2004-2015 CRF50F A Few Words About Safety Service Information The service and repair information contained in this manual is intended for use by qualified, prolessional technicians. Attempting service or repairs without the proper training. tools, and equipment could cause iniury to you or others. It could also damage the vehicle or create an unsafe condition. This manual describes the proper methods and procedures lor perlorrning service. maintenance. and repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part service procedure or a tool that is not recommended by Honda. must determine the risks to their personal salety and the sale operation ol the vehicle. it you need to replace a part. use genuine Honda parts with the correct part number or an equivalent part. We strongly recommend that you do not use replacement pans ol inferior quality. For Your Customer's Safety . A WAR N | NG Proper sewice and maintenance are essential to the customers safety and the reliability of the vehicle. Any error or oversight while sewicing a vehicle Improper service or repairs can cmale an can result in laulhr operation, damage to the vehicle, or injury to others. “"53'9 mmmon "Fl can cause Your customer or others to be seriously hurt or killed For Your Safety Follow the procedures and precautions in this Because this manual is intended lor the professional servrce techniuan. we manual and other service materials carelully do not prowde warnings about many basrc shop salely practices (e.g., Hot 7 a r pans—wear gloves). ll you have not received shop salety training or do not leel confident about your knowledge at sate servicing practice, we m recommended that you do not attempt to perlorm the procedures described Fame m Properly 10mm inslmcxions and in this manual. precautions can cause you to be serioust hurt Some ol the most important general servtce salety precautions are given 0' k'llea' below. However. we oannol warn you of every conceivable hazard that can Follow the procedures and precautions in this arise in periorming service and repair procedures. Only you can decide manual Gale'U'ly whether or not you should perlorm a given task. Important Safety Precautions Make sure you have a clear understanding ol all baSIc shop saler practices and that you are wearing appropriate clothing and using salety equipment. When periorrriing any sewice task. be espeCIally carelul ol the lollorring: - Read all at the instructions belore you begin. and make sure you have the tools, the replacement or repair pans. and the skills required to perlorm the tasks salely and completely. - Protect your eyes by using proper safety glasses, goggles or lace shields any time you hammer. drill. grind, pry or work around pressurized air or liquids. and springs or other stored~energy components. It there is any doubt. put on eye protection. - Use other protective wear when necessary. lor example gloves or safety shoes. Handling hot or sharp pans can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. I Protect yoursell and others whenever you have the vehicle up in the air, Anytime you lift the vehicle. either with a hoist or a jack. make sure that it is always securer supported. Use Jack stands. Make sure the engine is oil before you begin any servicing procedures. unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: ' Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. - Burris from hot parts or coolant. Let the engine and exhaust system cool before working in those areas. - Injury from moving parts. it the instruction tells you to run the engine. be sure your hands, fingers and clothing are out ol the way. Gasoline vapors and hydrogen gases from batteries are exploswe. