‘ 1996-1998 CBRSOORR HOW TO USE THIS MANUAL This servrce 'nanuai describes the service procedures for the CBRSOORH. FuHuw the Maintenance Schedule {Sedlnn 3) recom- mandatinns to ensure thettne vehicle is in peak oper ating condition and the emission levels are within the standards set by the US. Environmental Protection Agency and California Air Resources Board Performing the first scheduled maintenance is very important. It compensates luv the initial wear that occurs during the break-in period Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrate: procedures Iur remuvalfinstalla- hull oi components that may be required tn per-term sarvmn described in the following sections. Sectaon Atnrough 15 describe parts o'the motorcycle. grouped according to location. find the section you went on this pace. then turn to tho table 0! contents on the first page of the section. Most sect'ons start wrtl- an assembly or system illus- tretion. se'VIce information and troubleshooting for the section. The subsequent pages give detailed pro- Ceduree. If you oon't know the source ofthe trouble. go to sec- tion 21, Troubleshooting. ENGINE AND DRIVE TRAIN CONTENTS LUBRICATION SYSTEM m ‘ FUEL SVSTEM 7 E COOLING SYSTEM w I a ENGINE REMOVAL/INSTALLATION II —?VLINDEFI HEAEIVALVES .3 CLUTCH/GEARSHIFT LINKAGE II ALTERNATOR/STARTER CLUTCH I I: I CRANKCASEIPISTONICYLINDER I I I CRANKSHAFI'ITRANSMISSION 7 IE CHASSIS FRONT WHEEL/SUSPENSION? _ _ STEERING REAR WHEEL/SUSPENSION I I! HYDRAULIC BRAKE IE ELECTRICAL BATTERY/CHARGING SYSTEM Ila IGNITION SYSTEM IE: ELECTRIC STARTER IE: LlGHTS/METERSISWITCHES i m WIRING DIAGRAM E] TROUBLESHOOTING a I INDEX 7 E Date of issue' December, 1935 to HONDA MOTOR co. LTD SYMBOLS The symbols used throughout mls manual snow specific sen/Ice procedures, If supplementary informativn is required pertaining to these svmbwls, it would be explained specifically in the text without the use of the symbols 6“ V Replace the penis) with new one(s) before assembly. "7! Use recommended engine oil, unless otherwise specified ,7; Use molybdenum oil solution (mixture of the engine oil and molybdenum grease In a ratio at 1 : Ur Use multi—purpuse grease (Lithium based multi-purpuse grease NLGI #2 or equivalent). Use molybdenum nisultidn grensn (containing more than 3% molybdenum disulfide, NLGI 82 or equivalentl. Example: Molykoro' BR-Z plus manufactured by Dow Corning, UrS.A. Multi—purpose M-2 manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent). Example: Mnlykote‘ ER-Z plus, manufactured by Dow Corning. U.S,A. Honda Moly 60 (USA. only) Rucol ASP manufactured by Rucol Limiled, U.K. Race] Paste manufactured by Surnico Lubricann Jannn Use silicone grease. ,, _—J Apply a locking agent. Use a middle strength locking agent unless otherwise specified, Apply senlnnt. Use DOT 4 brake fluid Use the recommended brake fluid unless vtherwlse specified. Use Fork or Suspension Fluid. 1. GENERAL INFORMATION GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1-3 SPECIFICATIONS 1-4 TORQUE VALUES 1-13 TOOLS 1-17 LUBRICATION Sc SEAL POINTS 1-13 CABLE 8: HARNESS ROUTING 1-22 EMISSION CONTROL SYSTEMS IU.S.A. ONLV) 1-36 EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLV) 1-39 GENERAL SAFETY CARBON MONOXIDE If [he angina lllusl be iuiiiiiiig Lu uu mine wuik, make suie the area is well ventilated Never run the engine in an enclnaed area, m.— . Tin minim i-miiuini pin-minim i-niiiuu monuu'de glli iInii mii mm [on n} canimuinei: and may lead in mm Run the engine in an open area or wim an exhaust evac- uafiuii system in an enclosed area GASOLINE Work in a well ventilated area. Keep clgarenes. flames iii apalk: away ii uni III! Wulk aiua U! wiim gasoline is smred m..— - Gasullnp i: exmvmelv flammable and i: Explosivc under wr- iuin CUIHIIII'UIIL KEEP (1LT (IF REACH OF CHILDREV HOT COMPONENTS M - Enginr imil ulmiur 9mm piim lieu-nu may liar and remain (in: jar mm lime «fur [ht engine [lax bmi running. Il’mr rnsukn‘d glove: or wail unnl 1hr engine and exhaust system have canted bafare handling them pnm. USED ENGINE OIL m . - L'sed englm all my aim skin ram‘cr if rcpratz-dly Itfl in [DHIDL‘I‘ wiili Hu- skin for pmlanged periods, Although ml; Is unlikely units: you ImmlllI null ul'l an a daily [HAIL it i) will niiiimiii. in Ihnrflughly midi )‘nu’ naniti will: map and waltr as man as passillk afizr handling used ail. KEEP our 0F REACH OF CHIIDREN. BRAKE DUST Never use an air hose or dry brush re clean the brake assemblies, Use OSHA-approved vacuum cleaner or alternate meIhod approved by OSHA, desigiiad Iu iiiiii'i- mile The hazard caused by airborne asbestos libers AWARNIMG - Inhaled urban): fibu: hm bun faund IO mm respilizmn‘ iii-mm and mm. BRAKE FLUID CAUTION - Spirii K, mini .iii niniiini. piniin .ii- runner parii “it: aiming: (Ilt'm. Flau- a dim: (II/7p mm um Nina panr wlianci-ar rim nnem u sen'i'md KEEP OUT OF REACH OF CHILDREN 1-1 GENERAL INFORMATION BMTERY HYDROGEN GAS a ELECTROLYTE m_—__ Tilt tummy giws nff (Iplnnw gum, up xpnrkx, 11mm and [igmflzs away. l'mwdt [Idlqualt Mutilation when chargulg. The battery [animus sulfuri: acid (electrolyte). Cantu: with skin 07 en: mar mus: Mme bums. er prorzcrivr Marking am! u [m mum. , _ I/pkmnlyu grlr rm yourxkin, flush will! wallr. — u electmmc gm in your cyns. flush with walerfar a (can 15 minute; and call a phvsltlan immediately. Elem/lyre u puiwnum. — If mun-m1, dn'nk largr quanu'uu a} water «r milk and/n!- Iow with Hulk 0] magntxia 0r vegetable ml and (all n physi- cian. KEEP OUT OF REACH OF CHILDREN. SERVICE RULES 1. Use genuine HONDA uv HONDA-recommended pans and lubricants or their nqmvnlanrs Pans that don‘l moat HONDA’s design specifications may cause damage in me. mummycle. . Use ma special male designed for this product to avoid damage and incorrecx assembly. . Use only movie tools when sen/Icing me motorcycle. Metric bolls, nuts and screws are not imerchangeable wnh E nglish iasleners. . Illslall new gaskets, Oirings. cotter pzns, and lack plates when reassemhllng. When tighienmg hnlis or nine, hegin With the larger diameter or inner bolt first. Then tighten m the specified torque diagonally in incremental stops unless a panicular sequence ls specified. . Clean pans in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. . Aher reassembly, check all parts lo: ploper installation and opeietion. . Route all eleclrical wires as show on pages 1-71lhrnugh 1411,6an: and Harness Routing. 1_ GENERAL INFORMATION MODEL IDENTIFICATION (1) The frame saH’aI number IS warmed un We rigm 5qu UI llw slewing head. [db VEHICLE IUENTIHCATION NUMBER IVN) '7; Ii-e engme senal number is stamped on [he rigm V3) The Vehicle Iaemificazion Number (VIN) IS Incalad sidc ohhc upper crankcase. an right side of me Iranve near {he naming head on me Salzly Calllfication LabeI I51 COLOR LABEL IA) The carburetor Identifical'on numbers are sla'uped (5) The color IabeI IS anached as Shawn Whe‘ ordermg on (he uuake 51:16 althe Ea'buvetcr body as shown rmnrmden pans, always spemiy the des‘gnaled coIcrcodc. 1-3 GENERAL INFORMATION SPECIFICATIONS Cviinder arrangemem — GENERAL ITEM ! SPECIFICATIONS DIMENSIONS Overall langm 2.055 mm (80 9 in) Overall Wldm '96v'37: 675 min 426,6 in) Afier '9 585 mm125.9iii) Overall height '96 , '974 LIED mm (445 inl . Alter '57: 1.135 mm (4L7 inl Whazlbue 1,400 mm (55A In) Seat height 810 mm (31.9 In) Fuclpeq heighr ‘96— '97: 350 mm (15.0 m) Aher ’97 383 mm 115.1 In) Gmund clelrince 1m mm (5 Sin) Drv weigh: '96— ’87: 49 Emu/Canada Iype 183 kg (403 lbs) Calflornla “(DD 186 kg (410 lbs) Mlnr '97: L9 sures/Canada was 150 kg (397 lbs) Calrfomia IYDO 183 kg (‘03 IDS) Cum weigh! ’96 — ’97' 49 states/Canaan type 205 kg [‘5‘ lbs) Califnrnin Np: 203 Kg [459 lbs) Allm ’91 A9 slates/Canada rvfie 203 kg (“8 leI Caliluriiia type 206 kg «5; lbs] Maximum walgm capamy ’96 — '57: 49 Stiles/Clnidi Kypd 160 kg (353 lbs} Callramla [’va 160 kg (353 lbs) Ahcr ’97149 slates/Calirumla lvpfl 150 k91353lbs) Canada type lad kg (352 lbs) FRAME Frame rype Diamond ‘ Front suspensinn Telescopic fork Flum wheel uavel ‘IID mm {4.3 In) Him suspeiisiuu Swinqarm R02! Wheel [rival 175 mm “.9 In) Rsar damper Niuagen gas-filled damper, wim reserve tank From tire size '36— ’97: 130/70 ZR 16 After 97: ”0/70 ZR 15 (61 Wl Rear lire size '96 ISO/55 2K 17 All” '97: 130/55 ZR I7 {73 W) Tire brand Biidgeslone Front: BTbEF RADIAL/Rear: BT66R RADIAL G Mruliuliii Front: DOS/Rear: TXZS From brake Hydraulic duuble dim: hrlkl Rear braka Hydraulic single disr. brake Caswr angle 2" TraIl length '96 - '9 90 mm (3.5 In) After '97: 95 mm (17 In} Fuel rank capacity 18.0 lirer “.76 US “II, 3.96 Imp gal) File) rank reserve capacity 3.5 lncv (0492 U5 gal. 0,77 Imp gal) ENGINE Ema and slroks 71.0 x 58.0 mm (230 x 2.28 ml Displlculllmll 519 Cm‘ (SSJ CLHHI Compwssiun miu i1.ii: I Valve ma)" Chain drive and DOHC "flake vulva cpinl I5' BTDC ml 1 mm (0 0A in) Ii“ (7‘ BTDC m 1 mm (0.0‘ in) ”H GIGSOS 35‘ ABM Alli! '97 37“ AEDC After '97 Exhaust valve opens 39: EEDC A9 Slims/Canada [yrs JD” BBDC California Iypg close: II> ATDC Ind '95 — '97 III type: fl= ATDC Lubrication System Famed 91868qu and we: sump or) pump type Trochcid Caalmg sys‘em Liquiutooled Airhnmtion Paverfiker Crankshufi Iype Un‘n rvpe aninn dry mighi ‘ '96- '97: ‘9 mun/Canada type 56,9 kg 1147.5 lbs) California lype 58.2 kg 1150.4 lbs) After '97 A! sums/Canada type 66.3 kg msiz ihsi California type 67.6 kg um lbs) Fnur cylinder. inlina — GENERAL (Cam'dI GENERAL INFORMATION Starting system Charging system Regulator/rectifier Lightlng Aystam ITEM SPECIFICATIONS CARBURETOR I Carburetor type CV Constant Velocity) type, with Ilai valve Throttle bore 38 mm (1.5 in) DRIVE TRAIN Clutch system Mum-plate, we! Clutch operation system Mechanical type Transmission Constant mash, Grsneed Primary reduuliun 1.520 (76/50) Final reduction 2.687 [43/15) Gear ram 13! 2.727 (30"1” 2.769 (36/13I 2nd 1.533 [29/15) 2.000 (26/13l 3rd 1.600(2'1y'15) , , , 1.600(2'1/15l . . 41h 1.400 12mm 95 ‘ 97' 1.368(26/1El “‘9’ 97' 51h 'l 263 (24.49) 1227 (27/22) 6th 1.167(21l'18) 1,130 (ZS/2:“ Gearshift pattern Left loot operated return system 17 N ~ 2 — 3 — 4— 5— 6 ELECTRICAL Ignition system Full transistor digital ignition Electric starter motor Triple phase Uuluul allamaluv SCH shortedltrlple phase. Iull wave rectification Buttery 1-5 GENERAL INFORMATION _ LUBRICATION SYSTEM . ““"z m'“ “m ITEM STANDARD 591va umrr WV At draining" 3.5 |i1er(3.7 05 (11,31 Imp qt) 7* m 4.4 liier (4.6 US q1,3.91mp qn —— Al oil filter change 3.6 lixer (3.5 US 01., 3.2 Imp '41) -— Recommended engine oil HONDA earn“ all or aquiyalenl molul oil _ API service classification SE, sr‘ nr 56 Vlscosify: SAE 10w — 40 Oil pressure ax oil Drags-um switch 490 kPa (5_o kgf/cmi, 71 psi) 31 t 5,000 rpm (min ')/(80°C/176“F) OII pumo roxor l Tip claTdrance 0.15 - 0.22 (0.006 - 0 009) 0.20 10.003) Body clearance r 0.15 — 0.22 (0.006 — 0.009) 0.35 (0.014) Side clearance 0.02 - 0.0710001- 0.00;) 010100041 - FUEL SYSTEM ITEM spectncnlous Calburaml idsnlifica- as sum type '95 - '91: vrssa “0" "umbe' After '97: VPBCP l ’Calimrnia lype V '96 — '97: VPHBA After '97; VFBDA ' Canada wpc '96: ‘ VPBSA ‘ ‘97: VPsaB Afler '97: VPBCB iMain 1e: 49 slates rype '98 — '97: #11: (See page 5711) Allen ’57; #120 California was '96 _ '97: _ #115 After '97: 7 mo Canada type ’96: #115 '97: No.1.4:#115/No.2,3:#118 7 Aher '97: 0120 Slow jet 7 V 840 Jet needle numbev 49 siares rype '96 —797: No. 1, A: JSFB/No. JSFA ‘ Am '97: No. 1. d: JSFH/No. 2, 3; JSDD Calimrnin typn '56 r '97: No. 1, 4: JSFB/No. 2v 3: JEFA Amer '97: No. 1, 4: JsFNNo. 2, a: JSFC > Canada type '96: No, 1, 4: .ISFZ/No. 2, 3: JSFV 4 '97: ND. 1, 4' JSFHINO. ' 3i JSFA After '97; No. 1‘ a: JSFH/Nn. 2, a: .lsDD Pilot screw initial ‘96 e ’97- l 3 turns our opening Except Califomia type ”Her '97: 77 1 — 5/8 turns out ‘ California type 7 fl 2 lurns out Float level [ 13.7 mm (054 in) idle speed I Except Callfnrnla fyna . 1,100 g 100 rpm" ' California type 1,200: 100 rpm 7 ThruliléQrip nee play 276mm11/12 1/4 in) l 1R GENERAL INFORMATION __ COOLING SYSTEM n-EM spemncamous Coolant capacily Rammm and engine '98—'97: 2.77 lIIer12.93 US 01.2.40 Imp or) Aher '57- 2.64IiIer12.79 US 01.2.321mp all Reselv} tank '96— '97: 0 45 lnar (0 475 05 qt, 0.305 Imp qI) ‘ her '97; 0.35 liter (0 370 us qt, 0.310 Imp ml Rnrfinmr cap rehel pressure ‘ '96v 'BLI: 103 1137 kPal1.1~1.4kgi/cm‘,1e —20 psi) Aker '97: 107.9 kPa (1.1 kgflcm‘. 16 pal) Thermoskax Begin to open 80 , 84°C (176 V183°Fl Fully open BS’C (20TH 1 Valve 110 0 mm (0.3 in) minimum CYLINDER HEADNALVES _U““‘ '"’" ""’ ITEM STANDARD SERVICE LIMIT Cyllndav compression ’96 '97: 1.177 kPa (12.0 kgfi’cml, 171 pal) at __ 600 — 600 rpm After ’97: 1.2 kPa (13.0 kqflcmz. 136 psll at _ 350 rpm Cylinder head warpage E 0.10 (0.004) Valve, Valve clearance [ IN "3'" “”1“” ’96 — '9'): EX 0.19 — 0.2510007 — 0.010) -— After ‘97 EX 0.22 02810009 — 0.011) ' —— Valvv slam 0.13. IN 4475 — 4.4901111762 . 0.1768) 4.435 (0.17511) ex 1 4.465 — 4400101750 - 0.1764) 4455101754) Valve gulde I.D. IN I 4.500 — 4.512 (0.1772 , 01776) 4540101737) EX 4500—4512(01772—01776) 45401017117) Slam-m-gulda clearance |N 0.010 - 0.037 (0.0004 - 0,0015) EX 0.020 0.047 (0.0000 — 0.0019) — ‘ Valve guide projecfion above IN 14.50 443010575 , 0.583) — 7 W'inde' ““4 EX 1 14.80- 15.00 (0503—0591) 7‘ ‘ . Valve scat wldlh IN/EX ‘ 0.90 — 1.10 (0.035 — 0.043) 1510.06) Valve spring Inner IN/EX 357711.403) 34.07 (1.341) "99 'enfi'h Outer IN/EX 39.69 11.503) 57.79 (1 433) Valva line) ‘ Valve lifter 0.0. INIEX 25.975 . 25.993110221340233) 25.97 (1.022) 1 Valve lifter bore LD. IN/EX 25.010 720020110240 1.0245) 26.04 (1.025) Camshaft Cam lobe Excepl CalIIomla 1N 35.040 — 35201111410071.4203) 30.01 11.418) “9‘9“ We EX 35.800 - 360411114094 414155) 35.77 H.403) California IN 1 34.940 — 35.130 41.3755 — 1.3050) 34.91 11.374) 'Y” EX 35.100-35340113319-1.3913) 35.07 (1.3111) Hunoul 7— 0.0510002) . on clearance 0.020 — 0.062 (0.0008 - 0.0024) 0.10 (0.004) 1-7 GENERAL INFORMATION Unit mm (in) — CLUTCH/GEARSHIFT uNKAGE ITEM STANDARD SERVICE LIMIT ‘ Clutch lever free play 10 7 20 (3/8 7 3/4) 7 W — Clutch sprmg free length '96 — '97: 50.2 [1.99) 49.21193) Aher ‘97- 48 811.92) 47.01195) Clutch disc thickness '96 - '97 2.62 - 2.78 (0.103 — 0.109) 7 3 (0.09) After '97 2.92 — 10010.11 - 0.12) 2.6 (0.102) Clutch plate wamage 7 7 , W , 7— 77 0.30 (0,012) Clutch uutu gmde LD. 24.9935 7 25.0035 (0.99399 — 0.99451) 25.016 (0.9349) 0.0. 34.975 - 34.991 (1.3770 1.3776) 34.965 (1.3766) Malnsnart 0.0. at clutch outer guide 24.980 — 24.993 l0.9935 — 0.9340) 24.96 (0.993) Sllifl lurk, Fork 1.0. 12.000 - 12.071 (0.4724- 0.4733) 120310.474) W" 5h!" Claw thickness 5.93 7 5.00 (0.233 - 0.230) 5.91023) Fork shaft 0.0. V W 11.957-11.960 (04707—04712) 119510.470) r ALTERNATOR/STARTER CLUTCH ”""’ m'" “"’ ITEM STANDARD senvm LIMIT Starter driven gear boss 0.D. 51.699 7 51118110354 2.0361) 51.684 (2.0348) — CRANKCASEIPISTONICYLINDER 77 7 7 7 U” "‘ ('"’ ITEM STANDARD SERVICE umrr Cylinder 10. 71.000 41.015127953—2 7903) 71.10 (2.795) ”out or round 0.1010004) Taper if 7 ’7'" _ 0.10 (0.004) Warpage 7 0.05 (0.002) Piston. piston Plston mark direction “IN" mark facing toward the intake sidc 7— ""95 Piston 0.0. 70.965 — 70905127939 7 2.7947) 70.90 (2.701) Piston 0D. measurement point Piston pin bore LD. 15 mm [0.6 in) from bottom of skirt 17.001 —17.008 (0.0094 - 0.8696) 17.03 (0.670) Plston pln 00. 15.993 — 17.000 (0.6690 — 0.6693) 10.90 10309) Piston to piston pin clearance 0.002 7 0.015 (0.0001 7 0.0006) — Plston rlng7t07rlng Top 0.030 — 0.055103012 7 0.0026) 0.0510003” WW“ ”ham“ Second 0.015 7 0045100006 — 0.00111) 0.07 (0.003) Plstun rlng and gap lop 0.28 — 0 38(0011- 0.015) 0510.02) Second 0.40 - 0.55 (0.015 - 0.022) 0.7 (0 03) on (side rail) 0.: - 0.710.01— 0.03) 7 0.9 (0.01) Cylinder-to—piston clearance 0.015 7 0.050 (0.0006 — 0.0020) Cullnecting rod small and ID. 17.019 717.034 (0.5599 7 0.6706) 170410.671) Connecting rod-to-Diston pin clearance 0.0167 0.041 (0.0006 0.0016) l Crankpin oll clearance 0.030 7 0052100012 7 00020) 00610002) J 1-8 GENERAL INFORMA‘HON Crankshaft lrnnsmlssmn _ CRANKSHAFT/TRANSMISSION ”""' m’“ “N rrEM STANDARD smwcz umn 1 5.02 clearance 0.05 — 0.20 (0.002 . 0 0031 0.30 (0.0121 7 1101.001 ‘ 0.90 (0.01217 Main10urnaloi1claarance 0.017 - 0.035 (0 0007 - 0 0014) 0.05 (0.002! Gear 1.0. V M5, 6 23.000 - 23.021 [1.102A-110321 28.04 (1.104) ' 01 24.000 , 24.021 (0.9449 _ 0.94571 24.04 (0.9451 . C2114 31.000~31.025(1.2205— 1.2215) 31.04‘1122) 1 Bushing o D 1 M5, 6 27.959 727.990 (1.1007 ~ 1.1016) 279411.100) c2 30.995 — 30.900 (1.2197 1.2197) 309311.21ayfi C3, 4 30950-30375112135-1.2195) 30331112181 Bushing 1.0. M5 24.995 — 25.000 (0.9937 - 0.9945) 25.02 (0.9951 cz ' 27.935.49.000(1101341025) 711020.103» (mm-mun...“ M5. 9 0.020 — 0.062 (0.0009 — 0.00241 0.10 (0.0041 °'°°”’"°° c2 0.020 — 0070100009 - 0.00231 7 0.11 (0 0041 C3, 4 0.025 9 0075103010 - 0.0030) 0.11 (0.004) Mainshan 0.0. M5 24.991— 24990109990 0.9995) 24.90 (0.9931 Clulch omer guide 24.980 — 74 993 {0.5835 - 0.9340) 24.96 (0.9831 Counlershaft 0.0. c2 7 27.907479210111011 ~1.101s) 27.95 (1.1011 Bushing-tmshah M5 ‘ 0.0051 0.039 (0.0002 - 0.00151 0.09 (0.0031 ‘ “meme cz 0.005 — 0.039 (0.0002 - 0.0015) 0.00 (0.00:1) GENERAL INFORMATlON 7 FRONT WHEEL/SUSPENSIONISTEERING 7 .7 M ITEM STANDARD SERVICE LIMIT Mlnlmllm me (man depth 7 1.5 (0 06) Cold tire pressure ‘ Up losikg (200 lb) lead 250 kPa (2.50 kgl/cmr. 36 psi) ‘ :‘L‘a‘iiga’dmw‘ "‘9'“ 250 kPa (2.50 kgl/cmz, 30 psi) — Axle (uncut — 1 0.20 (o 008) Wheel rim runout Radial V 7 7:77 W 7 W 2.0 (0.03) Axlal — i 2.0 (000) * Fark Spring free ' ’06— ‘97: 243.2 (5.77) ‘ 203.2 (9.57) """9‘" ; After '07: 250.2 (9.85) 245.2 (9.65) Spring direction With (h: tapered and facing down Tube runout 0.20 (0008) Recommended (ark fluid Fro-Hand; Suspensiiuranluid 33-3 7 ( —- ) Fluid level 114 2 401.5 x 0.2) —— Fluid capacixy '96» '97: 561: 2.5 cm3 (19.0: 0.02 us oz. 19.7 _ t 0.09 Imp 01) After '97: 540 t 2.5 mJ (15.3 i 0.02 us 02,190 i t 0.09 Imp 01) i — 1 P's load adjuster sonlng 12 mm (0.5 In) from 109 of fork can i — .’ Rebound adjlmer sening 1 turn from full hard i Cornpression ’56- '57‘ 1 him from full hard — . 1 “I‘m” 59m"? After ‘97- 1.5 turn from (ull hard — i Sleelillg head bearing pve|oad 1,0 — 1.5 kg(_ (3.2—_3._3 (bf) — Unix: mm (in) — REAR WHEEL/SUSPENSION ‘ ITEM STANDARD i SERVICE LIMIT Minimum [Ire (read deolh 72.0 (0.03) Gold Ilre pressure 1 Up to 90 kg (200 lb) load 290 kPa (2.90 kgf/crn’, 42 psi) "7 I) gazgzigm‘im'm “‘9'" 290 kPa (2.90 kgf/cm’, (2 psi) ‘ 7, ~ Axle. mnom —— 0.20 (0.008) Wheel rim runoul ‘ Radial ——-—~ 2.0 (0.08) Axial —— 2.0 (0 ca) Shock absorber Spring free '95 — '97: 172.0 (0.30) 'i" 7 W 169.1 l6.68) '“9‘” Mar ‘97: 167.7 (6.60) 160.316.47) Spring dircclion Wim lhc tapered and facing up ’ Pre-Ioad '967 '97: 2nd position ‘ ( adjuster ”um“ After ’57: 3rd posman 7 ( Rahmmd adjuster setting 1 mm lmm full hard 7 Compression adjuster setting 1 turn from full hard — Dun. chum ‘ Size/link DID DIDSZSHV ecu — 12025 —— i RK RKGBSZSROZ1-120LJF —— ‘ ‘ Slack 20-30(1.2—1.0) 50(1.97) 1-10 GENERAL INFORMATION Unlt: mm [in l — HVDRAULIC BRAKE ITEM STANDARD senwcs LIMIT From Specified brake fluid DOT 4 7 Brake disc thickness 45 (0.18) 3.510.") Brake msr: runnut — 0 3010.012) Master cylinder 1.0. '96-'97 14.000-14053105512-0 5529) 14055105533) ‘1 A112) '97: 15.070— 16.913 (06206—06265) 1592610627) Masler piilon 0.0. ‘96 — '97: 13.957 — 13.994 (0.5495 — 0.5506) 13.915 (0.75490), After '97: 15.527 , 15.864 [0.6231 7 0.6242) 1501510623) Callpcr cylinder A ’96 — '07: 30.230 30.28011.19l12 - 1,1921) 302911.193) "D' After '9): 32.03 — 320011.251 —1.263) ‘ — a '96—'97: 77000—77050(10630—10650) 270511.065) After '97: 33.96—31.0111337 - 1.339) — Calipel pislou A '93—'97 30143—30193 (1.16139— 1.1939) 30140111900) OD Aher'97: 31965—31398(11585—13595) — a '96 '97: 26.936 , 26.966 11.0604- 1.0617) l 26.327 (1.0610) After '97: 33.895 — 339291133“ — 1.3357) — Hear specified mu fluid DOT 4 — Brake disc thickness 5010,20) 4.01016) Brake disc runuul — 0.30 ( 2) ’Kn'éfiéréyli’rfirTD. 15.070 -15.913(O.6245 — 0.6265) 1592510. 2707 Master piston 0.0. 16,327 —15.a54 (0.0231— 0624:) 15315100220) ' Culipercylinder 1.0. 38.18—38.23 (1.503» 1.505) 39.24 (1.506) Caliper piston 0 D. 38.115 — 38.148 (1.5006 71.5019) 30107115003) — BATTERY/CHARGING SYSTEM ITEM SPECIHCA‘I’IONS Battery Capacity i 7‘ 12v- 8A1) Currem leakage 0.1 mArmax. Voltage Fully charged 13.0 7 13.2 v 7 ”WC/53”“ Needs charging Below 12.3 v ‘ Charglng curren! Normal 09 A/5 — 10 0 Quick 10 No.5 )1 Allemalur A Capaciry ,_ 304 w;5,000 rpm Charging coil resistance (amuse-=10 0.1 7 0.30 . Regulator/rectifier regulated voltage 13.5 -15.5 W5,000 rpm 1-11 GENERAL INFORMATION — IGNITION SYSTEM . . e ITEM SPECIFICATIONS ; Spark plug NGK I DENso Slander; cnsan s I U27FEH 9 Optional CRREH El l UZ4FER 9 Spark plug gap 0.80—0.90 mm (0.031— 0.035 in) Ignition coil peak voltage 100 V minimum Ignition pulse generator peak value: Ignition liming “F” mark 0.7 V minimum 10° BTDC at idle Unit: mm (in) —— ELECTRIC STARTER ITEM STANDARD SERVICE uMIT Starter motor brush lung; 12.0 - 13.01047 - 0.51) 4.5(9181 j — UGHTS/METERS/SWITCHES * ‘ ITEM SPECIFICATIONS Bulbs Headlight lHigh/low beam 12 V — 45/45 w x 2 Pomtinn light 12v-5w Brake/tail light 12 v - 32/3 cp Front turn signal/running light 127v - 32/: up He; turn signal light 12 v - 3: (:9 License light I 12 V — 4 an Instrument Ilgm 7 ‘96 — '97; 12 v — 1.7 w x 3 After '97: 1.1 W x 2 Turn signal indicator I ’96 , '97: V 12 v'— 1.7 w x 2 ‘ AflEr'S'l: 12 V-I.1W)t2 High beam indicator '96 — '97' 12 V 7 1.7 W After '97: 12v41.1w Neutral inéicamr 4 '98 7; 12 v — 1.7 w Aftev'97: 12v—1.1w Oil pressure indicator ’96 7 ’97: 7 12 V - 1.7 W After'97: 12v—1.1w Side stand indicator '96 - '57: 12 V ~ 1.7 W (93:3;aenlliéiznperature Ailei 97. 12 V A 1.1 W Fuse Main ruse so A ‘Subfuse 10Ax4,2qu1 Faumomrswiléi i Slaflto close(ON) 987102‘C(208 r 216’F) Stop 10 open A 93 — 97"C (159 , 207°FI l Coolant temperature sensor resistance unis/Gain 55—60” TORQUEVALUES GENERAL INFORMATION I TORQUE ronuug FASTENER 1'er M" m 914“. M h) FASTENER TVPE Mm (knfm- MN 5 mm hex bull and nut 5 (0.5, 3 6) 5 mm screw ' 4 (0 a, 7.9) 6 mm hex bolt and NA! 10 (1.0, 7) 6|1lflls€rew and flange boll (SIlvype) 9 in. 5.5) 8 mm hex bolt and nut 22(2.2,16l I 6 mm flange hall (8 mm head) . 10 mm hex bull and nul 34 4.1 5, 251 5 mm flange boll 110 mm headland nut 12 (1.2, 9) 12 mm hex bolt and nut 54 <55, 40> 8 mm flange ball and nut 2612.7, 20) 10 mm nange hair and nu! . 39 mu, 29) - Tulque specifications listed hnlnw are Mr Important fasteners. - Drums shnuld be tightened to slandard torque values lisrad above. NOTES: 1. Apply sealant to lhe threads. 1. Apply a locking agent to the thrnnds. 3 Apply molybdenum disulfide all lo the threads and flange Sudan. 4. Apply grease ro (he mreads. 5. Srake. EL Apply uil to the threads and flange surface. 7 Apply ell-an englna ml to the O-rlng. B. U-nut. 9. ALOC bolr: replace wirh a new cane. fl ENGINE THREAD DlA TORQUE ITEM O'TY (mm) Nm (Ir , rum REMARKS MAINTENANCE Crankshaft hnln can 1 45 18 (1.8, 13) NOTE 4 Spark plug 4 ID 12(12,H7l LUBRICATION SYSTEM: , Oil drain bull 1 12 2913.0, 22] . Oil IiIIer :anridge 1 20 1011.0,71) NOTE 6, 7 y Oil pump drlven sprocket boll 1 6 15 (1.5, “I NOTE 2 Oil cooler boss 1 20 6416.5. 47) NOTE 2 COOLING SVS’TEM: ‘1 Water pump coverboll 3 G 13 (1.3, 9.4) l , Coolant temperanlrn sensor 1 PT1/8 10 (1.0, 7 2) NOTE 1 FUEL SYSTEM: Carburelor assembly bolt. 5 mm 1 5 5 (0.5. Al , 6mm 1 6 10(1.0,7.1) Vacuum plug for synnhrnnlmlmn 3 5 3.0 (0.30, 2.2) Bnns'Jomt [or luel valve 1 5 2.5 40 75,1.H) Carburcror insulator band screw 8 5 1 See below Insulator band screw tightening- 15.5 1 0 5 mm ENGINE SIDE —*l r—. CAREURETOR SIDE “15:, (15 mm ‘ 1-13 GENERAL INFORMATION 1* ENGINE (Cont'd) " THREAD DIA. l TORQUE ”EM my (mm) Nm ikgIm. lbflt) “MARKS ENGINE MOUNTING: ‘ Drive sprocket bolt 1 10 ‘ 5415.5,40) CYLINDER HEAD/VALVES: Breather plale flange bull 3 6 12 (1.2, 87) NOTE 2 Cylinder head stud bolt E B 25 (2.6, 19) Cylinder hand cover special ball 6 6 10 (1.0. 7.2l Camshaft holder flange bolt 10 6 12 (1.2, 8.7) Cylinder head socket bolt 10 9 4814.8, 35) NOTE 0 Cam sprocket ball 4 7 21117 (I, 14) NOTE 2 Cam chain tension” llher mounting hnh 2 6 )2 [1.2, 3.7) Air bleed tube Joint 1 10 25 (2.5, 18) CLUTCH/GEARSHIFT LINKAGE: Righl crankcase cover SH boil 7 6 12 (1.18.7) Clutch center lock nut 1 27 1251131 94.8) NOTE 5, 6 Gearshift pedal spring stopper 1 a 22(2.2,151 i Shift drum comer bolt 1 a 23(2.3,17) ‘ NOTE 2 Shift drum bearing :91 plate bolt 2 6 12 (1,218.7) ‘ NOTE 2 ALTERNATOR/STARTER CLUTCH: rm nranknasa mver SH bolt 10 s 12 (1.13.7) l Flywheel liangc boll I 10 93 (9.5, 69) NOTE 6 Srator mounting socket hair 4 8 ‘ 12 (1.2, 8.7) Slallul one-way clutch sockeibuli 6 8 16i16,17l NOTE 2 CRANKCASE[PISTON/CYLINDER: l Crankcase b011,“) mm 1 10 39 (4.0. 29) 9 mm 10 B 35 (3.6, 26) NOTE 6 H mm 2 8 24(24. 17) 6mm 13 6 I 17013.7) [innnncting rnrl nut H 8 l 34 (3,5. 25) NOTE 6 Lower crankcase sealing bolt, 20 mm 1 20 29 (3.0' 22) NOTE 2 18 mm 1 18 44 (4.5, 33) NOTE 2 CRANKSHAFT/TRANSMISSIDN: Mainshaft bearing set plate bolt 2 S ‘ 1211.111!) NOTE 2 IGNITION SYSTEM: l Ignition pulse generator cover SH bolt 8 6 i 12112.81) NOTE 1 Ignition pulse generator rotor special bolt 1 1D 59 (6.0, 43) LlGHTS/METERS/SWITCHES: Neutral switch 1 1n 12 (1.2, 8.7) Oil pressure switch 'I FT‘l/S 12 (1.2, 8.7) NOTE 1 1—14 GENERAL INFORMATION — FRAME THREAD DIA. TORQUE "EM my (mm) Nari (kglrn. le‘t) REMARKS FRAME/BODV PANELS/EXHAUST SVSTEM: Upper cowl stay mounting bull 2 8 26 (2,7, 20) [rnnt fender mounting bolt 8 6 5 ((1.5, 3.6) Exhaust pipe [Olnt nut 8 7 12112.81) Muffler mounting bolt/nut 2 H 2512 5, 19) Step holder mounting bolt 4 8 26 (2.7, 20) Footpeg mounting bolt 1 10 44 (4.5, 33) NOTE 9 Bank sensor 2 8 10 (1.0, 7.2) Handlebar weight screw 2 E 10 (1.0, 7.2) FUEL SYSTEM: Fuel valve 1 22 34615.25) Sub-air cleaner mounting bolt 1 8 7 (0.7, 5.1) COOLING SYSTEM: Fan "1010! nut 'l b 2.5(0.25,1.H) NOTE 2 Fan motor switch 1 FT1/B 18 (1.8, 13) NOTE 1 ENGINE MOUNTING: Left engine hanger bolt 2 1D 39 (4.0, 29) Flight engine hanger bolt 1 1D “(15,333) Engine hanger nut (Hear/upper) 1 10 39 (4.0. 29) (Rear/lower) 1 10 39 (4.0, 29) Engine hanger adjusting bolt 1 22 11 (1.1, 8) Englne hanger adjustlng bolt lock nut 1 27 54 (5.5, w) Engine hanger plate bolt 4 B 26 (2.7, 20) FRONT WHEEL/SUSPENSION/STEERING: Steering stern nut 1 24 103 (10.5, 76) 59: page 13-28 Top thread A i 26 — J Top thread 3 1 26 — Fork top bridge pinch bolt '96 '97: 2 B 23 (2.3. 17) After '97: 2 B 22 (2.2, 16) Fork boltum bridge pinch bull '96- '97: 2 10 49 (5.0, 36) After '97: 4 Fl 27 (2.8, 20) Front axle bolt 1 H 5916.0. 43) Front axle holder bolt 4 B 22 (2.2, 15) Front brake disc mounting bolt 12 8 20 (2.0, 1!.) NOTE 9 Fork cap ’96 - '57: 2 42 23 (2.3, 17) Atter ’57: 2 42 22 (2.2, 16) Fork socket bolt '96 , '97: 2 B 20 (2.0. 14) NOTE 2 After '97: 2 10 3413.5, 25) REAR WHEEL/SUSPENSION: Rear axle nut 1 1E 33 (5.5, 59) Rear hrake disc mounting bolt O 8 A2 (#3, 31) NOTE 5 Driven sprocket nut 5 12 108 (11.0, 80) NOTE 8 Rear shock absorber upper mounting nul 1 10 At (1.5, 33) NOTE 8 Shock aim plate nui 2 1D 44 (4.5, 33) NOTE 8 Shock link nut 2 10 44 (4.5, 33) NOTE 8 Swingarm pivot adjusting bolt 1 30 15 (1.5, 11) SeeoageiLZZ Swingarm pivot lock nut 1 30 64 (6.5, 47) Swillgarm pivui nut 1 18 93195.69) NOTE 3 Drive chain slider holt 2 6 9 (0.9. 6.5) 1-15 GENERAL INFORMATION — FRAME (Cont'd) 1 , THREAD DTA. 4‘ TOROUE ITEM ‘ D TV um“) ‘ N111 11‘9"“. “1"!) REMARKS HYDRAULIC BRAKE: 1 r . anr hrake CflleEf mounting bolt 4 ‘ 8 30 (3.1, 22) NOTE 9 From brake pipe mounting bolt 2 10 I7 (1.7, 12} From brake caliper assembly torx hall '95 v '97: B 3 32 (3.3, 241 NOTE 2 Afler ‘97: E E 231231 17) From m1 cup mounting nur ‘I 6 sum, 43) NOTE 9 Brake 1cvcr oivol Doll 1 6 1 (0,1, 0.7) Brake lever pivol Hut 1 6 G [0 S, 4.3) Brake hose oil bolt 5 ‘10 34 (3.5, 25) Pad pm '96—‘97: 3 10 1511.8,131 After '97: 5 10 18 (1.9, 13) Pad pin plug '95- '9/: 3 10 2.5 (0.25 La) After '97: 1 1D 2 41024, 1.7) Brake caliper hleeder 3 E 5 (06, 4.31 Rear brake hose guide bolt 1 6 12 1112, 9) Floor master cylinder juim nut 1 8 18118.13) Rear master cylinder has: )olnt screw 1 a 1 50,15,131) Rear brake caliper pm bolt 1 12 27 (2.8. 20] Rear brake ca1ipcr 1:01! '96 r '97: 1 H 23 [2.3. 171 After '97: 1 8 12 (2.2, 16) Rear caliper clamp bolt 1 G 9 (0.9, 35) NOTE 5] LlGHTS/METERSISWTTCHES: Side mud mountlnu bah 1 10 10 (1,0. 71 Side stand luck nut 1 10 29 (3‘0. 22) Sum stand switch muunling bolr 1 6 10 (1.0, 71 NOTE 9 Sula stand bracket bolt 2 10 4414 5, 33) NOTE 9 lgnmnn swnch mounting boll 2 8 7512.5,181 NOTE 2 TOOLS NOTES: 1. Equivalent commercially available in U.S.A.. 2. Not available in U.S.A.. 3‘ Alternative tool. 4. Newly provided mm GENERAL INFORMATION DESCRIPTION Carburetor float level gauge Oil pressure gauge attachment 0" pressure gauge Clutch center holder Flywheel holder Rotor puller Adjustable valve gulde driver Attachment, 37 x 40 mm Attachment, ‘2 x 47 mm Attachment, 52 x 55 mm Attachment, 24 x 26 mrrl Driver E Inner driver. 25 mm Pilot. 17 mm Film, 20 mm Filclt, 35 mm Flint, 23 mm Bearing remover shaft Bearing rernuver head, 20 mm Driver anve spring compressor Valve sou! cutter Seat cutter, 2715 mm (45” lN/EX) Flat cutter, 30 mm (32“ IN) Flat cutter, 27 mm (32” EX) Interim nutter, 30 mm (60" IN/EX) Cutter holder, 4.5 mm Pllot screw wrench Plvot adlllstlng wrench Snap rlng pliers Steering stern socket Hebrlng remover so! , Remover handle — Remover head, 20 mm — Remover weight Ball race remover set 7 Driver attachment, A — Driver attachment, 8 — Driver shaft assembly — Bearing remover, A 7 Hearing remover, B — Asaembly base TOOL NUMBER REMARKS REF. SEC, 07401 — 0010000 5 07406 — 0030000 NOTE 1 4 07506 — 3000000 NOTE 1 4 07724 , 0050002 NOTE 1 9 07725 — 0040000 NOTE 1 10 07733 — 0020001 NOTE 3: ‘ 10 07933 - 3950000 07743 0020000 NOTE 2 B 07746-0010200 9,14 07746—0010300 9,13, 14 07745 - 0010400 14 07746—0010700 14 07746 — 0030100 12 07740 - 0030200 12 07746 - 0040400 14 07746-0040500 13,14 07746 , 0040800 9 07746—0041100 I4 07746 — 0050100 13, 14 [17746 - 0050600 13. 14 07749 0010000 9, 13, 14 07757 - 0010000 8 NOTE 1 E 07780 7 0010200 07780— 0012200 07780 » 0013300 07780 - 0014000 077E1— 0010600 07908 — 42 20201 07908 A 4730001 5 (Except California typel 07908 — 4590003 14 07914— $A50001 NOTEZ: 15 07914 — 3230001 0791673710101 NOTEZI 13 07916- 3710100 07936—3710001 14 07936-3710100 07935 - 3710500 0774170010201 07946 — KM90001 07946 — KM90100 07946 — KM90200 07946 , KM90300 07946 — KM90401 07-946 - KM90500 07945 - KM90600 NOTE 2: 07936 - 3710200 07936 - 371020A (US A. nnlyl l NOTE 2: See page 13-27 1-17 GENERAL INFORMATION REF. SEC. Analog leswr (KOWA) DESCRIPTION TOOL NUMBER REMARKS Steering stam driver 07355 — MBUOOUO 13 DriVEr shafl 07946 , MJ00100 NOTE 2 14 Valve spring compressor anachment 07559 — KM30101 8 Driver shall 07964 — MBOOZOO 17 Pin driver O7GMD - KTBD10D NOTE 2 1‘ Shock absorber compressor 07GME 0010000 1:: Inspemion adamor 07GMJ — MLBD‘loo NOTE 1 17 Oil filler wrench 07HAA — PJ7D100 t Peak voltage adaptor 07HGJ - 0020100 NOTE 2 17 Lock nut wrench 07HMA — MR70200 NOTE 3: 7 O7VMA~ MATO‘IOO (Except USA.) 07VMA — MAT010A (U.S.A.nnly) Needle bearing remover D7HMC- MR70100 NOTE 2 14 anva gmda driver, is mm U7HMD v MLW101 8 Tapper hole protector 07HMG — MH70002 NOTE 2 B Valvé guide raamar, 4.5 mm 07HMH — MLM‘IO‘I NOTE 3: B 07HMH - MLOD10A Drive chain tool set D7HMH — MR10103 NOTE 3: 3 D7HMH — MR101OB (U.SrAr only) Film screw wrench 07KMA‘ MN90100 07KMA — M560101 with 5 D'lPMA - MZ20110 tcallfomla rype) 07KMA— MV5010A (U.SA‘uu|y) Fork seal driver, 45 mm 07KMD - KZSDIOO NOTE 2. 13 07KMD— K13010A Needle bearing remover set O7LMC - KV'JO100 NOTE 4 14 Shock nhsnrhar compressor anaohmen! 07NME MY70100 NOTE 2 14 Compression gauge anachmenl 07RMJ - MY50100 NOTE 1 8 Analog [ester (SANWAi SF — 15D NOTE 1 16, 17, 1E, 15 TH — 5H NDTF1 16,17,18.19 1-1R GENERAL INFORMATION LUBRICATION & SEAL POINTS — ENGINE LOCATION MATERIAL REMARKS Exankcase mating surface Liquid seakam (Three Bond 1207“ or equivalent) 10-15mm 10—15mm A :‘X/ : Igniliun pulse gelleralur cuver bull IIIrEads Coafing width; 65 t 1 mm Imarked ”A"? " Oil pressure switch threads Do not apply 10 ‘he (hrsad head 3 , 4 mm ‘— (D 1 — 0,2 in) Thermo unil threads 1-19 GENERAL INFORMATION — ENGINE (Cont'dl LOCATION MATERIAL REMARKS Cylinder head semircireular cut-out 5~1Drnm r _. ._ 5—10mm .