 11-7 Direct Air Intake (DA ) System Drive Chain ,,,,, Emission Control Intormation Labels (USA. only) 1-31 Emission Control Systems lU.S.Ai only) Engine Idle Spee Engine Installation. Engine Removal Engine Oil/Oil Filter Evaporative Emission Control System (California type only) Evaporative Emission Control System (California type onlyll Exhaust System ,. Fan Motor Switch Flywheel/Starter Clutch Fork ....... Front Brake Light Switch. Front Caliper Front Master Front Whee Fuel Line Fuel Pump . Fuel Tank . 24 Gearshift Linkeg 9-8 General Safety 1-‘l Handlebars .. . 12~3 Handlebar 5w tchi ‘18711 Headlight. I 18-5 Headlight Aim 3-21 High Altitude Adjustment lU.S.At onlyl ‘ 5‘23 Horn ..... Ignition Cori. Ignition Pulse Generator Ignition Switch Ignition System Inspection Ignition Timing License Light .i 18-6 Lubrication Bl Seal Po his 1718 Maintenance Cover... 2-3 Maintenance Schedule 3~3 Model Identification . 173 Neutral Switch 18-10 Nuts, Bolts, Fasteners . 3~23 Oil Cooler. 4-10 Oil Pan ‘4 Oil Pump 476 Oil Pressure Check, #3 Oil Pressure Switch 13-10 Pilot Screw Adjustment 522 Radiator Coolant 3-14 Radiator/Cooling Fan ea Radiator Reserve Tank . 6-12 Rear Brake Light SWItch 18-10 Rear Caliper .i 14719 Rear Fender A . 2-9 Rear Fender B , 28 Rear Master Cylin er 14-14 Rear Wheel 13-3 Regulator/Rectifier‘ 15~8 Seati 2»2 Secondary Air Supply System (Celiternia type only) Secondary Air Supply System (Celiiornia type only) Service Information Charging System/Alternator Clutch/Gearshift Linkage Cooling System .. Crankcase/Tranemlssion Cylinder HeadNelves Cylinder/Piston/Crankshaft . Electric Starter/Starter Clutch . Engine Removal/Installation Frame/Body Panels/Exhaust System Front Wheel/Suspension/Steering Fuel System ..... Hydraulic Disc Brake Ignition System Lights/Meters/Sw tches. Lubrication System Maintenance Rear Wheel/Suspension Service Rules INDEX Shock Absorber Slde Cover ,. Side Fairing Side Stand ., Side Stand Sw ch Spark Plug t. Specifications, Speed Sensort Starter Motor . Starter Relay Switch Steering Head Bearings . Steering Stem Sub Fuse Suspension , Suspension Linkage t Swingerm . System Tes ng Tail/Brake Light Tail Cowl Thermostat .. Thermo Valv Throttle Operation . Throttle Position Sensor . Tools ...... Torque Values. Transmission Troubleshooting Charging System/Alternator Clutch/Gearshift Linkag Cooling System Crankcase/Tranamraelo Cylinder HeadNalvea Cylinder/Piston/Crankahaft . Electric Starter/Starter Clutch 17-2 Frame/Body Panels/Exhaust Syatem 2.1 Front Wheel/Suapension/Steering ‘24 Fuel System 5.3 Hydraulic Disc Brake . 14,3 Ignition System 16.: Lights/Maters/Switchea. 15.3 Lubrication System ‘4 Rear Wheel/Suspension 13.2 Turn Signal 13.5 Turn Signal Relay 13.15 Upper Fairing 2.4 Valve Clearance 3.7 Valve Guide Replacement E-lt Valve Seat Inspection/Refacing 3.15 Water Pump ., Wheels/Tires .