— Sealant Cylinder head bolt lhreads and seating surface. Camshaft lobes/Journals Valve lifter cuter sliding surface Valve stem (valve guide sliding surlace) Connecting rod small and Piston pin sliding sum” Main lnllrnnl bearing surface Connecting rod bearing surface Crankshaft iournals M3/‘4, cs. cs shifter gear (shift inrk grooves) 10 x 44 mm pm outer surface Primary drive gear and sub gear sliding surface APFI Y AREA AF‘F‘I Y AREA Clutch outer needle hearing Molybdenum disullide oil la mixture ul 1/2 engine oil and 1/2 molybdenum disulfide grease) Pislun ling sliding area Main journal 9 mm bolt threads and seating surface (after removing anti rust oil additive) Cylinder head spacial bull latter removing anti-rust oil additive) Oil strainer packing Oil mnler center balt threads and seating surface Oil filter cartridge threads and O-ring Flvwheal bull threads and seating surface Starter one-way clutch sliding surlace Cnnneming rod nut threads Clutch center lock nut threads Clutch disc surface 4 Each gearteeth and rotating surface Each bearing Each Orring Other rotating area and sliding surtam Crankshaft hole cap “treads Each oil seal lips Engine oil Mu lgrpurpose grease 1-20 GENERAL INFORMATION ENGINE (Com'd) LOCATION MATERIAL REMARKS Cylinder head sealing oolt threads Locking agent Cylinder hood cover breather joint threads Lower crankcase sealinq bolt threads Starter true-way clutch outer boll threads , Coating width' 55 s 1 mm ’ Oil pump driven sprocket hnlt threads ‘ Shift drum set plate’bolt threads Shift drum center bolt threads Mainshaft bearing set plate bull threads Cam sprocket bolt threads Cylinder head cover breather plate oolt threads Alr suction valve tightening bolt threads — FRAME LOCATION MATERIAL REMARKS Steering head bearing sliding surlacc Mum-purpose grease Steering head dust seal lips Swingarru pivot bearing and dust seal lips Wheel dust seal lips Rear wheel side coller inner surface Shock absorber needle bearing and dust seal lips Shock link needle beating and dust seal lips Footpeg sliding area Passenger roorpeg sliding area Flcar brake pedal olvol sliding area t Throttle pipe sliding area Clutch lever pivot Ftllrnn seat catch hook Pillion scat pivot Gearshift pedal link pivot Gearshift pedal link tie-rod ball joints Side stand pivnr sunnne Throttle pipe cable and area Molyhdnnum rIlsIllllde grease Shock absorber spring adjuster cam surface Molybdenum paste Slesring stem top threads ‘ Engine otl Driven sprocket nut threads and seating sur‘lace Throttle cable casing inncr Choke cable casing inner Clutch cable casing inner Hrake pipe ,runt threads Brake master cylinder nuns DUI I brake lluld Brake caliper piston seals Brake caliper dust seals Silicone grease Front brake lover pivot and piston tipa Rear master cylinder bout inside and push rod tips Blake caliper slide pin surface Front brake caliper assembly torx bolt threads Locking agent Fork socket hnIi threads Handle grip rubber inside llnnda Band A or Honda Hand Grip Cement (U.S,A. only) Fork cap Orring ProrHanda Suspension Fork oil seal lips Fluid 53-8 ' 1-21 GENERAL INFORMATION CABLE 81 HARNESS ROUTING .55_ 797: (‘I COMBINATION METER 9P (5) COMBINATION METER ‘P (BLACK) CONNECTOR (BLACK) CONNECTOR I'll POSITION LIGHT CONNECTOR ( (8) HEADLIGHT SOCKETS (IO) RIGHT HANDLEBAR SWITCH (16) IUHN SIGNAL HELAY 6P IREDI CONNECTOR (17) HEADLIGHT RELAYS (9) TURN SIGNAL 6P , (11) RIGHT HANDLEBAR SWITCH //) (WHITE) CONNECTOR 2P (RED) CONNECTOR ) V T ”31 ACKI CONNECTOR \‘ ‘n 113) IGNITION SWITCH 6P ABLACKI CONNECTOR / II I g IIZ)TURNSIGNAL6P \\ I \\ , \ I /¢sv I15) IUSE BOX (14) RIGHT TURN SIGNAL CONNECTORS I18) LEFT TURN SIGNAL CONNI (:IUHS 1-77 GENERAL INFORMATION Ahev'97: 13)TURN SIGNAL RELAv (2) HEADLIGHT (4) HEADLIGHT LOW RELAY ._. HIGH RELAY P (5) CHOKE CABLE III TIIRo I TLE CABLES /‘ " ‘ / /:\ (6) CLUTCH CABLE ’/’ / \ L x / // o x (m FRONT POSITION :1 \ LIGHT CONNECTOR _ ‘C \\ ,/ C //\ £35K IV: /// fiI A Q \\ / // , )7 , \ Dz; , , x U o \ \\ \ / \ H1) MAIN WIRE HARNEss o o \\ \D \ (7) COMBINATION METER ( 20F CONNECTOR A .. \\ \ I U ‘ “0) NGHT TURN (9) HEADLIGHT SOCKtTS “II—iguflézmm (2) RIGHT HANDLEBAR SWITCH 6P (RED) CONNECTOR III LEFT HANOLERAR SWITCH ‘ ‘ 6P INATURALI CONNECTOR A I 43) RIGHT HANDLEBAR SWITCH 2? (RL D) CONNECTOR (6| IGNITION SWIYCH 6P (BLACKI CONNECTOR- \ ‘\\(4) LEFT HANOLEBAR SWITCH 5 5? (BLACK) CONNECTOR (5) FUSE BOX 1 -23 GENERAL INFORMATION '95 - '57: I3) IGNITION SWITCH WIRF (2) RIGHT HANDLEEAR SWITCH WIRE (4) LEFT HANDLEBAR SWITCH WIRE 1 -24 GENERAL INFORMATION After '97: (2) CLUTCN SWITCH CONNECTORS (1)1Im0TTtr mm rs , 7 (3) LEFT HANDLEBAR SWITCH me fly (4) CLUTCH CABLE 15) CHOKE CABLE / i - , v , , / ., / / F/ /// Iv u. u» v' -‘ 44,7) /\ 1101RIGHTHANDLEBAR k ,’ \ // SWITCH WIRE ( ’ : - \ no \ ":5 , v - x . \g \ , ‘ ‘ . ' m) r nnm BHAKI: Host .5, \\ i0) HrAUUGHT \ SOCKETS \ (3) FUSE BOX (7» MAIN WIRE HARNESS 1-25 GENERAL INFORMATION '95 - '97: (Z) THROWLE CABLES 11! LEFT HANDLEBAR SWITCH WIRE It) CLUTCH CABLE (5) HEADLIGHT RELAVS 1‘ 59w "llkgéfi 4 (€ LF?K , =3\»“\ 1. Jim / I . If 4E! 9/ - ,4/ \\ \ ’ 4/,\‘ 1-26 GENERAL INFORMATION Aha! '91 (2) FRONT COWL 51 AV (1) IGNITION SWITCH (3) LEFT HANDLEBAR WIRE SWITCH WIHE l4] CLUTCH CABLE (10‘ RIGHT HANDLEBAR SWITCH WIHE (9) FRONT POSITION LIGHT WIRE (6T HORN WIRE (3) HEADLIGHT CONNECTORS I'II LEFT TURN SIGNAL CONNECTORS 1-27 GENERAL INFORMATION '95 ‘ '5": J) (2) FAN MOTOR SWITCH CONNECTOR (”RADIATOR ~U " ' " ‘1 , \ K ,13. BYPASS HOSE \ I (4) WATER PUMP TOVCYLINDER / HEAD HOSE (8) OIL COOLER WA [EH TUBES (7) LOWER RADIATOR HOSE ‘~—:"\_// ‘x (6) WATER PUMP»T0-WATER JOlNT HOSE After ’97: [as 497: REAR VIEW Q Q m WATFR nose ,« ’ x ,v (2)THERMOSTAT , CASE V} \ \ V (3) WATER BVPASS \ HOSE l1) WAILH PUMP TO-CYLINDER HEAD ‘2’ “”551 GENERAL INFORMATION '96 7 '97: (3) AIR BLEED TUBE (4! SIPHON TUBE \7, (8t OVERFLOW TUBE (7) CLUTCH CABLE (6) UPPER RADIATOR HOSE Aher '57: (3) AIR BLEED TUBE (4)51PHON TUBE 1-29 GENERAL INFORMATION '96 - '97: [1) THROTTLE SENSOR WIRE ’ (2) CHOKL CABLE " 6 1‘ ’ (3) AIR BLEED TUBE g (4) MAIN WIRE HARNESS (8} ALTERNATOR WIRE “I 1 ‘/ (\y‘ (7) SIDE STAND SWITCH WIRE *5 (6) SPEED SENSOR was After '97: P” \, <2) énounn WIRE M) SIDE STAND ’ SWITCH WIRE (3| ALTERNATOR WIRE 1 1-30 GENERAL INFORMATION IN THROTTLE CABLES (SI CHOKE CABLE /' (6) CLUTCH CABLE (7) IGNITION PULSE GENERATOR WIRE [BI OIL PRESSURE SWITCH WIRE ”0’ OVERFLOW mm (9) FUEL TANK DRAIN TUBE 1-31 GENERAL INFORMATION (1) CRANKCASE BREATHER TUBE (Z) CARBURETOR AIR VENT TUBE 1 -319 GENERAL INFORMATION ’96 — '97: 11) CHOKE CABLE (3) CLUTCH CABLE [4) STARTI‘H MOTOR CABLE (E) BATTERY NEGATIVE CABLE ’I (6) ALTFRNATUH WIRE (5] SIDE SIAND SWITCH WIRE GENERAL INFORMATION III IGNITION CONTROL MODULE I7) REAR BRAKE HOSE \—-,/ 1 .34 GENERAL INFORMATION SECONDARV AIFI SUPPLY SYSTEM ROUTING (CALIFORNIA TVPE ONLVI I3) EVAPORATIVE EMISSION IEVAP) PURGE CONTROL VALV [2| EVAPORATIVE EMISSION (EVAP) CANISTER III EVAPORATIVE EMISSION (EVAF) CARBURETOR AIn VENT CONTROL VALVE / I '96 - '97: ’ f r IF VA VF I5) AIR CLEANER HOUSING (own ..I CK L I4) PAIR curmx vAI VI’: Ahar '97: IaI CYLINDER HEAD (7) CARBURETOR I8) FUEL TANK I3) EVAP PURGE CONTROL VALVE (1) EVAP CAV CONTROL VALVE - (2) EVA? CANISTER 1-35 GENERAL INFORMATION EMISSION CONTROL SYSTEMS (U.S.A. ONLY) The US. Environmental Protecticn Agency and Caliiornia Air Resources Board lCARB) require manufacturers to certify that their motorcycles comply with applicable exhausl emissions standards during their useful iile, when operated and maintained according to the instructions provided, and that motorcycles built after January 14 1983 comply with applicable noise emission standards for une year or 6,0UU km (3,730 miles) after the time of sale tn the ultimate purchaser, when operated and maintained arcnrdrng to the instructions provided. Compliance With the terms of the Distributui‘s Limited Warranty tnr Hnnda Motorcycle Emission Control Systems is necessary in order to keep the emissions system watmn'v In effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emissions rs very rmpor tant because. under certain conditions, they react to form photochemical snrug when subjected to sunlight. Carbon monoxide does not rum in the same way. but it is toxic. Honda Motor ($0.. Ltd. utilizes lean calbuletor settings as well as other systems, to reduce carbon monoxide and hydro carbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions inln the atmosphere. Blow-by gas is returned tn the combustion chamborthrough the air cleaner and carburetor (HAIR CLEANER HOUSING ” l2) CAREURETDR ’ <3 : (a) FRESH AIR 1-36 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM [CALIFORNIA TYPE ONLY] This nludel ccmpiies with California Air Resources Board evaporatlva emisston requirements. Fuel vapor lrorn tnc iucl tank and carburetors is routed into the evaporative ennssiun iEVAP) canister where it is absorbed and stored while the engine is siupped. When the engine is running and the evaporative emission iEVAP/ purge cunllul valve is open, iuel vapor in the EVAP canister is drawn mm the engine through the carburetor. Al the same time, the I’VAP carburetor Mr vent (CAVI control valve is open and air is drawn into the carburetor through the valve. HIEVAPOHATIVE EMISSION PURSE CONTROL VALVE IEVAP PURGE CONTROL VALVE) i I (ZIFUELTANK <3 (ZIFRESH AIR I <2: (SIFRESH AIR « [fill‘ut L VAPOR (4) EVAPORATIVE EMISSION fi (EVAPI CANISTER '96 — er '1 Ana, 9,: .2 (7IFVAPOFIATIVE EMISSION CAREUHFI’OR AIR VENT CONTROL VALVE (EVAP CAV CONTROL VALVE) NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: federal law prohibits the following acts or the causing thereof: (1) The removal 0! rendering inoperative by any person, uther than [or purposes of maintenance, repair or replacement, of any device or element at design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; lZI the use of the vehicle after such device or element of design has been removed or rendered inoperative by anv person. AMONG THOSE ACTS F‘HTSUMFD TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal at, or puncturing of the muffler, baffles. header pipes or any other component which conducts exhaust gases. _ 2. Remuval oi, oi puncturing or any part ofthe intake svsterlnv 3. Lack or proper maintenance, . 4r Replacing any moving parts of the Vehicle, or parts of the exhaust or intake system with parts ether than those specified by the manuiactureri 1—37 GENERAL INFORMATION EXHAUSY EMISSION CONTROL SVSTEM (PULSE SECONDARV AIR INJECTION SVST'EMI The exhaust emission control system incorporates a lean carburetor setting and no adjustment should be made except idle soeed by using the thronle stop screw. ICAUFORNIA DNLV) The exhaust emission control system congrats of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of Iresli air promotes burning ol the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide arid water vapnr This model has the pulse secondary air InIEdIDn tPAIRl control valve: it consists of check valves built into the pulse sec ondary air injection iPAIR) control valve. A pulse secondary air Injection (PAIR) check valve prevents reverse airflow through the system. The pulse secondarv air injection (PAIR) control valve reacts to high intake iiiariiluld vacuum and will cut o’rt the supply oi lresh air during engine deceleration, thereby preventing aherburn in the exhaust system. No adjustment to the pulse secondary air lnlcction system should be made, although periodic inspection at the compo- nent: is recommended (1) INTAKE PORT 12) PULSE SECONDARV AIR INJECTION [PAIR] CONTROL VALVE IMPULSE SECONDARY AIR INJECTION IFAIFI) CHECK VALVES I6) EXHAUST PORT 1-38 EMISSION CONTROL INFORMATION LABELS (U.S.A. ONLY) All Emission Cunuol Inlulmaliun Label is located Oil the side wall of the storage campanmem as shown The passenger seat must he opened to read It. I! plovides base xunmup specifications. VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL Aher making a high altitude carburetor adjustment, anach an update label on the side wall of the storage companment as shown. lrlstvuclions for obtaining the update label are given in fiervlce I filter N0 132‘ When readlusiing ma carburetors back (0 me low almuda speciluLailuus, be sum to remove this update label. VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TVPE ONLY) The Vacuum Hose Routing Diagram Label is on the air cleaner housing cover as shown. The IuHI lailk must be removed to read it Refer to page 2-2 for lueltanx removal GENERAL INFORMATION l1 lEMlSSlON CONTRO’L INFORMATION LABEL HIVACUUM HOSE ROUTING LABEL (”UPDATE LABEL V “RDNT a: vrmm F ACUUM HDSF RDUT I NE D I AGRAH INC I'M‘ILY xxxx Dnunive FAULV- Xxyx LIFERN]A‘1‘EHIC.E FRAME/BODY PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS (5) PILLION SEAT (3) FUEL TANK (4) SEAT (Z) UPPER COWL / // ,// (6) REAR FENDER (8) LOWER COWL {9) MIDDLE COWL 2-0 z. rflAIVIEIDUUt rHlIELDIEAnHuoI are I cm UPPER COWL 2'7 BODY PANEL LOCATIONS 2-0 SERVICE INFORMATION 2-1 FRONT FENDER 2-13 TROUBLESHOOTING 2»1 REAR FENDER 2-14 SEAT/FUEL TANK 2-2 SEAT RAIL 2-15 PILLION SEAT/SIDE COVER 2-3 MUFFLER/EXHAUST PIPE 2—16 ‘ MIDDLE/LOWER COWL Z-G SERVICE INFORMATION GENERAL - Gasolinl Lt IItIt-mt’ly/h "bl, and ir explmivt under certain candimm. KEEP our or REACH or CHILDREN. - swam hum may mutt fifth: exhaust system is not allowed in mi More compumnu m rkmmul ur "wired, Work In a well ventilated area, Smoking or allowlng flames nr sparks in the work area or where gasoline is stored can cause a lire or explosion - TI‘IIS SecIlnn covers removal and installation of the body panels, fuel tank and exhaust systam - Always replacr: the exhaust pipe gaskets after removing the exhaust plpe Irom the engine, When installing the exhaust system, loosely install all m‘ the exhaust pipe fasteners. Always tighten the exhaust clamps first] then tighten the mntlntlng fasteners, If you tighten the mountlng lastaners first, the exhaust pipe may not seat properlyr Always inspect the exhaust system for leaks after installation TORQUE VALUES Upper cowl stay mounting bolt Front fender mounting bolt Exhaust pipe joint nut Muffler mounting bolt/nut Step holder mounting bolt 26 N-m 12.7 kgI-m. 20 lbf-ft) 5 N~m (0.5 kgI-m, 3 6 lh‘HYl 12 N»m (1.2 kgf-m.9|b1‘ftl 25 N-m (2.6 kgf-m. 19 lbl-ft) 26 N-m (2.7 kgI-m, 20 lbf-ft) Footpeg mounting bolt 44 N-m (4.5 kgl-m, .13 Ithftl ALOC bolt Bank sensur 10 N»m11.0 kgf~m, 7 "JV-ft) Side stand bracket bolt 44 N-m14.5 kgf~m, 33 lbI-It) ALOC bolt TROUBLESHOOTING Excessive exhaust nolse Broken exhaust system - Exhaust gas leak Poor performance Deformed exhaust svslerrt - Exhaust gas leak Clogged muffler FRAME/BODV PANELS/EXHAUST SVSTEM SEAT/FUEL TANK REMOVAL Remove the two scar maumlng bolts behlnd me seat. Slide the seat back anc Ilrell u". - Gamhm lS txlmmcly flammablc and .s :xplnw't undtr u‘rmm ((vndil'ivns. KEEP 017‘ OF REACH OF CHILDREN. NOTE ‘ Belure disLurllIeLling Lhe lual lube, mm the fuel valve lever OFF Turn the fuel valvc OFF Remove the screw and fuel valve lever. Remove the luel tank lea: muwlliug bull, washer and Lolldr, Hen-(we MP. 'llal 'an frnnl mnlm'ng bolts and washers Dlsconnect me me tune and varnlum mhe Pom the fuel valve Disconnect the braalher tube anc overflow lube from the final tank the" remove the fuel tank, (ll FUFI TUBE (ZlvACUUM—TIUBE 7 l3l BREATHERTUBE FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION (ll Furl 1ANK l FUEL VALVE LEVER l7l VACUUM TUBE (bl FUEL TUBE l6? OVERFLOW TUBE II|>lallafiOD is in the reverse order of removal N OTE - Make sure me seat semng collars are m place After fuel tank Installation, (urn the fuel valve ON and make sure more is no fuel leaks. Align the seat hook with the Frame bracket and install the we! Install and righmn the Goal mounting bolts, PILLION SEAT/SIDE COVER REMOVAL Onen (he pllllon seat using me ignitian keyl FRAME/BODV PANELS/EXHAUST SVSTEM Remove ms rwr 'nmm’lng bo‘ts, nuts and pwl‘ion scat 355cm my Rpmnve ma Mn |mm chps. Remove the folluwmu: —$Crew: — Specm‘ bah — 5mg cover semng MK 5 [mg coHar — Setlng spaLu! Sennmm and remove the Sicc cover, 17x WI | \()N SiAV 1 ‘ , ",4 I1 ‘ SPEClAL BOLT \ (3113‘): COVER FRAME/BODY PANELS/EXHAUST SYSTEM Remove i'le screws and rear cowl, (Zl REAR COWL Hemove the two balls and remove the tall/brake Iighl asscm bly from xhe year fender. Disconnect the (ail/bvake light 3? (Natural) connector and rpmnvs the tall/brake llghx assembly. INSTALLATION {2r PILLlON SEAT lnslallarnn ls m mp, rnverse omer of removal ('ll RKGHT SIDE Cot/ER «31197 SIDE COVER FRAME/BODY PANELS/EXHAUST SYSTEM NOTF l1} ALIGN At lnstallal‘lon, align (he hooks between Yhe Side cnver and xea‘ cowl MIDDLE/LOWER COWL If REMOVAL Rcmuvc me mm clip. Tum lhe WM lasteners counterclockwise and relsaw the fat luv MlDDLE C «(3/ mm»! M , f‘ » Remove mu middle cowl CM ’l. Remove the SIX SDEClal bolts and lower cowl. \l OTE Duri'lg removal and msmllation, supper! the lower cowl securelyl (2) LOWER COWTASSEMBLV 2-6 Remove [he screw: and special boll, lIIefl >epalale lhe lower cnwl INSTALLATION Insxallaxion is in the reverse order of removal. (1) RIGHT MIDDLE COWL f‘\ (a) Lawn! cow: ” UPPER COWL REARVIEW MIRROR REMOVAL Remove the rearview mirror pivot book ['96 - '97)V Remove me following: — SH bolts/nuts ('96 - ‘97:) — Bolts/nuts (After '97:) — Raarview mirror 7 error plan: ('96 '97» — Rubber cushiun1'96 - ‘97:) FRAME/BODV PANELS/EXHAUST SYSTEM (1) RIGHT LOWER COWL I3) INNER LOWER COWL (2] LEFT LOWER COWL 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM UPPER COWL REMOVAL Remove the rlghl and 91‘ mrddlfi nnwl: (page 2-El Renew: the mm cl'p‘ SDeClSI bars, collar and richl upper cowl hna' panel. ’HTRlM CUP Himnve the mm clip and 'clcace [he con'leclol holder {rum (2) CONNECTOR HOLDER the upper cowl Drscmmeu llw Ugh! Iuln signal (Onnarmrz Remuve [he l-rm clip, spew: ham, rnmr am le‘t uppe' :ml mar 1am Remove \he mm cllp and release the relay holder bracket 1'06 7 '57» from me upper cowl, Disconnecl my left turn signal connectors, l’RIM CLIP,= 2—8 stcsnnect the pusmon Ix gm connecmr Rwease lhe remaining (ass and remove the wead‘ighl sockr as Remove the setting bait and remove the uppel Cuw‘ fur- warn NOTE - Hail-1r yo page 19-91:». hennhgm mm remnval,’|ns!allm|nn Remove (hc nut. sorting pmm and turn signal unit. Remove the turn CHDS and \nner rerdlB CCWI. FRAME/BODV PANELS/EXHAUST SYSTEM mfimfion Hair CONNECTOR .. {F I . _ 1 ‘ . (D‘HEADLEHT SOCKETS HISHHNUBULI 7 17‘; TURN SIGVAK UNH (1 r I\ UT/SETTING PLATE (2) INNER MIDDLE COWL \ FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN REPLACEMENT Remove me screws, plaslic washevs and rubber washars. Remove the windscreen and setting mus, .96 _ .57: Aftev '97: q (1IWINDSCREEN % (‘II WINDSCREEN (2] SETTING (2) SI' TIING NUT I3I RUBBER WASHER I4I PLASTIC WASHER " <5) SCREW (5) scnsw 14) PLASTIC WASHER INSTALLATION '95 - 497: (2) REARVlEW MIRROR (\ via \ ’ r (‘IIUPFER COWL {’3’ [AK [2) REAHVILW MIRROR (3) INNER PANEL I5) INNER MIDDLE COWL (3I BOLTS MI TURN SIGNAL UNIT FRAME/BODV PANELS/EXHAUST SYSTEM UPPER COWL INSTALLATION iZLINNER MIDDLE COWL moron rhc lnner middle cowl and secure ll with the rrim clipsr / I‘ll TRIM \ CLIPS lnsrall the rum :igual unil, set plale and ”UL Route the tun— mgnnl wxnn. mm m, Inna! Huddle cowl as shown, (II I\UT l2] SEWING PLATE lnsrall IhC upper cowl, aligning the bosses on the headllght Lnil with ma rubbar qrommats on ma uppar cowl stay. NOTI’ - Roure the wire llamas: imu me upper cowl properly (page 1721) - Be careful nor to plnch the position light wrre between me uppercowl and cowl slay. Install and llghlen the selllng bull. FRAME/BODY PANELS/EXHAUST SYSTEM Cum-“.1 1h»: .u‘n Slgna‘ currwflflrfi nstal t-e rem,’ hmdcr :Hgning KS boas mm the game in the mo! mxddle com as Shawn ’96 ~ ’97“ Secura (he homer mm the um. th \nsml‘ we rplfiv hnlcer usmg the same procedure. nstaH 'mo npnFr mw mne' canal and secure i‘. wizn (he him Mm Hits“ and tighuirv the special bulb. NOTE ~ Before instal‘ation, msta’l [he :uUm mm; the inner pane" ‘ (1)'T_R1Mf.1w REARVIEW MIRROR INSTALLATION “as _ '97: (4. RUBBER CUSHION f2) REARVIEW whoa: Set [he mmm Lushwon ('96 #9714 rmrrnr slam < 96 »‘ rearv m rmrmr \nszaH the bolls and man, then hghten me nuts whi‘e hum- ng me bans. \nstafil [he rubbs' Boat 52cher mm 1974 '1) ma 2-12 FRONT FENDER REMOVAL Remove the special bolts. brake hose clamps and fork cov- ers. Remove the Iron? fender forward, INSTALLATION 5 N-Iu 10.5 kgf-m, _ 3.6 be'fl) U) FORK COVER (3¥ FRONT FENDER Inmallmion is in me reverse order oi removal. N DTE Install the from lender stays and brackets as shown. - Inslall file long bolls into the [rum ‘uwer side. FRAME/BODY PANELS/EXHAUST SVSTEM n3) FORK cngR \ :\ VlélFRONT FENDER TDHqu: From fender mounting bolt: 5 MM (0.5 kgl-m. 3.6 lbl-hl FRAME/BODY PANELS/EXHAUST SYSTEM REAR FENDER m mo REMOVAL Remove the side cover wage 2731‘ Remove me nauw (page 16>?» WamnvP me rear shock absorber reserve lank band, Remove the reserve lank born the rear fender groove Disconnec! Inc following: ~ Slde mane switch connacmr r Allerlmlul cumvuuul Hamuve the ICM (Ignmon control modulc'v. Remove the wire harness clamp screw. Rellluvc m: bolas, nuls and regularon‘rectmm Drsrnnnnrv yhs vpgulfitnr,‘recnfler connemon Remove the slane' relay swimh anu rvlease [he wins lldllIESS (rum llle new (rude: Remove the bolt and rear brake rsccwuir, Ulsrnnnem me mm slgnal and IlCeHSe :Igm connecto's, Hemoveme 'carlcnucr mourning bolts and 'earfender. l1‘lTURN SIGNAL CONNECTORS 2-14 FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION 11) BRAKE RESERVOlR (5) REAR FENDER lnsmll the rear lender into the seal rail, while aligning [he from groove of ms rear fender with [he aubrframe NOTE » While installing the rear lender, ruul: the wire harne5 not smooth, Itmrtrnts tre throttle cab.es Mcasuvethe free plav at the tltrUtIIe gnu flange FREE PLAY 7 -6 mm [1/12- 1/4 In) TWattle grip free way can be adjusted at either and of the thrume cable. Mmor adjustments are made wtth the upper adtustcr. Hemove me dust cover from the adjuster Adjust We ‘ras pIzV bv ‘oosening Ihe luck Hut and turning We Adjus‘tt-H. Maior adtustmems are made with (he Iuwev ddju>Ie t ‘ 2» ADJUSTER [(1. mix NUT \ t « ‘ \7/ , He‘mve Ihe atr cleanev housmg mags 5 4), I V ' Adjust the tree pay qu>emng um lock nut and turn the adjtsm After adyustment, tighten the lock nut sncu'cly Rech (he Uttulue ULEIaUUH Reolare an, damagon parts, If «enessn'y 3-4 MAINTENANCE CARBURETOR CHOKE The chnxp eyfitam uses 3 Mel ennchrncnt circuit controlled av a 5: King enrichment (SE! valve. me SE valve opens the emiulrnent circuit via a cable when we Lhuke k'iob on the mp undgs .s pulled up C12“ for smoom choke knob operation and lubricate the choke cable it required. inspect rhe cable for cracks which could allow moisture to enter. Replace The cable if necessary. AIR CLEANER Remove the fuel tam (page 2~2l. FEHIOVE‘ the nine 5"ew< and Mr Cleaner housing cover. Remove and discard the air cleaner element in accordance with the maintenance schedule. Aiau lsulaLe the air cleaner element any time rt is excesr swely dr‘ly nrdamngp install the removed Dans I" the reverse Urdu! ul tumoval SPARK PLUG Remove the middle cowl ipage LG). sttnnnem the. spark plug caps. VOTE - Clea— around the spark plug cases with compressed air actors removmg, ana as sure that no debris isailowed :0 enter the Cumbusllun LhaInLIez. MAINTENANCE Removn ths Spark plug usmg a spark plug wrench. lnspect or replace as dcscrlbcd in [he malmenance acnedr ule. INSPECTION Check the followmg and replace it necessary (recommended spam plug: page 3-llr . Insulator lor damage - Elecll odes Io! wear - Burning condition, coloralxon: dark m llgm brown Indicates good condition. — axcsis‘lve lightness illdiuales mallunctioning ignition system or lean mixture —- wet or black sooty deposn Indicates ovcr rich mixxuve. REUSING A SPARK PLUG Clean the spark plug eleclrodes with a wire brush or spccxal slug cleaner. Clluuk Ulé gap between the center and sudP plnmndes mm a wirP-Iypa melhr gauge. ll necessary, adjust the gap by bendlng the side slamroda carelullyr SPARK PLUG GAP: 0.80 - 0.90 mm (0331 ~ 0,035 in] CAUTION - Tn p-‘r‘wnl :lmngr m m: rynmm head. lxandrllglmn l‘xz‘ .vmrk pine before unng a want/I 10113.7th [0 rim rparl‘fim‘ 1117mm. Reinslall lhe spark plugs in the cylinder head and hand (lgh'en, when unique m speed-canon. TORQUE: 12 Min ".2 k91~m,9|m-m REPLACING A SPARK PLUG Sex Ins plug gap to speclllcalion with a wire-type feeler gauge lsaa above) CAUTION - Dr. mm mm nplvrrn rllr rpmkpmg Install and hand ligmsn me new spark plug, lhen liglllell it about 1/2 of a (urn after the sealing washer nnnfacls the mat oflhe plug hole. ' 13' SPAR‘K‘PLUG WRENCH “(ll “ (2) SIDE ELECTRODE (3) INSULATOR 0.80 — 0 90 mm [0.031 0.035 in) 3-6 VALVE CLEARANCE INSPECTION NOTE - Inspect and adjust the valve clearance whi‘e the engme I: cold IILIeluw 35‘C/95'"F), Remove ma mlddln/mwpr cnwl [page 2-6). Rc-navc [hD cylindcr head cover {page 8-4:, Rel'luve [he cam chain tensionar lifter sealing bolt and wamer Tum the cam chain (euswurler liner shafi fully and sacure it us no the stopper ‘ool (See page 3-6) HPmm/P. Ihfi nrankfihnfi hnle can and ()7fth. Tum mo crankshaft clockwise, align the “1’" mark on the uqnmun pulse generator rulur wnh the index mark on Ihe \gnitian pmse generator rotor cover. {3) CAM CHNN TENSIONER LIFTER MAINTENANCE P a- ( 1) STOPPER TOOL MAINTENANCE The ti—Hng man's (”INC and "EX"? on the Cal" spluckets mum De flush with [he cyilnaer head suv'aue and facmg mn- waru .1»: shown '1! the timing marks or the cam sprocke: lacing ir‘ward, NH ”‘19 rranxswah ciocxwvse one fuil mm 13601 allu neaiign the :mmg marks wizh :"e Lyiwdei mead sun—hrs pELll0ll window, Male Sure thP aw nn ml leaks. CARBURETUR SYNCHRONIZATIDN NO - Synchmmm the carhwetors'wxlh the englne M normal Dpemllng lcmocvalurc, the (ransmission in neulral and lhe molorcvcle summoned securely on a level surlace. Remove the fuel tank and mlddle anl (56:8!an 2}. Remove the vacuum uluqs from \he engine intake pulls. MAINTENANCE TER‘ ~ Em \‘\P~‘«L‘\1"n ‘ MAINTENANCE Screw the adapters in the intake ports, Install [he 3—an juinl lo lhe fuel valve vacuum tube. Connect the fuel tube and vacuum mm m the fuel hank, Connect the vacuum gauge tubes to the adapters and 3-way loint. TOOt Vacuum gauge set 01LMJ ‘ 001000A (U‘SA. unlv) on M9373 - 021- XXXXX lU.S.A. onlvl Start the engine and adiusi the idle speed by turning (he throttle smp screw, IDLE SPEED: Except California type: 1,100 1100 rpm Calilornia type: 1,200 : 100 rpm Check that each carburemr intake vacuum pressure is wixhin 20 mm (0 S in) H9 of the base carburetor NOTE - The No 3 carburemr cannot be adjusted,- ll Is lhn hnsa nnr» hummr. - The No. 3 cylinder intake vacuum pressure is the base vacuum pressure. Synchronize to soecificatmn by (u'ning the adjllstlng screw With the phllllps screwdnvar as snown Rechack file Idle speed and each cylinder intake vacuum pressure st- it is wlthln 7n mm (DJ! lm Hg of the base carbur remr reading after snappmg the xhromc grip 3 7 4 times, 3—14 MAINTENANCE Remove the vacuum gauge Kubes. lnstal' ‘he vacuum mugs into the intake ports, and tighten mam securely ENGINE IDLE SPEED _ - If the engin: must be runmng to do some work. malt sure the arm Lt WEI! I'L‘nn'lalut Nl'l'l'Y run the each: in an Enclosed arm. The exhauxt cunmim pmlmnuux carbon munuxid: Km 1qu may uune hm uf rmurinumrxx and "my [pad m Jpn/h. NOTE - Inspect and adjust the Ime speed after a” othev engine maintenance llems have been uerformed and are within specifications‘ - The enginu Illusl be warm [0! mum: an: speed inspec- n and adwstmem Warm up the engine for aboux ten minutes. Tum :he throme stop screw as required to nb‘ain the speci- men xd‘e speed. IDLE SPEED: Except Galflamia type, 1,100 i 100 rpm California type: 1,200 + 100 rpm RADIATOR COOLANT m RESERVE TANK (2)35ka u vn, LIN[ Check fine coolant vaFI of H19 repe.=a| loo? as shown TOOL: Drlve chain mol set 07HMH - MR10103 0v U7HMH — MR101OB (us A anly) NOTE ‘ When usmg the specue! tool, Ioliom the mmmamuer's nonunion, MAINTENANCE m WEAR. ,\ / 11} DRIVE CHAIN TOOL SET 3-19 MAINTENANCE Lucaie lhe crlmped pm ends oi the mader link from the nut- Side of the chem, and remove the link wnh the drive chain [OOI sex TOOL: Drive chain lnol 3e! 07HMH — MR10103 or 07HMH - MR101OB lu.s.A. onlyi Hamnva lhe drive chain. Remove llle excess dlive chain links llom the new drive chain wlth the (1er9 nhmn mol Sal NOTE > Include the runner link when ynll thin“ the drlve chnln links, STANDARD UNKS: 120 links REPLACEMENT CHAIN: DID: DIDSZSHV GCEB - 12023 RK: RKGBEZfiROZI — 120LJF CAUTION - A’m'rr mm llk/ all [Im . l-imm. my" link. mum link ple' and 0m New Install lhe new drive chain into the swingarm as shown. Assemble the new master link, Ovrlngs and plate CAUTION - Imurl’ .«lm "mm 1;": lulu. mg unit/t "fin. Limo mum. unu'llulu” my plult u m. My mum. nllrm marljmug [in mm Assemble and set the drive chain lool sen TOOL: Drive chain wol set 07HMH A MR10103 or 01HMH —- MR101OB [USA only) Make sure rhauhe master link pins are installed Draucrly, Measure lile lllaslel I'lllk pill length prujeuled from the plate. STANDARD LENGTH: DID: 1.15 —1.55 mm (0045 — 04061 In) RK: 1.20 -1.40 mm (0,047 - 0.055 in) Sinks the master link pins. l2; MASTER LINK lli DRIVE CHAIN TOOL SET (3) MASTER LINK ill LINK 121103 LINK —_-—>l LINK l2) SWINGARM (1) MASTER lZILIvRING lal PLATE \ 3-70 Make sure that the pins are scaked qupevlv LIv IlledSullng Ille dlqlllele‘ ul the staked area usmg a Sllde Callpef DIAMETER OF THE STAKED AREA: DID: 5,5 , 58 mm [022 — 023 in) RX: 519 — 5.941"le (0.216 - 0.233 in) After staking, cneck tne staked area of the master link lor cracks. ll we I; a'w cracking. Ieplace the masmr link, D-rlngw mm mm CAUTION ~ 4 mm I mm: m In.” ‘Iva‘Vlf mam-r ’mknmtrltmhc um' BRAKE FLUID CAUTION - Dz! no; I'm .l',l"}'rrm NM gm 1 mlw: > I) n, alluwiiu‘lgn maltrtalm ler'lhc s; m w/Irn fillmg 1hr mmmr III/7M LII mu m WI LIMIIIIIJ.» Mm. . mm mm: mm Lm puma, pluAliL or rubbn purl: Plum u rug u n Ilm pm; Mwnm Ilh' mm; H rrn'lrrd l\0‘lE ~ When the "III“ level vs lnw. chuck the brake: pads for wear (see next page), A low fluid level may be due to wear of the brake pads. If the bake Dads are worn, the caliper piston is pushed uuL and Ihls accounts for a low reservoir level, If the brake pad: me not worn and Ihn fluid level Is low] check entlre system for leaks (see next page). FRONT BRAKE mm the handlebar to me left so that the reservoir is level and check the front brake Ieservoir level through the sight glass. ll the IPVEI IS near th. lower Invel llnn, check the brake pad wear (see next pagcl, REAR BRAKE Place the motorcycle on a level surlacc and Isunport it .Ipright position. Check the rear brake fluid reservoir level lI ma level Is near the lower level me, check thebfake Dad wear (see next page), MAINTENANCE (IISLlDE CAI ll‘lH l'll (iUUL) I2) NO GOOD ©©—:i5: l3) ( IIACKED l1) Ll‘l’tH LEVEL LINE (2) LOWFI’I LEVEL LINE: a. _._. 3-21 MAINTENANCE FRONT BRAKE PADS Remove the brake pad nnvPr< vat; — 97-: Check the brake pan (or wear. Replace the make Dads il when Dad 1: wum 10 xhe bottom of wear lunllguoove Refer to page 15 5, 6 for make pal: replacemem REAR BRAKE PADS Check the blake pad lor wear Replace the hmke pans ll either pad is worn to the bottom of wear llml! groovc. My Lu page 15-5 501 brake pad rep|acemenl BRAKE SYSTEM INSPECTION Firmly apply me brake lever or pedal, and check lh'el nu all has emered (he syMeIII. If the lever or pedal leels sem or spongy when operated, hleed the an from the sysxem. lnsuecl We Make hose and linings fur deterioratmn, mack: and signs oi leakage Tighten any loose l‘nir‘ga. Replace hoses and fittings .4: vequiued. Refertn page 15-3 (or brake bleeding procedurca '96 97: After '97: mWEAR , ‘ INDlCATOR l 3-77 MAINTENANCE BRAKE LEVER ADJUSTMENT The rhrance bemecn :“Ic [OD of The brake evev and Ihe gr I: can De ndIuQch by ILHn‘nQ the adjueIel DIRECTION A Brake lever further away from Xhe grlp DIRECTION El- Brake lever closer (o the grip CAUTION . .III “I,” » 'h: harks [z'Irr um IIIL Im‘av mm'l (M We BRAKE PEDAL HEIGHT ADJUSTMENT LuuurII me Iork nm and turn me push rod unu‘l me cuneu pedAI naught Is oblciflcc. , (3) BRAKE PEDA L1 BRAKE LIGHT SWITCH NOTE - The I-nm hmke Iigm swuch coes no: VBquIre adjuumenl m BRAKE LIG-HT SWITCH Adlusx mo D’ake Iigm :WIICII so that tI‘IP hrake Igm comes cn Iusx priul lu Ihe brake aclua‘lv hemg engaged. II ”I: Iight (Eula In rnme on, adieu the switch so lIIdl Ihe lughv rnmr‘s on a: me praperlime. Hole VIC switchbouy and mm UTE adjuster Dn nm turn the swiIch body. HEADLIGHT AIM m .In Imprnprrly adjusurd man-gm mu, blind ...I....mmg 4mm. 11! I. nmv run m 111:)" Hm mud/m n mjz 4mm. ‘ I2) HORI/IWTAC BEAM ADJUS‘TER I 56 » '97) VERTICAL BEAMJXDJUSIEH Wm '97:) NOTE - Ad‘usl I la IIeadl'IghI beam as specihcd by Iocal laws and IegulatInm Place the motorcycle on a leveI surfate Adjust the headhght beam vcnically by Iurninq Ihe vemcaI beam adjusting screws. ' (I) VERTICAL BEAM ADJUSTER (‘96 '97. A clockwise roIaIIun moves the beam up . HORIZONTAL BEAM ADJUSTER IA ‘ 3-23 MAINTENANCE Honzmvm beam amtmmsm: are made using the ho'izomal beam adjusting screws. A clockwise rotation moves the beam toward the right srde ofthe rider. A ‘96 7 '97: Horizontat oeam adtuster After '57: Vefllcal beam adjusmv ‘96 - '97' Vsmral heam aojuster B After '97' r Horizontal beam adjuste‘ CLUTCH SYSTEM Measure the clutch (res play at the end otthe clutch lever. FREE PLAY: 1D —20 mm (3/5 - 3/4 in] Mmur adjustments are made using the upper admster at the clutch lsvarv Loosen the \ock nu: and lum the adjusler. CAUTION - m 4m," mm be Jamml :rn tr pnxl‘tiortfld m Iar um. 1mm; rum-mm mm“! anwwn H the adjuster is threaded out near its limit and the correct free way Lavlllul be oblained,1urn ths adiuster a” the way in and hack nut one turn. Tighten the lock nut and make a "1311'" amnstment as (7) CLUTCH LEVER £2 "a, descrined below. Maiur adiustmenzs are periormed at the clutch arm. Loosen the rock Hut and tum \he adiust'mg nut to adjust free play He‘d the adjusting nut socurety whue tightening the lock rtuL - r1 Draper Iree play cannot he nhtamed, or the clutch slips dur- rng the test ridc‘ disasscmole and Inspect the clutch osee sec- :iurr 9b, 3-24 MAINTENANCE SIDE STAND snpam the mn'n'nane or a level surface. III SIDE STAND «.o‘» ’ ‘ \ Check me swae grand sDrIng Ior damage or IusS of tension Check \he We stand assembw for freedom of mnvament my: mm mm? the m1» stand pm): If necessarv. Check the we sranc ignixion cur-o" svswm. # SI! astrIUe llle vHquvcvcle and raise the SIde stand — Slat: me engine wxvh ms. nansmmsmn m neutraI, than shift the rransmrssmn IMO gear, thIc squeezing me cluxch Iavar. FulIy Iower me side stand. 7 The ang ne s'vumd Slug as the side stand is lowered II mm: XS 3 prob‘em thh the .ysrcm. check me 51:16 stand swnch IscclInn 19). SUSPENSION MEL (“spasmswn - 1.0m. Wu"! or damaged Suspulsinn parts impair malaru'tlc m. bmn and [umnIL Repair or rephm any dunmgul (umpmn‘nh bnfare riding. Riding a "talurryrla wry/um mwmmn I‘m-was»: ymr ritA‘ u] an under" and possible injury, FRONT SUSPENSION INSPECTION Check the achon n! the "mm by operatmg the (rum brakes and compressang the Iron! suspension several times. Check the emire assembly for SIgfls of Iedks. damage or nose fasIeners. RepIace damaged componems whwch cannot be repaired. lighten aIl nuts and bDIlS. Refer to Section 13 for fork service. FRONT SUSPENSION ADJUSTMENT N OTE - To adIusI boxh aides equally. serme dam and Iah damp- ing adjusters (o the sum: poerion SPRING PHEvLOAD ADJUSTER Sprung are load can be adjusted by tummq (he adiustev, DIRECTION A. Increase the wring pm—lnad DIRECTION B: Decrease (he spring Dre-load PRE-LOAD ADJUSTER STANDARD POSITION: 12 mm (o 51..) from up of 1m nap MAINTENANCE COMPRESSION AND REBOUND DAMPING ADJUSTERS CAUTION my n’ mmmz - 4mm minm M mumIII-"Mum - no my *m'r‘ mu» .nlymlcr Sumu mm “In the gnu: {IJWI'IU'P u, m nufimmr: mm m mammal, - m mm mm m. wrmmlnnlw WWW. mum A mu (hum mm!“ ., .w Imam-mam Immn The compression and rebound dampmg can be adiuslad by Iurning lIIe adiuslels‘ DIRECTION H: Increase the damping force DIRECTION s: Decrease the damplng force Tum the compresslm" amuster rInnkwms ”mil n mam Then mm ma Ed‘IIISTEF courterclockwlse. COMPRESSION ADJUSTER STANDARD POSITION. ' E '97: ‘ Ilum outfrom (uII hard A-ter ’JI‘ 1,5 turn out from full hard Turnvhp rphmmd nnwsrev clockwuse unnl II stops. then turn Ihc adxuslcr coumcmockwisc. REBOUND ADJUSTER STANDARD POSITION 1 mm nut Irom full hard REAR SUSPENSION INSPECTION Suppon the wolo'cycle securely and ms» thP mar whnaI rm mp. gmund. Check Ic'wom swungarm bearmgs by grabbing the rear wheaI and attemphng \u muve me WIIee‘ >ILIe ‘Iu aide. Replace the naming; i‘ any ooseness 5 noth Checkths acnon DI the shock absorber by CUIIIprES>IIIQ Il 3w- e-al (Imes Check the enme shock absorber assemny for swgns of leaksI damage or loose Iasteners. Replace damaged wmpumm. vaiuII cannot be InpAI'ed. Tighten all nuts and bolts Rcficv Io semen 14 for shock absorber serv‘ce. 3-76 MAINTENANCE REAR SUSPENSION ADJUSTMENT III FIRE-LOAD A\DJLISI:EFI" SPRING PRE-LOAD ADJUSTER Sprmg pre»‘nad can hp amnusd hv IIImIng the nmIIsmr 45 ng a pm scanner. DIRECTION A: Increase [he swing meoau DIRECTION a» Decrease me spring pre-Innd PREVLCIAD ADJUSTER STANDARD POSITION: 2nd groove on Ibo adjustet: ‘96 — '97 am gvoove on Ihe adjusm» Mm '97 COMPRESSION AND REBOUND DAMPING ADJUSTERS CAUTION II II n Urn I-‘IHHVIIIIK III. Inmpmu (IIH‘ m- m .u I m. » mm mm mm In mm MIMI m .m ,IJI‘IIM Wm I‘; (bummed. Ihe nompresslan and rebound damawg can be adIusch by ummg ("C admirers. DIRECTION H. Increase «In damping Inm DIRECTION s. Decrease me damplng Iorce mm the camprassvon Jamar ummm quII II Mug: mu II.“ we adlusIer cmmercImm, COMPRESSION ADJUSTER STANDARD POSITION: 1 tum nu1lromfull hard Tum 2h» rthInd arIIIIsti-u flnCKW'ISEII'IIIII1510p5,!h2nlu1n he adIusIer counterclockwise. REBOUND ADJUSTER STANDARD POSITION 1 turn nm from full hard USTER NUTS, BOLTS, FASTENERS Ch I that aI' chassis nuts and hnlIs 5r: lIgI'ItE‘IE‘d Io the-r car- rec: InrrIIIP vaIues lpage 1713?. Check Ihax aIl safely cIIDs hose clamps and cabIe stavs ave in mace awrl properly seculed 3-27 MAINTENANCE WHEELS/TIRES ,v mnnE AIFI PRESSURE GAUGE NOTE - Tire pressure should I76 checked when the tires are COLD. RECOMMENDED YIRE PRESSURE AND TIRE SIZE. l FRONT l REAR fire pressure l ‘ m (km/amt, us” l 250 (2.50, as) l 290 (2.90, 42) Tue '96 , '97: l 130,70 — zms I 13055 , zn17 5“" Aher '97: 130,70 , zme ‘ 130/55 7 ZR17 (61 w: 173 w) Tire Bridgastone ‘ erase RADIAL lBTSGH RADIALG : WW Michelin Tx15 l szs Checkthc tires for cuts. embedded nails. or othcr damage. Check the front and rear wheels for trueness (raIar to section l} and 14h Measure the tread depth at the CDI’IIOI of the tires. Replace the tires when the tread depth reaches the following lllttlla. MINIMUM THEAD DEPTH: FRONT: 1.5 mm (0.06 In) REAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS VOTE III STE'E ‘NG HEAD BEARINGS ‘ r' . 4 - Check that the control cables do not interfere wlth handle bar rotation. Support the motorcycle securely and raise the trnnl wheel eff the ground, Check that the handlebar moves freely from side to side. II lhe handlebar move: unevenly, bindg, at has vertical move- ment, rnspectthe steerlng head hearings [Seminn 13) 3-78 MEMO LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM I1: EXHAUST CAMSHAFT a ‘A- I \fi IS;—j—LHJ 12) INTAKE CAMSHAFT \ (3) PISTON-\‘% I???) /. , MI CHANKSHAFT ‘— —‘—‘,_gf ll: 15) MAINSHAFT\ I12) OIL PRESSURE SWITCH I (5" COUNTFWSIIAFT/ I74 OIL COOLER «firm I #1 5,—7 ‘— I11. OIL PUMP (8': OIL FILTER (9: PRESSURE RELIEF VALVE I1OI OIL STRAINU] 4-0 4. LUBHIUAIIUN SYSIEM LUBRICATION SYSTEM DIAGRAM 4—0 OIL STRAINEHIPRESSUFIE RELIEF SERVICE INFORMATION 4.1 VALVE 4-4 TROUBLESHOOTING 4.2 °"— PUMP 4-6 OIL messune INSPECTION 4.3 °"- COOLER 4-10 SERVICE INFORMATION GENERAL AWAI’INING - [flirt engine mun be running n; llu Hunk wm, mnl’r m, an arm It well-Irradiated. Never run lhr: engine In an enclosed arm. The exhuutl l-unrnins pni!flnllvl.t rnrlmn mum gas that may :11th lass llf mnsn'muness and may lead w death. Run the flight: in nn nnrn nrm 0r with an exhausl :mmmnn systtnl in an analysed ma. - L‘scd engine all may tausl' skin mm ifrepeluedly la]! in runrnu will: the xlrinfnr pmlnngrd panndse Ahhougll Hut 1: unliktly miss; you handle used ail on a daily bum, h it still mlvixnblr In Ihrrrnughfy wash your hands wuh snap and water as slum as pamhh njlw hnnllll'ng “ml uI'l. - The orl pump can be serviced with the engine installed in the frame - The service procedures in Ilris section must be perlormnd wnh the shame nil draincd. . When removing and installing the. all pump, use care not to allow dust or dlrtto enter the engine. - Ii any pnmnn of the on pump is worn beyond the specified service limits, replace the oil pump as an assembly. . After the oil pump has been installed, check that there are no oil leaks and that nrl pressure I: correct SPECIFICATIONS Unit mm Iin) ITEM STANDARD SERVICE LIMIT Engine uil Capacity ‘ At tlrarmng 35 liter 117 US at, 341 Imp an — AI disassembly 4.4 Iller l4.6 US or, 3,9 Imp cm —— AI oil filter change 3 6 my (MI US qt, 3.2 Imp qu — Recommended engine oil Honda GNd 4-slrnke ml or equivalent motor OII APl service classification SF Ill 56 Viscosity: SAE 10W — 40 Oil pressure at ml pressure swrtch 490 kPa l5.U kgf/cm‘l 71 psi! at , , 6.000 rpm/(BO‘C/WGEF) Oil pump rnrnr Tip clearance 0.15 — 0.22 (0 006— 0309) 0.2010008? Body clearance 0.15 — 0.22 (0.006 — 0,009'I 03510.01“ - Slde clearance 0‘02 — 0.07 (0.001 — 0.003l n 10 [(1004) TORQUE VALUES Orl dram holt 29 N-m (3,0 kgf~m, 22 lblrfll OII filter cartridge _ 10 N~rn (1.0 kgf~m, 7 lbf-ft) Apply ml to the new 0 ring Oil pump driven spmcket bolt 15 N-m (1,5 kgl-m, 11 Ibf-ftl Apply a locking agent (0 the threads Oil cooler boss 64 N-m 165 kgf»m, 47 IDI-fll Applv a lacking agent to the threads on pressure switch 12 N-rn r1.2 kgf-m, 9 lbI-Il) Apply sealannn the threads TOOLS Oil pressure gauge 07506 — 3000000 —1— Equivalent cnmmercrallv available in U,S.A. Oil pressure gauqa attachment 07510 — 422mm) Oil Iillel wrench U/HAA r PJ70100 4-1 LUBRICATION SVSTEM TROUBLESHOOTING Engine oil level tau luw - on consumption - innrnnl ml leak - Worn pisron ring or incorrect pinion ring inslallarlon ' Worn valve guide ur seal an nr nu nil prgssule - Clogged oil orifice - lncorracr oil being used No oil pressure ~ Oil Ievcl too low - Oil pump drive sprocket broken - Oil pump damaged lpump sham > Inwrrm! nil leak Low oil przssure - Clogged oil strainer screen - Oil puma worn or damaqed - Internal uil leak - Incorrem ml helng used - Low oil level High oil pressure ~ F‘Iuggr-d nII hlmr, gallery, or metering orifice - Incorrect oil being used 4-2 LUBRICATION SVSTEM OIL PRESSURE INSPECTION Nn‘l - ll the oil plessu’e indicamr lrght remalns on a few scar and; mack ma lr‘dlcator sysrcm bolero checking Xhe oil pressure. Check me u I level (page 3.11, Warn— .p the engme [0 normal operating :emperalure (anarcximamly HO”Cl176"F). SEO!) the engine and disconnect the all prawns swrlch WIre culllleulul flc-m the mum Remove the oil pressure swuch and cumml an oil pressure gauge and anaclllllelll lo the switch hole, TOOLS' Oll pressure gauge 07508 — 3000000 [Equivalent commercially uvailuble in U.S.A.) on pressure gauge attachment 07510 ~ 4220100 (Equivalent commercially available in U,S.A,) Slar' (M englne and Increase the rpm to 6,000 rpm and read the oil pressure. OIL PRESSURE ISD “’0 (5,0 kgf/cmz, 71 psi, at 6,000 rpm/{BD‘C/WfitF) 570:) the englnc and remove the tuuls. Apply sealant m ma lhlead: at up: oil pressure swllch D0 "01 EPP‘V M W "W" “W I 3 4mm ~4—lfi‘lrrl7lm \_; ‘lllt l kc: Insrall and rlgmen 110 [he weofied torque TOROUE' 12 Mm (102 kgh‘n, 9 IDH!) CAUTION - mam/ll Connecrthe uil preaaule swltc’l connenlm r I." \ “ l1) CONN'FCTOR LU BRICATION SYSTEM OIL STRAINER/PRESSURE RELIEF VALVE REMOVAL Drain the engine cu! (page 3-12. Hemnv: the exhaust pipe lpage 246i. Remove the 0H pan flange bolts and oil pan. Remove the pressure «elief valve and O»ring Remove the oil strainer and gasket. Clean the oi‘ stralrer screen INSPECTION Cncck the operation of the pressure rciic' valve by pushing on the piston. Disassemble the relief vaiva by removing the snap ling. I'ispccl the piston for wear, aricking or damage. Inspect the sunny (or weakness or damage, Assembie the relief valve In the reverse nrdar nl disassem- blvt (4) HELIEF VALVE BODY 0 I2) SPR‘NG ”K m SNAP RING is: PISTON 4-4 LUBRICATION SYSTEM TRAINER ' " INSTALLATION mo” $f , @mgxu Apply oil to the new gasket and install it onto the all strmnen luslall the oil strainer min the crankcase thle aligning its boss wnh the groove in the crankcase. Apply oil In than new 04mg and Inslall it onto xhc reIIef valvsI lnstall the relic! valve ‘Inm me crankcasa. Clean [ha uil pan ”MW sullace thoroughly. [ (I) Al’I'LY AHEA Apply Three Band 12078 or an aqmvnlnnv to me mating sur lane CAUYION - 0,. mm Impn Wald/ll more man luminary lnslall the ml pan and nghten the flange Dolls in a crisscross nanern In 2 , 3 slaps, Install Lhe exhaust pipe (page 2-17l Fill Ihe crankcase wwh recommended oI’I (page 3 131, N OTE - Aher InstallatIon, checkmal there are no oil leaks. LU BHICATION SYSTEM OIL PUMP REMOVAL Remove the clutch assembly (Dog: 9 4). Remove the of! pump driven spl ockex boll/washerv Hemnve the following: Oil pump driven sumckex — Oil pump drive chain — on pump drive sprocket — Drive sprocket collar Remove (he flange bull: and ml sump membw. DISASSEMBLV NOTE If any nnmnn nt the nil pump |s_wnrn beyond the spec:- fied service “mix. replace :hc oil pump as an asaembly. wae me bun, oil pump travel and dowel pin. (”HOLT (2) COVER 4-6 LUBRICATION SYSTEM Remove the thrusl washer and drive min. Disassemble the oil pump, 12) DFIIVE PIN [II WASHER INSPECTION Temporarnv insxaH the oil uump shah. Instal‘ III: uuler and inner roIors into the oil pump body Measure the tip clearance. SERVICE LIMIT: 0.20 mm (0 008 in) Measure the pump budv clearanw. SERVICE LIMIT: 0.35 mm [0.014 in! Measuve the side clearance uslng a straight edge and feeler gauge SERVICE LIMIT: 0.10 mm (0.004 in) LU BRICATION SYSTEM ASSEMBLY {1| ()U | ER ROTOR (\\\ «2) INNER ROTOR ‘ O (7} PUMP SHAFI' Q\ \_ / m coven [6) OIL PUMP BODY {5) DRIVE P|N (4) WASHER luslall the outer and inner rotors mm mg ml pump body. (H OUTER ROTOR Insmll thn ml pump shaft mrough the on pump body and lflflEV romr. (2) INNER ROTOR (3} PUMP SHAH Install the drive pin into the hole in the pump shaft and align the pin with the groove in the inner rolur as shown. Install the thrust washer. (1] DRIVE PIN (2) WASHER LUBRICATION SYSTEM Install the Uuwel pin and oil pump nnvar, tnen llghten (he ll) DOWEL PIN l3: BOLT cover bolt securely at INSTALLATION Install mp. ml pump me me crankcase whila aligning the pump shah lug with the water pump snarl gruuve. lnsiall and :lghmn the three flange boll securely. Apply oil to ma oil pump driv! spluckel collar, drive sprocket and dIIVE chain lnslall the following: -— Drlvs spruckel collar — on pump drive :nrnnknt — Oil pump drive chain Oil pump driven sp'ocket LUBRICATION SVSTEM Inmu Mp. m1 pump dr'ver‘ snrnckat wum us “OUT” mark facr mg ouxward. Apply a lucking ugem to We 0"! pump driven spruckex bolt mreads Install and lighten the driven sprocket boll/washer to the spam ificd torque. TORQUE; 15 N-m [1.5 kgi‘m,11IM‘m lama“ the cluxch assembly ipage 9-8). OIL COOLER REMOVAL Drain ms Bnqine oil (page 3-12). Rmove (he on “key camidge (page 3-12) Dram me comm vpnge 5-4). Disconnect the Coolant mbas f'um (he oil cuuler. Remove the oil cooler boil. Rauluve the on cooler and O-ring 4-10 LUBRICATION SVSTEM INSPECTION C"e:k he oil coole' fur Ieakage Ur damaga INSTALLATION m OIL COOLER BOLT GA N-m (6 5 kgI-m, 47 mm [2) OIL COOLER \/ I3) OIL FILTER CARTRIDGE w N-m11.0 kgf‘m, 7.2 Inf-ft) AppIy mI m w nPw U-rmg and InsfaII r nnm mp ml ronler InsmH the an comer. ahgn‘ng us gmde groove With the boss on (he crawkcase. 4-11 LU BHICATION SYSTEM Apply a lock ng ageul |u lhe o:l cooler bolt threads Install and lighten me ml cnnler bolt to the specwicd torque, TORQUE: 64 NM (6.5 kngm, 47 le0 Connect the coolant lubes and secur: “mm with (hp rlamps lwstall the oil hlver mnndge lpage 313l' ml mp. crankcase wwh recommended engine oil (cage 3-13) Fill the cooling system {page 643). 4-12 MEMO FUEL SYSTEM 5-0 5. I'UI:L SYSItIVI SERVICE INFORMATION 5-1 CARBURETOR INSTALLATION 5-19 TROUBLESHOOTING 5-3 PILOT scREw ADJUSTMENT 5-20 AIR CLEANER HOUSING 54 HIGH ALTITUDE ADJUSTMENT (U.S.A. CARBURETOR REMOVAL 5-5 ON”) 5'21 ‘ CARBURETOH SEPARATION 5-5 (SESSEODR‘IIIX wpguowb‘l') SVSTEM 5.72 cARBURETOR DISASSEMBLY 5-7 FUEL VALVE 523 CARBURETOR ASSEMBLY 5-11 CARBURETOR COMBINATION 5-15 SERVICE INFORMATION GENERAL AWAKNING ' Gum/int i! u'twmrlyflammabk and is explosive under certain Fundill't‘fl- KEEP "III‘ III" REACH OF CHILDREN, [lending or Iwmmg lhc cunlml cable: will impair Inmorll nprrnlllml and could must [he cabin to Slitk ar bl‘ml, rnIIIIing in In“ :1] Ivchitlc tnnmL ' Work In a well vennlaled area, Smoking or allowing llamas Or sparks in the work area or where gasoline is smred can muse 11 (Ire or explosion. CAUTION n.» W .1- mnw :lrz' maphragm: befnr: I-Imm ufr umi fuel pdrmgri Aim :anxpre'ssa‘d uIr rm limp/Traci": MIL-III be dam-WI 4 Reler m secliun 1 (or fuel tank removal and Installation, - When dISassemhImg luel system pans, note the Iocafion U! the Orrings. Henlam them with new ones on rsasserlIblv. - [More dusassembl‘mg me carburatur‘ place the suitable container under (he carburetor drain lube, loosen The hall and drain me carburamr. Ahar removing the carburetor, wrap the Intake pans of The engine with a Shop towel or cover It With. a nicer: of Taps no pl event any foreign mmerial from dropping into me engine. The vacuum chamber and float chamber can b: serviced with the carburetors assembled. NOTE If Ihe vehlcle is To be srored for more than one month, drain the float bowls. Fuel left in the Ilual bowls may nnIIse clogged i915. resulllnq in haul Starting or ponr drivaahillry, 5-1 FUEL SVSTEM SPECIFICATIONS ITEM SPECIFICATIONS Carburetor Identiflca- 49 mm type '95 — '97: vpasa "°" "WW After '97: VPBCP California type '95 — '97: VPHBA ' After '97: VPBDA E559; type '96: VPBBA '97; VT’SBB After '97: vaaca Mam yet 49 states type '96 -- ’97: #115 lSee page 5-11) After '97: 1 #120 California type '95 - '97- 1 «115 After ‘97: #1 2!] Canada type '96: #115 '97: 7' V 7 N071,4;II115/No.2t3:#118 After '97: "3:120 Slow jet #40 Jet needle number ‘9 state: type '96 » '97: No. l,A:J5FB/No.2731J5FA After '97: No. 1, 4: JSFH/No, 2, 3: JSDD California type '99 — '97: N11. 1, I: JSFB/No, 2, a: JSFA l After '97- No, 1, A: JSrAan. 2, :1: JSFC Canada tvpa '96: Not 1, A: JEFZ/Not 2. 3: JEFY '97: "No. 1, A: J5FB/No. 2. 3; JEFA Mar '97: '7 7’ Not I,I:J5FH/No.2,3:15133 Pilot screw initial ’96 '97: 3 turns out ’ ”em” Except California wpe Alter '97: 1 5/8 turns out W 2 Iurns out Float level 13.7 mm (0.5l1n) ldla speed l Except California type 1,1ou .+ 100 rpm l Califurnia lype 1,200 l 101) rpm Throttle grip Ires play ‘ 7 7mm 11/12 -1/4.rr) TORQUE VALUES Carburewr assembly bull, 5mm 5 Man (05 kghn, 3.6 mm) 6 mm 10 N-m (1,0 kgI-rn, 7 Int-m Vacuum plug for synchronization 3.0 NAm 10.30 kgf'mt 2,2 IbI-fx) Boostjoimiorfual auto valve 2.5 N-m (0.25 kgi-m, 1.8 lbf-ft) Fuel valve 3‘ N-m (3.5 IngI-m, 25 lbf-ft) Suh—mr cleaner mnuntIng bolt . 7 N~m (0,7 kgt-m, 5.1 lhfrfl) TOOLS Carburetor float level gauge D7501 — 11011111011 Pilot screw wrench (California vacl O7KMA MN90100 or 07KMA M5601o1 with 07PHA 7 M2201 10 ‘ , (California only) 9 or O7KMA- MV901OA (U SA only) (Except Caltfornia type] 0/908 ~ 4220201 or uwoa v 4730001 (Except calIfornia type) 5-2 TROUBLESHOOTING Engine won’t to start - Too much tuel getting to tho cngina — Air cleaner clogged Flooded carburetors - lntaka air leak - Fuel contamiHand/deteriorated - Nn luel to carburetor — Fucl strainer clogged 7 Fuel tuba clogged — Fuel valve vacuum tube clogged —— Disconnected fucl valve vacuum tuba — Float level mlsadlustsd — Fuel tank breather tube claggnd Lean mixture - Fuel jets clogged - Float valve laully - Float level fort lnw - l’tml line restricted - Carburetor air vent tuba clogged - Intake air leak - Throttle valve faulty - Vacuum piston faulty Rich mixture - Starting enrichmnm valve in ON position - Final valve faulW - Float level too high - Air iats clogged . Air cleaner element contaminated - Planned carburetor FUEL SYSTEM Engine stall, hard to surf, mugh idling - Fuel Ilnfl restricted ~ Ignition malfunction ‘ Fuel mixture too lean/rich - Fuel cur-lammated/deteriorated ' Intake air leak - lnle speed misadeSted ' Float level misadiusted - Fuel tank breather tube clogged - Pilot screw misndlusiad - Slow circuit or stoning enrichment circuit Clogged - Emission control system mallullction (California typel Allavhurn when engine braking is used - Lean mixture in slow circuit - Air cut-off valve mall‘unction - Emission control system is malfunction — Secondary nlv supply system faulty — Loose, disconnectad or deteriorated hoses of the emission control system Backfiring or misliring during acceleration - Ignition system malfunction - Fucl mixture too lean Poor performance (driveabilityl and pour fuel ooonomy - lgn on system malfunction - Emission uuuuul system malfuncnnn — Secondary air simply system faulty —lnn.-re, disconnected or deteriorated hoses oi the emission control system 5-3 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL or an Cieaner eIemem replacement. Remova the we! tank Ipage 272). Dtscnnnam mp snh-air cIeaner housing air tube. Remove the bolt and Sub-Elr manner hmtsmg Disconnect the crankcase breather tube from the cur oteaner Wousittg Luosen t've carburetor connectmg tum: hand screws Rulltuve [Ive buIl and a'tr cIeanar housing. Rpmnw [he may 1. <51 ’1) C NNE_CTING_TUBE BAND SCREWS INSTALLATION I‘M AIR CLEANER HOUqING. ' InsiaII [he atr manner housmg In the ravnrss order of temoval @ t2) SUBAIH gLEANER POUSING 5—4 FUEL SYSTEM CARBURETDR REMOVAL ,‘m Trignrng snw SCREW V; q AwARNlNE - (Mullins IF cxlrcmtly flammable and it cxplmiw and" mm". rnndmuns. Remuve [he air cleaner hnusing (page 5 4). Hernm-e mo throme SIDD screw from the bracket DlsconnCCI me mmnla senw. cunneczor ”m Crow CABLE ‘% Lousen [he screw and msmnnecx tho choke cable from the cal- buerr Remove the throttle cables lrum ihe cable holder and discon- nem [he ihroule cables from th» rhrnma drum. Remove the air vent mbe from me quide. lnnsan the engine Side insulator band screw: and remove the carburetor asssmbly. NOTE - Aher remnvlng the carburclor assembly, do not pldLe It up side down or the air intake might be deformnd - Seal the cylinder head intake pnns with a shop towel or Cove! ii with piece chime in prevent any foreign materia| frnm dropping mm the engine. FUEL SVSTEM CAHBURETOR SEPARATION NOTE . The vacuum chamber and float chambw can be summed wrthnm separating the cnrhtlremrs Loosen the screws and remove the insulators; Dlsuunneul the Iuel tubes from [he fuel juinl. Disconnect the air vent tubes and subair cleaner tube NOTE - It is nu! nenessary to remove me thronle sensor from the carburetor body. ll necessary, remove the screws and throttle sensor nom the narhuramr hndy Remove the starting enrichment valve arm screws and wash ers, Remove the atarlillg enrichment Valve arm, thrust spring and plastic collars. Loosen and remove the carburetor connecting nuts. NUIE - Loosen the nuts qraduallv and alternately. Remove the: choke cable hnldnr (3) AIR VENT TUBES 5-6 Seaarate the No 3'4 na'nuremr: Imm me No, ‘lI2 carbure- mrs. Rafiove :he fulluwiug. — No 2 carburetor synchrnnwafmn spnng — 3-way aIr Iain! pIpe/O~vings Dowel pin (5 mm bolt side) — Distance collared duwul pin (6 mm bull side) SepaIaIe the No 1 carburetor from the No 7 CarhIIernr Remove xhc foIIowirIg: — No.1carburalar synchruIIizaIiuII sunny — TIIIusI SpI'Ing _ AIr )nlnt nmher plpe — All vem qunI pipe/0 rings — 3-wav1ueI joint pIpa/O-I‘Ings 7 Dowel pin (5 mm bolt side) — Dowel pm Is mm hon smaI SCDOYJIC ma No. 3 carbureror from the N04 4 carburemr. Remove HIE FoHowIng 7 N15 narhIIrmnr synchronlzatinn sprmg 7 Thrusl spr‘Ing _ A‘Ir Iamr rubber pipe — AII vevll joint pIpe/CI»rings 7 TIwr-Iy fur-n In‘n! pIpe/OrrIngs 7 Dowel pIn <5 mm bah 5IdeI — Dawal pm (6 mm bull side) CARBURETOR DISASSEMBLY NOTE - Nme the Inceuon of each carburetor pan so they can be rcpIaccd In their original locations, AIR FUNNEL Remove me screws and airfunnel hoIdar‘ FUEL SVSTEM ‘:‘~III SPRING /r* * \\'[2)A|R JOINT (4] DISTALVCE COLLARED DOWEL PIN ‘ IrII AIR JOINT 15) FUEL JOINT 12) THFUST SPRING No. 4 No 3 {4) AIR VENT JOINT ». I. "“ ‘,. ”’SPR'NG' // T ;I6)DOWELPINS (SIAIRJOINT /1 / ISIFUFIJUINI" ,2,” I2: THRUST SPRING/ :- (1) SCREWS (2 AIR FUNNEL HOLDER 5-7 FUEL SYSTEM Remove the air funnel hum me ho‘der Remove the O-ring from we camuramr body. STARTING ENRICHMENT VALVE Remove mp Siamng enrichment {SE} valve nux‘ Remova the» spring and starting enrichmem 45E) valvc. DIAPHRAGM/VACUUM PISTON Rgmuve (he screws and vacuum chamhar cover NOTE - As the compression spring Is very long, It wa jump out or 'he carhuremr when the cover is removed. ‘3) O’HING (1} SKIHEWS (ZDHOLDEH (2) SE VAI VI (1) SPRING (2) CHAMBER COVI’H 5-8 Remove me diaphragm spring and dlaphragm,’vacuum pis- ton from \he carbuveluv body. Iemporanly mate” a 4 mm screw I‘exarnule: vacuum cham ber screw) Inm the Jet needle holder. PuH the sclew and remove llle jel needle holder. CAUTION . 82 (mm nut to (1mm my alluphruyrr.‘ ~ Lu. W mum mm "mm luv/div h) [mt/""5 m,» [n mvrdlr Remove the spring, jet needle and washer from [he vamulm plsmn FLOAT AND JETS Remove lhe screws and flual chamber. FUEL SYSTEM (1) DIAPHRAGM SPRING (70 WASHER (2) FLOAT CHAMBER (Z) DIAPH RA/GMNACUUM PISTOA (Z) JET NEEDLE HOLDER iv (Z) JET NEEDLE \A «1:4 mm SCREW ‘1 (1) SPNNG 1) SCREWS 5-9 FUEL SYSTEM Hamnve the float pin, float and float valve. Inspect the lloat luv delunuation or damage. lnspect the float valve seat lor scores, scratches. clogging and damage. Check the fin of ma float valve wneru it uonlacls lhe valve seat for stepped weal or contamination Replace the valve It tha up Is wnm or contaminated, Chuck the operation of the float valve. Remove the following. -— Mam iet v Needle Jet holder A Slowjel Tum the pilot screw in and record [he numher 0| turns It takes befnre n saats lightly. Remove the pilot screw. spring‘ washer and O-rin94 CAUTION - Uunmgr :0 mm mm mm m: will occur mm pum .rtrm‘ u m: agarmr my 5an Inspect each JET lnr wear or damage and veplace lf ncccs SEWt Clean the fuel strainer In the Hoar valve <9»! uslng the mm, pressed fllr from the float valve seat side. l3) FLOAT VALVF 1,”, FLOAT PIN (7) VAle SEAT l1) FLOAT VALVE (1) MAIN JET (2) NEEDLE JET HOLDER I I. l1] FUEL STRAINER 5—10 FUEL SVSTEM [1an open each an and fuel passages in me carburetor bodv wim compressed air. CABBUBETOR ASSEMBLY (ll VACUUM CHAMBER COVER (3) JET NEEDLE HOLDER (6) AIR FUNNEL / l' “1 55 VALVE lb] CAHBURETOH aonv * . E "‘7’sz [7) .JL I NEEDLE \ (7‘i SLOW JET l‘5' SPRING .\ (a) FLOAT vm \IL \) (m lLOAT 113:- PILOT SCREW (1'1) THROWLE VALVE/VACUUM F‘lSIUN (m MAIN JET FLOAT AND JETS (11» NEEDLE JFT HOLDER 410) FLOAT CHAMBER install the following. — Slow jet — Needle let holder 7 Mill" icr CAUTION gum Canada may Insmll me punch markrd mm mm mm m; \‘n. J and Na 5 lurllun'lun. H ' u.’l m; a my fur! Tm m" an rnrrd 0r .i a! Insrall me pllol screw and rerurn ii \0 is original pusiliull as noted during removal Perinrm the mini screw adjustment procedure if a new pilot \ screw is installed [page 520), ll) NEEDLE JET HOLDER (1) MAIN .lET 5-11 FUEL SYSTEM Install mp llnat and float valve m the carburetor body. then lnstall the float pin rhrougn the body and float. FLOAT LEVEL INSPECTION With (hp llnat valve seated and mo flour arm just touching the va!vc, measure the float level with me suecial mm as shown. FLOAT LEVEL: 13.7 mm (054 in) TOOL: Carburetor floax level gauge 074m - 0010000 The float cannot be adiustad. Replace \he final assembly if the float level is out nV spenih- calion Install a new O-ring in [he (lual chamber Irma” the float chamber Install and "gram-r mp. three flour chamber screwsl W'LOAT CHAMBER [m SCREWS 5—12 DIAPHRAGM/VACUUM PISTON Check the condition a! the Orring on the RI neeoie hoider. Veaiace ii necessavy. Apaly oil to the O-ring Install the washer, ict nccdlc. spring into the vacuum pis ton, DIESS live jet Heedia holdei iulu ll».- vacuum pislvu until you feel a click indicating that the O-ring is seated mm the grnnve in the vacuum piston. install the diaphragm/vacuum piston m the carbureto: buuyl diiguing the diaphragm tab with the groove 05 the carbure- tor hnriv Hold the vacuum piswn almost full open 50 the diaohragm is not pinched by the chambe' cover. install rm: nhnmher mver with the spring, being careful not to damage the snring. lnstali and 7rghmn Yhe vamulm Chnmhar hover screws CAUTION - 0,, um ,w it my .1 31m mi.” .1.“ MM». vmrr STARTING ENRICHMENT VALVE Install the starting enrichmenl (SE! vaIve and Spring. FUEL SVSTEM iii DiAPHRAGM,’\’ACUUM PiSTON / l X 13‘ JET NEEDLE / _ 1/ (st '75 OrRiNG / . i2iWA$HER (6i HOLDER (7] SPRING [4| CHAMEER COVER (20 S K (I) SE VALVE {73 SPRING 5—13 FUEL SYSTEM lnslall :he starting Fnrlchmert lSEl valve ".u( and lighlen ll securnly AIR FUNNEL Install the air funnel into me holder as shown. C'lcck (hal the O-ring is in good condition, replace il news- Sa'vl lnslall me O-Ii'vg lmn Me grnnve nnhe carburetor body. Align the cut-out on the air lunna! with the groove in the car- buralor body, then lusts" “I: an funnel/holder lnslall and 'Jghlen (he huldel sclews. (1) SE VALVEtN’UI imAlR FUNNEL u \ \ ‘Qs 1?, (2) HOLDER K v (1) AIR FUNNEL 5—14 FUEL SVSTEM CABBURETOH COMBINATION ’/«e) AIR VENTJOINT (7? AIR JOINT 10 N-m [1.0 kgf-m, 7 lel) k ' \\ 1 b T n \\ §\\:\\\ ( u ‘NSULA O {BITHROT‘FII SENSOR f \\:\\\ ‘\\\\ (11)CONNECT|NGBOLT,5mm \\\\\ fl \\ ‘\ \1 (13h CHOKE CABLE HOLDER (17) C()NNEC1|NG BOLT. 5 mm 5-15 FUEL SVSTEM NOTE No. 4 - Always replaro the O-ring with new ones. lnsrall (he lollow‘ng: 7 Dowel pin l5 mm boll aude) - Dowel pin Is mm bolt sxdal —- 3-way rIIel Imnt pIpe/new O-rings — AIr vcn! jolnr pipe/new Orrlngs lAIAlR VENT 7 Air Iomr rul'zloar Dupe l‘ll SPRlNG — Thrusl - 'II // 41T (6) DOWEL PINS 5U" H I3)AlR JOINT — \lo A narhummr synchromzarlan sprlng ‘5. Full JUINT/ .. H/ Asaemble the No. 3 and We Nul 4 carburetors. (2’ THRUST SPRWG lnsxall the following: Dowel oln (5 mm boll side) — Dowel pill (6 mm ball side) — 3rway final Imnt pIpe/new O-rIngs — AIr vent Joint pipclncw O ring: 7 Air jolm rubber was 7 Thrus‘. spling — Nn 1rarhuretor synchrcnlzarion spring ‘\*11I SPRING 413) Am. JOIN! \ \ ‘lSl FUEL JOlNT I2I THRUST SPRlNG Assemble me No.1arldlhe Nu. 2 udIbngluIs, 16) DOWEL PINS \ \ lnsrall mp Inllnwmg: 7 Dowel Dln 15 mm bolt side) 7 Distance collared dowal pln [6 mm bull side! _ 3-way aiI Iain! pipe/O~rings — No 7 rarhIIrHl‘m svnnhrnnrzmmrl sprlng Assemble the No.3/I1 and me No, 1H2 carburelurs. (3! DOWEL PIN (1:- SPRING peLified 111 FUEL VALVE zorque, TORQUE: 34 MM (3.5 kgf-m, 25 lbm) NOTE - Do not ovenightan the luck nut. FIII the Vui‘l tank and make‘ Sum 'hpre are no hm! leaks 5-24 MEMO COOLING SYSTEM SYSTEM FLOW PATTERN '96—'97: (.1‘, HFSFHVL \ANK (2) SIPHON TUBE (1| AIR BLEED TUBE CYL‘ NDER HEAD HOST 17,! WATER PUMP (1/ THERMOSTAT (2b WATER BVPASS (E) RADIATOR i (3! WATER PUMP 6-0 6. COOLING SYSTEM SVSTEM FLOW PATTERN 6-0 THERMOSTAT 6-5 SERVICE INFORMATION 6-1 RADIATOR 6—8 ‘ TROUBLESHOOTING 6-2 WATER PUMP 6-11 SVSTEM TESTING 6-3 RADIATOR RESERVE TANK 6-14 COOLANT REPLACEMENT 6-4 SERVICE INFORMATION GENERAL - H'atl until the ammo I: an)! befnre newt,- mnavinn the mtliulur (up. Remuving 1hr rap whit: the Night: is Ital and in: runhutt Lt under nmme may taint writ/tn uniting. - Rutliulur t‘ualnnl it mi. kn,- ii away/ram eyes, mauth. Skin and clothes. — I} any coolant gets in yaw cycs. nnSc lhcnt with water and cansult a doctor immediately. _ Ifnny mutant in swalluwad. indm vomiting. gang: and mum u pliysiitnn ittttttldintrb'. — ”any mulunl Km un yuur itin urdulhtts, rinse Iltnmughly with [wintry n] walrr. - KEEI' ("T ()F RFA (‘II III' {‘IIIIJJIt‘IzN. - Use only distilled water and ethylene glycol the cooling system. A 50 — 50 mhflllre is recommended lor maximum corrosmn pruleuliult. Du not use alcoholbased antitreem. ~ Add cooling system at the rnsnrve tank. Do not remove the radiator cap except to refill or drain the system - All nonltng system services can be done with the engine in the frame. - Avoid spilling coolant on painted surfaces. - Anar servicing [he syle-In, check fut leaks with a cooling systnm tester. - ReIei to section 19 tnr tan motor swttch and coolant temperature sensor Inspection. SPECIFICATIONS ITEM SPECIFICATTONS ‘ (:nnlttnt capacity Radiator and engine ’96- '91 2 77 liter I? 93118 (H.144 Imp all After '97; 2.64 liter 12.79 us qt, 7.32 Imp qt) Reserve tank '96 , '97: 0.45 Iilet (0.475 US qt. 0 396 imp qt] - After '97: 0.35 liter (0.376'US qt, 0.3m Imp nu Radiator cap relief pressure ‘96 , '97: ‘ 108— 1:47 kPa 11.1 71.4 kgt/cml, 16 20 psi) Aflar ’97: 1073 kF‘n (1 1 kgI/cm’, 16 psi) Thermosta: I Begin to open 30 Bd’C 1176 ~ 183‘FI Envy open 99c (203$) Valve lift 7 8 mm in} in) minimum TORQUE VALUES Wale! pump cover bolt 4 13 N~m (1.3 kgt-m, 9 Ibt-m Cnniant temperature sensor 10 Nm (1.0 kgl-m, 7 Iblim Fan motor nut 25 N~m (0.25 kgl-m,1.8lbf~fti Apply a locking agent to the threads Fan motor switch 18 Nm (1 B kgt-m, 13 Inftt) Apply sealant to the thveads 6-1 COOLING SVSTEM TROUBLESHOOTING Engine temperature too high ~ Hunky radlamr cap - lnsufflcicm coolant - Passages blockeu ln ladialul, hoses cu watel jacket - All in system - Faulty water pump - Thermostat stuck closed - Faulw lampelalure gauge 01 Luoldlll lelllpe'ature sen- sun - Faulty mnlmg fan momr - Faulty 1cm motor switch Engine temperaturo too low - Faulty temperaluw gauge Dr coolant temperature sen- SUl - Thnvmnstat stuck open - Faulty cooling fan moxar switch Caulunl leak - Faulty water pump mechanical seal ~ Dctcriorated Ovrlngs - Damaged or deter‘luraled gasket - Loose hose connection or clamp - Damaged nr detencrated has: - Faulty radiator cap 6-2 SYSTEM TESTING m. - 'Hu engine must be cool befar: removing 1hr radiator up, or severe scaldlng may rmrlr. COOLANT (HVDROMETER TEST) Remove rhe radiaror capr Test the coolant gravity using a Ilvdlomeler (refertc sechon 5 DI the Commun Service Manual Inr “Coolant gravity chan”lr For lellel’fl corrosron promotion. 3 50 — 50% solution of ethylene glycul and disrillad warar is recurrunurrdeu (page G-Mr Look for contammnrinn and replace the coolant if necessary. RADIATOR CAP/SVSTEM PRESSURE INSPECTION Remove the radiator can [see abovel. N OTE - Before installrng the mp In the tester, wet the scaling sur- Incas. Pressure lest lhe radiator cap Replace rhe rammnr up If It does not hold pressure. or if relieI pressure I: too high or ran low. It must hold specified pressure Iur at least 6 seconds, RADIATOR CAP REUEF PRESSURE: 108 — 137 IrPa (1.1 ~ 1.4 kgflcmi. 16-20 psi) Pressure the radiator, engine and hoses, and check for leaksr CAU‘HDN - Exczur'yz prmrrrp mrr (Inning: m cooling mum components. Dn ml and 137 Va ”.4 kgfltm’. 20pm. Repair or replace components ifthe system will not hold spear fled pressure for at I855? Fr secondx . .. COOLING SYSTEM 6—3 COOLING SYSTEM CUULANT REPLACEMENT PREPARATION m_—_ - Radium: main": 1'( [ruir In... it aw... fin... Iyn, "mum, (kin and cloth“. If any raglan: gm in mm mm. rinse Ilmn with um and wnmll a damn immmimi _ If"... nmlrml in anllnwrd, mm... Innuling, garglz and run- ruu a phymmn llnnudmlclj‘. 7 If any coolant gm .m ya... skin In: (lalhts, mm lhomunhlv will! plumy 0/ win. - KEEP ()L'T 0F In‘F-tf‘" 17F ('II’IVDRE’VV NOTE - The eflectivenpn nI nonlnm finnrenxes wnh Iha accumula- non of rust or ifmcrc is a change in the mixing proportion during usage. Therefore, Ior ban performance chanqa (he cuuianl veguiarly as weuified in the maintenance scheduie - Mix Oniv drsznlled, vow thENII wavm wnh the annIreem RECOMMENDED MIXTURE: 50 - 50 (DiEfiIIad water and antifrsuzu) REPLACEMENT/AIR BLEEDING _ ~ Tlvr rngiur mm! he Hm! ’79]an vrvlrlllg the molmg Utter". nr Jet-ere scalding may ”TU”. VOTE - thn fiiling the sysrem or reserve tank with a cooianr (checkinq coolant Ievelr, piece the mulorcycle in a verlicai position on a flat, level surface Rcmovcmc radiator cap. Remove [he dld‘ll bulI on [he Wale: pump Cove: and dialn me sysrpm mania—n Re nsrazl the drain bol‘ with ma nsw seaiing washer. {II ANTIFI’IFI IL SOLUTION I IETHVLENE GLYCOL BASE SOLUTION) (2) LOW MINERAL OR DIST” LED WATER (3) C001 ANI n DRAIN a OLT/SEALING WASHER] 6-4 COOLING SYSTEM nemnve the radiator reserve tank mounting bolt (page 6-12). (2| RESEFl VE TANK Discowneul the siphon lube and dram >he reserve tank coolant. Empty the cnnlant and rrnse the lnstde ol the reserve tank with water fislnstall the radiator reserve tank and hymen the bolt lpagc 643). W the system wrth the recommended coolant through the f‘llcr upcnlng up to filter neck. Remove the radiator reserve tank rap and fill the reserve tank to the upper level line. Bleed air from the system a: lullow, t Shift the transmission intn nPIIrrHl. Start the engine and let it K‘HP. rm 2 — a mlnuIeS. 2 Snap the throttle 3 , atrmss to bleed a‘rrlrom the system 3 Stop the engine and add Luularll up to the proper level rl necessary Reinstall the radlatnr map, A. Check the level or coolant in the reserve tank and fill to MP unper level if It is low. THERMOSTAT REMOVAL Ammme - The mguu mus! hr ml N'fnn' Stp‘it'mg m L'oalmg tum", or (were roaming ”my mun, '96- '97~ Dram the coolant LDSQQ 6m Remove the carburetor (page 5-5) Drsmnnent the upper radiator hose and air bleed tube lrum the thermostat houslnq. Remove tne bolts and thermostat h0h<|ng hover, COOLING SYSTEM Remove the O-ring and thermostat After ‘87: Dram (he cuulanl (page 6-4). Remove the fuel tank Ipage 22: Disconnect the upper radiator hnsa trnm the thermostat CSSB CDVEI. Hnmnvs YhP halts and thermostat case cover Remove the O-I’Ing and thermostat. INSPECTION m‘ - um I'm-"laud [10 c and uduqum m prultcrimt . Krrp flmmmrlrlr mart-"mt ufl‘uy frum rm llIL’L‘In'L‘ healing nlcmnnt. V‘suatly Inspect the thermostat for damage r-Ieat the ware; with an EIELIIIL hating element :0 operating temperature Int 5 mmtlI‘F-s, Suspend the thermostat in heated water to check us opera- Iion. NOTE . Du not Iel the thermostat urthertnometertouch the pan. or you wm get ‘Ialse leading, chIacc \hc thermostat ifme valve stays open at room mm, perature, or if It responds at temperatures other than those spectfied THERMOSTAT BEGIN TO OPEN: BO 734 C (1167 183 F) VALVE LIFI'; 8 mm 10.3 In) minimum 3195 10(203 “Fl éRMOs‘rA \I TH 3 , .1 ¢ ‘ 6-6 COOLING SYSTEM INSTALLATION '96 v '97: lnstall (he lhermuslal lulu [he cylindev head WM} 125 hole lacmg upward Insmll a now 0 ring into the groove of me marmosxat hous- ing covey lnslall and ugnlw the housing cover bolts Connect th ramamr upper hose and alr bleec tube [0 xhc hmlslng cover. Full me Syswm Wvlll recommended coolant and bleed mp mr (page 675) I-xsmll the carburetor lpagl: 5 l9). After '97’ lnstall IN: Vermoslat into the [hernlu>iu\ case wulv iis hale facing prard lnslall a new U-nrg Into (he groove of rho thermonal case cover, Install and xlgmen me (hermuslal case cover bolts Connect \ha upper radiator hose to the thermostat case cuver, Fill the system with Vecummende'd coolant and bleed the alr (page 6-4ll Install the fuel tank, COOLING SYSTEM RADIATOR REMOVAL rHSPHDNTUBE , '2)A|RELEED4TUBE r 9/ , \ Dram the content (page 6 4‘. Remove me middle and lowe' cowls (Semun 2r, Di>LOI1necl the srphm mhs and Er bleed tune frorr‘ me radr amr DISCOflnCCl :he upper radiator ruse. Drscnnnect (he [an mowr switch connecmr Drscomvem [he Iuwel Iadiator hose Aim. ‘ ’ 12! LOWE H IATOR HOSE Remove :he upner m \anr Inmamr mmmrmg farms, :0" ' I2) RADIATOR 7‘ ‘, m MUUNTING sons ‘3': and ramamr assembrv, / CAUTION - Hr mr'rm’ IN: n ddnnwt My mdnum'rr'rr, DISASSEMBLV Diauuwlec‘ the fan motor swrtch connermr and rereasp vhe wrre trnm ma mumps. Remove the mrec SH bolts. ground evelen and fan motor/ shroud assemblv, 6-8 COOLING SYSTEM (27 COOLING FAV Rer‘ove mg ml and :Dalwng fan Ron-eve me mu am: (aw motor m NUTS FUr fan r"nmr sthch ‘nfurmauon, refer to page 19-20 ASSEMBLY m RADIATOR (2D COOLING FAN 131 FAN MOTOR ‘MSHRDUD 18 N'm (1.8 kgl-m, 13 Inf-f1) 2.5 NAm (0.25 kgf—m, 1 B ”3”“ 6-9 COOLING SVSTEM HstaH We Ian mumr em: (*2 sh oud and UngII we Hula msm‘l [he uou‘ing [an mm: the Van momr shah by a‘igning :he flax smaces ADDW a ockmg agcm ‘3 the coolmg fan nu: "reads. Install rhe tighten me nut to me spawned :orquc TORQUE 7 5 Mr“ [D 75 kgl-m, 1.8 [hf-fl) Install the fan mororr’shroud assemb‘y omo rm: radiator Raul: the Van mulur switch curd and ground eyelet progeny Inmn and ngmen the 5H bolts, Connect the fan motor swltcn wire to the fan motor switch anu damp u A: :huwn. <2) VUJ’S ' r1 FAN MuruH r‘H COOUNG FAN \ ' . \ (2) FAN MOTOR SWITCH WIRE <4 BOLTS 6-10 COOLING SYSTEM INSTALLATION EAUTION bl ”mm '1: I " 14mm? :m "1.1mm: LLI'I I'IsLaH we Iadlalul‘ dlwgl'ng it: gyuvw'lel way the buss on :he‘rame mm» me upper and lower mounting mums and bows. Tighten [“c belt: securewv Cumen the Ian molor connector Cunnscx the Lower rad’atov hose Cnnnm mp Hpnlflr mmmm rnse Connect mo swphon “ADC and air alccd mm: (0 mo radwator Fi | Mt syske'w wlLII IeLuulmendrd coolant (page 675] I’Vs'éh (HP mvrIrHP and lnwar rnw‘s (SFthnn 24 WATER PUMP MECHANICAL SEAL INSPECTION )nspent the Kama e ho‘e for signs of. coo‘am leakage N then: is \cakage, the mechanical seal is defective add replace me waer pump as an assumb‘y. COOLING SYSTEM REMOVAL '96 - '97: l2) PUMP—fo-CVLINDER HEAD l1lBYPASSHOSE/,, HOSE 7 V (a) PUMP coves /' “I \ -\ An» '91- m WATER BYPASS Disconnea the following: — Watcr pummnrcylindar head hose (‘98A '97.) 7 Bypass hose - Water pump-to-oil comm hose — aner radiator hose Remove the M0 SH bulls, two flange bolts and water pump cover, (4) PUMP- I'D-OIL COOLER HOSE 45’ LOWER RADIATOR HOSE Remove Ihi O-ring Irum the water pump body Disconnect the water pump-m-wnter 1mm hose and remove the. water pump body from the crankcase. INSTALLATION '96 - '97: After '97: (ll WATER PUMP BODY (3) 93' mum; (4] WATER PUMP COVER 13 N m (1.3 kgl‘rm. 9 mm) .\ 14) WATER PUMP 13 N-m 11.3 kgf—m,9lb1rhl COVER 6-12 COOLING SYSTEM Aupw cngmc an to a new O-nnq and uvsm w unto me steamed ponior cfthe wale' pump. \nstal "15' water pump unto the crankcase wh'tle awiqning the water puma sha’t groove with the uil pump >haf-t end Lament the watc! pumpvtovwator mint hose and Mg- Ien the clam) screw. Align the mountlng bolt hnles In the water pump and crank case and make sure the water pump '5 securely mstaHed. main“ 3 new O-rmg ink) the guoove in the water pump I- :Ad‘l we water pump mwr and tzgnter thc (our bats to the '55 A - «'2' PUMP‘TGCVUNDER "r A” 111, Um: remove me ramatm reserve rank (mm the flame Dlsconnect the overflow tube and siphon lube. Drain xhe cat-rant from the reserve rank. INSTALLATION Instaflanon ‘5 m the reverse Greer of removal NOTE \nstaH the radiator reserve tank alignmg us bussgw with the meme mm and SM. 6-14 MEMO ENGINE REMOVAL/INSTALLATION '39 N-m M D kgf-m, 29 Ibf-m 39 N-m (4‘0 kgl-m. 29 mm) 54 Nm {5.5 kgf-m. d0 lbf‘fll 11N-ml1,1kgf~m,- 8 lm-h) M N‘m (5‘5 kghn, \ V Fr \ \‘g‘ 33 mm «a? ‘ \SR \ V‘ \ flxJ-F’ W‘fiy m ‘ \0 fig 26 N~m {2.7 kgfrm. 20 MM!) “xx 9.; it my» 54 N-m (5 5 kgt-m, ‘0 1mm 7-0 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-1 ENGINE REMOVAL 7-2 ENGINE INSTALLATION 7-5 SERVICE INFORMATION GENERAL - During engine removal and installation, suppon (he motorcycle uslng n safety mm: m nmsi CAUTION - nil nil. me (in, mutual m “piling ,mim - The following componcnrs can be servlced wlrh (he engine installed in (he Irarrla. — AlIemanr (Section 10) — ClquIl (Section 9) — Cylinder hand/valves [Secllnrl HI — Gearshift linkage (Socrion 9) , Oll cooler (Section 4) — Oil pump (Sucliun 4) — Shift forks/shift drllm [Semmn SI — Water pump (Section 61 - The (allowing cuniponenu requile engine Iemuval (or service. — Crankshaft/transmission [Sec'lnn 1?) — l’lsmnl'cylinder (Section 11) SPECIFICATIONS fl ITEM SPECIFICATIONS Engme dry WGlght Except Calilurnia M '96 - '97. 55.9 kg (141.5 lbs) ‘Ype After '97: 7 65.3 kg (155.2 lbs! California lvpe ’96 — '97: 68.2 kg (150.4 lbs) After '97: 67.5 kg (149,1 lbs) Coolant capacity Hammer and engine '96 , '97; 2.77 lifei (2.93 us qt, 2’44 Imp (In Afler '97: 1.641ilar12.79 us ql, 2.32 Imp qr) Engine oil capaciiv AI disassembly \ 4.4 lircr (3.3 U5 qr, 3.9Imp qt) TORQUE VALUES LeII Englne hanger boll Right anlne hanger boll Engine hanger nu! (Rear/upper) Ifieal/luwel) 39 Nvm (420 mm, 29 lbml 44 N-m (4.5 mm. 33 Ibf-III as N-m (4.0 kgl-m, 29 IbI-llI 39 N~m (4,0 kgI-m, 2s lbI-ft) Engine hanger adjllstlng nnn rngme hanger adjusting boll lock'nur Engine hanger plate hon Drive sprocket bull TOOLS Lock nut Wrench ‘11 Nem(1.1kgI-m,8|bf'm 54 Nm (5.5 kgi-m. 40 IbHKl 26 Min (2,7 kgI-lrl, 20 MIN“ 54 Mm (575 kgI-m, 40 IhI-III 07HMA — MR7I'I7I'II') 7-1 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL rlll’SlDE STAND SWITCH CONNECTOR Remove lnefollowanl 7 Midd e nllC lower Bowl (Sectlnn 7) — Fuelmnk mags. 2-2: — Exhaust syslem lpage 2 ll) 7 Carburetor :aaqe 55) Disconnect mp alternator 3P cunnemar and side stand swncn connector. Release ‘he alwrnatnr and Slde stand swnch wlres from me clams. Disconnect the following connector: {17 CONNECTORS — lgrmion pulse generaror 2P (Black; connecmr 7 Sperm 59mm SW (Blank; nnnnnrxnr 7 Oll pressure swxlchmcurral sw‘lrcmhcrmo sensor 3P lBlackl connector Disconnect the «lr bleed mm and upper ranlatn' hose Nnm me lhermostal housmg cover, Dlscunnect the spark plug my; 7-2 ENGINE REMOVAL/INSTALLATION .__.__.. Remove ma non a'vd staner motor ground ”we, (2) STARTER MOTOR CABLE Remuve the nut and «may motor cable, ’ ' " Remove me clutch cable (mm the hulde: and lifter arm Remove the radiator lower bracket DOHS. Disconnect the Inwer radiator hose from (he waxsr pump ' I 12) GEARSHIFT PEDAL LNK cover Remove the huh and gearshih pedal lmk. l1) LOWER RAD‘ATOP HOSE ENGINE REMOVAL/INSTALLATION Ramove the SH ooh», wwe sp'ucku: cover and gums plate l3! DRIVE SPROC ET V Loosen the may axle nut and make the dnve chain mack lqu‘ Rem owe Ule bulll washev and awe sprucket. npmnw: me ‘Mrfllnwer engme hanger mu Loosen the engme hanger adjustmg mm lnrk nut while no‘dmg the adjusting bow using me special moi, TOOL: Lack nut wrench 07HMA — MR70200 x1) L0_Q< «LE WNFNZ‘JL], 7-4 ENGINE REMOVAL/INSTALLATION 711'“ the adjusling boh counterflnnkwuse m retease {he duju: mg bah from m». angme. 1|) ADJUS IN Tm RIGHT HANGER 30L Remove ma rlgm engine hangev bolt and distance mnar. Remove m... \efl engine hangp! hnlvs Remnvp MP rear uDDer engine hanger bu‘L/nux, distance uu|~ Isrs and spacey. Loosen the engine hanqer bracket bulls. Remove [hp rear/\nwar engme ranger boil, then remove the engine from me (rame. ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION m sous CAUTION ' (It . am in 11.: A,“ ,.. w w my” 1/: [name r‘nmmmg finwm :w Hm mum ' n: r irnmhvd bdrm If the cngmc hanger plaxea are removed, inelaH the hanger plates and Ioosely InsIalI me bOIKS. NOTE » ane m: dIrec'Inn m m». hanger hnlts InslaII the engéne mm the frame I InstaH the marxlowcr engine hanger bolt. InCvIlndeI head warpage V 0.10 (0.0041 Valve. valve l Valve clearance l (N 0.13 0.19 (0.005 — 0.0071 . 9‘13““ '00 — '07 i rx 0.19 a 0.25 (0007 ~ 0.0101 — ’Aher '97. 1 Ex 0,77 — 020111.005 , 0.0111 — Valve stemioD. 7 IN 4.47r—4,490 (0.17624117681 4.405 (0.17531 ‘ EX 7 7 4.455 — 4.430 (01750 4117541 1 44551017541 7 Valve glllde I.D. IN 4500 — 4.512 (0.1772 — 017751 l 45401017371 I Ex 4.500— 4.512 (0.1772 41.17701 4540 (0.17371 ‘ Slenl—IO-guide clearance IN 0.010 0027100001 - 0.00151 1 EX 0.020 , 0.047 (0.0000 — 0.00191 —— I Valva guide projection abova IN | 14507140010575, 0.5831 1 — l W'MQ' “93" EX I 1‘8fl—15.DO(01533 0.5911 ‘7 —— '. Valve sear width lN/EX l 0.90 ,1 10 (0.0357 0.0431 l 1.5 (0.061 Valva 511an Inner lNlEx 35.77 (140111 34.07 (1.3411 "59 leng‘" Ourer ‘ IN/Ex 39.59 (1.5631 37.79 (1.433) f Valve lifter Valveiher 0.0. Irv/EX 25.970 — 25993110220 — 1.021331 25.07 (1.0221 l Valve llfler bar; LD. IN/EX ( 25.010 ~26.026 (1.0240 -102401 2604110251 8-1 CYLINDER HEADNALVES Unit: mm (in) ITEM 1 STANDARD 5:1:ch umn Camshaft Cam lobe l Except California ' IN 1 35,040— 35.700114109452331 as m 11 41a) "“9” 1 WW EX 3 35.800— 36.0.10(14094_1 4189) 3577 (14001 l Calilumia lype IN 340940—35.180(1.3756-1,3850) 343111370 7 l , ex 35.100453401103319-1.3913) 35077110387117 Runout 0.05 (0.002) 011 clearance 0.020 — 0.062 10.0005 — 00024) 01010004) TORQUE VALUES Breather plats flange bolt Cylinder head stud bolt Cylinder head cover special boll Camshaft holder flange bolt Cylinder head socket boll Cam sprocket boll Cam chain tensioner lifter mounting bolt Air bleed luszoint TOOLS Cnmnmssmn gauge attachment Valve spring compressor Valve spring compressor attachment Tappet hole protector Valve gum driver Adjustable valve uuidc driver Valve guide reamar. 4.5 mm Valve seat cutters Seat cutter, 27.5 mm (55‘ IN/EXl Flat Butter, 30 mm (32‘ IN) Flat cutter, 27 mm {32“ EX) Interior cutter, 30 mm (605 IN/EX) Cutter holder, 1 5 mm 12 N-m (1.2 kglvm, 9 letl 25 N-1r1(2t8 kgl-m, 19 lbl-lll 1O N-ml110 kg'rm, 7 ”3”!) 12 N-m (1.2 kgf-m. 9 lbf-ftl 47 Mm (418 kgf-m, 35 lbf-fll 20 N-m (210 kgl-m, 14 ”WM 12 N-m l1.2 kngrnl 9 lbf-fl) 25 Mm (205 kgf-ml 1H lhf-fll 07RMJ — MVSD‘IDO 07757 A 0010000 07559 - KM30101 D7HM6 — MIT/0002 07I lMD -— MLOOlU'I 07743 - 0020000 07HMH — ML00101 — llluse are uonuneruiallv 07780 — 0010200 0/780 — 0012200 07730 70013300 07730 - 0014000 07721 — 0010600 Apply a lockan agent to the threads Apply all m the threads Apply a locking agent Lu the threads l'quivnlentnnmmarcially nvallnbla in U.S.A. Not avallable in USA or 07HMH — ML0010A(U.S.A. only} available in USA. 8-2 TROUBLESHOOTING CVLINDER HEAD/VALVES - Engine top-end problems usually allecl engine performance These problem ran he rllagnosed by a compression lost U: by (lacing engine noises to the top-end With a sounding rod stethoscope. - H the performance IS poor at law speeds, check for whltc smoke in the crankcase breather tuba, If the lube is smoky, check for a scizcd piston ring (Section 9). Compresslon too Io’wl hard flaring or poor poflurmance allow speed - Valves: - Incorrect valve adjustment 7 Burned or barn valva — Inconecl valve liming — Broken valve spring — Uneven valve scaling - Cylinder head: - Leaking 01 damaged head gasket — Warped nr cracked cvllnder head . Worn cylinder, piston or piston rings {Semlon 9i Compression too high, ovethuting or knocking - Excessive carbon hnild-Ilp nn mstnn crown or on com- bustinn chamber Excess Ismnke - Cylinder head: — Worn valve stem or valve guide Damaged slam seal - Worn cylinder, piston or uislon tings (Section 9) Excessive noise . Cylinder head: Incorrcm valve adjustment —- Sticking valve uv Lnuken valve spring — Damaged or worn camshrm — Loose arworn cam chain Worn or damaged cam chain tensioner -— Worn cam spluckel teem - Worn cylinder, piston or rnstnn rings lsmron an Rough Idle - Low cylinder conlplessiun 8—3 CVLINDER HEAD/VALVES CYLINDER COMPRESSION TEST MA, _A_ A; ~ Ifm album Imnl I..~ ”mun”; m H.) (um? and. mm xmr m." 1hr arm n er-vrnnkzrcd. ,\(I'rr run 1hr ulgmt m an inflated arm. The u—Imusr mnmzm puuum/m mrlmn manrmdc pm llml mm ”lust hm Ufmuxrl’uurmrx and may ll/Izd III din/uh. Warm up ma mgme to normal operntmg tampa'ilu's Stop me cv‘ginc and remove the 3H spark plug cap: and 'emove (he one spark plug 31 a ume‘ \IOTF - To measure me Wlindel cunmression DI edCI‘ L‘ymlden lemove cnw one plug a! a lime \rs‘al‘ a cowprcssion gauge, TOOL. Cumpression gauge anachmem 07HMJ - MV50100 (Equivalem commercially available in USA.) ’Jpen -. a throttle aH this way and rank ma Pngma wwh the starter motor urm: me gauge reading stops rlsmg T'm maximum reading ‘9 usualtv reached within 4 - 7 sec- D'IUS. umdumg «9 me ballerv, do nut ope:ate We many "water for mm 'han wan «2mm: Compression pressure: 1,177 kPa (12.0 kgf/cml, 171 psi} 2:1 500 - 600 rpm ’95 - '97. 1 2 kFa [13,0 kgI/cmi185 psi! at 350 rpm After '97‘ Low compress on can be caused bv‘ — BIown chinder head gasket 7 Improper valve admstmem — valve .eakage Worn aiszon ring or cylmdev ng" compression can be caused by — Carbon drpusiIs in combustion chamber or an aistnn CYLINDER HEAD COVER REMOVAL Remove [he IuIluwmg: — He! ran»: 4mg» 777x 7 Muddla’lower cowl (page Z 6‘ 7 Air c‘eaner housing (page 5-41 _ lgnniuu um ausevflbly \pa 7-67 Remove the radiator Jowm mounting bolt and move (he 'adialo' forward, \\\ {1" nm r 8-4 CYLINDER HEAD/VALVES Rcmcve the bolts ana aw ueflaclor D>SEDN195§ 11-:— kreatlwr (“he I'nm rm cyhnder head cover. Hemnveme ‘mlowmg, Specie nulls — Washer: 7 Cyl nner hnad rnvnv — V’ackmg CAMSHAFI' REMOVAL Remove the (Minder heat.- cove‘ Ipage 8-4}, Remove the crankshafi hole cap and O»ring. mm the crankshah clockwise, a ign the "T" mark on the igmion pulse generawr rotor with the index mavk on me \gnilion pub: Henelator rotor cox/Fr, Make sure me Me. 1 plsmn 15 m TDC (Top Dead Center) on the compression woke. CYLINDER HEAD/VALVES Remove the cam nham tensmher hfter sealing Doll and sealing washer. Turn [he lensvoner filter shaft fully in [dnckwlst-J and securc <1 using vha stonpertool. This tool can easily be made tram a thin 11 mm thicknen} piece of steal, 15 mm 19 mm 15 mmr F15 mm ‘ METERXAL THtCKNESS. 1.0 "rm 4.5 mm If you plan to replace the camshafl and/or cam sprocket] luu>en the cam sprocket bolts as fnllnw: NOTE ll is not necessary to remove the cam mmnket from the camshaft except when replacing the camshaft and/or cam sprocket. — Remove the cam sprockel be” from imake and exhaust Camshafts, NOTE He caratul not to drop the cam sprocket bolts Into the crankcasc‘ — Turn the crankshaft one tun mm (360‘), remove the other mm sprocket bolt from the camshaftst Rcmovc thc cam sprocket from the camshaft, Remuv: the cam chain guide H hnIL (2 SEr\L\NG WASHER 8-6 Loosen and 'e"ww Hie camshaft home» hnlrs, mm remove li‘e cam chain guide Fl, ramshan halaers and camshafts. CAUTION ~ Fm», WM 1., le‘ 1mm" w mm m a rnvtcmn pamrr: m ”pr it \vU ‘ \l, . ht :unu’nafl unlacr n1:gh:brm!. VO‘E - Hllspn'Vd me cam chain with a piece 0! wire [0 prevent the chain fvom falling into the crankcase. - it is not necessaw Eu lemme :he dowel plns lrnm the camshaft holders Remove the valve liheis and slums NOTl' - Be careful rim to dallmye the valve lifter bore - Slum may stick to the inslnfl at the valve lifter. Do nm allow the shimsto fall imo the crankcase. - Mark all valve lifters and shims (0 ensure uuneul reassemr bly in. man or'glual localiuns, - T‘Ie valve liflet car be sunny mmnved With a valve lap ping too D. magnel, ~ The shim: can be easily removed with a lweeAEIS m magnet. INSPECTION CAMSHAFT HOLDER inspect the bearing surname of the camshaft holder for scor mg, scralcv-es. or cwdcncc of insufficiem lubrication. inGpeclthe oil orifices of me mum [ur ulugging, CAMSHAFI’ RUNOUT Support bulh ends of the camshaft wnh Vrhlnrks arm check the camshafi runom win a dial gaugc' SERVICE L|MIT: 0.10 mm (0.005 it‘l) CYLINDER HEAD/VALVES l1) BULIH 8-7 CYLINDER HEAD/VALVES CAM LOSE HEIGHT Usmg a mmrometer. measure each cam lobe ncwgm. SERVICE LIMITS. IN ExcepI California type' as 01 mm 11 415 ml California type: 34,91 mm (1.374 in) EX: Except Callfornla type: 35.77 mm (1.408 inI Cal'flomifl lvpe‘ 35 D7 mm ([381 in) CAMSHAFT OIL CLEARANCE Wipe any m1 Imm the JournnIs of the camshaft, chindcr head and camshah hoIdere. .ay a strip DIplalsfig3.15mleuglhwifi.I on mp of each camshaft um Hal. Wash the czwsnah homers and Ughlen me bake in a 055- uu» palIe'n im 2 73 steps NOTE - Do not mme the camshafit when wng plasngmlge, TORQUE: 12 N4“ (12 kgI-m, 9 IbH‘t) Remove the ramahafl hnlners and measure me Wldlh of each plashgaugc The wines! INC-mess determines the UH :Ieara'mu. SERVICE LIMIT: 0.10 mm (0.004 in! I When lhe service Iilmis ave exceedeu‘ rapIace the camshaft 3rd raved the CHI r‘ea'anm’. I'm—Mme the cylmdev head and camshaft homers as a set If the c‘cavance an exceeds :19 serwce IIm‘L 8-8 CAM CHAIN GUIDE B Moon the cam chain guide for wear or damaqs. CYLINDER HEAD REMOVAL Disconnect Hie following. — Camshaft (page H-B) — Coolant rempcrarurc sensor connecmr , Arr bleed rubs — Upper radiator hose ('96— ’97) 7 Water hose (Ann ‘97:! — Water pump~mrcvlindnr head host: (‘96 — '973 Bypass hose ('96 - ’97:) — Thermuwfi saw clamp bolt (Aher '97) Hemnve the lower radinror hose and push radlamr as lor Vorward as possible whan removing cilinder head. Remove rhe cam chain tensionar mounting my nul and seal- inq washer, Remove the cam (ham 'enmnner. Remove the lek upper engine hanger bolt CYLINDER HEAD/VALVES (1D CAM CHAIN GLHDE R .12: AIR BLEED TUBE 11) CONNECTOR \\ (E) THERMOSTAT \7 CASE CLAMP BOLT (After ’97 A, 7m - PPER RADIA'OR g» HOSE ('96 , '97" ‘ WATER HOSE @(After’SI) $5» / -.~ Fax ‘22 15) BYPASS TUBE \"95 — '97.) 1A) l'UMP-TOACVL‘NDER HEAD TUBE (’96 '57:! CYLINDER HEAD/VALVES Remove the {we 6 "1m flange bolts x“ 6 mm BOLTS . (2) 9 mm_SPEC|AL BO‘LTS Remuve Ihe (en 9 mm snma‘ hnns NOTE - Lousen the 9 mm :nenlal hnlvs m a mssmm: narern m 7 - 3 stems. Remove the cvlmdar nead‘ Remove ma dowe‘ pins and L‘ylmdw head gaakel‘ “Pmrw! w» :gnmo’t pulse generator roxor cover (page 17-71. Remove me bolt, Cam mam gum}: am: Lollav CYLINDER HEAD DISASSEMBLY Remove the spark Drugs from the cvlindar head. mm“ the Iappet hd: pmtecmr mto'mp valve Imer hnre TOOL: Taupe! hOII prumctur 07HMG - MR70002 8-10 CYLINDER HEAD/VALVES An Pmnvfi‘ert moi can casuy a: made irorv a p‘asuc 35 mm Mm ccnminev 55 shown. TOP VIFW Reh‘cve the 0am, spnng comers 05mg [he specie! 10015 as shown. TOOLS: Valve spring compressor 07757 - 0010000 Valv: spring compressor anachmam 07959 — KM30101 CAUTION ~ I": n. \(n' J02: n,’ :tnmm Jo rm! L‘Jmprcs; 7’75 1‘ng p ”1757103 mun Remove the Folk)» ving. — Sprmg retamer — ()utfir rd Inncr vawc springs Va‘vc — Stern sea! — Im‘wer and outer valva snnng Seals NOTE - Mavk al paw r1 ng dusassemb‘y so they can be placed mm Iocatwons. hank n their 0' ‘(41 STEM SEAL ’L’h INNLH SPRING \‘13 RETAINER (2) OUTER SPRING CYLINDER HEAD INSPECTION ' ‘ '0“ch CVLINDER HEAD V Remove carbon deposws from «(a cumbustiuu chambers. Cnecnne spark plug he‘s and valve areas for rranks NOTE - Avu u unnagmg the gasm COTI’ER (A) VALVE GUIDE @ ‘\ “9' ’(ar RETAINER \ @r > \ ‘ \ g ‘ ‘\ (9) INNER SPRING ' K ., ' ‘ \ © 8/ (10] OUTER SPRING x g \ MT,\ I12) INTAKE VALVE <11) EXHAUST VALVE 8—17 CVLINDER HEAD/VALVES Clean me cv'lnder head assembly wim solvent and blow thlougll all uil massage: willl UUlllp'eSSEd air. lnsmll the lnner and outer valve sprlng seats. ' ('lrl VALVE ' Install me new slam seals. ‘ (2) SPRING SEATS ' ‘ aka Slem seal has identlficalian praiecnon on [he \ , cum surface. lnslall each slum seal lu Llueir proper pusiliuu. ' fi 0 ‘ 1° \\(3) STEM SEAL _ ‘lu INNER SPRING [5) HrTAINEH (b) OUTER SPHlNCl Lubricate the valve stem: wlth molybdenum nlsrlmna ml and meenme valve mm the valve QuldB. To avovd damage to the sram seal, turn the valve slowly when lnsemng. Install the valve springs with me (ighlly wound coils facing the con'lbustlon chamber lnsmll we valve sprlng retalner. g E H) FACING THE COMBUSTION CHAMBER lnsfnll 1hr, vmnn hole nrntecmr mm the valvP hfler horn W TAF‘F‘FT HOLE PEOTECTOR TOOL: Tappm hole protector n7HMG — MR7ouoz {Not available in U.S.A.) lnstall the valve Cutters using the special mo! as shown. Tu plavam lua, u’ Lellsiull, 'Ju llul culllpress the valve spr'lrlg mnrema" nearsurv TOOL: ' Valve spring compressor 07757 — oo1oooo Valve spring compressnr nnachmznl D7559 - KM30101 8-18 CYLINDER HEAD/VALVES lll PLASTlC HAMMERS Tao the valve slew: gelllly Wllll [Wu plastic hammers as allow" to seal the Carters flr'nlv CAUTION . WWW W . .lluJu lmlmw 1/“ ml [hm]. Wm.-.mpmm: - h‘n‘ .inmuul- CYLINDER HEAD INSTALLATION ‘ m CAM CHAIN GUQEX 4n.- 'v lrseall the collar onto me cam chain guide plvol. _ ‘ lnsrall me cam chain gulde and lithan the non. v ‘ lhsta‘l the :gnivinn pu‘sa ganamnr rotor cover lpege 17-9n lnmall mp dnwel mm: and a new cyllnder head gaske: as show: l'lSlall xhc CYllfldef head. Apply all m the mrams and 59.3th surface of me 9 mm soecml bolts/washers and install lhcm‘ lnstall the M0 6 mm flange bolts. ngmen the 9 mm special bolts in a crisscross pattern in 2 — 3 snaps to the spammed torque TORQUE: 47 MRI (4.8 kgl-m, 35 lbf-fl) Tighten the H mm flange nnns CYLINDER HEAD/VALVES Instafl the left upper engrnfi hanger mm. , \ m HAVGEF BOLT 1 Tighten the hanger bah to the specified (orque‘ ' TORQUE: LEFT 39 Nm [4.0 kgf-ml 25 [bf-h] InstaH the cam chain lensloner mm the nylinder head \nsml the new SEEIlng washer and tighten me nut. x , g} CANLCHAINTENSIOfiJER Installthe Iollowlng: W CONNECTOR\\‘L ‘ 42; AIR BLEED — Camshaft (page as) I6>THERMOSTAT , Q" TUBE 7 Coolant temperature sensor connector CASE CLAMP ’ am _ A" mead xube um I . UPPER RADIATOR Uopcr radiator hose (’96 » ‘97:) — Water hosa (After ‘97.) — Watev pump‘Io-cyl'xnder head hose ('96 — .9” — Bypass hose 1'96— ‘97:) Thermosxar case clamp bolt {After ’97:) IAfxar '97" HOSE ['96- '97:) _- WATER HOSE 79 .5Lm(Afier '97:. $9 \_ f /\;5_ :5: BYPASS TUBE (’96 — ‘97:} :14) FUMP~TD-CYLINDER HEAD TUBE ('95 — '97:) CAMSHAFT INSTALLATION Apva mowbdenum disulfide oil to [ha outer mute uI [he each valve Iifter, Install ma shima and valve Iifiers into me valve liner bores. 8-20 CYLINDER HEAD/VALVES IV ms cam sorockels me 'emoved‘ instaii the cam sprockets iii Na 1 CAM LOSES unlo We Camsha‘ts NOTE - install the inlake ram spmckm mm me nmmg mark ilN) caning nufward and the NDJ cam lobes iacing up and out as shown. - Insxali the exllausl Lam sprocket with the timing mark (EX) fac ng outward and w. No 1 {mm lobes faclng up End nil! RS shnwn. , . .3: EXHAUST (2AM Ciean and apply a IUL’kmg agelll lo lhe cam spiocket bolt threads, (2} BOLTS /’ Temnnranly msmll the cam sprockei Dons. Him the crankshah clockWise and align the “T" mark on [he 1 I‘ ig. ' ion puxsa ganarawr rumr with UK: hidex mavk on [he ; M" ignuiuu pulse generator rmm cover «1) ”T" MARK Apply molvbdenum diaulfide oil is the camshafl mum“ on the cylinder head and camshnh holder. CYLINDER HEAD/VALVES nstaH t'e ca'“ sham over the cam satockets and than ">13th;-mtdkuam.‘exhcua‘tLdHlahdfls, \JQTE - sttaH the mt» camhllafl lu .he correct ‘OCaUOnS Wll" ma tnpnnttcattnn math-s "IN' Intake camshaft “EX .Ex~aus: camghaft - Make sure thdt the titrttrtq marks on :re cam sprockets are ‘acmg outward arm flush with the cyhhdet head upper su'iacs as shown Instcl‘t the camshaft homers onto the camshafts. NOTE . lnstaH the each camshaft ho‘dcr to the correct tocattons W‘th ths identtfication markst "\N" I‘Wtake camshaft haidet "tX"' tthm cnmshah hnldpr TP-‘porar 1y Irstall the elghleen holdev bolts untit the cam hornets Itg-ttly Contact the cylinder head sums, CAUTION - 23mm r the mmn‘hm lwtm mm ht; hut-s “mm n‘tg’h‘ ‘rl'lh' a rams/ta homr lo Mu)“. Vflfita“ the cam chain guide B, cam chatn gutde mountmg but and rewaimng carrshaft hotder butts, Whtte pushmg the cam chain gmde u m the dtmmton n! the camsha‘t rotoer, temporarflv tightcnthc holder bolts, 8-22 CYLINDER HEAD/VALVES Tighten a” :amsha‘v homer so'ls m the numevica‘ order . ' ‘ 7"» ’l'” BIOLTS assist: on the camshafi~ homer. TORQUE, 12 NM [1.2 kglvm, 9 let) ‘n Casi me cam sprocths warn. mmoved, ugmcn mo cam sprockex hnlfs to the specified torque. TORQUE: 20 NM (2.0 kghn, 1‘ “JV-m Turn me crankshaft clackwise one full mm (360“) and tighten the mher cam sprockc! nous. Tiqmeu the cam chain guide 5 how Remove the snapper tool from me cam clmin (ensioner lvfler, InstaH a new sealing washer and tighten me 593an boll. Hecheck the valve timing, (3) TENSIONER UFTER ! 8-23 CVLINDER HEAD/VALVES CYLINDER HEAD COVER INSTALLATION Apply sealant lu lhe cylinder head semi-circular cul-ouls as shown lnstall the cyllnuer head packlng Into the groove of the cylinder head cover, Install the cylinder head covev anlo the cylinde: heau. lnsmll ma washars wwh mmr "UV" mark hung up lnsmll and tlgmen the cvllndel head cover spemal bolts to me specified torque. NOTE - Tigwten me "A" marked suds bolls firm. YOHOUE' 1D N-m (1 0 Itgf-m, 7 IM-H] (1) JIM” CUT-OUT 8-24 Corneal me brcamm tube, Insm m;- 21H dehecxar and txghten the hon: NUH - WhHe hmdlliug [he ail def-sewn route 1m- mam wwe new mass and a.» mm mm n'nperw as snnwn. lmlafl and hgdter‘ thp ramamv lower mnurmng bolt, Insmn m: foHow‘ng: — Hmltvcfl cL-il dh:elllLl‘)’ luage 115} >Aiv deane' hnmmg [page 5-4) # Nmma lower cowl mags 2 6\ Fucnam {sage 2m CAM CHAIN TENSIUNEH LIFTER REMOVAL Remove (he righl middle cowl (Gage 2-6) Remove the ban and nghl rmddle cowt bracket, (1D RADIATOR CYL|NDER HEAD/VALVES ' m BOLT ‘2 M‘DDLE COWL BRACKET CYLINDER HEAD/VALVES Remove the cam chain lans‘onar sealing bak and sealing m SEAI ING Bun (2) SEALXNG WASHER washer. Turn me tensluner shah fully In (clockwlsc) and secure ll using the slopper 1qu In plevenl damaging the cam chain, See page 8-6 for detail of the moL annvn the halts and mm nhnln mnsioner lifter. (2)TENSIONER Remove the gasket "V ‘ LIFTER INSTALLATION Install the new gasket onto the cam chain tensionev Imu. NOTE . Mme me duremion ofthe gasket. 8—26 Install the cam chain lensioncr Ilfler into the crankcase and ngnren the mounting balls to the specified lolquev TORC‘JE: 12 Nrm (1‘2 kgf-m, 9 Ihi-m Remove the «rapper tool. lnsrall a new scaling washer and lighlen the sealing boIQ securely. Install thfi removed pans in the reverse order of removal. CYLINDER HEAD/VALVES (“TENSIONER LIFTER l [ZlEOLTS ,4”, m SEAI 1m ‘30 i 8-27 CLUTCH/GEARSHIFI' LINKAGE 12 NM (12 kgl‘m, 9 lbflfl 9-0 9. ULU I CHIEEAHSI'III'I LINN-“it SERVICE INFORMATION 9-1 TROUBLESHOOTING 9-2 RIGHT CRANKCASE COVER REMOVAL 9-3 CLUTCH 9-4 GEARSHIFI' LINKAGE 9-11 RIGHT CRANKCASE COVER INSTALLATION 5-16 SERVICE INFORMATION GENERAL This section covers service ol the clutch, gearshift linkage, shtft drum and shift forks. All service can be done with the engine installed in the frame. - Transmission ml ViscesItv and level have an effect on clutch disengagement. When the clutnh does not disengage or the motorcycle creeps wlth clutch disengaged, inspect the transmission 0" level before servicing the clutch system. SPECIFICATIONS — CLUTCH/GEARSHIFI' LINKAGE . . ”m“ "‘m M ITEM ‘ STANDARD ‘ SERVICE LIMIT Clutch lever free play 10 r 20 (3/8 — 3/4) — l Clutch spring tree Iangth '96 — '97 50.2 (1.90) 49.2 (1.93) After '97: 43.3 (1.92) 01.01135) Clutch dlsr. thickness ’96 ’97: . 2.62 — 2.7810103 — 0.109) 7 3 (0.09) After '97: 2.92 - 3.051011 — 0.120 2.0 (0.11m Clutch plate warpage — 0.3 (o 012) cmmn outer guide I 0. 24.9935 4 25.0035 (0.93399 — 0.98450 25.016 (0.9349) . 0.0. ‘ 30975—31991113170713770 34355113706)— Mnmshnft 0.0. at clutch outer guide 24.930 — 24.993 10.91135 - 0.1mm 24.96 (0.533) snm fork. Iork Fork LD. 12.000 — 12.021 to A724 — 0.47331 . 12.03 (0.474) ““3" I CIaw thlckness’ 5.93 — 5.00 (0.233 — 0.225) I 5.91023) Fork shaft 0.0. 11.957 — 11368104707 - 0.4712) 1 11.9510 070; TORQUE VALUES Right crankcase cover SH bolt Clutch center lock nut 127 Mm (13.0 Gearshift pedal Spring stopper Shin drurr center bolt snm drum bearing sel plate bolt TOOLS Clutch center holder Driver Anachmen1.37 x M) mm Attachment, 42 x 47 mm Pilot. 35 mm 0772‘ - 0050002 07749 7 0010000 07746 — 0010200 07746 - 0010300 077‘s ~ 0040801] 12 N~m 11.2 kgI—m, 8 7 lbivft) kgf—m, 95 [bf-ft) Apply oil to the threads Stake Ihe nut 22 N-m (2.2 kgI-m. 16 IbI-Il) 13 Nirn (2.3 kgI-m, I7 lbf-ftI 12 N>m (1 7 kgI-m, 8.7 lbf‘fi) Apply a lackIng agent to the threads Apply a locking agent to the threads EquIvalcnt commercially available in us A. 9-1 CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Hard fa shift - Incorrect clutch adjusrmenr - Improper oil viscosiw - Beul shifl l'ork . Hem shm rnrk shah - Bent fork claw - Damaged shifl drum cam groove . Luuse sluppel plale boll - Damaged stopper plate and pm - Damaged gearshlh spindle Transmission iumps oul ol gear - Worn shah drum stopper arm - Weak or broken shift arm return sprlng - Loose stopper plala boll I Berll shill lurk slwafl - Damaged shm drum cam groove, - Damaged or bent shift forks ~ Worn gear engagement dogs or slols Gearshift pedal will run! ra'urn . Weak or broken gearshlh spindle return spring - Bent gearshift spindle Clutch lever no hard m pull ln - Damaged, kinked or dirly ulululr cable - Damaged clutch lifter mechanism - Faulty clutch llher hzanng - Clutch lifter piccc lnsralled lmproperly Clutch slips when acczlernting - Incorrect nlumh adjustment - Worn clutch disc - Waak clutch springs . Transmission all mixed with molybdenum nr graphm: additive Motorcycle mops wkh tho anginc idling - lnuurreul clulch adjustment - Clmch plate wan-lad - Loose clutch lock nut - Oil level me high - llnpruper uil visuusily - Damaged clutch mm mechanism - Clutch llfter piece lnsrallcd improperly 9-2 CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL Dram U'e e'Vglne oi“ (pagp 3-12) Remove the clutch came holder 5H bulls and mulch cahle hclder. [hen disconnect (he clutch cable 0mm the clutch arm‘ Remove the right crankcase covav SH boIzs and vigm cranncasa COVER Remnve the geskc‘ and dowel pins. CLUTCH LIFTER INSPECTION fipmnve the clutch fitter arm, rmurn spring and washer I1: I ll WLH ARM (3) WASHER Check the return spring for fatigue or damage. (2' LIME“ ARM Check the clutch lifter arm shah for Wear 01 bending W“ RETURN SPRING 9-3 CLUTCH/GEARSHIFT LINKAGE CFcck 1'6 need‘e bearings for wear, damage or \nnsa h’ Crack Fe dust sea‘ for ‘auguo or damage CLUTCH REMOVAL Remove the clmch flange bokc, GDringG and pressure plate. Hpmnvp Ihp rmith hher mace and Dea‘ mg Ilamnvmheiollowing Clutch dwsc C 1Aher 'um — Clutch discs B —C|ulc|\ pldies 7 Clutch disc A iJudder spring —Spring seat Unstake (he Clulch cempr lock nut 9-4 CLUTCH/GEARSHIFI’ LINKAGE ‘rlnid we. clutch ccnlcr with [he ciutch cenlel huldgrr lhen 110% me look nut, TOOL. Clutch canizr holder 07724 — 0050002 {Equivalent commercially availnbla in U.S.A.) Disrarn the iDCk HM. Harrow-1. me ionk washer, thrust Wagner and clulch neutral. (1) LOCK WAéHER Rel l love (he \vashm Hemovctho ignilion pulse gellerulur luml cover {page 117) H A\igvl lhe primary rl'lvfi gear and sub gcar mom with a screw- driver as shown. Pull oullhe ciulci‘ ouler and outs} guide CLUTCH/GEARSHIFI' LINKAGE INSPECTION Clutch lifter bearing Turn the inner race ofms Iihar bearing wirh your fingan The bearing shuuld luln smoo‘hly and (lee‘y wilhuul exues» srve ptay V necessary replace me bearing Ciurch spring Measure the clutch spring free length. SERVICE LIMIT: ‘96-'97: ‘ 49.? mm (133k!) After '97' 47.0 mm (1.85 in) mulch center Check me grooves of rhe clutch center for damage or wear caused by xhe Mulch plates. Replace if necessary Clutch disc Replace (he cluwh discs if they show signs of scoring or dis- culorafionv Measure the disc thickness of each disc. SERVICE umr, ‘ss — ‘97: r 2,3 mm 10.09 in) ‘ Aflev '97: 2.6 mm (0.102 in) (1) L‘FTER BEARING CLUTCH/GEARSHIFI' LINKAGE Clutch plum Check eacr disc plaxe Ior warpage on a surface plate using a ‘eelar gauqe‘ SERVICF LIMIT' 0,3“ mm (0.012 m) Clutch uutevlclutch outer guide Cher‘k lha .7. (3) CLUTCH DISCS C CLUTCH/GEARSHIFT LINKAGE l tmhclific bear‘n irmme 'ess a me. . ‘. «TIUF'ER P‘ECE rsa r rg p u p _ g.“ Irate“ (Mg clutch \i‘xer piece imo the mamshah Iran 1 the r‘re:IIIII drum. lnstall mp gearshlh cam whlIe hnIr‘Img the svnpper arm llsmg a screwdfivcr as shown. AppIy a lncklng agent to the geavshlft cam socket bolt threads. Install and lighten lIIe wcku bull lu llm specified lurque. TORQUE: 23 N1“ [2.3 kqlrm, 17 Ihf'fll CLUTCH/GEARSHIFT LINKAGE . I lnmal! me rhrusr washer and gearsmfr g E £ 1 , ‘ ‘ K ,4, u \ fl 2/ p {Q 4‘57/ m APPLV SEALANT (3) IQLT 9-17 ALTERNATOR/STARTER CLUTCH 12 N-m (1.2 kgf-m. 9 Hui-f!) 12 N-m (1.2 kgfrm, 9 Ibl-fi) 10-0 10. ALTERNATOR/STAR I I:H ULU I un SERVICE INFORMATION TROUBLESHOOTING ALTERNATOR COVER REMOVAL I STATOR SERVICE INFORMATION GENERAL 10-1 10-1 1072 10-3 FLYWHEEL REMOVAL STARTER CLUTCH FLVWHEEL INSTALLATION ALTERNATOR COVER INSTALLATION 10-4 10-5 10-7 108 . Thls secxlon covers service of the alternator, flywheel and skaner ululch All servme. can be done with (he Eng'me lnSZHIImJ 'w the frame - Reiarto «man lsfor alternator szaxor lnspeuion. SPECIFICATIONS r ITEM STANDARD Unll: mm (inl I SERVICE LIMIT I [firmer driven gear boss OD. 51.695 — 517718(2‘O3SA — 20361) 51,684 (20348) TORQUE VALUES Left crankcase cover 5“ bolt Flywheel halt Stator mourning socket boll Swner one-way clulch socket nnlv TOOLS Flvwheel holder Rotor puller TROUBLESHOOTING Engine does not mm - Faulty sxaner Clulch ~ Damaged idle gennshaft 12 N~m112 kgf-m, 9 lbi-fil 103 N-m ('10 5 kgV-rn, [6 "3th Apply oil w flu: “Heads 17 Mr“ (12 kgf-m, 9 lbf-R'l 16 N-m (1.6 kgf~m,12|bl~ll) 07725 - 00110000 07733 — 0020001 0, n77 Apply a lockzng agcm :o the ("leads Equvvalanl commercially available in USA 3050033 10-1 ALTERNATOR/STARTER CLUTCH ALTERNATOR COVER REMOVAL Remove me sea: am: mwddle’lowc' cowl (Section 2)‘ Dvscannect {“8 altsmator 3P1Whitelconnecxw Release the elm new: wue hum {he wue clumu, Remove [he allernamr cover SH be“: and alternarcr cover. CAUTION - Ma Jllm. wfl H vmywrruin dilutm‘d m :r > ‘Imu. NOTE mp engmp ml wwll run out whcn Um alternator army is rammed Set a clean ml nan under me engine and add the recammenaod all to the specified \evel afier Installfir mu. Hemve ”m gasket and dowel p'm 10-2 ALTERNATOR/STARTER CLUTCH STATUE ”'GHOMMET _ (nu/IREHOLDER REMOVAL Remove ‘he ancrnalor wire grommet from (he altamaxor covey, Remove We socket bolt and slamr wire holder Remove me snckat bolts and stator. INSTALLATION 12 N-mL17 kgfim‘ 9 ”1141) ml lit //17) W )LDLH i1? STATOR instail the stator imo the alternator cover. Apply sealant to the ere grnmmef. than insvall ihe Wire grommet Inlc the alternawr groove sccuwlv. Inelall and tighten the SOCkBl bolts to the specified zurqua, TORQUE: 12 Mai (11 kgI-m. 91mm Instali {he wire holdev and tighten this sucks! boh, ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL Femuw [he ahwnalurcuvertpage1072’, Hold the flywheel usmg N‘e flywheew hmdar. then remove (he Hywhcci bolt. TOOL Flywhaal holder 0772!) - 0040000 (Equlvalem commercially available in U.$.A.b Remove the washe" HI rLVVVHEEL HDL FRmnvP the Vlywheb usmg me spec‘s: mm. "_—LLEH’1 - . . TOOL: Rotor puller 07733 — 002000‘ or 07933 - 35500170 Remwe the woodqu key Remove (he stane! mm: gcar shaft and \die gear, (7] STAHII {I IULL (itAH V , 7 _-, 10-4 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH INSPECTION Check me operation ul me unarway L'IulLIl by luming (he driven geek You snouid he ahlP. m mm the drlven gear :ounterclockwisc smoothly, but the gear should not turn clockwise DISASSEMBLV Remove the starter dnven gPar hv mmmg n counterclock- wIsP Hold me flywheel with a flywheel holder, and ramuve llie sraner clurcn mounting lurx bulb. TOOL: Flywheel holder D7725 - 0040000 Hen-row the star-er nnP~wnv Cllflch assemnlv‘ INSPECTION Check Iha slanar driven gear luv Abnormal wear or damage Measure the starter driven gear boss 0 D. SERVICE LIMIT: 51.684 mm l2.0348 in) Chuck the oneAwav clutch for wear or damage and replacg if necessary 11', ONEWAV CLUTCH 10-5 ALTERNATOR/STARTER CLUTCH ASSEMBLY H) STARTER DRIVEN GEAR (2) ONEJNAY CLUTCH 3} FLYWHEEL (A! CLUTCH OUTER 16 N-m H 6 kgf‘m, 12 leU Apoly ui‘ to the sxansr one-way dutch. ('I) JBON VWAy Install the onerwav clutch into the clutch oulcl with the - flange mdeiacmg In, f} (21 CLUTCH OUTER IMtaH me smner one-way clutch assemhly onto me fly- m (WF'WAV Cl UTCH ASSVMULV wnw. » ‘ (2) FLYWHEEL 10-6 ALTERNATOR/STARTER CLUTCH Awa a lamina agsm m the starter Clutch outer mountlng bnlnhmads Halo mc flywheel wlth a flywheel lluldel, and nghten mp. staner clutch muuullug (olx bolts TOOL: Flywheel holder 07725 — 0040000 (Equivalenf commercially availab|e in USA) TORQUE: 16 N-m [1.6 MIN“, 12 “TH” lualal‘ the stanar drzven gear Into the one way clulch, Flcchcck me one~wav clutch upaualiolm Von should [)2 able \o mm the driven gem counterclockwise Mlloothly, bur the gear should nol turn clockwma FLYWHEEL INSTALLATION Applv oil m we 3mm idle gear and ear smart, and lnstall Illel‘l. Clean any all from me cranksnafi laperl lnstall me woodmff key an m: clankshafl, ALTERNATOR/STARTER CLUTCH ll.“ l llle flywheel alignvng me key way m the llvwhesl mm the wandnlfl key on we mmksmm Apply 0‘! lo we flywheel boll threads and sealing eql’are l~slall :“e we)” e‘ and llywueel bu]: *{Dld m9 llywlleel uhil‘g me ’ywnee‘ holdel, than ngmen :lue Bolt :0 the sppclherl fnrqlm TOOL: FIthGOI holds! 07725 — 0040000 lEqu-valem commelclnlly availablc in U,S.Al) TORQUE. 103 Mm [10.5 kgl-m, 76 let] ALTERNATOR COVER INSTALLATION g Aonlv seaiam to Inc maxing surface of the crankcase as E ”/75”;l/5¥/’§‘fl shown. 91 6), JD lnstall 1h: dowel pi' and new gaskel 10—8 mull [ha anevnawr Cover CAUTION - 1m u-nmmw can" mum” -- mgmmax amulml I“ w ,‘Iw NIL ' c Hum/J luv. ‘h’ Lm Mu !ns(al' and hghten ms SH mm to me spemfled torque. TORQUE: 12 N-m (1.2 kgi‘m, 9 lbltft) Route me auernamr wue uuuuuvly (page 1721‘, Camp mp. anernamr wl'c with a wire clamp. Lonnecx mo alzcrnawr 3P1Whirejrconnsctor. Add m vecomwendeb on up to proper level (page 3712). lnstaH 11% war, Inwer and rmddle cowl Section Zln ALTERNATOR/STARTER CLUTCH 10-9 CRANKCASE/PlSTON/CYLINDER 27 NW! [2‘8 kgf-m, 20 Inf-fl) 39 Nvm (4.0 kgf-m, 29 mt“) Zb N-m (2.5 kngm, 13 IBM" 11-0 'I'I. CHANKUASt/I’ISIUN/UYLINUtI‘I SERVICE INFORMATION 11-1 PISTON/CONNECTING ROD 11-4 TROUBLESHOOTING 11-2 CRANKCASE COMBINATION 11-12 CRANKCASE SEPARATION 11-3 SERVICE INFORMATION GENERAL - This section covers crankcase separation for service at the crankshaft and plsmn. ~ The iollowmg parts must be removed before separatlng the crankcase. — Alternator/flywheel (Section 10) - Clutch/gearshift linkage (Section 9) 7 CylilIdE-I head (Section 8) — Engine (Sentinn 5) — Uli pump lScction 4i - Mark and store the disassembled parts to ensure that they ale installed in their original locations. ~ Mark and stun.- the bearing inserts to ensure that the parts are installed m the carrect location: during reassembly. If the inserts are improperly installed, they will block the oil hole. causing insufficient lubrication and eventual englne seizure. lhe connecting rod bearing inserts are select fit and are identlfied by color codes, Select replacement Dealings horn the code tables. After installing new bearings, recheck them witll a plastigauge to verify clearance. Apply molybdenum dlsulfida oil to the Clank pill duling assembly. SPECIFICATIONS m — ALTERNATOR/STARTER CLUTCH ””“ """ ""’ ITEM STANDARD sERVIcE LIMIT 5mm driven gear 00s.- 13.13, 51.699— 51.718120354—20361) 61664120349) — CHANKCASE/PISTON/CYLINDER — umcm—mim’ ITEM STANDARD SERVICE LIMIT Cyllnder ' ID. I 71,000— 7101512 7953— 7.791501 71.10 12.795) 001 of rouné” — I 010100011 Taper — 1 010100041 Warpage 005100021 Piston. piston Piston ”talk direction "IN" mark IMlng toward the intake side — ”"98 min 0.0. 70955 - 70.9115 12.1930 7 2.79471 I 709012.791» Wistun 0.0. Illeasulemem point 15 mm 10 s In) Irnm bottom of skirt I # i Piston pill bole ID. 17007 -17.DDH(D.6694 7 0.66961 I 1703106701 I Fislul: pin 0.0. 15.99: — 17.000 (0.6690 7 0.6693) 1 169510.669) Pisluu-lu-pislun pin cleflnce 4 0.002 — 0 015100001 — 0.0006) A 7 Piston ring-to-ring I Top I 0.030 — 0.06510 0012 — 0 00251 0.08 10.0031 WWW “95'3““ ‘ Second I 0011' 7 0 045100005 7 0.0018) 00710003) I Piston ring and gap Ton '. 0.20 — 0.3310011 70.015) 0510.02) ‘ Senand 0.407 0.5510010 0.0221 0.7 (0.031 7 ‘ on (slde Iaill ! 0.2 7 0.71001 0.03) 0,910.04) 'ciylinder-mtpismn Clearance 3 0.015 0.050 10.0006 7 0.0020) — Connecting rod small and l 0. ‘ I 17.016 47034106699 — 067061 17.01: 10 67l) Connecting rod-m-plstnn pln clearance 0.016 7 0041 10.0006 - 0.00161 — Wankpln nll clearance 0.030 r 0.052100013- 0.0020l 006100021 11-1 CRANKCASEIPISTONICVLINDER TORQUE VALUES Crankcase bolt,1n mm 39 N m (4.0 kgf—ml 29 mil!) 9 mm 27 N-m12.8 kgl-m, 20 IN“) Apply oil m the threads 8 mm 25 N-m l2 5 kgf-m‘ 1n mm) 6 mm 17 N-m (1.2 kgflm, 9 lel) Connecfing rod nut 33 N'm (3.¢ kgf—m. 25 Inf-fl) Apply oil In Ihe ihreads aner crankcase sealing bolt. 20 mm 29 N-m (3.0 kgf-m, 22 [bf-fl) Apply a locking agznt m the threads 13 mm 64 N-m (A 5 kgf-m, 33 Ibl-h) Anply a locking agcnuo the lhfaads TROUBLESHOOTING Cylindor compression: is too low. or engine is hard tn start - Blown cyllnder head gasket - Worn, stuck or broken piston ri q . Worn 0! damaged cylinder or piston - Bent valve‘ or ham and nevarlnmed valve seat cylinder compresslnn is too high, or Inginl avail-eats or knocks - Carbon dnpnsims on the cylinder head and/or piston crown Piston sounds - an cvlinder, puston and/or plston ring - Worn piston pin hole and piston pln - Worn connecllng vud small and Excessive smoke - Worn, sluck or bruken pislon ling - Wum valve stern seal Excessive noise - Worn connecxing rod big and Deming - Bent cullneciing rnd - Worn crankshnh main lournal bearing - Worn transmission bearlng - Excessive crankshaft runout 11-2 CRANKCASE/PISTONICYUNDER CRANKCASESEPARAHON {HSHUNGRU NOTE Rafa! to Service Normafion (page 11-1) for removal of necessary parts belure sepuraling the crankcase. Remove the seahng plug and O-nng. Remove the upper crankcase 6 mm bulls/sealing washers and 3 mm bulls/sealing washers .v 1‘16 mm BOLTS (1) 6 mm Bo'LT’ 7- >(3) 91m" BOLTS .‘ _ _ _. U1 Remove Khe lower cranknase 6 mm halts and 10 mm belt. I nnsnn me lower crankcase 9 mm belts in a crisscross pat- (cm in 2 3 sreps, {hen remove ma bohs and sealing wash- 97$. Benarme the lower crankcaSc (mm the upper crankcase. Hamnve the dowe‘ pins and ml orifices A and B. 'U) DOWEL DINS 11-3 CRANKCASEIPISTON/CVLINDER PISTON/CONNECTING ROD *M=—(1)NUT<; 4 PISTON/CONNECTING HOD REMOVAL ‘ '12) BEARING—{AP CA UTION - Do my min-mm m: I‘em‘mk mum. rim NIH}! hr “Mum it my.» wig-nu! “mam in .m- .m.,-r: hrm‘mg in; . Immm um um hr uhlmm‘d. n‘, Jnng m rnginr damagt. NOTE Mark all part: during removal so they can be replaced in their uriginai lucallons. Remove the cap nuts and connecting rod hnnnng nap Remove the piston/connecting rod assembiy from the top of the cylinder. PISTON REMOVAL Remove the piston pin clip with pliersi Press the piston pin out of the piston and remove the piston hum line Lumiecting rod. PISTON DISASSEMBLY Rsmove the piston rings. NUit ‘ Do not damage the piston rings during removal. 11-4 GRANKCASE/PlSTON/CYLINDER Remuve any carbon deposits from me pisron ring gruoves, usIng an old piston .mg 3: shown. PISTON INSPECTION Temporarily install the pisxon rings to their proper position with the mark facing up Measure the piston ring to ring groove clearance With the rinqs pushed into the grooves. SERVICE LIMITS: Ton: 0.08 mm (0.003 ml Second: 0.07 mm (0.003 In) Inspecl the nistnn rm wear or damage lnsan (ha piston ring squarely into the bottom 01 the chIn- der and measure me .zng end gap. NOTE - Push the rings Enlo the cylinder wiUI the [up uI lhe piston to h nun: they are squarely in rhe cylinder. SERVICE LIMITS: Top: 05 mm (0.02 Inl Second: 0.7 mm (on: in) Oil [side rail]: 09 mm (0.06 in) Measure ll».- diameler oIIIIe pislun al 15mm (0.6 in) from the bottom and 90 degrees m the plsmn pin hole. 3... SERVICE LIMIT: 70.90 mm (2.791 In) CRANKCASEIPISTONICYLINDER Measure me piston pin bore. SERVICE LIMIT: 1703 mm ((1670 inl Measura rhn 0.0, loc piston pin. SERVICE LIMIT: 1633 mm (0.669 in) Calculate the, piston-IO piston pin claarancu. STANDARD: 0.002 - 0.015 mm (017001 - 0300601) CVLINDER INSPECTION Inspect the mp of the cylinder [0' wdipage, SERVICE LIMn’: 0.05 mm IGIDDZ inI Inspect the cylinder bore for wear or damage. Measure me cylinder ID, in X and V axis at Ihrer- levels. Take the maximum reading ta derermine the cylinder wcar. SERVICE LIMIT: 71.10 mm (2.795 in)‘ Calculaie LIie pisiun-to—cylinder clearancel Take a maximum reading to determine the clearance. Refer to page 11 5 for measurement ul me pision O D, STANDARD: 0.015 — I) 050 mm "1.0006 — 010020 in) , 11-6 CRANKCASE[PISTON/CYLINDER CaIchaze m» taper and out of round aunree levels .n X and I Y axis, Tan: :1: maxlmum reading: to ueleullivle (hem SERVICE LIMITS' Tapar: 0.10 mm [0.004 in) om 0' round: 0.10 mm (0.004 in) The cylmdev must be reboren and an OVEI'SIZE! pismn fined II ”I! service lmms an: exceeded. The ‘ollowing oversize piswns an.- available . . .l , 0.50 mm (0.0mm) 9'“ J7' 1.00m!“ [0.039. I Aher 37‘ 0.25 mm (0 010 Im ”he nllul| and collneclillg rud. NOTE - lnstall the connecting rod with its all hole side facing the "IN" mark on the piston crown, {1) TOP RlNG (ll lDENTlFlCATlON MARK (N OIL HULL (3) "IN" MARK / (1) F‘ISTON [Z] CONNECTlNG ROD 11-10 Au ' mil to the pialOI u cute] surface lrstall the piston pin, and finnum it using a new piston pm clips. N OTE - Do not align the piston DII'I clips end gap with the piston cut out. Install the pistan/conncctlng rod assembly into the cylinder using a commercially available piston rinq comptessor tuul, CAUTION m NIL-1H”); m piston. 12mg rarefld not to Janina Illr mp Mir/m Um. titurmuiflpui mi wuuudlhr t tum!“ rm - Hruu-vtln‘mrt “Hymn“, Ihrty ”aim mm» mm mulpm mm [hr 1 mm line rod bu}! thrcads N OTE ~ Install [hC piston/connecting rod assembly with the pi: ton ‘lN” mark facing to the intake side. Usn thc handle of a plaque hammer to tap the piston into cylin- der. NUIF - War: 3.1 5 Wm Uu'tlutn:u [UJI : ts ‘lusll Wl‘il ii‘e up Surf ‘ "i {la cvll Apply molybdenum disulfidc oil to the ctankpin bearing sur faces. Install the beating cap. Apply oil to the connecting rod nut threads and sealing sur faces. Install the nut and tighten the nuts gradually and alternately, TORQUE: 33 N-m [3 I kgf—m, 25 lM-fll CRANKCASE/PISTON/CYLINDER CHANKCASEIPISTON/CYLINDER CRANKCASE COMBINATION Aprrlv ; ignr, h .r ‘hfirmlgh coating c‘r lquld Cca cm (a We '0 cxcsp lorae ~i u ll'lq our 5': ball‘ 9 Hill arr—a and . 5— al 355‘ nal bo'r 'lcwe' 5:11“: dlba as install the three dowel pins. lnsKall Ull uriliLes A and B into rm: nrnnkcase as descrlbcd below NOTE - Install oil mince A With Its smaller oil hole side facing (he -nwer crankcase. - lnsmll oil orifice E by aligning its cut-out wlth the upper crankcase gruuve and oil hole lacrng m min, rear. Clean the crankcasa 9 min bulls \horuughly wlth solvent and blow urem dry Apply clean engine ml to (he 9 mm bolr threads and seating surface and install them. Loosely inslall all the lower crankcase hnlts. Make sure me llnpel' and lower crankcase are sealed securely. From the inside to cursive. lighlell ilie lower crankcase 9 mm bulls in a crisscross panern in 7 - 3 slaps. TORQUE: 27 Nm l2,8 kgf‘m, 201M“) Tigman the 10 rrrrn bolt, and then the 6 mm hnlrs TORQUE: 10 mm boil: 39 NM (4.0 kgfrm, 29 IbM‘t) 6 mm huh: 12 N-rn (1.2 kgl-m, 5 lbf-ft) lnsmll the upper crankcase balls and scaling washers. N OTE - The sealing washer locations are indicated on the upper crankcase usinglhe‘ '"A nrark. TORCIUE: 3 mm no 25 N—m (2.5 kgtm. 1a Ibf-ftl 6 mm bolt: 12 NM (1.2 kgl-m. 9 Ith) -. (us rn'n BOLTS 11-12 CRANKCASE/PlSTON/OYLINDER InstaH xhe new O-ring and sealing plug (1’ NEW D-RING 11-13 CRANKSHAFI'ITRANSMISSION 33 N-m (3‘4 kgfrm. 25 Inf-ft} ‘? Nvm l1 2 kgf~m, B Ith) 1 2-0 12. CRANKSHAFI/TRANSMISSION SERVICE INFORMATION TROUBLESHOOTING 12-1 12-2 CRANKSHAFI' TRANSMISSION 12-3 12-9 SERVICE INFORMATION GENERAL the crankcase mum be separated to service the crankshaft and transmission. Helcr to section 11 for crankcase sepa- ration/assembly. 1 Be careful not to damage the crankshaft main journal and Journal bearing while removing or installing thn crankshaft. Marl: and stnre the disassembled parts to ensure that they are installed in their Ol’lglnHI locations. - Mark and store the bearing inserts to ensure that the parts are in their correct locations during reassembly. If the inserts are improperly installed, they will block the oil hnln, causing insufficient lubrication and eventual engine seizure. . The main iuulnal bearing insens are a select fit and are ldentllled by color Cudgs. Select replacement bearings from the code tables. After Installing new bearlngs, recheck them with a plasrigauge to verity clearance. Apply molybde- nirm drsulfrdc oil [0 the main journal during assembly. SPECIFICATIONS _ ., Unit: mm 0n) ITEM STANDARD I SERVICE LIMIT CldllksIlafl Slde Llealance 0.05 0.2010002 — 0.008) 3 0 20 i0 012) ‘ Runoul — " 0.3010012) Main journal oii cluaIaI'IcE 0.017 — 0035100007 0.0014) 0.0410002) iTransmission Gear l.D. pm 6 28.0004 ”1.071 (1.1024— 1.1032) " ZED/111.104) — C1 z4.000-24.0211n 9449»0.045/1 240410.946) "c2.3. 4 31.000410251122054 2215) 1 310411222) . Bushing 0.0. Ms, 6 l 27.959 - 273801131007 -1 1010) 27.94.11.100) 02 ) 30.95540930112107—1.2197i 30 1210) C14 30.950 30975112135 -1.2195) 30.93 (1,218) ’ Bushing I D MS 24005 ~ 25.006 (0.9537 — 0.9345) 25.02 (0.935)— 'c2 7 27 905—20.00611.1018 1.1026) 230211.103)— Gear-w-bushing ‘ M5. 6 0 020 — 0 05710 000157 0.00241 ‘ 01010004) “1 “man“ . :2 I 0.020 — 0 070 (0.0000 0.0020) 0.11 (0.004) I c3, 4 0.025 — 0.075 (0.0010 - 0 0030) 0.11 (0.0041 Mainsnan 0.0. i M5 24.957 - 24980109030 — 0.91335) 24 96(03331 Clutch outer guide 24.930 — 24.993 (0.9335 — 0.9510) 74 515 (0.903) Countershaft 0.0. 02 27.557 7 Z7.980(1.71011—1.1016) 27 5011 101) Bushing-to-shafl M5 0.005 , 0039100002 7 0.0015) 0.0010003) damn” 0.005 — 0039100002 00015) I 0.0010003) C2 12-1 CRANKSHAFI'ITRANSMlSSION TORQUE VALUES Connecting rod nur 33 Nm (3.4 kgf‘m, 25 Ibfrfll Apply oil Io [he threads and sealing surface Mainshafl bearing set. plate Doll 12 Nail (1,2 kgl-HI, SIM-l1) Apply a lacking agent to the threads TOOLS 0' var 43 mm l D. 07746»0030100 A Incluue l, 25 r' w 07746—0030200 Azrachn‘e‘! "B' collar D7964 — MBDOZUU Excessive noise Transmission iumps out oi gear . Worn connecring mu big em: bearing - Wom gear dogs and slots - aenr connecting rod - Ban' rnrk shaft . an crankshaft main journal bearing - Broken shift drum stopper - Worn lransmission bearing - Worn or bank shin forks - Broken shift linkage return spring Hard to shift - lmpraper clutch operation Engine vibration - Incorrect transmlssion ol| welghr ~ Excessive crankshan runuul - Incorrect clulcll adiuslmenl - Bent shift fnrk - Bent fork shaft - Bent fork claw - Damagedslrilldrullluamgruove - Bent shift spindle 1 2-2 CRANKSHAFI'ITRANSMISSION CRANKSHAFT m TIMING'EPROEK'E‘T ’ REMOVAL r Sepavale [he uauktase halves (page 11-3), Hemnve the cam Chaln and timing sprocket. Remove the connecting mu healing cap mm and bearing Lava, CAUTION my. u. qum m M Hwy w rhrmrmm 1"an m,- Drml (mm m ,nmm nldl'klgng Hm mmkpm mm {hr rmmrmng rod hall 1"“.sz Remove the crankshaft Remove the main journal bearings from both me crankcases, CRANKSHAFT/TRANSMISSION PRIMARY DRIVE SUB-GEAR REMOVAL m SNAP RING 2 Remove the special snap ring and friction spring. Remove the pr'llndly ullve sub-geal, collar and springs (2) COLLAR , ‘l (3: SPFlNGs’ l’l‘ SUB-GEAR PRIMARV DRIVE SUB-GEAR INSTALLATION ' ‘2' GRPOVE lll:la|| the collar with its groove Slde facmg m lnsrdll the pnmaly mm sub-gee! onto me pllmaly drive v, m PRIMAnv DRIVE GEAR gear, aligning me hole; hetwean mp. gear l7‘lfilm»(itAH 13v HOLES 12—4 Apply molybdenum disulfice ml to [he area shown ln lhe illus‘ratlonv Install the Irlmlnn sprlng and new spec.a| snap ring CAUTION - )ul. 7! u\' u: m.’ map mm L a war rmg mm' mm Vilm‘mn} m 5741" rm: mlz mlm‘ nl‘ere rnql'lu' Jaman‘ . 1mm." My" Md l/u . - v.24.- rl IN m l l ,pmnl mg “l, m Imp- nll/uvm 10!le wwlil I'fllfln m ~ (hr «mm mm. map mu .m M .,< mm Nil/717w , I mm frann’A/Illfl mmuu .n mull ”l Inslall the. spnngs lnw ‘hc pr'lmarv drlve gear as shown, STARTER CLUTCH NEEDLE BEARING REPLACEMENT Removc [I10 needle bearing with a cunnneyulally available universal bearing puller CAUTION - Tn pmvm 11:; {'7' ha]! muil. 11w mH' from my llmnm [:qu mm (he mm“ ,mrnlll proprrh‘. wnrn “manual m:- l'llgv .m llmbk ax {II'J'KUOPX Pless a new needle henrlng onto me crankshah using a hydriHIm press and special lOOI. TOOL: Anachmant "B" {collar} .07964 , MBOOZW CRANKSHAFT/TRANSMISSION a? (2m; SPFCIAI SNAPRING {ll FRICTION SPRING (1) SPRING (2) WOI’IN MAIN JOURNAL (1) NEEDLE BEARINGS BEARING \ ID ATAL-‘IMEHT' E' COLLGR § l1» 9 NEEDLE BEARING 1 2-5 CRANKSHAFT/TRANSMISSION u the special tuul is Hot available prepare a suitable collar, m WASHER 7.1, HANGE BOLT Washer and 8 mm Hangs hnlt lexample; 1|vwhe,. holll tor W the Dearlng mstallation, Assemble the above ltems, and screw the bolt qvaduallv, than ihstall me new needle beellllg. -/ :3) COLLAR | l mm HtAHlNL} l INSPECTION CRANKSHAFT RUNOUT Hold the crankshaft both end. 59! a dial lndicator on the cenlel main journal ul the crank- shaft ”mate the. rmnkshnft two revolutlons and read runout at the ccntcrjournal. SERVICE LlMlT' 030 mm (0 012 inl MAIN JOURNAL BEARlNG l1(1) MAW JOURNAL BEARINGS Impact the main journal bearing inserts for damage 0r sep- aratiun Inspecl the Dearlng inserts for unusual wear or damage Reinstall the upper crankcase's main journal hearrhg rnserts, men careful lawer the crankshaft In placer WlDL‘ the oil tram the bearrng inserts and journals. P." a piece ul plaahgduge on each journals NOTE - Du Hul uu: the plastlgauge over the oil hole in the main nearrng lmlrnal hr twp. rrankshafl. - Do not rotate the crankshaft during inspection. 12-6 Assemble xhc crankcase halves. Tignren (he 8 mm Lions [0 Ihe specified torque TORQUE: 27 Min (2.8 kgf-m. 20 lhffl) Remove the 9 mm bulls and lower clankcase Measure the compressed plasrrgnuge on each journal. SERVICE LIMIT: 0.04 mm (0.002 In) Ii main heaving clearance is heynnd vnlernnce, sales: a ieplacement hearing, MAIN JOURNAL BEARING SELECTION Record the crankcase LD. letters flom the pad on the left side Ur [he upper crankcase as shown. NOTE - The letters (A, H or (I) on the upper crankcase arc the norms for the journal l,D.s from Ian m right, Record the corresponding main journal OD. code numbers from the crank weighr. NOTE - The numbers (1, 7 m 3) on the crank weigm are the codes for the main journal O‘D.5 from left 10 righrr Cross reference me case and journal codes to determine the replacement bearing color codes r CRANKSHAFTITRANSMISSION “*5 [1iCRANKCAsgLD‘éODES (”MAIN JOURNAI O D CODES 1 2-7 CRANKSHAFT/TFIANSMISSION BEARING THICKNESS: A {Black}: Thick B (Bluwn): A c (Green): i D (Yellow): E (Pink): Thin CAUTION (1‘ IDENTIFICATlON COLOR - .1110 um .g m- heurlngx. rérlm‘k (lip (Ital-Ann: mm a plum- Haltglr‘. lmwm l 1 {mm p um mm m w 1’ Wm dumugs MAIN JOURNAL BEARING SELECTION TABLE '\\\\ CRANKCASE LD. CODE LETTER \ \ \ A B C j \\\ 37 coo—37.005 rnm SIMS-31.012 mm 37.012 , 37.018 mm \‘\\\ (1.A566—1.45695nl 11.45697 1,45721nl (1.4572~1.457Ain) 34 000 - 34.nos mm E D c (1.3335-13338inl lPinkl (Yellow) 7 lGIeenl CRAN KSHAFT 0 r). 33 93a — 34.000 mm D c 5 CODE LEl'rER (1.3333 ~ 1.3386 in) (Yellow) ‘ (Gleenl rmmwn) 33.938 , 3339‘ mm c B ‘ A (1.3331 —1.3383inl (Green) (Brownl [Blackl INSTALLATION lnGlOll the main journal bearings into the upper and lows! crankcase. NUH: . The heaving 13b, :IIUUILI be aligned with the grooves in the case Apply molybdenum disulfide oil ‘0 the upper and lower main lournal bearings. Install the crankshafl. CAUTION - n.1,»; lmmllu'lml [Jaw/ll"! all llm [yum «r T06 '70)“ Dcud (mm-v, m mm. aamaein; mg ('lqume wall 1m lellmlmg rod 11111.13; 12-8 CRANKSHAFT/TRANSMISSION \nstall xhc connecting rod bearing caps. Auply oil (0 the connActmg md nut threads and scaling sur M Vac“ s, \nmaH and tighten me lluls guaduafly and alternately TORQUE: 33 N-m [3.4 kgfm, 25 ml“) lnsmll me nming sprocket by allgmng the wide teen: between me crankshaft and sprockel‘ InstaH the Cam LIIaifl. Assemble the upper and Iower crankcase (page 1142’. TRANSMISSION REMOVAL/DISASSEMBLY Separme he crankcase ha‘vcs lpage 11-31‘ Remove the bulls and mainshafl bearing set plave Remove the mamshafi arm countershaft assembly. Remove the onlice plate f: om the munmmah 1 2-9 CHANKSHAFT/TRANSMISSION Remove the counter-shah bearing act ring and dowel pins. D‘sassemble me max’nshaft and countershaft. Check me gear dogs, dog holes and xaem ch abnorma‘ wear a: lack of lubuiualion. Measure m In nfeanh gear, SERVICE LIMWS: M5, M6: 28.04 mm [1110‘ in) C1: 2t!“ mm [0.946 in) 02. C3. 84: 31.04 mm [1222 in) Mensum the LL}. and (LL) of each gear bushing SERVICE lJMI‘I’S: 0.D.. M5, MB. 27.94 mm (1.100 in) (2: 30.93 mm [1.218 in) C3. C4: 3033 mm [1.218 in] I.D.: M5: 25.01 mm [0,985 in) C2. 28.02 mm (1.103 in) Check the shift fork groove of the shifter gear {or excessive wear or damage 12-10 CRANKSHAFI'ITRANSMISSION Measure the O n m the mamahaft and counter-shaft, CLUTCH OUTER GUIDE M5 SERVICE LIMITS: l l { M5: 24 96 mm (0.933 ml “ ' ' Clutch ulnar guide: use mm (0.933 in) (:2 27.96 mm (1.101 In) BEARING REPLACEMENT NOTE . Do not try to mmnva the ccuntershah bearing from me man. Ii the bearing is worn or damaged, replace (he comp tcrshaft as an assembly, Tum the outer (ace nl each hannng With your finger. The hnanngs should turn smooihly and quietly. Also check that me bearing inner race lils Lightly on the shaft. Remove and disuard (he mainshah hearing, i9 vhe map. does llul mm smoothly. milelly, or «is loosely on (he mainshafl. Replace. lhe countersunk, collar. and hearing as an assembly, if the race does not turn smoulhly, quietly. oI fits loosely on me countalshalL (1) MAIKSHAFT Press nut the malnshafl from the bearing using a hydraulic press. lnslall a new mainshah hearing onto the mainshai‘l by press 11) DRIVER B ing the mmnshafl bearing inner race using the special moi. TOOLS: Driver, 40 mm L!) 07745 - 0030100 Innee driver. 25 mm 07746 - 0030200 (2) lNNER DRIVER 13) MAINSHAFT BEARING v 12-11 CRANKSHAFTITRANSMISSION ASSEMBLV [1) M2 GEAR (1ST! (2) M6 GEAR (1ST) @§@é@ (3) M3“ SHIFTFH GLAR 115120“ (7) OIL SEAL 15DMA|N$HAFT/'M1 GEAR (111') l8} COUNTERSHAFT ‘93 ‘7 m A" ‘29” (a) MAINSHAFT BEARING (12’ C5 SHIFTEH GEAR (241’) (‘1) C1 GEAR GOT} CRANKSHAFI'ITRANSMISSION Assemble lhe lrauamissiun gear and shalls. (:nar earh gpar wnh rlsan El’lglne oil and check for smooth movement Apply molybdenum disull‘ide oil (0 {he shifi fork qroovas in ma M311, C5 and CG gFar INSTALLATION insmi me dnwnl pins nn mu. uppermnmse holes. lnslall the sol ring inro rhc groove ol the crankcase. Install the mainshah and cauntershaft Dv aligning the scum tershafx bearing groove with [he set rlng on the crankcase, and aligning the beaiiiig tap hole: Willi [lie dowel pins. Apply a lacking agent In the mainshah bearing 53‘ plate bolt threads Install the mainshafl bearing set plate wrlh its“OU1 SIDE" mark facing our and righren me bglrs to the specified torque, TDRDUE' 12 N-m [1.2 kgfm, 5 IhI-hh Assemble (ha crankcase (page 1142‘» FRONT WHEEL/SUSPENSIONISTEERING Ahar '57: '95 — '37: 23 N-m (2.3 kgV-m, 17 IbHfi 103 N-m (10.5 kgi-m, 7G Ihf-m 22 N-m (2.2 kgf-m. 16 mm! 30 N-m (371 kgf-m, 22 Ibf'fi) After '9 . ‘Q \ 5 N-m (0.5 kgl-m, ‘ y 3.6 mm g: g h 13-0 13. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 13-1 FRONT WHEEL 13-8 TROUBLESHOOTING 13-2 FORK 13-14 HANDLEBARS 13-3 STEERING STEM 13-23 SERVICE INFORMATION GENERAL AWARHING - .4 wnmminuml (um am at ,0": rmluuu \lupyl‘ng yum, Dismni ranullm'nmrd pm and rlmn a mnmmumlld 4m will! (1 high qmflir) 1mm drgrrrning ngrm. - wnon servicing the from wheel, fovk or smearing stern, suppun lIIe motorcycle using a safety smnd or hoist - ReIer Lu seuiun 15 fay brake system information. - Use only hres marked ”IUBI LL55" and tubeless valves on rim marked "TUEELESS TIRE APPLICABLE". SPECIFICATIONS um: mm Uni — FRONT WHEEL/SUSPENSION/STEERING ‘ ITEM STANDARD 1 SERVICE umn Minimum mp tread nemh — ‘ 1.510.136) Cnld 1er I Up to 90 kg (700 lh) lnad ‘ 250 Rh (2 50 kgIlcm‘. as rm} —W I ””55“” 1 Up m maximum weigm capacity ‘ 250 kPa (2.50 kgflcml. as psi] ‘ Axle runoul I I 0.2001008) . Jheel vim E21 1 — 1 2 0 (0 00) 1mm ‘LAW , , _ mm m m '7 ‘ Spvlng tree Iengm I ’96— '97: 248119.77) 243219 571 1 After '97: 250.2 (9.85) 245210.05) 5mm mremmn | wnh me lapcrcd end facing down 7 — A Tube mnoux . 0.20 (0.008) Recommended fork fluid ' F'rranndn Suspension Fluid 55-8 - -; Fluid lam “414(451 n21 - Fluid capaciw 7 '90—'97; 56112.5cm311SOLOD7USnI,197 7 A u 09 Imp 02) Arm '97: 540.: as cm7 (13.3 : 0.02 us 02,190 _ z 0.09 Imp oz) ‘ Pre-mad adjllsiflr semng 12 mm {0.5 in} (mm (on a! fork can ‘ — Rebound adJuster sefllng 1mm 1mm mu hard I — ”Compression ’96 — '97. 1mm 1mm IuII hard 5‘15“?“ ”Ring AIlal '97: 1.5 (um from m hard 7 Steering head bearing prelcad ' V1.0 — 1.5 kg! (2.2 — 3 3|be 7 13-1 FRONT WHEEL/SUSPENSIONISTEERING TORQUE VALUES Steering srem nul Top rhread A Top thread 3 Fork lop bndge plnch bolt Fork hrmom brldge pinch bolt From axle bull Front axle holder boll Front brake disc mounting bolt Fork cap Fork socket hnlr TOOLS Steering stern socket Ball race remover sax ’ Drivur auachmenr, A — Driver annahmant, B — Driver shah assembly — Bearing remover, A — Bearing remove-l, B — Assembly hase Sraering stem drlvcr Fork seal driver, 45 mm Driver Attachment, 42 x 47 mm Pllol, 20 mm Bearing remover shall Bearing remover head, 70 mm TROUBLESHOOTING Hard Stwring Alter '97: ’96 — '97: Aher '97: '95 — '57: Afler '97: 103 N-m (105 kg1-m, 7B lbl-ftl See page 13-28 See page 13—7R J N-m (2.3 kgf—m, 17 lbf'fll ,22 N-m12.2kg1»m, 16 Ile) : 49 N~m (5.0 kgl-m, 36 Iblsfll 27 N-m12.8 kgf~m, ZOIthl 55 N-m [ELI kgf—m, 43 lbftfll 22 N~m (2‘2 kgf-mr 16 lbltfl) 2O N-m12.0 kgl-rll, 14 lbl-fl) ALOC ball 23 N-m (2.3 kgf-rn, 17 Inf-ft) 72 N-m l2 2 kgf—m, 16 lbf'fll 20 N~m (2.0 kgf-m, 14 le‘kl Applv a locking agenl lo the threads 3:1 N-m (3‘5 kgl‘m, 25 Ibl-lll 07916 - 3710101 07946 , KMSOOD‘I D7946 - KMSO‘IOO 07946 KM90200 D7916 - KM90300 O79A6 — KM90401 07946 - K M90500 079‘s - KMBOEOO 07946 — MBOOOOO O7KMD — KZ301OO 071494 0010000 07746 — 0010300 077110 - 0040500 07746 — 0050100 0/ 746 - 0050600 - Faulry or damaged steering head bearings - Insufficient tire pressure - Sreermg head bearing adiustment nuttou light Stars to an: sida or does not truck straight Bern lurk Bent axle Wheel Installed incnrremly Faulty steering head bearings Bent frame Worn wheel bearing Front whuol wabbling - Bent rim - Wurn front wheel bearings - Faulry rlre - Llnnalanced lrre and wheel Worn swlngarm plvol components Unevenly adjusted right and loft fork legs or 07916— 3710100 Not available in U.S.Ar No! avallahln in US?» See page 13-27 or 07KMD — KZQO10A1IJ.H.A.nnly) an available in USA Wheel turns hard - Faulty wheel bearing - Bentham axle - Brake drag Son suspansinn - Insufficient llui n lurk . Weak fnrk springs - Tire pressure too low Hard suspension - Incorrect fluid weighl - Bent fork tubes - Clogged lolk fluid passage Front suspension noisy - Insufficlem fluld in lurk . Loose York fasteners 13-2 FRONT WHEELISUSPENSION/STEERING HANDLEBARS REMOVAL ‘2} GRIP END Remove me screw and the hand‘ebar gnp end. Discald the screw. \ IUSCREW ‘ Disconnect the Iron: brake switch wires co~ncctors lrorn mc swuch‘ Remuve the waste! cylinder haldel bolls‘ haldel and master nyl nnm a: SCREWS Disconnccr (he zhrome cables from the lhrmtle pipe and 'H THROTTLE CABLL [NDE remove the huusiug. Remove the th-ome mpp mm 'he ngm hanrnphar FRONT WHEEL/SUSPENSIONISTEERING 3ls:onnsr1 mp mm. mm wlre cannacmrs from me switchl ‘ (3) CLUTCH LEVER BRACKET l 1’ BOLTS Remove the clutch lcvcr holder bonsr holder and clurc‘n lever \ bracket assembw. Remove thP «Jews and leh handlebar swirch, Tn IUF B_RlDGE PIN-”CH BOLT HTETJNUT CAP Remove the screw and handlebar end. Remove we handle gnp from the handlebar if necessary. anove the following: — Top bridge plnull bolts 7 Handlebar pinch nous — Holder brackets Choke cable holder — Steering slum nut cap Remove the sleerlng slem nut. Remove the mp bridge and handlebars. 13-4 FRONT WHEELISUSPENSIONISTEERING INSTALLATION I3I STEM NUT \ /A\\LZ) TOP BRIDGE i ‘ , \~._~ a \ Tc’npora‘ily insiaIl me handlebars mm the fork prpes. InsxaII ms [op bridge and ligIIleH me sleeling stem nm to we >peciried :oique TORQUE: 103 N-m (10‘3 kgf‘m, 76 Inf-fl) Align We stopper on {ha hannlahnr hnss With the groove In (‘II HANDLEBAR l3) TOP BRIDGE Ina mp bridge, InstaII ma faIluwing. — HuIdeI brackets # Chnke mmIe hoIder 7 Top briago pinch bolts — HandIebar pinch bull: lighten the top bridge pinch bolt: xo the specified torque. TORQUE: 23 Nvm (2V3 kgl-m, 17 IbI-fl) Iigmen me handlcbo' plnch bolls. -:*II I , ’ I t TZICHDKECABLE V- I : i ._ 4- Iris a he )Ieeilng 5 am nu cap HOLDER I3) HANDLEBAH PINCH HOLT HANDLEBAH WEIGHT REPLACEMENT Remove me griu from the handlebar 7 Slraiglllen the weight retainer tab by Ihe srrewdrivar m punch Temporanlv InstaII me gnp end and screw. then remove [he “’ LOCK'NG TAB W handlebar weight by turning the grip and. N OTE - Apply lubricam splay {CRC 5-56 u! an equivaIenlI IIIiuuin the wt, looking hole to the rubber Ior aasy rpmnval [5) RUNNER CUSHION IA! INNER WEIGHT \ [2| RETAINER I3) LOCKING HOLE ' RING 13-5 FRONT WHEEL/SUSPENSIONISTEEHING Remove the grip and from the handlebar weighr. Discard line retainer, Install me new retainer onto the handlebar weight. Insrall the grip and onto the handlebar weighr aligning irs buss wilh me slut in “IE handlebar weiglll. Install a new mourning SCUBWV Insert the handlebar weighr assembly imo (he handlebar. Tum lire handlebar weight and Iluuk lire relainer lab will: the hole in the handicban Applv Honda Band A or Honda Grip Cement (USA. bnlyl to the inside of ‘he grlp and K0 the clean surfaces Of the left han» dlubar and liuulliu grip. Wall 3 A 5 minutes and install the grip. Roiare the grip for even application of the adheslve. NUIk - Allow me adhesive to dry for an hour before using. Install (he left handlebar swilch aligning ils locating pin wirh the hnle in the handlebar. (1i HANDLEBAH WEIGHT 65% (3) WEIGHT (ZIgRETAINER HI LOCKING (5) l2) RETAINER RING HOLE LOCKING TAB I I I I I I (1) I NNEFl WEIGHT I I I i I I I I . I (1) LEFT HANDLEBAH SWITCH HOUSING I I /,/;’\ \ :c?// / // /I‘ I :’¢:/ v 1 3-6 Txghten the forward scvew fivsl, \hen the year screw, Inszau the clutch level bracket assembly by alignmg the and u! (h: bvacket wnh the punch mark nn (hp handlahnrv muau mp clutch :ever bracket holder thh the “UP" mark hang up. Txghzen the upper bclt first, then the lower bun. (:nnnncr the Mulch swttch wires. Apprv grease m the :hdlng surname M the thrown pups" sttall the (Name Dunc on the tight handlebar, Apmy grease to the throttle cable ends. Connect the throttls cables to the throme pipe. Ins-tall the nght handtebar swwtchnnrome housmg by alignr tng its meaning pin with the hole in the nand‘ebar. FRONT WHEEL/SUSPENSlON/STEERING ('H LEFT HANDLEBAR SWITCH HOUSING E"? . 3“? V2) scfiews ‘ My CLUTCH LEVER BRACKET I3! BOLTS \ . K 13-7 FRONT WHEEL/SUSPENSION/STEERING l1) HIGH! HANDLtBhH—gWITCHIH IRUTYI F HOUSING , ,, ‘ l, T gnten me quEr strEw flrfi', than the lower screw. I 7 g lllsld‘l the Hlaslel cyliwder by aligmng rhp firm at rm: master cy‘inder WK" rm: punch mark on (he handlebar. lns'all the master cylinder hmder wirh me "UP" mark faclnq up. Tigluen we upper boll first, then (he lanr hnl? Connect the brake switch wires. 7 l2} UP” MARK ‘(7) GRIP END Install the gnp and and rlqmen me new muunllug mew / FRONT WHEEL REMOVAL m , . a wmamlnawd 1mm lliu' ur pull mm ”up; 1g puwr. D‘Arflfll ummmiuuln’ [lfldr and tlmn a rmxlaminalrd disc will! a high quality hm: dcgnmslm: agrnlr Suppon ms "lmurcvule aeuulelv usrng a safety stand or a hoist Hemove me bolts and reflectors (page 1516), Remove the muullling bulls and brake callpers CAUTION - Supprln Mm mm rum, wid‘ a pm.» ml wlu' w mm H mm rm wwmwmr mm Ih-n' Ur, nulrms! (blah-m» NOTE ‘ Do nut operate :‘lc brake lover aker the brake calipers a'e removedr 13—8 Luuseu [he vigm hum axle pinch bolts Remove the £1le hnll Loosen ma left lrum axle pinch bulls. Remove the axle and lhe (rant wheel Remove the side collarsl INSPECTION Axle Selthe axle in V-bluck and muasyre me lunuuL Amual runnul is 1/2 the tnlal inmmtm reading SERVICE LIMIT: 020 mm (0.008 in) FRONT WHEEL/SUSPENSION/STEERING m Plfifl'gsons . : 1,. ‘ ' 12) AXLE :06,”ka %\ ‘ : m RIGHT SE COLLAR (l) AXLE 13-9 FRONT WHEEL/SUSPENSIONISTEERING Whul bearing Turn the inner race at each bearlng wlth ynllr hnger. lhe hearlngs should turn smoothly and quietly. Also check that the bearing outer race fits tlgntly in the hub. Remove and discard the heanngs If they do not turn smoothly. qllmtly, nr if they fit loosely In the hub. NOTE - Replace the hearings in pairs. Install the new bearings ‘mlq llle lluu using the spec‘lal Iools luage 13-12). Who-l rim runoul //-\\ Checkth: rlm runhm hy plncmg the wheel in a turnlnq stand. / ,/—~\\ Spln the wheel by hand. and read the runout using a dial //’ \\ indicator, I ‘ Aclual lulluul is 1/2 the total indicatur reading. ‘ ‘ / l l SERVICE LIMITS: \:\ /’/r’ "\ Radlal: 2.0 mm (0.08 In) L: 4 , .l_J Axial: 2.0mml0.08inl T \\ j . Wheel balance lzll HOTATING DlRECTION CAUTION . MARKS - “7w! hat/1m dirrlrlly mm the :uzhl‘lznu handling and am all ”rm o/rhc mmm'n'n‘t' .vllwuvx L'het‘l’ hulum um. ml. lim hm hm. rammed ['rmh the urn N DTE - For optlmum halanne, the ter. balance. mark la pamt dot on the alde wall) must be located next to the valve stem, Remoum the tire if necessary. ‘ Nole the rulaling dllecliorl marks on the wheel and tire, Remove the dust seals from the wheel. Mount the wheel. tire and brake discs assembly in an inspec- tion stand. Spin the wheel, allnw n to stop, and mark the lnwest (hem/h /// ’7 ~\ \\ estl point ofthe whccl w'lth a chalk, ( (pm Do this two or three t'lmes to verify the heaviest area. ll [he / wheel is balanced, it wlll not stop cnnslstently in mp. same ( (‘0’ . (V o or ] IH l nnsmnn \ “19%;? élfyfll" /) \ \\ ~ / To balance the wheel, lnslell wheel weights or. the highest \\ \\ C/‘y / side of the rim. the side Upposlte the chalk marks Arm ,usl \ ‘3# Vr’ / enmrgh werghl so the wheel WIII no longer stop in the same \ 1 / position when it is spun. Do nor add more than 60 grams to V "‘9 ”‘99" ll} lNSPECTION STAND 13-10 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLV (1) nm rs ~ Remove rhe UU‘ls and Luaku discs. Remove the dust seals Illslall me bearing remover hear! mm the baarlng. From the nppnsne Slde, Install rm: bearing remover shaft and drive the bcarlng our 01 the wheel hub‘ Remove xhe distance Dollar and dl‘we out the other hearing TOOLS: Bearing remover head, 20 mm 07746 — 0050800 [Equivalent commercially availnb|e in USA.) Bearing removar shaft 07m; 7 0050100 (Equivalent cnmmarcixlly available in USA.) ., \ ‘ 'IWI REMOVER HEAD (Z) REMOVER SHAFT ASSEMBLY ZON-m(7nkgf»m,14lblfl) (2) RIGHTWHEEL BEARING ‘ s‘ x” F (5) BRAKF DISC ‘ Tr 13-11 FRONT WHEEL/SUSPENSION/STEERING CAUTION . V " '_ nmmvrn - \‘m. mm}! 'hv' ala‘ hy‘nlu ‘ (um llu' hrarmgr in; bar: mm m m having mus" hr r'c‘plar‘J u uh nm arm's. Dnve in a new 'iyhl bearing squarely lns‘a“ the diflante collar, then drive In the lah hsarmg usmg the specua‘ too‘s. TOOLS‘ Driver urns - 0010000 Attachment. 42 x 47 mm 07746 A 0010300 Pllom 20 mm 07746 — 0040500 - Du mu gm grruw m. m» 1mm mun w flapping panw will (.9 ”my“: lnsxall the brake discs on the wheel hub. “OIL ' Aliqn this rmafing difecl'xun marks belwaen the disc and h e‘ \nsmll and tighten the new mounting bolts to the specified mrque. TORQUE: 20 N m [2,0 kgf>m,14lbfl't| Appw qraasa in ma dust 563‘ ups, lhen mm” the dust seals Nome wheel hub INSTALLATION hits“ the side co‘lars Install the {mm wheel between the fork \eqs. Applymm \ayer of grease to the from ax‘e surface. halal! [he "on axle from (he leh side‘ 13-12 Huld the axte and ttghten the axle bmt to the specified torque TORQUE: 59 N-m (8,0 kghn, 43 let) Tighten the nght nxta pinch bolts to the summed torque. TORQUE: 22 Min (11 kgl-rn, 16 IIJHt) Install the brake calipers and tighten the new mnuntlng butts to the specified torque. TORQUE: 30 M"! (3.1 kgf-m, 22 lel) with the front brake applied, pump the fork up and down soverat times to seal the axle and check hmke operation. “ghlen the Ian Axle pinch bolts tn the spemtied torque. TORQUE: 2 Nut (22 kghn, 16 MM!) FRONT WHEEL/SUSPENSION[STEERING ”'3‘ 11)Axtt HOLT sK FRONT WHEEL/SUSPENSION/STEERING Ch ‘ the clearafice DEIWEEV‘ ll‘e bvake disc arld fozk axle / ~—«/ $413 BRAKE msc h'ankm rm each smn MTFJ Inmalla'mn The clearance should be at least 0.7 mm‘0D31nl. 12) FORK AXLE BRACKET FORK REMOVAL Remove me from wheel [page 13-20 Remove the bolls‘ lurk covers, Iruru (andev and slays, /’c/ ,l (1) FORK CAP Loosen the lap bridge pinch non ana Handlebar aunch bolL ; \Nllerl llve [mi leg will be disassembled, luosen the fork Cap, V w rln nm mmov? ‘1 yet 12! TOP PINCH BOLT// (PIVNCHfiBio T (3) HANDLEBAH '96 - ' _ After ’97: .Uuaan lhe lurk bullu'n pinch buhls) and remove the Vork {1' BOWOM PINCH BOLT 'uhe from the fork (op budge handlebar and steeliflg slemv CAUTION , hm ml marh’r r lmjrv mm“ (2) BO‘I'FOM PINCH BOLTS 13-14 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLV HI FORK CAP CAUTION - Bo :m'rful no! to srmn h #:0me tube or damage 111: dun val. Tum me pre-load adjuster counterclackvme mlly m loosen the spnng pyessure, Remove the (ark can hum the fork lube. Hold the rebound damping auiuswv will! a 14 mm spanner] ' (1) FORK CAP We“ luusuu and Ien1nvethe5ork can from "in damper rnd CAUTION - Dr: no! rmw‘ 1' [hr ”my“: dam/W mljuw: ,mm m,- dump” rm u. [ml damping ,mw mil I)! (hung: Push [he spuing coHar down and remove me sprmg sent. Remove inc following: -— Spring lain! plate — Spring Luna: — Spnng 1mm male 7 Fork spring Pnur nm tha fork fluld by pumping the fork lube up and down several times. FRONT WHEEL/SUSPENSIONISTEERING Hold thn fnrk Slldel‘ in a vice wim sohiaws or a shop towel‘ (1} FORK SI IDFn Remove the fork sockcx boll wilh a hex W(enclL NOTE - lf me fork dampev turns together with lhe socket bull, tern» oorarily lnstall the lurk swing, spring collar and sprmg seal. Remove the fork dampev assembly "am the fork mbe. 12! FORK TUBE Remove the dust sea| ' l (1) DUST SEAL Remove (he uil seal mopper ring, CAUTION - Ho Ho! 50mm Lira/ark lube Hid!!!" sulfate. (1) STOPPER RIN 7-, 13-16 FRONT WHEEL/SUSPENSION/STEERING Pull lhe fork (”he am until you feel resistance lrom the slider hushlng. Then move it in and our. tapping the bushing lightly until me Iork lube saparales lrurn the lurk slider. The slider bushing will be forced out by the fork lube hush- mg l Remuve lhu oil luck piece and U—rlna from the lurk Glidel. Remove the all seal. back-up ring and slide: bushing from the fork tube. (A) SLIDER BUSHJNG NOTE (2) OIL] SEAL - Do not ramove llle lork tube bushing unless I! rs neccs saw Io replace it wivh a new one. Remove the compression adjuslev from the fork slider l1) COMPRESSION ADJUSTER INSPECTION Fork spring Measure the fork spring free Iengxh. same: man: M i '96 — '97; 2432 mm «157 in) After '97: 245.2 mm [9.85 in) , 4+ 13-17 FRONT WHEEL/SUSPENSIONISTEERING Fork tubI/slidur/pismn Check me lurk lube, fork slider, and lmk dampnr for score marks, scratches, or excessive or abnormal wear. Check the rebound spring for laligua or damage. 11) FORK SLIDE'R Replace any components which are worn nr damaged 3-; ,9 ‘ . ) FORK DAMPER Place the fovktube in V»bloc|( and measure the runuut. Achlal mnmn Is II? the total Indlcnlnr readlng. SERVICE UMIT: 0.20 mm (0.003 in) Fork tube bushing Visually Inspect the slider and fork tube bushings. Replace the bushings ll [hum is excessive snoring or scratch- mg. or rf the teflon is worn so that the :opper survace appears on more than 3/4 af the entire surface‘ (7) BACKUP RING Check the back-up ring; replace il il mare is any diswnion a! the points shown. 13) CHECK POINTS (4) COPPER SURFACES Cumprewion adjusts! Chezlr the needle of the cnmprnssinn adjuster for wear or damage. Replace the compression adjuster if necessary. (1) COMPRESSION ADJUSTER 13-18 FRONT WHEELlSUSPENSION/STEERING ASSEMBLY (3) DUST SEAL I2) STOPPER RING l7) FORK CAP (I [I (I / 23 N-m (2.3 kgtm. 17 Int-m ,' / J, / ' ,* mom LOCK PIECE / ,’ / ' 14) DIL SEAL “ 1% k. Q (5) BACK~UP I g,\ g ”ml: I ‘§\\*Im SPRING SEAT \. , (6) SLIDER BUSHING 6 (SIJOINT PLATE (ID) SPRING COLLAR (15) FORK SLIDER" / (HI SPRING / / I ? I I II I (14) FORK TUBF \ 70 N-m [2 0 kgf-m, (13) FORK TUBE (12) FORK DAMI’L H In lbI-Ill BUSHING Before assembly, wash all parts with a hlgh flash or new flammable solvent and Moe them dry. Apply Imk fluId lo the new O»ring and install It onto me com- pression adjuster. Install the compression adjumcr Into the fork slider and tighten it. (ZI COMPRESSION ADJUSTER lnslall a new fork (ube bushing if the bushing has been I4) OIL SEAL [2) SLIDEFI BUSHING removedl Install the slider hllshmg, back-up nng and a new oil sealt NOTE Install the oil seal with its marked side facing up. (3) BACK-UP RING (I) FORK TUBE BUSHING 13-19 FRONT WHEEL/SUSPENSION/STEERING Insrall the lam damper inlu the lurk lube. V, I5) I ()HK SLIDER Apply lurk mm m a new O-rmg and ”15m” it Into rho groove olrhc all look piece. Install the oil lock piece unto the lurk damper emd 11] FORK DAMPER I4) FORK TUBE Inflall the inrk lube Into the fork slider. (3) / @ao-ame {2) OIL LOCK PIECE ~ Hold the fork slider in a vise wilh sull jaws U! a shop towel. I'll HJHK SLIDER Apply a locking agent to (he fork sucker holr thads Install the socket holr wrth a new seallng washer. (hcn lighrcn the bolt to the specified torque. NOTE . Ifthc fork dampcrrurns ragemerwith the seeker bolr, rem- porarilv Insrall rhe lurk spring, spring collar and spring seat TORQUE: 20 NM (2.0 kgf-m. 14 Ibfrhl DI'IVe me oil seal In uslng the special tools. In I I) IK 3; AL DRIVER TOOL: Fork Sill driver U7KMD — KZ30100 or 07KMD - KZ3010A IUISA. only] Install the stopper rlng into the rork slider gluovu seLunsly. |r1¢la|I Ihe dust seal. 13-20 Pour me Speclfied amounl u' vecommended fork “lllf‘ ln’n we 'uvklube RECOMMENDED FORK FLUID: Pro Honda Susponsion Fluid 55-8 FORK FLUID CAPACITY: ,96 - ,97, 561: 2.5 cm:l19lo 2 cm us all ' 19.7:0.05|nlp01l Maw 540:2.5 cm3118.3:0l02 us uz, ' 19.01009 Imp 01) Pump the flampfir run several times until the fovk lluld flows out Irom (he oll hole on the rebound damping adjuslev‘ Measure lhe all level from the mp nlthe Inrk tube while com pressmg the mhe all Me way ancr slroklng ma lork tuba slowly more lhan 5 times and lhe damper rud more than 10 limes. NOTE - Be sure the nil level Is me same in me both lorks. FORK OIL LEVEL: 114 t 4 mm [4.5 t 0.2 in) Full ma lurk tube and damper rod up and insxall ma lurk spring Wlxh the tapered and lacing down. Inmall the spring joint plale, spring collar and spring jDInt plate Push the spring collar down and Install the spring seal. FRONT WHEELISUSPENSION/STEERING (1) OIL LEVEL (1) FORK SI’HING (1) JOINT PLATE (3} JOINT PLATE .1) I 12) SPRING COL-LQR 13-21 FRONT WHEEL/SUSPENSIONISTEERING Insral! new 0 rings onto th fork can and rebound damping ,, 17) FORK CAP adiusxer. - Apply fork fluid m the new 0»rings, Instal! rhe fork cap onto the rebound dampmg adiuster. Ho‘d rhe rebound damping adjuster and screw the fork cap ' m FORK CAP unlo the dampinq adiusKer‘ Screw the fork cap into the (ark tube (1) FORK CAP INSTALLATION InstaH the fork legs into the slaying slam, handlebar bracket and York lop bridge Align the top and of (he fork lube with the upper surface of "19le bridge as shown. 1 3-22 FRONT WHEEL/SUSPENSION(STEERING '96 7 '9_m Ann '97. T‘gwsn me buzlum budge pmch bows] m the spammed m BOTI'O PINCH BOLT \mque ; TORQUE: 49 Nrm (5.0 kgl‘m, 36 IbHU ‘ {A [2D BOTTOM P‘NCH BOLTS (1) FORK CAP / Tigmen me fovk can (u The specificd torque (if it was removed‘u (21/70? PTNCH BOLI< TORQUE' 23 Nm l2.3 kaf'm.17|bl-m ./ Tighlen me too bridge pinm Lu)“ \0 \IIe spew-ed torqur‘ TOROUE' 73 N m (2.3 kgf-m.17|th) Tigmen m9 hand‘ebar umd: bull. Inan me from fender szav onto the iork, then instal‘ me Mom fcndc' and Turk cover {page 243). TORQUE 5 Nvm (D 5 kgi-rn, 3 6 let] \nstall mo front wheel (page 13.12)‘ STEERING STEM REMOVAL Remove the from whee‘ lpage 1318. Remove me from fender \‘nagp 2-13] Remove the Dons and Tram brake hose iuim. iemovg me bolt and Mom unit FRONT WHEEL/SUSPENSION/STEERING l1) .‘HkM NUT CAP Remove the sxaering stem nul can Loascn the smering stem nut. Hemovemefmklegslnags13-14: Ramovc me stem nut and the (up brides. S'ralgmm vhe tabs of the lock washer. Remove ma ‘DCk nm and luck Washer. Remove me S‘eerlng sxem bearing adiusting nut using the 509‘ cia‘ wok TOOL: Steerlng stem socket 07916 - 3710101 or 07916 - 3710100 1 3—24 Remove the following —— UJSl’ seal Uppc' bearing inner race 7 Uppe' bea'mg — Sreellhg stem — l nwer heanng BEARING REPLACEMENT NOTE - Always replace the bearings and race: as a set. Replace (he races using {he Ball Race Remover Set as descv'bed in the follnwmg pmcanure TOOLS: Ball race removal Set 07946 — KMSODM (Not available in U.S.A.I 07946 - KM501DO 07946 - KM90200 07946 — KMBOEOO 07946 - KMWW'I 07945 - KM90500 D7946 - KMBOBOO - Driver attachment, A [11 — Driver anaehment, B (2] — Driver shaft aiwmblv m —— Bearing remover, A (u — Bearing remover, B (5? # Assembly base (6! Insrall the ball race removsr imo [he hand pipe as shown, Allgl" bearing ernver A WIYh the groove in the steering head‘ Lightly lighten nut B with a Wrench. N OTF - Note the Install ion damn.” of the assembly base Hmdmg 7hr: drlver shaft With a w'ench, rum nur A gradually to remove the upper outer race, FRONT WHEELISUSPENSIONISTEERING m DUST 515i (5) NUTA (3) ASSEMBLY BASE (2) NUT B ‘ (Sl UPPER OUTER RACE 11] RACE REMOVER [m DRlVER SHAFT (7) DRIVER AWACIIMFNT 13-25 FRONT WHEELISUSPENSIONISTEERING lnsrall ball race remnver H as shnwn and remove the lower ouler race using the same procedure as lor the upper outer race. Align the bearing remover with the groove in the sleering head. Install a new upper uuler mug and [he baIl race remover as shown, Hold the derBr shaft with a wrench and lurn nut A gradually until the groove In driver attachment A aligns with the upper and of [he slewing head. This will allow you lo inslaIl the upper omer race. I7! DRIVER AWACHMENT (1) RACE HEMOVL’H 6.) (SI LOWER OUTER RACE 2 (7) DRIVER ATI'ACHMENT (A) DRIVER SHAFT II— -(2) NUT B (3) ASSEMBLY BASE (bl NUTA I3} DRIVER ATTACHMENT (AI ASSEMELV EASE (1) DRIVER SHAFT (3I DRIVER ' A'I'I'ACHMENT (TI NUT A 1 3-26 Install a new lower outer race and ball race remover as shown. Molding the driver shaft wnh a wrench turn nut A gradually until the graove in driver attachment 3 aligns with the upper and at the steering head. This will allow yeu ta install the lower outer race. U.S.A,only: N OTE - Always replace the hearings and races a5 set. Replace the steering bearing ouler races using the special tools listed below. TOOLS: Main bearing driver attachment 07916-ME502no Fork seal driver weight 079l7rKA501W Oil seal driver 07965-MA60000 Installer shaft Installer Inlchmcm A Inst-Her attachment E Removnr nmchmenl A Remover attachment B lnsIaII the spacial Innnls Into the steering head pipe as shown. Align remover attachment A will: the groove in the steering head. While holding the installer shaft with the wrench, turn the upper nut gradually to remove the upper bearing uule: race. o7VMF-K230200 07VMF-MATD‘IDI) 07VMF7MAT0200 07VMF-MAT0300 D'IVMF-MATOAOO FRONT WHEELISUSPENSION/STEERING I4I ASSEMBLV BASE l3) DHIVER (1) DRIVER SHAFT ATTACHMENT «9 v RACE (3) DRIVER ATTACHMENT UPPER NUT v— MAIN BEARING DRIVER ATTACHMENT FORK SEAL DRIVER WEIGHT\ UPPER BEARING OUTE R RACE REMOVER ATTACHMENT A»: LOWER NUT/ INSTALLER SHAFT I J ATTACHMENT 3,1] F IN STALLER 13-27 FRONT WHEEL/SUSPENSIONISTEERING Insrall the special rools Into the steering head pipe as SIIUWIL Allgn remover attachment 8 with the groove in the steering head. While holding me Installer shah wllh Khe wrenchl turn the lower nul qradually lu remove the luwer bearing outer racer lnslnll ll new upper hearing cuter race and the special loois as Shawn. While holding me Installer shah with ma wrench, turn (he lower nul gradually until lhe groove in installer dllschmenl A aligns wllh rhn upper and no (he steering head. Thls will allow you to install the upper bearing omer race, INSTALLER ATI'ACHMENT A_ \f—iflh e INSTALLER SHAFT—Bf > UPPER NUT REMOVER ATTACHMENT B”; LOWER BEARING OUTER RACE \ OIL SEAL DRIVER FORK SEAL DRIVER WEIGHT MAIN BEARING DRIVER ATTACHMENT IOWER NUT / UPPER NUTM INSTALLER A‘I'I'ACHMENT A UPPEH HEARING OUTER RACE INSTALLER SHAFF INSTALLER ATTACHMENT 5” OIL SEAL DRIVER FORK SEAL DRIVER WEIGHT MAIN BEARING DRIVER A'I'I'ACHMENT LOWER N UT 1 3-28 FRONT WHEEL/SUSPENSIONISTEERING lnsrall a new lower nednng outer race and ma spamal tools I UPPER NUT as shown, While holdlng me Installer shaft with me wrench. lurll lhe .Inper nut gradually unlll ma groove in inslaller attachmenl B aligns with the lower end cl lhe Steerll’lg hand This will allow vuu I!) install me Ian hearing ouler race MAIN BEARING DFIIVER ATTACH MENT FORK SEAL DRIVER WEIGHT\\ INSTALLER ATI'ACHMENTA\ INSTALLER SHAFT- LOWER BEARING OUTER RACE \:7 ’i INSTALLER ATTACIIMI NI B / 10th NUT/’ ' lemporarily install {he steering Slelll nul onto the slam m (3) DUST SEAL prevent the (hreads from be'lng damaged when removing llie Iuwel bearing inner race from the stem. Remove the lower bearing innu race with a chisel or eun elem tool, being careful not to damage the stem, Remove the dust seal m STEM NUT Apply grease lo new dusl seal lips and Inslall it over the steering stem lnsrall a new lower bearing inner race using a special tool and a hydraulic press. — I3) STEERING STEM DRIVER TOOL: Steering stem driver o7stBooono I2l LOWER INNER RACE w v I‘ll DUST SEAL 13-29 FRONT WHEEL/SUSPENSIONISTEERING INSTALLATION (1) STEM NUT CAP {'967 '97:! k / [2) STEM NUT Kc‘éQ (3: TOP BRIDGE \ (15) LOWER OUTER RACE 34, @116 (H- LOWER BEARING 1M LOCK NUT I: , ‘r ’ ‘ x12! LOWER DUST SEAL , k; ‘ a p ° (5:: LOCK WASHER I ' 5 ' ’l‘ ‘ N , (m AUJUST‘NG NUT h m UPPER [JUST SEAL \m UPPER INNER RACE ‘39) MPH n B! AHINU g (11) STEERING STEM Apprv grease {0 upper and lower bearings and bearing Yates. \nstaH the WWW bearing onto the sleenng stem \nserl me lnearing sxem \nm the steering head pipc. \nsta‘l upper bearing, inner race and dust seal App‘y on to the bearing adjustment nut lhreads. \nstall and ngmen me 5mm hearmg ad’usting nut to the mi- tial quuc‘ TOOL . Steering slam socket D7515 - 3710101 or 07916 , 3710100 TOROUE' 25 MM (2 5 kg+nm 18 Ibf'ft) 13-30 FRONT WHEEL/SUSPENSION/STEERING Move the steering stern nght and left, lock-tu-lock, five ttrnes to seat the hnanngs Make sure that the steering stem movco smoothlvl without plav or binding; than loosen the bearing adiustinq nut, Rahghwn the beannq adjusting nut to the specified tuvque. TORQUE: 25 Nrm (2,5 Ital-m, 18 lbl-fl) Recheck that the steering stem moves smoothly willluu| play at billdmg. lnstall the new Inck washer onto the steehng stem, Align the tabs of the lock washer with the gruuves 7n tlm adiustmsn: nut and bend lwo opposite tabs lshoner) dawn mm the adjustment nut groove lnsvall and finger lighten (ha lock nut. Hold the look nut and further tighten [he luck nul wlthiw ‘L/A :urn (90:) enough in align lts grooves win the lnttk washer tabs Bend the lock washer tab; up into the lock nut groove, _lt ocx WASHER 13-31 FRONT WHEEL/SUSPENSION/STEERING Install thetoo budge, lnstall the tnrk legs (page 1322). lnstall the steering stem uul. Tighten the steering stem run to the speclfied torque. TORQUE: 103 Mm (10.5 kgftm, 73 IM-fl) Install lhe steerlng stem nu| cap, Install the tmnt lender lpagc 2 13), Install the tram wheel (page 13-12l, msmll the horn unit and (ighlcn the bolt. Install the liont brake ulpe join! and Collar. Install and tighten the Hlountlng bolts STEERING HEAD BEARING PRE-LOAD Remove [he uppev uuwl lpage 2-7) Support the motorcycle using a safety stand or hoist and raise the front wheel of! the groundl Pusltlon the steenng stern tn the strntght ahead posmon. Hook 5 sprlng scale to the fork tube and measure the steer- ing head beaylng Dre-load, N OTE - Make sure that there is nu cable u: wit: harness interfsr- ence. 'l he preload should be within1.0 71.5 kgf (2.2 4 3,3 lbfl. ll the readings do not fall within the lirnib, lower the front wheel to the ground and adjust the steamy hearing DUNS? lng nut i2) STEM NUT 13-32 MEMO REAR WHEEL/SUSPENSION 64 NM! (6.5 kul-In, 47 Int-n) 15 Nm (1 5 kgf-rn, 11 mm) 12 N-m 1L2 kqf-m. 5 INT!) 93 N-m (9.5 kgf-m, 69 Inf-fl) 93 N~m (9.5 kgf-rn. 69 lbf-m 44 Nm (4.5 kgf-rn, 33 Ibi-f!) 14-0 I4. HEAR WHttUSUSPtNSIUN SERVICE INFORMATION 14-1 SHOCK ABSORBER 14-9 TROUBLESHOOTING 14-2 SUSPENSION LINKAGE 14-14 REAR WHEEL 14.3 SWINGAHM 14-16 SERVICE INFORMATION GENERAL .1 ARNING A cunmnunmd brake dis: or pad "dam flopping pawn. nitrard mmmiumd pads mt dun u mmznmd um wish a my: quaun- brake legrwu'ng ugenl. - Th: Mun-l "mm" mnuu'm mm undzr high pmsm. Du mu allowfir: 0! mm near an )Irurl absorber. - Ilrfnnt dirpmz 0/ m shack absorber. mime me unram (page 14-11;. - When SENICIIIg the rear wheel, suppomhe motorcycle using a savory srand or hoisx, ‘ Reier Io section 15 for brake system miormalion. Use only me: marked ”TUBELESS" and tubelas: vaivus on rim marked ”TUBELFSS 1 IRE APPLICABLE“. Use genuine Honda repiacsmant bulls and nuns for aII suspensinn pivot and mounting point. SPECIFICATIONS — REAR WHEEL/SUSPENSION ”m" "‘m ""’ ITEM STANDARD SERVI‘X IJMI‘I' Minimum tire tread depth 2.0 (0.03) Culd tire pressure Up to 50 kg (200 lb) load I 290 kPa (2.90 kgf/cmi, 62 psi) - Upto maximUm wcith capacilv ‘ 290 kPa (2.90 kgI/cma 42 psi) *' Axle runuui ’ 0.20 (0.003) WheeI rim runom I Radial — 2.0 «um I Axial — _ 2.0 (0.03) Shock absorber Spring frae length '96 ~ '97: 172.6 (6.30) 169.1 {6 BED Afler '97: 167.7 (6.60) 164.3 (6.47) Spring direction \Mth the tapered and facing up 7—— # Preiload adjuster '96 — ’97: 2nd position — 59““ After '97: 3rd yusilion # Rebound adiuster swing 1rurn Irum Iull hard 7 Compression BHIUSIEI' sening 1mm from full hard — Drive chain Sue/link DID DIDSZEHV GC&B - IZOZB —— RK HKGBEZSROZ1 7 IZOLJF —— Drive chain Slack '7 30—40(1.271.s) 5011.97) 14-1 REAR WHEEL/SUSPENSION TORQUE VALUES Rear axlc not Rear brake disc mounting bull Driven sprocke‘ nut Shock nhsnrher upper mounting nut Shock arm plate nut Shock link nut Swingarm pivot adjusting bolt Swingnrm plvot lock nut Swingarm pivor nur Driva chain slider bull. Drive sprocket bolt Rnnr hraka has: mounting bolt TOOLS Swingnrm lucknut wrench Bearing remover set — Remover handla — Remover head, 20 mm — Hemnvar waight Pin driver Needle hearing remover Needle bearing remover set Driver shaft Driver Ananhmenr, 37 x 40 mm Anachmcnr, 42 x 47 mm Attachment, 52 x 55 mm Attachment, 24 x 26 mm Pilot, 17 mm Pilot. 20 mm Pilot, 28 mm Bearing remover shah nearing remover head, 20 mm Shock absorber compressor Shock absorber comprsssor attachment TROUBLESHOOTING Soft suspension ~ Weak shock nhsorher spring - Incorrect suspension adjustment - Oil leakage lrorn damper unit - Tire pressure too low 93 Nim19.5 kgl-rn, 69 Ibf-fll A2 N-rn ll 3 kgi-m, 31 071*“) 108 N-m (11.0 kgf~m,80lb1-m 44 N~m (4.5 kgtm. 33 Inf-f0 44 N-rn (4.5 kgl~nr, 33 Inf-ill 44 Nrm (5.5 kgt-m, 33 lbl-ftl 15 N-m (1,5 kgf-m, 11lbf‘fli 64 N~m (6,5 kg‘l»m, l7 Ibf-fll 93 N-m (9.5 kgtm, 69 lblelll 9 N-m (0.9 kgf‘m, 6.51bl-fl) 5‘ N-m (5,5 kgf—m, 4010140 12 le1.2 kgf'm‘ 3‘7 IbHKI 07908 4690003 07935 - 3710001 07936— 3710100 07936 — 3710500 07741 , 0010201 ALDC halt U nu! U»nut U-nut U-mrt or 07936 — 3710200 07936 — 371020A (USA only) Not available in U.S.A. n7GMD -— KTHO100 07HMC MR70100 07LMC — KV30100 07916 —- MJ00100 07749 ~ 0010000 07746 - 0010200 07746 — 0010300 07746 — 0010400 07746 v 0010700 07746 — 0040400 07746 — 0040600 07746 - 0041100 07716 — 0050100 07746 ~ 0050600 07GME — 0010000 Not available in U.S.A. Not available in U.S.A. Not available in USA. Not available in USA, 07NME — MY70100 Not available in U.SVAV Steers to one sida or does not [rack straight - Bent rear axle - Axle alignment/chain adlusrment nol equal on bulh sides Hard suspension - Damaged shock absorber mounting bearing - Benr damper rod - ‘ Damaged swrngarm pivot bearings . Bent swingarm pivor - incorrect suspension adjuslrrrem - Tire pressure too hlgh Rear wheel wobbling - Bent rim - Worrr rear wheel bearings - Falrlry rim - Unbalanced tire and wheel - Tire prassura too low . Faulty swingarm pivot bearings 14-2 REAR WHEEL/SUSPENSION REAR WHEEL REMOVAL Support the rnulorcyuie seuuuely wng a Imisx o1 equ‘walem Ha-rmvs. ms Bx‘e nut and washer. Pusfi (he rear wheel luvward. Demil the drive chain {mm the drwen spmr‘xm Rcmovc the mm: from the 19?: side and remove the rear ? wheat I, ~ (5 , Remove the 5169 collars. INSPECTION Axle P‘ace [he axle in V-blocks and measure the runout. Ac1ualrunout|s1,’7 the tnral nndma'lur readmg. SERVICE LIMIT: 0.20 mm (0.008 in) 14-3 REAR WHEEL/SUSPENSION Wheel bearing Tum the Inner race of each hearing wnh your finger. Bearings should turn smoothly and unlerly. Also check that me bearmg outer race ills llglllly In Llre llub. Remnvn and dlsnnm me bearings If the races do not turn smoomly and qulctly, or i! may fit loosely in the hub. NOTE - Replace the wheel bearings in pairG. Whnl rim runnul Check the nm runnur hy pinning the wheel m n mrnmg stand. Spln me wheel slowly and read the rumour uslng a dlal indln Gator. Actualrulruuli>1l2 {he lmal indicator reading SERVICE LIMITS: Radial: 2.0 mm [(1.08 in) Axial: 2.0 mm (0.08 in) Driven sprocket Check lire uundiliorr ul Ill: linal driven sprockei teeth Replace the sprockei .r wnm nr damagpn mulmu l7ll1l'r‘lACF NOTE ll the final driven sprnckev requires replacemem, Inspect _ the drive chain and drive sprocket l’\ / \ A l\ [K H ‘ Never install a new drive chain on a warn spruckeK or a j, / \ wum chaln on new splockets Both chain and sprocket mun he rn gnnrl nonrmmn or the replacemanl sham or sprocket wrll wear rapldlv. Wheel b-Iance * See page 13-10 for wheel halanma DISASSEMBLY Hemnw‘ ll'lP hnlls and brake drsc. ‘lcmovc the right dust seal. ngl BHAK‘E nlsc 1 4-4 Hemuv: the driven flange a:spmh!y from We left wheel hub. NOTE - ll yuu will be dlsassemhle the drlven flange, loosen the rlrlven sprocket nuts before removing the drlven flange from the wheel hub. Rellluve me wheel dampe’ nmhm Remnwme (J-rlngA Dvlvnn flanga bsiring renluval Luusell (he dr'lven sp'orke' m": Remove :hc drlven flange: from me wheel hub, [hell remove the driven spruLket llul: d splocket Hemnve vhe dust seal. Rerrove me r‘lnven flange collarl Dnve om (he drlven "Ange bearing REAR WHEEL/SUSPENSION l1l DRIVER FLANGE ASSEMBLY l 3 \ DRWLN FLANGE 14-5 REAR WHEEL/SUSPENSION Wheel bearing removal lnsla‘l lhe beanng remover head inlo the hearing From me Opposite side, install lhe bearing remover shah nm-l drlve the hanrlng nm lo9 wheel huh. Remove the distance collar and drive on the other bearing. TOOLS: Bearing remnvar held, 20 mm 07746 - 0050606 [Equivalent commerclally avallabla In U.S.A.) Bea lug remover shah 07746 — 0050100 [Equivalent commercially available in USA.) ASSEMBLY 4m llllAKk DISC l4,3kgl~m‘ ms «.0 311mm ‘G‘fi/ if? / 0 4 l N LLAR -z: RlGHT DUST SEAL’ ‘ ’DSTA CE CO l3) UllthN FLANGE él / l‘ll HKJHI WHttL BtAHI 1U?) N m ll1,U Kgf m. 80 IDl-‘(l gift 01:29» Wheel bearing installation (ll DRlVER CAUTION - mm [NU-1U m ”m Imam“ mm» m hmnmu rm my. lcnm' m. m l'wal'mg Hum nu mm: 01 mm up» man: Drive in a new rlght bearing squarely Install the drstance Collar‘ Ihen drive ln the left Side hParlng TOOLS: Driver 07749 — 0010000 ‘ Attachment. 42 x 47 mm 07746—0010300 Pllot, 20 mm 07746 A 0040500 MENT’PILOT 14-6 REAR WHEEL/SUSPENSION Driven flange bearing installation -l'1 l DRIVER Drive me new driven flange beating into lhe driven flange using the special tnnls TOOLS: Drivar 07749 - 0010000 Attachment, 52 X 55 mm 077“ - 0010‘“) Film, 2!) mm D7746 — 0040500 Install the driven flange collar. Inslall the wheel damper rubbers mm the wheel hub. Apnlv oil to the new O-ring and install it inlu [he ngUVE oi the wheel hub lnslall ma driven flange assembly intn (ha left whael mm. "'7‘ 13' NUTS H the driven sprocket was removed. insiall the driven sprocket and (igmen the nuts, YORQUE: 108 Mm (11.!) kglrm, BIJ'let] Apply grease to the dusi seal lips, then install it inlu (he dd» yen flange. REAR WHEEL/SUSPENSION Install the brake um win ll: "DRIVE" malt faclng out lnstall and ughten the new mm m the specmen torque. TORQUE: 42 NM 14.3 kgf-m. 31 IbH‘!) INSTALLATION Anply grease to the Slde collar lnSlde and grooves. Install the side collars. lnnta'l the rear brake caliper bracket onto the guide of the ‘I - ‘9‘ [1] CAMPER BRACKET swingarm, ‘ blace the rear whgel mm the awmgarm lnslall the dnva cham over the dnven sprocket lnsh’i“ the axle from me Ieh side. 14-8 REAR WHEEL/SUSPENSION \nstaH the washer and luose‘y instaH the axle nut Amnst me dnve cham slack \nan 317). ‘5 T ghren the axre nul lo the specified quue. TDROUE' 93 N'm (3.5 hat-m, 63 "at"! SHOCK ABSORBER REMOVAL Support 1m: mmmcycrp snmnrelv using a hols! or equivalent. Remove me sing covers (Dane 23» Remnvp ch? reserve rank band, Remove the upper ano lower mounting bulLs dud slquk absulbev. 5m MouN r rm; Buns r fi=~ DISASSEMBLV NOTE HI SHOCK AHSL)HHI;‘-< COMPRESSOR 12) ATTACHMENT - Make sum (he sDrirg adiuszcr is set ro me when new Hon before disassemble me shock absorber. Install vhe shnnk absorber compressor and attachment omo me shock absorbcr as shown. TOOLS’ Shock absorber compressor U7GME , 0010000 Shock absorber compressor anachmenr 07NME - MV70100 [urn the compressor screw and compress the spr'mg. REAR WHEEL/SUSPENSION Rcmcvc lhc spr‘mg seat slopoers. Remove the special 100‘s and remove the spring 5931, splulg and sunny auiuswv, ' 41'- SPRING SEAT STOPPERS INSPECTION (1) QAMPER UNIT / ‘lusuaHv inspect [he damper uuil Iul den-Inge Check for me: Damoer rod for bend or damage 7 Damper uml I'm deluuuatiuu u: on leaks — Bump rubber for wear or damage Inspect all me omer pans for wear or damage. Measule the spring free length SERVICE LIMIT: I '96—‘97: 1691 mm (6 56m) After '57~ 1m 7 mm (G fin In) Mark me 2: mm [0.3 ml poswtlon as shown of the damper 1011‘ Place the damper mm on a :Lale and measule we fume I reqmred to comm-955 me damper to me H mm m .1 m) I COMPRESSION FORCE: 15‘4 - 200 kg (34.0- 441 lbs) ll m;- enme mqman vs Ins: than 14 9 kg 132 8 Has), gas Is leak- mg. Examme the damper rod and replace the damper um f It we hem or sue-ed 14-10 SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the reservour tank end to mark the drilling poinr‘ Wrap the damper unit Inside a plastlc bag Support the reservmrtank in a was as shown. Through me open end oi (he bag. insen a drill motor wim a sharp 2 ~ 3HIuI15/64 — 1/8 in] mi“ bll. hummus - on not us: a dull drill bu whit}: mu earn: a build-up ojtxcn- sire hull and prexsurc inkide the damper. (main: to rxploslon uml mm pmunul injury - m shack ahxnrher cunumu nilmgtn gin and ail under high prmum Du mil drill unyfnnhcr dawn 1hr damp" can rlmn nu memuremem L'il'rn abare. 07 you may drill Mm IIIP all dumber: m" nruping nmlrr high pmim may mm wrimu punurml injury. - Alwnyx wear at prmctmm m amid gum-g metal Shawn; In your ms when the gas presxun ls RIMS“, The plastic bag is nnlv ln/mdnl m .rmmwi. from m (draping gm. Hold m: bag around the drill motor and briefly run the drill motor inside ma bag; this will inflate (he bag with air irom u...- mulul and help keep the bag {mm gelling caught in me hlt thn ynn mm LOWER JOINT NEEDLE BEARING REPLACEMENT Remove Llie pivul cullar and dust seals. Sal Lil! dampel in a hydraulic press, CAUTION ~ Pm 1' rm dump“ "11}:an Vim/Indiiamimig Mum. [wring/1p Press the needle bearing out from the lower joinl. TOOL. Pm driver D7GMD , KTBU‘IDD . (No! available In U,S.A.) REAR WHEEL/SUSPENSION l2l RESERVOIR CAP \ (2| DUST SEALS l1) PiN DRIVER / HEAR WHEEL/SUSPENSION Pack a new needle bearing with multirnurposa grease. W DRIVER Press Ihe needle bearing inlu lhe towel joint so that the needle bearing casing is Inwar R mm (D :I m) hemw me and of the Ioweuomt as shown H mm ((13 In) + ’ "1f”? TOOLS: ¥ Drive! 07715 - Dfl‘IDflGD Aflachmeni, 2‘ x 26 mm 07746 — 0010700 Pllot 17 mm 07746 - 0040400 1-1] r—fi‘NEEDLE BEARING Apply grease m the dusx seal lips. InsmH the dust seals and pivot collav. l7) PIVOT COLLAR 90‘ \ \\\\\ m was} DUST SEALS ASSEMBLV {8} SPRING ADJUSTER ,(3) PIVOT COLLAR (61 SPRING SEAT (4] DUST SEALS 14-12 InstaH the spring adjuster arm the damper unit InsraH me sorinq with ll: lapered and facing up. \nstall {he spring sear. Install the shock absorber nomvressul and attachment mm the shock absorber as shown TOOLS: Shock absorber compressor o7GME - omonon shock absorber compressor nflachmen! 07NME — MV‘IOIDD lurn the compressor screw and cumpress the spring InsraH rha sprung seat Mappers securew. Remove ma tuuls. INSTALLATION InslaH the shock absorber imo the frame will: the rebound damping adiusler lacing lu me right Rome the ruwrvo'rr hose properly, Instarl and nghtcn the upper and luwer Inountmg bolts/nnrs to me specified torque. TORQUE M N~m (4.5 kgfm. 33 lbf-h] REAR WHEEL/SUSPENSION (“SPRING AUJUS'EF‘ 12) SPRING ' REAR WHEEL/SUSPENSION Pas flan (he veawvuiv as shown and seems ix wizn a band. V m BAND ‘35?" SUSPENSION LINKAGE REMOVAL/DISASSEMBLY Sllfipn" m: mmnrnycle seaurew using a hoisl u: equiva» lent. Rewiov: we mum pipe (page 2715. Rc'novc the cxhausx was moummg con and ruhhar Remove the following: — Shock abaurbel lower mourning bUIt/nul 7 fihnak arm plate bolt/nut (shock link side! Shock arm pIate boltinut (swmgarm side) — Shock arm plates 7 Shock IIIIIK :uukel buIL/nui — Shock Imk‘ , 1" ‘12) SHOCK ARM PLATES (3', SHOCK LINK Remove me pwm collars and mm SEEIS flum um shuck link. m PIVOT COLLARS INSPECTION Check the nus! seals and cnIIars for wear, damage 0! *angue, Check ‘ha needle bearings for damage or loose m. Ifme needle hearings are damaged repIace them. (2| DUST SEALS 14-14 SHOCK UNK NEEDLE BEARING REPLACEMENT Press the needle DParmg ml of the shock lmk using specxal mnl: and a nydraullc prcas. TOOL: Pin driver 076MB 7 “80100 (Not availablo in U.S,A.) Punk me new needle hearing wnh mum-purpose grease. Press me new needle bearing into the shock link so thax the needle bearing surface is lower 52 » 5.7 mm (0.20 r 0.22 inl mm the and ol the shank link surface NOTI‘ v7—____. - Press the needle bearing mm thfi wing aligning its tabs with the groove In the can“. and mm! the lower pad run a< (II BOOT Remove the snap vmg from the master cyhnder body using my spams! tool as shown. TOOL: Snip ring pliers D1514 — SAsoum M 07914 - 3230001 Remove me push rod, maslev piston and spx‘mg. Clean the Inside n? ma cylinder with brake fluid. INSPECTION Check me mum bum, plimarv cup and secondary mp Inr Ialigue or damage Chm: ma master cylinder and piston for abnormal scratches. Measure the master cylinder LD. SERVICE LIMIT‘ 15.925 mm (0.6270 in] Measure me mamar cvlindev piskun ODV SERVICE LIMIT: 15 815 mm [0.626 ml HYDRAULIC BRAKE 15—15 HYDRAULIC BRAKE ASSEMBLY \ 0 ii @3 5a" 16) SNAP HlNG (G) BOOT CAUTION - Km, We pawn, rugh, \pmug vmfv rum and ‘mm as .1 m.- do not mmnmzz mJn'u/ua’ mm Com 3H parls with clean brake fluid be'ore assembiy Dip the piston In brake "Uld. Install the sprung to the ptston. Install the oismn assembly, Apply grease [U the pisLuu L'Lmlacl auea onhe push rod CAUTION - When zlumflme lh!‘ rum. do not III/(7w flu hp; Iu mm insult um /(1)SPHING 2 PRIMARY CUP //( ) I—(3I MASTER PISTON \\(4> PUSH ROD (3) MASTER PISTON %. ‘%g (2) PRIMARY CUP A , 2" (1) SPRING 15-16 HVDRAULIC BRAKE .nstaH the pusw roc mm the master cvlmder. :2» SNAP RING 11) 95H ROD nsxaH the snap rinq using :‘Ie >pecial tool / CAUTION - B. r1r1u:nv/,yml;- he z.‘ rrmm .enml '1‘ {he TOOL‘ Snap nng pliers 07914 , SAEODO‘ or 07914 — 3230001 Install the boo! :3. SNAP RING PLiERs Apmy wk; mm m a new 0 ring and man it onto me ,u) @0 mm tszgERvom JOINT resmvmr 1mm. 7. I lrszau me raservui' juim mm the master :ylmder \nslall and : qmen [he suew (1) HESERVO‘R JOKNT (2) SCREW \ TORUUE‘ 1 5 Nm [0 1b kwlm, 1‘1 "if-h) INSTALLATION P‘ace the masmr cvhnder onto me frame. lnstau the step quard and \iglnen the bth5 Install the make hose with me oil non and new sealing washers. Push the evele‘ ioinl ageinsl Ihe Stupper_ men women me ui‘ bull lo the specified mrque, TORQUE: 34 N m (3.5 kgf-m, 25 “1”!) ‘— (2; STEP ngnn . m MAST53 CVLINDER 15-17 HYDRAULIC BRAKE mm and :xghlen me braxe resarvm" mounkinq bun, <1» BRAKE RESERVCKTE" Connect the brakc pedal m the push rod Iowcr ioim. man“ (he Joim pm anc secure fit With a new comer pm. Fm (he reservtw m the) upppr Ipum arm hlaad mp make wys- xpm wage 15-3’. FHONT BRAKE CALIPEH '96 - ’97: REMOVAL -;m the from make hydraulic system (page 15-3. Remmr: [he bo‘: and reflecmr Remuv: We w my aealing washels and brake hose eve‘er :mnt Remove the ca‘ipcr mounting boils and the brake pads 'paga 15-5). CAUTION - Amid wily‘mc (dew mum. plum: wrv'ubbnpafl; rum Hum .Iu'rI/uu Wu ”mm. in .m mm ,3 mm; 15-18 DISASSEMBLY lr‘sxaH cor'ugateu Leldboard or soft wnnr sham between We: pistufls Appw sma I sqmrts 01cm pressme to me mid wlel :u (emcvc :hc pisxons. m; , - no In)! Mr lu‘glz pmmrr mr w [mug [hr nnzzlr um close m [In- mm Remove 'm: mur calmer asscmmy on x: and separate ma rahper "aw-:3 Hcmcv: me 'ONOWHQ — Jmm 5&1}: 7 Ca \pel mxmn A 7 (.mp9! msxon B AOTE . Mark the pwsions ".0 cnmrc CDH’ECI rgassemb‘v Push (he dust Seal: and pwston S9a‘< n and W1 them out. CAUTION - i1. “mum rm. (’M'm’ mm. .2 Clean me 553‘ grooves w (h c‘ean b'ake fluid HVDRAULIC BRAKE ' ,7 ,. {HCAEDBOARD ‘ / / 41‘, ASSEMBLY BW 11, JOINT SEALS (2r CA.\PEH PISTOK A r\\ l / 13) CAL‘PER PISTON B (1rDUSTSEAL (2)W5T()N/‘EAL HYDRAULIC BRAKE INSPECTION {hpnk m9 ca'mer cyhnderlor swing ov when da"‘age. Measu'e me caliper cyIInncr |.D SERVICE LIMITS A, 30.29 mm (1.193 in] B- 27 06 mm 11 I105 in) Check the cal [20' pinto”: Vor scratches, Scarlng nr nMPr damaqe‘ Measure! ms. nahnpr pmnr O D SERVICE LIMITS: A130‘14O mm (1.18561n) B. 26927 mm [1.0510 in) ASSEMBLY A11 L'ALLPER BODV 12) JOINT SEALS E Nm {0.5 kg! m, 4 L! mm g; / .77 N-m(33kgI~m 741hMV) / fig / :31PI5T0N SEALS’ 0 \D \'\ / \ ‘ \ (a) DUST SEALS @\ (5) CALIPEFI PISTON A V \\ 2.5 Mm {0.25 kgV-w,181h'-III (6) CAUPER PISTON 8 TB N»m (1.8 kg! m, 73 Ib'fu 15-20 HYDRAULIC BRAKE Cod! Khe new pmnn seals wuh : ean brake hwd. lllJONT SEALS l?l l‘lSIl'm SEAl 5 fine: me new cum seals w PISTON l3) PiSTON SEAI /, 6 N-m [0 5 kgV-m, A 3 leU 27 NT“ 12.8 kglrm, 20 lblvft) //(4i PIVOT BOO l /.r’§) PiVUI (JLLAH (6) PAD SPRING m N»ml1l‘l kGlAm, m IU,2‘:> kgfm,18ibfm‘96 ’87- ‘3 'W" '1” i011. kgi-n-, 17 inti Aher ‘97 Coat "15 new plston seal wxm clean brake fluldi Caal the new dust seal Wllh silicone grease, '3‘ PISTON / l’ulal‘ mp nision seal and dust seai mm the groove of the / caliper body 1/ qul l- e L'nllper pizlun with clean brake fluid and install i1 me me raliper ryllnder With its opening and towaid lhe / x 0% Dan, (1‘, PlSTON SEAL’ ’ ~ /1 / , <2) DUST éEAL lwsxal‘ the pad spring me me caliper body. ,’ l2l [100T if the Lalipe: and mum vii bums are hard or deteriorated, (enlacn chem wnh new nne< Aaplv silicone glease to the inside ohhe bracket pin boot. igi PlVOT COLLAR lnszall Ihe blackel pin Deal and collai illlu me L'diipul. // Q m PAD SPHIRG 15-28 HYDRAULIC BRAKE r mslall \he cahpev pm uuoi i010 (hi 1:1:er " ‘ZI CALIPEF BRACKET /, (1D BOOT/ INSTALLATION . {1v CAMPER Apmy <|lmnn9 grease to the caliom pin and inglall (he caliper onto the bracket. mm" (hr.- blake pad<1nage15fil Inna“ and Ug'ucn the caliper bracksl bah n: [he we IOYQLIE‘ TORQUE '96- '97. ‘ 23 N‘m (2 3 kgf-m 1" ‘fll Afier '97. 22 NM! [2.2 kg m,16‘b‘-fl“ inelal’ the brew hose eyele! m (Ive ca‘iper body with two new saaiing washers and (HI bnlt °ush the hrakp hose eye‘e‘ to the stopper on the caliser, than ughten the oil boa :0 [he specified lurqua. TORQUE. 34 Mn] (3 5 kgf—m, 75 Ibf fl] ML and weed (he rear brake 'wdraJm: svslem mags 15~3y BRAKE PEDAL REMOVAL Remnve anc discard Inc brake pads! join cotter pm, Remove lhc ioinx pm, HYDRAULIC BRAKE -emove (he nous, 512p guard am maslev uylmJe' dsw ,_ \(31MASTEfiLVLmDER Remove the socket Duhs and 'Fchl :lep Mu‘del assemblv. H‘ SOCKET BO/LTS ’ V UWOQK the return sprmg and remove me brake lrghr swirch (row the yap raider. Umwk We Luck: uwa‘ rem s spfllrg KW HI \UHV SPRING 111 SW‘TCH‘SF‘RIKG Remcve me rompeg mountinq mm, ‘Dclpaq, brake cedar H: BUM <3: HHAKr mm; :HU wave washel \\ , \ \\ 14‘ WAVE WkSHER (2‘! FOOTDEG 15-30 HYDRAULIC BRAKE INSTALLATION I2: MASIiH CVLINUEF \H BRAKE L‘GHT SWITCH \ -,g%\ I (3) STEP GUARD 26 Nm (2 7 kgf-m, 20 mm u N~m (t5 kgrm, ~ 33 lbw \ \ I ( } BRAKE PEDAL ‘ . / / (9) STEP HOLDER :’ (5) FOOTPI K; \ (8) WAVE WASHER (7r SWITCH SPRING Anply greaae to the slwdmg surface of the brake pedal and 12) BRAKE PEDAL fuolpcg. AssemMe me blake pedal, ngm forum-g and wave washer‘ Insmll the right iooxpcg assemb‘y onto the slap holder alignmg [he cut-mus nexween Hue 'Uulpeg and holder {3} FOOTPEG 11) WAVE WASHhH Insxal‘ a new fompeg muurmllg bull and lighten ix :0 the specineu luluue TORQUE: 44 N»m14.5 kgf-m, 33 {thl Huuk me make pedal mmrn sprmg Install me brake light switch and hook (r0 switch spring, 5' mvfiv non 15-31 HYDRAULIC BRAKE msmH m: ngH SZEp halcer assemn y mm m: "am; lnszaH an: ngmen we fight s‘cp hamc' socket bolts spewfled lu‘uu: TORQUE: 28 N m l2.7 kg! m, 20 lb! m mm“ m» n-asnzr ryl nrsr and amp gxmn’t men :xgmefi the mounrng bolts Y1 WNUH‘ ‘ mml ill: Lune yum lo we pus}: rud Iuwer jmm. \nsra I ma ;n m pm am > > 0 i (ZHZATTERV | l | J I .. /‘A%: fig (4) REGULATORK HLIIHHKH (.1) Al TrnNATOH YtLLOW G REEN RED . WHHT §mo< 15. BAI ItHY/UHAHEINU bibltllll SYSTEM DIAGRAM 1&0 CHARGING SYSTEM INSPECTION 16-6 SERVICE INFORMATION 16-1 ALTERNATOR CHARGING COIL 16~8 TROUBLESHOOTING 16-3 REGULATOR/RECTIFIER 16-8 BATTERV 16-5 SERVICE INFORMATION GENERAL - l'hc mm gives uflexplun've gmu; rm. tpwkt, 11mm and crzan'm‘s away. rmm ndlqlmfl‘ ventilation I'hrn merging. - m barmy runluim Sui/Mir arid ltkctruiyle). Emma with skin or (wt may mutt» mm hum. Weurmmmc crmrrr'ng andrz rm mum. —- [lakmwlyle gm un _vaur5kln.flu5h with wutrr. _ lfL-Icrlralytc gels In yuuruyn,j1ush with mun/Mat teas: 15 mums andtalla phylum, - Elerrrnlm it poimnuus. _ lju'uI/ttwrd. drink lav-gt quantities a] water or milk mid/ulluw will: mm 0/ magnesia or vegetable ml and call a phi-mm... . Krnt or rat REACH or CHILDREN. - Always turn all the ignition swrtch belore dimonnecting any alscltical component CAUTION - Stmlt' m. U ml . rr-rrpmrern min he damaga‘i Lfrrr-rrrrrrals nr connector: m an". m! m' riitrmmn'ted trlrrlt‘ rhc ignition :wm‘h Ll 0N .rn: r ..r r .rrt .r pr-wrrr - For extended storage, remove the battery] give it a full charge. and store it in a wul, dry spare. rnr mnxrmum service Irle, charge llle stored battery every two weeks. - Fur a battery remnrnrng in a stored motorcycle discuttnucl the negative battery cable tram the battery terrrrinal. NOTE v The marntenanne tree battery must be replaced when it teaches the Pnr! of its service life. CAUTION m - m Eumrrr nil-t tiirm’d w he rt‘mm't‘d..lrrwnprr'ng m roman: JIM mim- ttlpsflt'ml mt r‘fI/J rntiytlamagt’ lin' imam . The battery can be damaged ii overcharged nr rrndercharged, or it left to discharge for long perind These same con; ditions contribute to shortening the “life span" of the battery. Even under normal use. the performance oftha battery deteriorates after 2 — 3 years. . Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and evenr tually die out. For this reason, the charging system rs often suspected as the problem Battery overcharge often results from problems in the hattery itself. which may appear to be an overcharging symptoms If one of the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery Under these conditions, the electrolyte level goes down quickly. . Below troubleshooting the Chargmg system, nheck for proper use and maintenance of the battery. Check it the bat tary is lreuuently under heavy load, such as having the headlight and taillight ON inr long periods of tlme without rid- ing the motorcycle. - The. battery will selfrdischarge when the motorcycle is not In use. For this reason, charge the battery every two weeks to prevent sullation [rum occurring - Filling a new battery wrth electrolyte will produce some voltage, but in order tn achieve its maximum performance. always charge. the battery. Also, the battery tile is lengthened when It :5 Initially chargedt - When checking the charqrng system. always (allow the. steps In the troubleshooting lluw chart tpage 16-3). 16-1 BATTERY/CHARGING SYSTEM Battery chnmmg This model ccmes wim a maInIcnancc frcc IMF! banery. Remember me fallowyng about MF batteries. — Use only Ihe electrolyte max comes with the battery — Use all ohhe electrome — Sea! the battery properly Never upon the seals again CAUTION - Fnrbanm chart-Hg, do an! [inrcdrlxr [Ilav'gmy mmnmm mm- W: whim m.- Imam) In» mum.» rurrrnluvx‘lmrqmg mm may damage Ike buzrerv SPECIFICATIONS r‘rEM SPECIFICATIONS flanery Capacity 12 V—SAII ounem leakage 7 7 7 V V 7 0.:nAIIIax: Voltage Fullv charged 13.0-13.2 v (NFC/“3"” Néeas}harging Below 123 v cnargxng current Normal 0.9 NS » 10 n Quick 4.0 No.5 h Alternator — Capacity 334 Wib,U00 rpm Charging coH resistance (ZU‘C/EMVFI fl 1 '0 3 n Hogulalon’veclifier regulaIed voltage 135 — 15 5 V5000 rpm 16-2 TROUBLESHOOTING BATTERY/CHARGING SVSTEM 1. Battery undercharging (Voltage not raised to regulated voltage). Measure. the. charging vnitnge With the battery fully charged and in good condition ipagc first Standard requlatad voltage is not reached when ihe engine speed increases l l i t ‘ Check the voltage between the ballely line and ground line of the regiilavnr,‘remmer ipnge 16M Correct l ,,)—'_ _ Check the resistance of the charging cm at the charging cuil line ol the regulator/rectifier connector (page 15-“), l Correct Correct Check the battery current leakage (Leak test: page 1677!. COT'BEI incorract l ~ Faulty himery Disconnect the regulalur/wclilier L‘ollneclul and recheck the battery current leakage. Cnrrnm Innnrrnnv V - Shonad wire harness - Faulty ignition switch , >- rniilty regularnmentitinr lticunvcl . - shorted Wire harness - Poorly Connected Culmsclul Incorrect ”— ——~—’ Check the alternator charging coil lpaqa 16-8). Correct Incorrect ‘ i ‘ - Poorly connected alternator connector - Faulty charging coil - Faultyregulator/rectifier 1 6-3 BATTERY/CHARGING SYSTEM 2, Battery overcharging [regulated vnlmge too high]. Measure xhc charging voirage mm the bar Correcr (aw fully charged and in good condiliun >~ hmlfy battery (933616-6L Regulated voltage greatry exceeds the standard value. v ‘ Check me. mnnmmy hervvenn lhn grmmd Imp. Imam“, and1ramr: allhc regu‘aron’rccfificr connector —* ' 0W” WWII w W”? harness (page 16-8). - Poorly connamed mnnemnr i r Correct ——'- Faulwrequlator/racfifier - Poorly connected connector 1 6-4 BATTERY/CHARGING SVSTEM REMOVAL Remove the scat (page 272) Remove me battery Holder ham, D:5»‘nnnpm the negatlve cable and than the posifive cable, and remove Ihc banery. INSTALLATION Instal: the oancry in me reverse order a! ramovai with [he propev wiring as shown, NOT m - Connect the DULIIIVE leiniiuai liist and then the: neganw cable Aflor Installing the banery, coat the terminals with L‘IE‘MI grease. Ramble“ (he removed pan< VOLTAGE INSPECTION Mmme its battery voltagp ”mg a mgim mimimeier, VOLTAGE: FulIy charged: 13.0 —13.2 V Under charged Below 12 3 V Tuuu , Digi‘al mummexev Cummelcially avaiIahle in u.st. BATTERY CHARGING mfl - The twin, Kim u/[nplntl'lr' gmfl: Ami marks. flaws, and :mru't‘llrt awa I'rmm adrquaic vmnlallon when charging. - Turn power 0 [T m m;- rhurcrr, mu m m.» bunny larmimzl Remove the battery (:nnnem 'he-chargcr DOGIUVO m cable to the battery post- 17) “M ILHY livc mmrmmal Connacx (he L‘IIargei negative (—i cable to thP hanery negar [we (7: te'r’mnaI ’ , Normal ()ulck Charql’ng curreni 09A ADA ‘ Charging (.me 5 - 101mm; 0 5 hour CAUTION - {Jim in Int! ‘ mum ”in hr am :71 mi ("iU‘L'UhW m Am; ,p. mm ‘1 , mum i min-4m .1“ in. (mm rm rim; we ”may M W ipwniid on m. pm [my . Mum uni-w m w .im; IIIV‘ J...‘ iv w w mm rm' hiuh'm 16—5 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION NOTE - When inspecting the charging svstarnl check the system components and lines step-bv-sleu according to the hou- bleshooting on page 16-3 - Measuring circuits With a large capacity that exceeds the capacity at the tester may cause damage to the tester. Before starting each test, set the tester at the highest capacity range first, thzn gradually lower the capacity ranges until you have the correct range. - When measuring small napacltv circuits. keep the igni- tion switch off. I! the switch is suddenly turned all during a test, the tester fuse may blow REGULATED VOLTAGE mspscnom NEE—— - Ulltr mgr". mm he running to do some work. make sun the arm is wtll—vrnnlalcd. [Vt-var run um :nginc in an anclnsnd mm. m ulmusl tannins palmnnut turban monaxr'dr Km 1qu may mm [m ufrunn‘imlmrss uml may Mid m tlmlh, N OTE - Be sure the battery is in good condition before perform» mg this last. Warm up the enqine to normal operating temperature. Stop the engine. and connect the multimeter as shown CAUTION - n WW“ a dim. mutt- trlrlulultl} mum. n w. W :in putrmt .ml lrr‘gum’r m-mlmm .7» rub/r - Do not dirt/ulnar: ms 2mm or an) mirlz' m we t‘hurt‘lltg tit-1m it‘ll/tum firll su‘rlt‘kln" nfirrlw mummy m'rlrhv Failure In fnllrm IlllK ,m-WW um .1“. e .va law a! timing: n.,.,,m..m Restart the engine. Turn the headlight on Hi beam, measure the vullage on the multimeter when the engine runs at 5,000 rpm, Standard: 13,0 -155 V at 5,000 rpm The battery is normal if the specified regulated voltage is displayed on the multimetert NOTE - The speed at which the voltage starts to rise cannot be Checked as it varies with the temberature and loads of the generator 16-6 A frequently discharged battery IS an indication that it is deteriorated even it it proves normal in the regulated volt- age inspection. The charging circuit may be abnormal if any of the follow ing symptoms is encountered. 1. Voltage not raised to regulated voltage (page 16—1]: - (then or short circuit in the charging system wire har ness or poorly connected connector. - Open or short of the alternatur. - Faultviegulator/rectifier. 2. Regulated voltage too high (page 165): - Poorly grounded voltage regulalur/rectilier. - Faulty battery. - Inulty regulatar/rectlfier. CURRENT LEAKAGE INSPECTION Turn the ignition switch off and discunnect the negative bat- lery cable Ilom the battery. Connect the nmmeter 1+) probe to the ground cable and the ammeter ( 4 probe to rho battery 1—) rerrnlnal. With the ignition switch 0", check fut curretll leakage. N DTF - When msasuring currenl using a tester, set it to a high range, and then bring the range dnwn tn an appropriate level. Current tlciw higher than the range selected mav blow out the fuse in the tester. - While measuring cuirelll, do not turn the ignition on. A sudden surge oi current may ninw out the tuse tn the tester SPECIHED CURRENT LEAKAGE: 1 mA max, Ii current leakage exceeds the specified value, a shorted cirr cuit is likely. Locate the short by disconnecting connections one by one and measuring the current, BATTERY/CHARGING SYSTEM (1) NORMAL CHARGING VOLTAGE iii-H'E'GULATED VOLTAGE _—V—l—I—fi—-¥'—i ENGINE SFEEDV—p rpm I1) ABNORMAL CHARGING VOLTAGE l3) BATTERY VOLTAGE IZI GROUND CABLE 1 6-7 BATTERY/CHARGING SVSTEM ALTERNATOR CHARGING COIL NOTE - I: is not necessary Io remove the slator coil ‘3 make this IFKI INSPECTION Remove lhe seat lpage 2-2) DlSCDnnCCI xhe regulatorxreclifier iallcrnmon 3F connector. l‘l ALikHNAI Check the resisldltLe belweeii all three Veleow lemiill SIANDARD: 0.1 — D 39(3120'C/58‘F) Check :or culiliuuilv belween all :nree Yeliow lermindIs d'iLI Ground There should be no cunnnurtv. Replace me dhemdlw mm. :r leading: am no Lleyu'ld me Slannard. m ii any w m ha( cnntimmy tn grflllnd Rs‘cr :o sccnon 10 for smor removal. REGULATOR/RECTIFIER SYSTEM INSPECTION Remove the right sine cover (page 2 Fig uve [lie 'aguldlur’re' Tia mounting bulislnu‘; and dis- COrI-ect the regulamr,’rectifler Connectn“ and check it for loose comac'. or corroded terminals. i”) ALTEHNN OR 3:" CDNKEL‘TO’I / H m; regulated manage reading (see gage 15m :5 am nhhe specmcation. measme the vu‘tage between co‘nectm wr- mlnSIS Mire harness we) as follows: hem Tarminal Specification Benery charging um; ’VVhlfP w nanny Jnllaée‘ I Ian: and ground! should regisle' Yellow and |ln:_| Yellow Ground lino Green and Continuity wound should sxisx 16-8 BATTERY/CHARGING SYSTEM If all campanants of the charging sysmm are. nnrmal and 11) REGULATOR/RECTIFIER [2) NUTS more are no mess connections at the regulator/rectifier cun- ‘ - ‘ nectors, replace the reguler/raczifiar unite REMOVAL/INSTALLATION Remove me regu‘alor,’recrifia1 unit mounting bolts and runs, D'rsconnecl me connectol and remove [he vegulaluv/veulifiev um! Insxall ma regulalonreclifier unit in the reverse order of removal 13> CONNECTOR 16-9 IGNITION SVSTEM SYSTEM DIAGRAM A (SI CLUTCH SWITCH I3) IHHOTILE SENSOR '96 — '97: III IGNITION CONTROL MODULE (6| IGNITION SWITCH I‘IZ) MAIN FUSE IIU) IGNITION PULSE GENERATOR IS! SIDE STAND SWITCH IEI NFUTI‘IAI SWITCH I13) NEUTRAL (14] CLUTCH SWITCH INDICATOR DIODE (6) IGNITION SWITCH I7) FUSE 10A —IIIV_®_I§._,T¢_I MEI—- 3 I: e :9 m/m—n—o/o—H BI I11I MAIN FUSE (15) SIDI' STAND 30 A In FUSE ‘ID A INDICATOR R [2) BATI'E v (m FNGWE STOP DOWN (a) NEUTRAL I. ’ SWITCH _ SWITCH _m_a/L_s ”'j—G \ 9w 453$ UP To Tachometer <— I9) SIDE STAND SWITCH , Gm—I/o—sm S ’ I5I CLUTCH z EIW—d ‘1 SJ SWITCH “y w LEE é}! ) r H I10] IGNITION PULSE S (‘I I III GENERATOR IGNITION m‘ M (”IGNmCN CO'LS I'" CONTROL ”6) I I MODULE BI BLACK Ir 9/3 .3, 7 YELLOW SPARK ’ BLUE ELucsl Ill GFIEEN HED ' ' 7 T ’ w WHITE LIGHT GREEN I3) THROTTLE SENSOR 17-0 17. IGNITION SYSTEM Mm '97; (1| CLUTCH SWITCH I‘I‘II IHROTTLE SENSOR ~ (2) IGNITION SWITCH um BATTERY / 13) IGNITION COIL I4) FUSE/DIODE ,v, N“ . ,I/ ’5; \ISI NEUTRAL SWITCH IsI IGNITION V} CON I HOL \ IV MODULE 1 (8) MAIN FUSE 42: um push a. e e . —@—E “ ”mum Y ID} 5le smo swam— U‘ Ian-mu Is) waits) ma “m" I V]! um u vs NA 7 |*."| r IWI'CI'NW“ m m w mung.“ I win, v :4 am M m (‘3) |GNITION CONTROL MM 5, mm. I $® § :II‘IImmm ~ “3“" 1‘9 1 P 1‘9 " L ”’m‘ 2; m 6" 'm = -: = = z 1. fl“ In; SPARKPLUG ' u. Lane-mm n .2“ 17-1 IGNITION SYSTEM SVSTEM DIAGRAM 17-0 IGNITION COIL 17-6 SERVICE INFORMATION 17-2 IGNITION PULSE GENERATOR 17-7 TROUBLESHOOTING 17-3 THROTTLE SENSOR 17—10 IGNITION SYSTEM INSPECTION 17-4 IGNITION TIMING 17—11 SERVICE INFORMATION GENERAL At some ' lithe engine must be running to do some Hark. make sure the arm is Well tumbled. Never run the angina ”I an cnrluscd Eran. The exhnut‘l contains poisonous carbon monoxide not that may cause lass uf consciousnns and may lead to death. CAUTION - Sums aimlnml campunen/s mm be damaged .1 Iemxmalt 0r mnmm are (married or drmnnmed wlzllc m: ignition mm is ON um} ruin!” it pmmi. - When servicing the ignition system. always follow the steps in the troubleshooting sequence on page 17 3. - The ignition timing does not normally need to be aoiusted since the Ignition Control Module (ICMI is factory preset. - The Ignition Control Module IICM), may be damaged iI dropped. Also il‘ the connector is disconnected when current IS ilnwmg, the exnnsslve wattage may damage the mnduie Always turn mime Ignlfinn swnnh hatnre anlnlng. - A faulty ignition system is often related to poor connections, Cheek those connections belore proceeding. Make sure the battarv 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 at the spark plug. > Use spark plug n'lne current hem range. Using spark plug with an incorrect heat range can damage the Englrie. SPECIFICATIONS ITEM SPEUFICATIONS Spark plug ‘ NGK oenso Standard 1 CRSEH 9 U27FER 9 Unfinnal CHBEH 9 U7“ HI 5 Spark plug gap OED-0.90 mm (0.031 —D.035in) Ignition coil peak voltage 100 V minimum Ignition pulse generator peak vuilagé Ignition timing . "F" mark 10’ BTDC at Idle TORQUE VALUES Crankshaft hole cap 18 Nvm (1 8 kgf'rn. 13 let-m Apply grease to the threads Spark plug 12 Nrm (1,2 kgf—m, 9 lbl-m Ignition pulse generator rotor special bolt 59 Nm (6.0 kgf-m. 43 lbift) Ignition pulse generalur cover SH bull 12 N~m (1,2 kgI-m. 9 lbf-ft) ADDIV Sealant to the threads (2 places) TOOLS Innis diagnostic tester (model 625) or Peak vnltage adaptor O7HGJ ,- 0020100 with Commercially available digital multimeter (Impedance 10 MEI/DEV mini mum) 17-2 TROUBLESHOOTING - Inspect the loilowrng before diagnosing the svstem — Faulty spark plug 7 Loose spark plug cap orspark plug wire connoclion 7 Water gut into the spark plug cap lleakillg llle igriiliull coil oecuildaly voltage) - if there is no sparIr at either cylinder, temporarily exchange the ignition corl wttlt the other gnnn one nntt parlnrm the spark test. ll there to spark, the exchanged ignition coil is faulty. - "Initial voltage” or the igniilon primary coil is the battery voltage with the ignition SWilEl’l ON and angina 5100 switch at RUN (The engine is nul cranked by the starter lnului). No spark at all plug: IGNITION SYSTEM Unusual condition T Prohibit «use (Check 'fll numerical order) gnitlon coll u'lmnrv voltage Np initial voltage wtrn ignition and engine stop :wltche: ON. lomer electrical components on norntali Initial voltage I: normal, out it drops down (a 2 4 V while cranking the engine. ai voitage is nor mal, htti nn peak vnliage . An open circuit in BlackNVhlle wire between rite igni- . Faulty lCM (In use when "to initial Volliga is normal . incorrcct peak voltage adaptor connections. . Undurchargco battery. . No voltage nerweeri tlle Blackiwnltc l4) and Body . $liur| Liiuuil itt tut . Faulty vi e sl‘lllJ swiluli ul neutral switch 8. . 10.l-aulty [CM lin cage when aoovo No . Faulty peak voltape adaptor connections. Faulty angina slup switch tlon call and engine stop switcn. while disconnecting ICM connootpr, uruund H at the ICM mum-connector or iooson lCM connection An nnen r. it or loose connection in Green wire. An open nirattit nr lno. mnnec n in Yellow/Blue and Bluer’Yellnw w r-s herwaen the. ignttion mils and lCM. ' n primary rnil An open circuit or loose LurlileL’liull in Nu 7 iulatefl circuit wires. ' SldB “and BWIKCVI tin - Neutral switch llne: ‘ GreenM/l’llla wire, Lignt Green and Light Green/Rea wrro. Faulty ignition pulw qens'amr (measure the peak vait~ apei. 9 are normal). willie L'rirlklrrg the engine 2. Faulty peak voltage adaptor. 3. Fnttlty lCM (in case when above No 1, 2 are norm Inlllal voltage is normal, but peak voltage l) 1. Thu multimeter impedance is inn low, hnlnw in Mm lower than standard valun. DCV 1. Cranking speed ts tuu law ilrattery tindercnargt-dl. 3. The sampling timing orthe luster and rtteasutert pulse wore not synchrontzed (system is normal ti tneaaureti voltage is over me slandard voltage at least ulltel, A. Faulty icM iin case when above No. l - 3 are normali. Initial and peak voltage are normal. but does not 1. Faulty spark plug or leaklng ignition coil secondary snark. curmnl ampere, 2. Hultv ignitiicom—___— lqnlllon pulse Peal voltage is Iowa“ than standard value. 1 The multimeter imoadance la too low; below ID Mn/ qenerator DEV 2 Cronlttng speed is Inn lnw (battery uncercnargeal. 3 The sampling tinting oi inn. tester and measured pulse were not syntluurlisell (system is nnrmal il maastlred ‘ voltage is uverttre standard voltage at least more) 4, Fiultv ICM (in case when above No, i - 3 are lttiin‘ia‘il ‘ Nn peak voltage. 1. Faulty peak voltage adaptor, ' 2. Faulty ignition pulse generator Ignitinn switch Tnero ts a continuity between Black and Pink ten l, Faulty ignition switch, (After '971 minals in oltiicr ortlto directions. 2, Specified tester I; not used. rnera is no continuity octwcon Black om: Pink 1, Blown ruse lat lo A. tarminpl: in either at the directions. 2. Fauitv Cl'lglflc stop switch. 3. Fauitv tdnltton swttch ‘ 1 4. Specmed tester is not used. 1 7-3 IGNITION SYSTEM IGNITION SYSTEM INSPECTION [ . , m mommummmn NOTE - ll [here is no Spark at any plug, check all conneciions for Innse nr poor cuntaci before measuring each peak v0ll~ ago. . Use rawmmended digital mulnmnmr or commercially available digital multimeter With an impedance of 10 MINDCV minimum. - The display value differs depending upon the internal impedance ul (lie multimeter, - If using Imrie diagnostic inner (model 625i, follow the 'x .. ..._.. manufacturer's instructlons. (”PEAK VOLTAGI’ ADAPTOR Connecr ms peak vullage adaptor to the dIgIlIII multimeter. u: use (he lmrie diagnostic fasten TOOLS: lmrla diagnostic (ester (model 625) or Peak voltage adaptor D7HGJ - 0020100 wifll Commercially available digital multimeter (Imp-dance 10 Mil/DOV mlnlmuml IGNITION COIL PRIMARY PEAK VOLTAGE V limFARK PLUG NON: - Check a” system connections before inspectmn If ”19 system I5 disconnenren, Incorrect peak voltage mighl be measured. i - Check cylinder compression and check llial the spaik plu "re installed correcfly shift the transmission inlo neutral and disconnect the all spark plug caps from me spark plugs. Cunnem a knuwn guud spark plugs lo (he spark plug caps and glound the spark plugs m lha cylinder as dune in a spark 7" Inst, 17-4 With the ignition coil primary wire connected, L'umleul llie peak vuiiage adaplcl or Irnrie testertu the ignition coil CONNECTION: No. 1/! call: Black/Whit- torminal h) - Body ground l-) No. 2/3 coil; Blue/Vellow terminal (4) - Body ground [—I mm the ignition switch ”0N" and cnginc stop switch to ’ RUN”. Check lor initial voltage :1 this time. The battery voltage should be measured. ll the Inl'lHI voltage cannot be measured, check the power supply circuit ircfcr to troubleshooting. page 174). ciaiiu lIw engine with the starter motor and mid Ignl'lnn caii primary peak voltage. PEAK VOLTAGE: 100 V minimum m— 7 - mid lnurhmg 1h: .vmrk ylugs and mm probe: to prmm elu- m: Shack. II the peak voltage is ahnnrmai, check for an open circuit or poor mnnnctions in Yellow/Blur: and Black/White wires. It not dcfccm are found in the harness, raler m IIIB lruuble— shooting chart on page 17-3. IGNITION PULSE GENERATOR PEAK VOLTAGE NOTI - Check cvlinder compression and check that the spark plugs are installed normally. Remove the scat lpage 2-2). Disculmed the multi-cnnnentnr from the lCM. Connect ihe peak voltage adaptor or Imrle tester probes to the connector terminals of the wire harness side. TOOLS: Imrio diagnostic tester (model 625) or Puk voltage adaptor 07HGJ - 0020100 with Commufiallv Iv-ilable digital multimeter (impedance 1!] Mn] DCV minimum) CONNECTION: Vollow terminal (¢.) - White/Vellum l-) Crank the engine with the starter motor and road the peak voltage. PEAK VOLTAGE: 0.7 V minimum - Avoid touching nu» spark plugt and lrrler probes m prlvtnl d“- Irir tlmrk. IGNITION SVSTEM (DIGNITION COiL (ZITO SPARK UNIT '9 ‘ l I PI'AK VOLTAGI’ ADAPTOR (4H PROBE i2) PEAK VOLTAGE ADAPTOR 17-5 IGNITION SYSTEM ll the pzak voltage measured at ICM mull! ccnnecwr ls annnrmal, measure we pcak voltage a: me pulse gellelalul connector. Remove the Iuél tank [page z-zl. nzsmnnect me ignrtion pulse generator 2F (Blackl connector and connecr {he resrar probes [U the lemlinal (Yellow and Whlter’Yellow), In the same manner as at me lCM connector, measure the pfiak voltage and compare it to the voltage measured ar me ICM conncmor. - llthe peak voltagP measured at the ICM ls abnormal and the one measured ar the ignition pulse generator is rrur» mal, me wrre harness has an uperl LIICUII or loose con- necliulll - Ir both npak vnlmges measure are abnormal, check each new In the lroublcshuming chart. II all irams are normal, the lgnirron pulse generator is faulty See section 10 Mr Iglllliuu pulse generator replacemom, IGNITION COIL REMOVAL/INSTALLATION Remove the folluwing. ~ Alr cleaner hOLlSIng lpagp my — Mzddle cowl (page 26! Disconnect IIle spark plug Luvs hom me plugs Dlsconrecl {no prlmary wires from (he Ignition coils. Remove me DDIIS afid igniliuh Cuils. lrmallmlrm s n me reverse orde' of rcmovat lPEAK v0. AGE ADAPTOR 12)°UL$E GENERATOR 2l-' C6NNEC7OH PARK l‘l m. CfiPSE. 17-6 IGNITION SVSTEM IGNITION PULSE GENERATOR REMOVAL Remove the foilowing: — Fuel tank ipaga 272) 7 Middle/Iuww chi (page 2-5! ’Jismnnect the ignition pulse qenevalol 2P (Black) nnnnec- tor. Release me win: from (h? Wire ciamp. Remnva the SH bulls and iqnixiun pulse genernmr roIor cover ‘ (ZJIGNITION PULSE GFNI'HAIOR' Remove tho gaskel and dowel pins. Removeme wire qlummetfmmthennver. i3HGNiT10N PULSE GerATofi l1} efiommew Remove lhe boil; and ignmon pulse gcnmator I 17-7 IGNITION SYSTEM Shin ma :ra‘sm salon me am gear and apply rcpr brallcl Felnuve rue .ghllpn pulse generamr romr bolr, NOTE - ll‘ :Ile engine is uul ul lhe heme, remove the allernalor cnvPr lpage 10-7: and hold the flywheel wlth the flywheel homer (07 125 ~ 0040000‘, then remove the bolt. INSTALLATION lnsrall the IgnI‘IOn pulse genelalal Iota-l by allgnillg we wlde gram/P. wwh rha wlde teeth 0‘ me crankshm lnsmll lhe washer and rnmr hnlr Shift mo lransmiosion .nm 5th gear and apply rear brake Tiqh'larl me lqmliun puIse qenaramr rpmr polr. NUIE - ll lhe engine is cm a! frame remove the allsrnzmr cover (page 1M) and hold lhe flywheel with the flywheel IluIdel lU/ r2: , uuduoum, men Ilgh'Pn vhe hnll TORQUE: 59 N-m 16.0 kgI-m, 43 lbfAhI IfislaII (he ignnion pulse generator intomc cov:r. ('IHGNITIOV PULSE GENERATOR ‘13)GR0MMET App.y seaIaul [U the wire grummea, lIIeu IrlslaII i: imo the 3 grrmve nl w- (‘nVPr ' Install and llgnlcn (he lgnillpn pulse generator bolts 17—8 IGNITION SVSTEM Apply “quid sealanl to the mating surface of ma crankcaae as shown install the dowel pins and a new gasket W" Y‘— Anply sealant to the threads ul the two bolts indicated by “.2" mark an the uuver. Install my igniruon pulse generator rotor cover and Iiglllell the SH hnlf to me spcciIicd torque. TORQUE: 12 N‘m (11 kgI~m. 9 thfl -‘ ' ”i1 \ ,l N EUL§_E §§NERATOR ROTOR CUVER Route IhE ignition pulse gencmor wire prnperly. Cunnecl the 2P (filackl connccwr, Clamp the wire with rhe band. limall (he remnvzd pans in me reverse Drdef of removal. 17—9 IGNITION SVSTEM THROTTLE SENSOR INSPECTION Remove the on manor housing Ipage 54y Dimmnem the throws sensor 3P tonnattor Iihnrk thy nonnector for Ioose or corroded terminals. Connect the inspection adaptor between the throttle sensor uulmecmrs‘ TOOL: Inspection adaptor o7GMJ - ML80100 INPUT VOLTAGE INSPECTION Yurn the Igniuon swnch O’v, Mua:ure and teLuld the Irrpul vuIiage dl The Inspection adaptor termmars ”mg a drgltaI mmtrmeter CONNECTION: Red clip lo) - Gruell clip (-1 Slandnrrl' 4 5 - 55 V I! rne measurement is out o! specihcarion, check the folrow mgr — lnnse nonnernnn n? ma I(:M mHmArnnannr Open circurl in wrre harness OUTPUT VOLTAGE INSPECTION 52' a drgrtal multw‘éte’ I0 rm: mspecnon adaptor term'rnals CONNECTION: While clip I.) — Green clip 1—) T..rn tnc ignmon swnch 0N and measure and record the 0.1mm voltaqe wnn the throme {mlv openr Compare the measurement to the result of rm: InIlnwmg caIcuIarion Measured input Voltage X 0824 : V0 The sensor rs normal .6 me measuremem mnprn vn'rag» vaIue rs wrthrn V0 : 10% nrvaI-r’s CLIP 17—10 IGNITION SYSTEM Turn the IhrottIe smp schw nmmrerclnckwuse fully, and measure and record thc omput voltage wnh [he mrome fully closed Culllpale 1H: measurement to the mum n6 the ‘allowmg caIELlIatlnn Measured input vohage X 01 = Va The sensuv ls nulmal if (he measuremPnY mnpm vnllaga value IS WIthln Vr, ~ 1th Using an analog menu, check that the needle of (he voll- mamr swings sluva when the throttle ls oaned gram-ally. CONTINUITV INSPECTION Disconnecx me lCM muIli»cuIIlIeuiuv and lluuttle sel‘sjr 'w cannectur‘ Cwedr ‘or connnmrv between lhe ICM and lhronlc senaor. IV [have :5 «a conr‘nuiw, uheuk l‘le out! 0- sho'! crrcun m w re harness. IGNITION TIMING m _ - I] Inc mm; mun br rulumm m du mm arm: is u‘rll-l'l'mi/ultll. Nun nm flm Night. in rm Fnrlmt'd arm. - l’lw urlmull nmmim pniwunm mrIum mwmxldt gas Ilml mm- «on mm and may lead :0 dam/1. :rlr IIIHllt tmr llu> umv' Imc "j run. VOTE llean the ms: lOn’S lar TIITII"g lighr, operanon. Warm up the Engine. Sun the englne and remove the crankshaft holc caD. Canncouhc timing light lolhe Nu. ‘I :palIr plug wire 51.1". We Ehgll’le and la: II rdle. IDLE SPEED: Except CaIiIurnia type. 1,100 2 mu rpm California type: 1.200 t 100 rpm The lgHKIOH Iimmq is cuwec: II the "F" mark lthe punch marksl aII5n> with the lads: mark on the xgnmon pu‘sc gen eratcvr 'ufilnr FIN/PR Increase the engine speed by' lning thE [hrottle :mp screw and make :ule the “F" mark hegms to move counterclock wxcs when rha anglne spccu m approxlmalelv 1,600 min ' lrpml. 17-11 IGNITION SVSTEM Check me ()~rmg IS In good condition, repiace ii neces>¢ly. App‘y ml to (he 0 mg anc InstaII and \ighlen [he fimmg hnIe C3D, 17—12 MEMO ELECTRIC STATER SYSTEM DIAGRAM '96 - '97: T I‘ll STARTER RELAV SWITCH (4) CLUTCH SWITCH /(5) IGNITION SWITCH 13) SIDE STAND SWITCH (5} IGNITION awn“ (a) EATTEHY (I) SYARYFR RFIAV ;\ swmm i e I a M (3) STARTER (a! FUSE ( 7 WW" um 9) MAIN \ 1o. FUSE \ a 5 Son > 7 3 L (m) square»: swnmn o\\o anW/O—VM (m ENG! 510» (I2: NEUTRAL / SWITCH (u) mum» SWITCH Q (4) CLUTCN INI’IICAY R Dlo E I SWITCH / L; .m “—0 ' I. ‘ ”I 3 3 m NtuTnALA (9) SIDE STANDE swncn m, swmzH (w) uIDL .TAND/ INDICATOFK j n.7w) l £izm<§ -- LUNI was»; 18-0 18. ELECTRIC STATER SYSTEM DIAGRAM 1870 STARTER MOTOR 18-4 SERVICE INFORMATION 13.1 STARTER RELAY SWITCH 18-10 TROUBLESHOOTING 13-2 DIODE 18-11 SERVICE INFORMATION GENERAL - The starter mom can be removed wiIII IlIe engme im the frame - For (he SIarIer drive and driven gear removal,’m - Open circuit in wire harness - Loosar or poor contact connector Stater motor turns annlne slowly - Low hatterv voltage - Poorly cunnected battery terminal cable - Poorly connected stunnr motor cable > lnltlt’y starter motor - Poor connected battery ground cable Starter motor turns, but angina does not turn - Starter motor is running backwards Case assembled improperly _ Terminals cunnected improperly - Faulty starter clutch - Damaged or faulty starter drive gear Starts! rulav switch "Clicks'. but engine does not turn over - Crankshaft does not turn mm to engine problems 18-3 ELECTRIC STARTER STARTER MOTOR dw sfifimn CABLE / ‘1 - V REMOVAL / ‘ With the ignimm \u'iuh arr, n'mnrr [In nzgmvt [ab/I a! the bunny I an? unin'ng [hr xmmr molar, Remove :hc fue‘ ‘ank (page 2-2), Remove Ihe nut and the s'aner momr cable from [he staner motor Remove mo smner motor mouming bulls, gloulld wire, wire clamp‘ PuH the slarmr motor out of the crankcase. DISASSEMBLV NOTE - Record the \ocatmn and number 0' shims‘ Remove me following: — Slaner motor case bolts _ Hear mm assemmy <21 SEAL RING 7 Sea) ring — Shims I13) SHIMS (1) CASE BOLTS H) REAR COVER I 1 9-4 — Front Cover a<<9mh}y — Seal nng Locx washer — lnsulaled washev — Shims — Armature INSPECTION Check In! cnmlnulty hatween (he came terminal and the brush wire (the ind‘xgo colored wire or the insulated brush homer)‘ There should be cuminuily, Check for nnntlnuny between me motor case and the cable terminal. There should be nu cuminuilv. Inspert the brushes for damage and measure the brush |cnglh. SERVICE LIMIT' ‘5 mm "1.18 in] ‘ ELECTRIC STARTER [2| SEAL RING {AV INSULATED WASHER // {'6} ARMATURE .«L‘. s 43:.» / :5) smms m FRONT COVER (3) LOCK WASHER 18—5 ELECTRIC STARTER Check the bushing ofzhe rear cnvnr inr wear or damage. (1) BUSHING Chock (he "on! cover oii seal for iaiigue 0i omen damage‘ (1) OIL SEAL (2i NEEDLE BEARING Check lhe needle healing for damage. (1) ARMATURE lnspefl the nnmmmamr bars for discoloranon. Bars dlSCOlO'ed in pairs indicate grounded armature calls, in which case the staner motor must be replaced. NOTE - Do not use emery or sand paper on the Cummuldlol. Check for continuity between individuai commutator bars? were should be continuity, 18-6 ELECTRIC STARTER Also, check for contmully between Indwldum commutator bars and me armature shaft: mere shou‘d be no cominuiry. Ramuve me iouawzng Mm NUT — Nm ®<—(zn WASHER — Washer «(3) wsm Arum; : 33:11]?“ /’ \\\§.._ ,(4, O-RING — Brush ho‘derassamhly / - 3* \ / (5» BHgSH HOLDER — Erushnerminal ( fir“? ASbEMBLV Q fim / \ {6! BRUSH TERMINAL ASSEMBLY ‘x '\,\_’—m SHIMS @@ 12) ARMA1UHt ‘ @ @ ("db SHIMS \ (M KNSULATED WASHER l5! LOCK WASHER ‘ (G) SEAL RING (7) I HON] CUVEH (1?” FEAR COVER (RI MUYOH CASE /, \ _ (12) SPRING // © S e (.62 B 6 C 0 (11) BRUSH HOLDER I10} BRUSH (Sb SEAL RING 18-7 ELECTRIC STARTER Set the brushes on the brush holder. HI BRUSH HOLDER Install the brush holder onto me motor case, {Si/ALIGN NOTE - Allgn the terminal holder plate boss with lhe glroE of the mom! case. Install the [ulluwing' Mm Nlll , 0””‘9 ©<—(3) WASHER — Insulators @ Washer © }<—<23 wmnmorrs — Nut © \ Ot—(H 0 ENG NOTE . Install [he insulators properly as nnmd dunng removal. Install the armature in me morur case 'p’” s. [5) SEAL RING (Tr ARMATUHE Install [he shims on tl-rp armature shaft. NOTE - Install the shims propArly as noted durlng removal, Install the lnsularcd washer and lock washer on lhe anna- lure shaft, Install th,» seal rmg unto the motor case 12) SHIMS (3‘ INSULATED WASHER (4) LUCK WASHER Install the seal ring on [he muluv case. (1) SFAI RING [3) REAR COVER Install the shims on the armature shaft. NOTE - Install the shlms prnnerlv as noted during removal. Assemble the moror case and rear covuv, aligning ill: blush welder 505: with [he groove im the rear cover, 12l SH'lMS 188 ELECTRIC STARTER r2) MOTOR CASE (H Fvom COVER \nstau the front cover [0 the motor case. Make sure the index lines a'a a‘iqned, (3) {NDEX UNES \nstd‘l and lighten the mm. mm: securew. \J (1» CASL BOLTS INSTALLATION Aup|y mean engine ml to me new 0 r‘ng. InstaH a new Orr-"g onto rm: sraner motor buss. lnsrsl‘ the sIarrer muluy inm rhe crankcase, Rome the Starter luulor came and ground cabler \nsrall Llre cabies and wrre clamp, lhcn lighten the bolts and nutsecure‘y. ELECTRIC STARTER STARTER RELAY SWITCH OPERATION INSPECTION Remove the right side mver IpagP 7.3) Shir‘t the t'ansmission into neutral. Tim the ignition switch ON and depress the starter swriuli button, The Call IS normal If the Starter relay switch CIICkS. it the switch “CLICK” is nul heard, Ilisuecl the reiay swrtuli JSI’lg the procedure nelnw GROUND LINE INSPECTION Disconnect the relay connectorl Chm ior cont n1 i'y he'wefin the Green/Red WW? and grntrnd if there |S continuity when the transmisswn is in neutral or when the clutch is disengaged and the side stand switcf‘ is up, Jie growl circuit is tiurltlel (ill iieulldI, there Is a siiglit resiEtPnre due to the diode) VOLTAGE INSPECTION Conner} the sinner relay swnrh rnnnehtnr Shift the transmission into neutral. Measule the vuliage between the Yelluw’fied wilt! (.) and gt’nimd at the starter relay switrh rnnnprmr There should be battery voltage only when the starter switch button 55 deoressed with the ignition switch is ON. CONTINUITV INSPECTION Disconnect the starter lelay connector and cables. Consect an ohmrneter to the Starter relay switch largo tcr "iiiials. Connect a fully charged 12 v batterym the starter relay switch connector terminals (Verlowr’Red and GreeniRed). Check lor continuity between the starter relay swutch termi idis. There should be continuity white 12 V battery is connected \9 the starter relay switch connector terminals and there snniild be no EDntInuity when the battery is disconnected II) RELAY SWITCH CON VECTOR 18-10 DIODE REMOVAL Remove righ1upuelcowhnner cover (page 2 8‘. Open rhe fuse box and rcmove rha diode. INSPECTION Check for rnnnnulty wvm an ohmmerar. Normal dirsmion: Cominuity Raver“ direction' No cnntinuity INSTALLATION lnsml [he dwudes In the reverse order of removal ELECTRIC STARTER 18-11 LlGHTS/METERS/SWITCHES After '97: (“CLUTCH SWITCH IZI IGNITION SWITCH (III COMBINATION METER (11) SPEED SENSOR , (A) FRONT BRAKE LIGHT \\ SWITCH ’— 19) RFAR BRAKE LIGHT SWITCH (BIOIL PRESSURE SWITCH I7) SIDE STAND SWITCH (6) NEUTRAL SWITCH Mm '97: mm: mu m , (a; Milan um mwxm (3 9 I2} BATTERY m was UM" w my :9» mama ‘w: mm mama u w urr mm «M moi-mum: mm mm m mmwm n m ”i 1111 $33?! $34.7“ v . n - \fi_,._.._, usulmm. Tum-«snow s. ° ’ “ swm awn" 5‘ 5 -— -— .mm "- 7 T " 'flr’ mtssuns ”mam“ nammmms "" “EM“ swrma WW" W 19—0 19. LlGHTS/METERS/SWITCHES SERVICE INFORMATION 19-1 COOLING FAN MOTOR SWITCH 1920 l TROUBLESHOOTING 15-3 OIL PRESSURE SWITCH 19-21 HEADLIGHT 15-4 IGNITION SWITCH 19-22 POSITION LIGHT 19-5 HANDLEBAR SWITCHES 19-23 TURN SIGNAL 19-6 BRAKE LIGHT SWITCH 19-24 LICENSE LIGHT 19-7 CLUTCH SWITCH 19-24 TAIL/BRAKE LIGHT 1‘3-7 NEUTRAL SWITCH 1944 COMBINATION METER 19-8 SIDE STAND SWITCH 19-25 SPEEDOMETER/SPEED SENSOR 19-13 HORN 19-26 TACHOMETER 19-17 TURN SIGNAL RELAV 19-76 COOLANT TEMPERATURE GAUGE] SENSOR 19-18 SERVICE INFORMATION GENERAL MA vl [tn/item Ixmdllglu bulb brcmnt! my In]! while the headlight ls ox. and mum-I. huljnr .. um» nfm .7 i: Imam an, at surr m m :1 ml dawn htforc uniting. - L‘sz' an clmm healing t'll'mem ii. rm“ Hm mum/mum”! tm'x'lmr far u" Ian motor switch impaction, Keep all flummablc mmeriub away [mm the «1mm Immng mum. Wm ”mam L'lulltlllg, Insulated 5'10» 2: and m prulertian. Note the following who" replacing the halogen headlight bulb Wear clean gloves while replacing the bulb Do not am linger prints on the headlight bulb] as they may create hut 5pm: kill the bulb and cause Is tn fall 7 ll you tourh the hull) with your bare hands. clean it with a alum moistened with alcohol to prevent lls Efflly failure‘ — He sure to install the dust cover after reulacing the bulb. ~ Check the battery condition bslure pErIutttliltg any inspection that requires proper bancrv voltagev . A cuntinuity teal Lnll be made With the swi'rhes installed on the motorcycle. - The following color rode: am used thvoughout this section, Flu : Blue G = Green Lg = Light Green R — Red Bl =Black Gr=Gray 0 CAPS PUH [he indmmv lamp can out o‘ comh‘nahon mmnv inwer case Tum :he Iju h maker 45' cmmlerc‘ockwisc remove it fru’n /, Vhe lanr case mm 'cslacc the DU”). (HBULBxBULE SOCKTW DISASSEMBLV '35 - '97: Remove me «raw and mp meter knob, /' // \‘ (2} TR‘P MT 1 LH KNOB a] SCREW 19-9 LIG HTS/METERS/SWITCHES Remove the six seH-xapo‘mq screws‘ Wire Liam: a w uppex Lise Hemove the screw’washcrs, men remove the speedomeiar, lachorrete' and coolant temperaluve melev. Remove 3“? hnlh sockets and combmatlcn meter sub hm ness. After '97 ksmove the screws, chcvc [he combination upper case. Hemove me speadomcxcr. manometer and primed circuu board iromme lowercase. Qamnve me hmh snnkets from Xhe printed circuit board cage 19 121‘ . (1" SCREWS \\ m TACHOMETER l3) UPPER CASE \ 13> FRWTED CIRCUIT BOARD 19-10 LlGHTS/METERS/SWITCHES ASSEMBLY ’96, '57: Assemble the CUllIlJillthll meter in the reverse order oi lemuval. 135TACHOMETER lllUPPER CASE (2)5PEEDOMETER (Al COOL/\NT TEMPERATURE GAUGF 15lSUB HARNESS l6) LOWER CASE NOTE ~ Connect the termmals and Install the sockets are accovd» mg m the color codes indicated on the lower case. ' Route the sub-harness as shown in ll“: illusltation 19-11 LIGHTS/METERS/SWITCHES ASSEMBLY Aher '97: Asensr3r do“ nm m-w mommy, rcmace wnh a new owe 19-13 LlGHTS/METERS/SWITCHES After '97: FiemUvE—(ire iuei 1a,... ipage 2 z» liflmni/fi the mic: and ippid OK 3F connector \ , I1) SPEED SENSOR 3P£C_lNN_EQ 35‘ Remove the nuns and speed sensnr LE- 121 SM I u SEVSOR i NOTE - Release the sensor wure [mm the WM clamp on the drive snmnknl covert LIG HTS/METERS/SWITCHES true“ (he speed sensor in the reverse order of remova., NUT? ~ Alwgn (he hexaqowa‘ uv’l'wun of me speed sensor wah the duve spvocket ban head REMOVAL/INSTALLATION After ‘97 Hemnve the fuel tank mags 2-2. Disuunr‘ecl :nu speed sarsur 3P connector, Hemnvp n» ha": and {pePn‘ spnsnr ‘nsraH lhc space sensor m the reverse order oi removah r1r$§om<é , ‘l ‘ ~v " w‘ . Amp} usmsm 19—16 LlGHTS/METERS/SWITCHES TACHOMETER fl—fi, Mt IQH INSPECTION '96—'97: meve the Co’flrjll’la‘ on mPtPr trn—n the hrarkat (page: 191 7r CWECK far loose or poor CD“IJCI terminals 0' he tachometer. Canncct the peak vultaqa adapzor [U the laullwllelel Elacki Velluw telrlrmul cud g-ourtc CDNNhCI ION: Black/Yellow (H and Ground H Sta", me an'llle at t] ltvL—aaule tre tachometer mpm voltage PEAK VOLTAGE:10.5 V minimum lftrm value is llu’l'mL wpldce the tachumeter ll Ht: n easured valttF l< hPlnw 105 V, replace the tgmtton rnnrrnl module llCMr. ”the VEIJF < n V rannrm tne tollowtng: thrrrwe tt‘e seat {pegs 2 El and disconnect the CM lnullir EOI‘HCCIOI C‘ltik tor :,nlmtmy hetwaen the manometer terminal and lnr: KIM mttlttrconnector Blacn>>cmbly and a COLOR Bl/W Y/R Bu/w BI/R LlGHTS/METERS/SWITCHES \ 11) ENGINE STOP SWITCH (2) STAR I ER SWITCH i—fly RIGHT HANDLE BAR .‘EWI I CHES CONNECTORS A A ( gY/R TURN SIGNAL swrrcu \\ w H L BAT: PH PL " n 7 I - «r. c : N ‘ ‘ c» c "I L ’3? ‘ :7 07—:- COLon‘ GV I Lb o Bl/Br | !W 0M1 \ I E] TURN SIGNAL SWITCH (2) HORN SWITCH I DIMMEH serCH HORN svmcu i ,i erI HANDLEBAR SWITCHES CONNECTORS ‘\\ HL I Lo Hi \\ ‘ Ho BATE Lo o——o , FREE A n (N) c———c C PUSH o——3 Hi ,3 o coma Lq ‘ B|/BI $3“ 0 Lb (I w 01w ”I" coma BuNV w Bu (1 (a) gEu/w c: aI/ar (G): Horn ground wire (From Hu Iermmal) 1 9-23 LIGHTS/METERS/SWITCHES BRAKE LIGHT SWITCH FRONT Disconnect ma "ron: brake lighx 5w [ch connccmrs. Time show: he Cami-"wry with the brake ‘sve' apphed and mm Ihe'e should be com Huny with me clulch Icvcr appllcd, and more shoula be no caminuiw wuh the clutch Levar vs reieasau, NEUTRAL SWITCH w c comma Hemnv‘e ‘h? Mel ‘an Kpfige 2Q). D‘SCOHWBCK me neut'a! switch connector. Sh“; the :ransmiss‘cn mm neutral and check for canhmmy nthPen m: Lxght mean wire termmai and grou-xd. The’: shomd Dc continuity wxzh me lransmisswn us In new :raL and nu Comir‘uily whe'x u u hamuunmn > ”'10 geu. 19-24 LlGHTS/METERS/SWITCHES SIDE STAND SWITCH _ FITCH 3P cowrmon INSPECTION Hemnvp the seat usage 2 2-. Dtscannact me 5qu aldnd SWHLI'I 3P IIGreerJ connecto' Cherk 9m cnnhnmtv between the wire :crmmals of the stde stand switch connector. Continuity should most between lhe color coded wire term“ nab as Mluws \ \ \ \ GNV wax G S de stand nnwn \ _, : Std: stand mp t 1 REMOVAL D‘srnnnem the 5409 stand swwch 3D war-zen} connector. Remove the butt and Mde stand swtlth (21 SIDE SIANU SWEFCH Vi) BOLT INSTALLATION mm the side stand swltch by aligui'lg III: Much pm wrh (7‘8 sIdE slum] “0‘: and the ignul switch ’Jnct‘xo-u r inn“ rnnnprvnra ”the above (ems are aH n 'mal, check the {elm-«inc. Dwaum' eLl 'Jle lum 99ml Lonnectms hm me ve|ay (o‘cv corncctor wi:h a jumpe' wire, Stan me engma and e tux» 5 mm 119M by lummg [he “may ON. 5mm: me man and grav :ermmels of the turn slgna‘ } Afler‘97v ‘ 1 f v I Light comes on Lxgnt does not came on j \ ' ‘ - Broker w r: harness. v 2 Check [Dr cunt?’ uity belw=eu me Ewen lelmiud‘ u’ the why connector am: ground V l Cuntir'uxtv No conh‘mly V , ~ Bvuken gruu'vd wvve - Faulw :u'n signal re av. - Pam connection of the cannec 19-26 700 AR ‘11"?! 20. WIRING DIAGRAM '96 v ’97: 1 73' mm SIM nma'ca z W 50M mmmi a NEvmaL Mono: 5 aIL mm: mm 5 3m , 5 WI IIImImmum m WWII mm vzuasiruvt 5mm“: mm: ncmMEYER f A m mum; a m Iw WV mm‘ m WEI c nu (ILIEA.IIIL.W.W5IIIW] n muIMIIIWSIIIIn] Mr; mm; l1" 1th Imm. 5.I :w IE am am mm mm 5mm 5mm n L am vw , , ,7 fl 5me WWII W ’7’ 7,7,7 7 , ,7 , WI SI I“ III.» 5W mm a. NI HD ans ‘ \_ Io ‘zam - vaaarsz ms or: was (“A ’; .s : v “I“ aw WIN-V ’ I Busu 0—0 mm «yo aw BI mm m awown v vmow u omsg Eu BLUE LI: um aw: a GREEN Lg new GREEN RED v PM w mm: a, Gwnv Imm mum \mmu z m I.“ wavaz‘; mm m ‘6 , w v— cmmm Fuss mx 7- v n— mnnrnzsznwn svszosman W —— I m In I VIE“- «Imam! NS M ”VIZ/2E? BurV ‘ —Lw—{D—mw a V r— : -——G—H:)—-G _) WI— \ —Lh—f:D—Lb g E __ r” , w sum mm Wm M 17 m n ”I ’ WWI ' {I «‘2: vi 5, , *Wsz‘m‘m g)1”me I A? ma E3; WNW & SIIIIIEI’IIIII. Is I, K m I, YEI x I, Ia“ , a a ma Wm M any m m I aI IwC Imam W I manme a ‘R mm‘nsmukhsmm I (x mm B u—D ‘m ufl )Imm __ I I_G_.r—a _ V 433—5— \7/ w o—EH—o ; l k In a a a a j I g am 1M1 III m II- a —G-—- i ”Ev— a o _ IZVZZ/JWXI u IIIINII ‘ a: I , a / 7‘ v r AL 1v ‘5 > 7 v G 352% WI ’--u , WI —5 - I r > V T ——g Hmm z x > > °; a \ j 5 3 g ; Imus 7 a II, m m 0/st f 7I 5». fl aI_a, sI I I \ , ———-—-G—CI"—. G /' um smrm mm mm . mamm am. swzmmz svvv WEN cm am MI gm" ms m: 5m, .cmz ,w mm: 00302- MAS - E700 20-1 WIRING DIAGRAM Aher '97: mm» (5* ESE: @"i E: Nzwunxvs ”mm... 1 Mimnufim mm mum uw-S w A nu smwwn a m WWW“ §~m mm 7m mm «mm m. WSW mom mm m Ntmmuv E moms 32mm mumou Ems fizxq 13%;; swimswsak . mmnonmmnm Mam sum M Wm M 5 :wwsmmm ‘ mama 7 E:*— m mmmm v m“ ,g m m a, . a—_ M ""W‘ 5: a“: 1, WM mnwmwwm m m w v mi? L , ., W, ALI—53% [:0 L u—m—u - 1—5“ w «em—F“ /}[:f~o—«>o-u I I I ‘99— —C)<)—o_ \, W Li” FROM WM swam mum ’ 4mm ‘3 K' 95 , ‘3 m— an a /« “ fig :34 w | EM , m .u W 5;: s 6* an m K : , 5 u— ¥ ,; ., ., .. 5 m. Wm WC. Mum mm' mm 'unmsmun Wm mnnswucu mm m“ Mflm MR fiwvm I A mm symp- -O 5mm ms mm mm mmssuaz mum srmrzn auwnss‘mfiswwm / / / / ”WM mm swank 5mm suugwm imwisvmswvm mmswm m \_ a w: rm ‘5 any m (Evuw a‘ m ; Eu 0‘ a [wars : mm w E i??? mm mm: means»: a, u. nmuu'umznmzn mm ems; new mg “on cam VIMK Gnnv W we 5mm swwcx 003OZ-MAS-A000 20-2 Z'I. IHUUBLtSHUUIINli HARD TO START ENGINE LACKS POWER AND IDLE SPEED ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW 21-1 SPEED 21-2 POOR HANDLING 21-3 POOR PERFORMANCE AT HIGH 21-4 21-4 ENMNEDOESNOTSTARTORISHARDTOSTART 1, Check the [owl llow to carburetor l Health-rig carburetor l 2, Perform a spark lest - Good Spark l t 3. Remove and inspect apatk plugs Good l l l V A. Stan by followmg normal procedure l Engine does not start t 5 I est cylinder compression Possible cause Not reaching carburetor —“'- Weak or no spark Wet l’lug #___#,' Engine starts but stops - Low Compresslnn ———- Clogged luel line and Iilter Pinched fuel vulva. vacuum tube Clogged fuel tank breather Faulty spark plug lnuled spark plug Faulty ignition control module Broken ut shorted spark plug wire Faulty ignlvinn swttch l-aulty ignition pulse generator Faulty engine stop switcll Luuse OI disconnected Ignmon system wtres Flooded carbuletor SE valve 0N pnsmnn ll-lrcmle valve open Air cleaner dirtv lmnroper choke operation Carburetor incorrectly adjusted Intake pipe leaking Improper ignlnnn timing (Faulty ignmon coil or ignition pulsa goneratorl Fuel contaminated Valve clearance too small Valve stuck open Worn cylinder and piston ring Damaged cylinder head gasket Seized valve Implupel valve timing 21-1 TROUBLESHOOTING ENGINE LACKS POWER 1, Raise wheel nlf the ground and spin by hand Wheel pills freely V 2. Check tire pressure Pressure normal 3. Accelerate rapidly from low in second 7 Engine speed reduced when clutch is released l r A. Accelerate lightly tnglne speed increase l l 5 Crier-Jr ignition timing Correct V 6 Test nyllnrler cnmnrnssmn Normal r 7. Check carburetor ror clogging Not clogged V 3, Remove spark plugs Not fouled ar discolored V 9. Check oil level and condition Co rrect r 10. R we cylinder head cover and inspect Illhrlna'lnn Vail/strain lubricated properly Possible cause Wheels do not spin ——. lreely . Pressure low ———*- Englne speed doesn’t —""' change accordlngly when - clutch is released ' Engine epeed does not ——- increase - Incorrect ———4- Incorrect #- Cloggad k " ' - Fouled or discolored *- lncorrect —-—-. Valve train not lubricated properly ' Brake dragging Wurrl or damaged wheel bearing Faultv tire valve Puilcluied tire Clutch slipping Worn clutch discs’plates Warped r-Illtch mace/plates Weak clutch spring Additive in engine oil sr valve ON position Clogged air cleaner Restricted lual flow Clogged muffler Pinched fuel tank breather Faulty igrl‘ ion control module Faulty ignition pulse generator Valve stuck open Worn cylinder and piston ringer I eaklng head gasket Improper valve timing Calburetor not serviced rreqllently ennllgh Plugs not serviced trequnntly enough Spark plugs are the incorrect heal range Oil level too high Oil level too low Contaminated oil Clogged oil passage Clogged oil control orifice r 11. Check for anqine overheating Not overheating 17 Accelerate or run at high speed — l I Enuine does not knock TROUBLESHOOTING Possible cause Uverheating _4.. Engine knocks —————>- POOR PERFORMANCE AT LOW AND IDLE SPEED 1. Check carburslul pilot screw _, adiustment Correct I 2. Check for leaking Intake pine No leak i 3. Perform spark that l Good spark l 4, Check ignition timing 7 Coolant level low Fan mnlnr not working ifaulty fan motor switch) Thermostat stuck cluse Excesslve Carbon build-up in combustinn chamber Use of poor quality fuel Clutch slipping Lean fuel mixture Wrong type or fuel Worn piston and cyliiidei Wrong type of fuel Excessive carbon build-up in combustion chamber Ignition tlm'ng to advanced (faulty ignition control mndulel Lean hie! mixture Possible cause lncorrcct Leaking Weak or intermittent ——~- spark lncorract —————>- See section 5 inns: insulator clamps Damaged insulator Faulty carbon or wet fouled spdlk plug Faulty ignition cnniml module Fanny ignition coil Broken or shorted spark plug wire Faulty Engine stop switch Faulty ignition pulse generator l nillty ignition switch Loose or disconnected ignition sttem wires Improper ignition timing (faulty ignition control module) 21-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED l. Disconnect fuel tube at carburetor and pump the vacuum line l hurl Hows freely l 2. Remove the carburetor and check rur clogging l Not clogged 3. Chec‘k valve limlng Carrier A. Check rgrrrriurr liming Correct V 5. Check valve swing —-~ r Not weak POOR HANDLING Possible cause Fuel flow restricted —'- Clogged " > - Incorrect > - Incorrect > - Weak >- Clogged fuel llne Clogged fuel tank breather Faulty fuel valve Clogged fuel filter Clean Cam sprncker nnr rnstrrlled properly Faulty ignirrnn nnntrnl mndule Faulty ignition pulse generator Faulty spring Possibll causv 1 Ir :teerlng rs heavy 7 If ellher wheel I: wnhhlmg ——" 3. ll the motorcycle pulls to one side Steerlng stem adjusting nut too tight Damaged steering head bearings txnessive wheel bearing play Bcnt rim Improper installed wheel hub Swingarm pivot bearlng excessively wnrn Bent lramc Faulty shock absorber front and rear wheel nm aligned Bent lork Bent swingarm Bent axle 21-4 ll. INUEA AIR CLEAN? R AIR CLEANER HOUSING ALTERNATOR CHARGING COIL ALTERNATOR COVER INSTAI l AIIUN ALTERNATOR COVER REMOVAL BATTERY BODY PANEL LOCATION BRAKE FLU-D BRAKE FLUID HEPLACEMENTI‘AIR BLEEDING BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH BRAKE PAD/DISC BRAKE PAD WTAR BRAKE PEDAL BRAKE SYSTEM CABLE 81 HARNESS ROUTING CAM CHAIN ILNSIONER LIFTER CAMSHAFT INSTALLATION CAMSHAFT REMOVAL CARBURETOR ASSEMnI Y CARBURETI)“ (IHDKE (SARBURETOR COMBINATION CARBURETOR DISASSEMBLY CARBURETOFI INSTALLATION CARBURETOH REMOVAL. CAI-IBURETOR SEPARATION CARBURETOR SYNCHRONIZATION CHARGING SYSTEM |NSF‘I’(31IUN CLLITCH CLUTCH SWITCH CLUTCH SYSTEM COMBINATION METER CODLANT RF PI ACLMENT {IUULANT TEMPERATURE GAUGE/SENSOR COOLING FAN MOTOR SWITCH COOLING SYSTEM CRANKCASE COMBINATION (:RANKCASE SEPARATION CRANKSHAFT CYLINDER COMPRESSION TrST CYLINDER III AU ASSEMBLY CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD COVER REMOVAL CYLINDER HEAD DISASSEMELV CYLINDER HEAD INSPECTION CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL DIODE DRIVE CHAIN EMISSION CONTROL INFORMATION LABELS (USA, ONLY) EMISSION CONTROL SYSTEMS (USAL ONLY) ENGINE IDLE SPEED ENGINE INSTALLATION ENGINE OIL/OIL FILTER ENGINE REMOVAL EVAPORATIVE EMISSION CONTROL SYSTEM [CALIFORNIA TYPE ONLY) FLYWHEEL INSTALLATION FLYWHEEL REMOVAL FUNK 12-3 8-17 8-24 “-4 810 8-11 6-19 1811 3-17 1-39 1736 3-15 7-6 341 7 Z L 3-17 10-7 10 4 13-14 FRONT BRAKE CAI IT‘ER FRONT TLNDER FRONT MASTER CYLINDER FRONT WHEEL FUEL LINE FUrl VALVE GEARSHIFT LINKAGE GENERAL SAFETY HANDLEBAR SWITCIILS HANDI [BARS HEADLIGHT HEADLIGHT AIM HIGH ALTITUDE ADJUSIMENT (USA. ONLY) HORN IGNITION COIL IGNITION PULSE GENERATOR IGNITION SWITCH IGNIIION SYSTEM INSPECTION IGNITION TIMING LICENSE LIGHT LUBRICATION 8: SI AL POINTS I IIRIIICATION SYSTEM DIAGRAM MAINTENANCE SCHEDULE MIDDLE/LOWER COWL MODEL IDENTIFICATION MUFFLL/EXHAUST PIPE NEUTRAL SWITCH NUTS, BOLTS, FASTENERS OIL COOLER (III PRLSSURE INSPECTION OIL PRESSURE SWITCH OIL PUMP OIL STRAINER/PRFSSURE RELIEF VALVE PII I ION SEATrSIDE COVER PILOT SCREW ADJUSTMENT PISTON/CONNECTING ROD POSITION LIGHT RADIAT UH RADIATOR COOLANT RADIATOR RESERVE TANK REAR BRAKE CAI IF‘I,R REAR FENDER REAR MASTER CYLINDER REAR WHEEL REGULATOR/RECTIFIER RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKCASE COVER REMOVAL SEAT/FUEL TANK SEAT RAIL SECONDARY AIR SUPPLY SYSTEM (CALIFORNIA TYPE ONLY) SECONDARY AIR SUPPLY 5Y5) EM ICALIFORNIA TYPE ONLY) SERVICE INFORMATION IALTERNATORJSTARTER CLUTCH) (BATTERY/CHARGING SYST EM) ICLUTCH/GEAI'ISHIFT LINKAGE) (COOLING SYSTEM) ICYLINDER HEAD/VALVES) ICRANKCASE/PISTONICVLINDER) ICRANKSI IAI» IFTRANSMISSION) 15-1E 2-13 15-10 13-8 3-4 5-23 9-11 1-1 19-23 13-3 19-4 3-23 5-21 19-26 17-6 17-7 19-22 17-4 17-11 19 7 1-19 d»0 :1-3 26 1-3 2-16 19-24 3 27 4-10 4-3 19-21 4 6 4-4 2-3 5-20 11 4 19-5 6-8 3-15 6 12 15-26 2-14 1514 12-1 22—1 INDEX SERVICE INFORMATION TROUBLESHOOTING (ELECTRIC STARTER) 18—1 (POOR PERFORMANCE AT 10w AND (ENGINE REMOVAL/INSTALLATION) 7»1 IDI I' SPEED) 2173 (FRAME/BODY PANELS/EXHAUST SYST EM) 2-1 (POOR PERFORMANCE AT HIGH SPEED) 214 (FRONT W)IthL/SUSPENSION/STEERINGI 13 I (REAR WHEEL/SUSPENSION) 14v? (FUEL SYSTEM) 5-1 TURN SIGNAL 19-6 (HYDRAULIC BRAKE) 154 TURN SIGNAL RELAY 19726 (IGNITION SYSTEM) 17-2 UPPER COW). 2-7 (LIGHTS/METI'RSISWITCHES) 19 1 VALVE CLEARANCE 3-7 [LUBRICATION SYSTEM) 471 VALVE GU|DE REPLACEMENT 8—H (MA)NTEN/\NCE) 3—1 VALVE SEAT INSPECTION/REFACING B715 (REAR WHEEL/SUSPENSION) 1L1 WATER PUMP 8-11 SERVICE RULES 1-2 WHEELS/TIRES 3—25 SHOCK ABSORBER 14-9 WIRING DIAGRAM 20-1 SIDE STAND 3-25 SIDE STAND SWITCH I945 SPARK PLUG 3 5 SPECIFICATIONS I~4 SPEEDOMETERISPEED SENSOR 19713 STARTER CLUTCH 10-5 STARTER MOTOR 18-4 STARTER RELAY SWITCH 18-10 STATOR 10-3 STEERING HEAD BEARINGS 3-711 STEERING STEM 13 23 SUSPENSION 3—25 SUSPENSION LINKAGE 1A~14 SWINGARM 1446 SYSTEM DIAGRAM (BATTERY/CHARGING SYSTEM) 16-0 (ELECTRIC STARTER) 18-0 (IGNITION SYSTEM) 17—0 SYSTEM FLOW PATTERN 6—D SV51I:M TESTING 6-3 TACHOMETER 19-17 TAIL/BRAKE LIGHT 19-7 THERMOSTAT 6-5 TIIRL)| ILE OPERATION 34 THROTTLE SENSOR 17-10 TOOLS 1-17 TORQUE VALUES 1713 TRANSMISSION 12-9 TROUBLESHOOTING (ALTERNATORJSTARTER CLUTCH) 10-1 (BATTERY/CHARGING SYSTTM) 1673 ICLUTCHIGEARSHIFT LINKAGE) 972 (COOLING SYSTEM) 672 (CRANKCASE/PISTON/CYLINDER) 11-2 (CRANKSHAFT/TRANSMISSIGN) 1272 (CYLINDER HEAD/VALVES) 873 (ELECTRIC STARTER) 18-2 (ENGINE DOES NOT START OR IS HARD TO START) 7 2171 (ENGINE LACKS POWER) 2172 (FR/\ME/‘BODY PANELS/EXHAUST SYSTEM) 2»1 (FRONT WHEEL‘SUSPENSION,’STEERING) 13—2 (EIIEI SVSTLM) 573 (HYDRAULIC BRAKE) 1572 (IGNITION SYSTEM) 1T-3 (LIGHTSIMETERS/SWITCHES) 19-3 (LUBRICATION SYSTEM) 42 (POOR HANDLING) 21.4 (408) 22-2