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries - Use only a nonllammable solvent. not gasoline. to clean parts. - Never drain or store gasoline in an open container. - Keep all cigarettes, sparks and llames away from the battery and all fuel-related pans. L L HOW TO USE THIS MANUAL Thrs saunas manual aescnbes we service pmcsames In! me CRFSOF Follow ms Mamlenance Scheflme 45mm 31 Iecommendahuns m ensure manna vahlclc s m pm npemhng common and the ammo" m ave mm me sundaru 521 by the U S EeromenIaI Pmledlon Abemwem am cmmm Aw Resourres Beam (mam Pcmlmung me hrs! scheduled malnlenanca .5 very woman I. moensales nu ma mmal wear mm arms awmg m. mamn penod Mums I and 3 angry m (he male malmcycle Segue" 2 wusxmss proomurea to: removamwallanbn DI componean man may be manned lo psnmm Samoa assumed m we tmxbwmq sechons Samoa 4 Imuugh u (135ch pans ov me mmbuycle qmnped mining w mama Fm me sachm you wanl on rm: page (hen mm lo we ms av coulems on m «51 page 0' m. seer-an Mos! secmns slavl mm an assmnbly m mum nmmm senate mbvmnnon and "Dumashoaung iav me seclmn 1M sumquenl pages gm asunsa plocadmas It you don‘! know me sauvce 0' ms Imubis 90 la Sadlun 15 Trmmesbbbxmg CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE Your sunny, and me savery 01 mars .5 Why .mwum Tb new you mm .uvbmuau 0005mm we have pmva >31st messages and 0mm mmvmahon Ihluugmul m; manuaI c» couvse u ‘5 no! pradxcal O! pnsshm (c wam you show all um.- humus assnclalad mm sevwcmg nus mucus m mus! use yaw awn gbba wage/new vbu wm hm} Impor‘anl savery mlolmahm m a army 0' tom: mam-1mg - Salelylamls bum: vemcle . Samy Massages r preceded by a salely ate" symba I and on: nlmree 51qu woms DANGER WARNING m CAUTION Thus ugnaI wards mean You WILL be KILLED m SERIOUSLY HURT .1 you com Inflow Insxlucuofls You CAN be KILLED or SERIOUSLV HURT “WARNING w you don! mum mslmchms va CAN be HURT n u no"! vmmw “CAUT'ON “7mm 'fl - IAsImcuons v haw vo sewte m-s vemcle cnnocfly and sawa ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM FUEL SYSTEM ENGINE REMOVAL/INSTALLATION CYLINDER HEADNALVES CYLINDER/PISTON CLUTCH/GEARSHIFT LINKAGE ALTERNATOR/CAM CHAIN TENSIONER CRANKSHAFTITRANSMISSIONIKICKSTARTER I I I I I I I I I I I FRONT WHEEUBFIAKEISUSPENSION/ STEERING REAR WHEEL/BRAKE/SUSPENSION ELECTRICAL CHASSIS IGNITION SYSTEM WIRING DIAGRAM As you man mls manum you mu m mmumanan mal Ls pvecedaa by a m symbol The pmpase uI Ihvs messaga Is In new brmm damage In yam vnhlcle omsv pmpen'y orlha Irwnanmem TROUBLESHOOTING INDEX , I 1 I I I I SYMBOLS The symbols used throughout this rnenuel show specific service procedures ll supplementary inlormation is required pertaining to these symbols. it will be explained specifically in the text without the use at the symbols. g ‘ Replace the pants) wtth new one(sl belore assembly. 7' Use recommended engine oil. unless otherwise specified. 7' Use molybdenum all solution (mixture at the engine oil and molybdenum grease in a ratio at t : 1) '6 ‘ Use mum-purpose grease (Lithium based mum-purpose grease NLGI #2 or equtvelent). Use molybdenum disumde grease (oontainmg more than 3% molybdenum disulliae, NLGI #2 or equivalent). m Example: MelylteteD [IR-2 plus manufactured by 00W 00me U.S.A. Mum-purpose M-Z manutactured by Mitsubishi Oil, Japan Use molybdenum dleutlide paste [containth more than 40% molybdenum dlsull’tde, NLGI lt2 or equivalent). l Example: Molyltoleo G-n Pasta menulectured by Dow Corning USA, «fit Honda Moly so (use only) Flocol ASP menutectured by Rocol leued. U.K. l Floool Paste manulactured by Sumtoo Lubricant. Japan fl Use silicone grease. 1* i Apply a lockan agent. Use a middle strength lodung agent unless otherwise specified. Jflfll ‘ Apply sealant. 7 4r 7 7 7 Use DOT 4 brake fluid. Use the recommended brake lluid unless otherwise specified. - Use Fork or Suspension Fluid. 1. GENERAL INFORMATION SERVICE RULES MODEL |DENT|F|CAT|0N ........................... ,. GENERAL SPECIFICATIONS ...................... .. LUBRICATION SYSTEM SPECIFICATIONS - FUEL SYSTEM SPECIFICATIONSMnun-mm- CYLINDER HEAD/ VALVES SPECIFICA‘HONS ........................ ,. CYLINDER/PISTON SPECIFICATIONS CLUTCH/GEAHSHIFT LINKAGE SPECIFICATIONS->-------~-~---->-----~-- ALTERNATOR/CAM CHAIN TENSIONER SPECIFIcATIONs ..................................... .. 1-7 1-7 "L7 CRANKSHAFT/TRANSMISSION/ KICKSTARTER SPECIFICATIONS FRONT WHEEL/BRAKE/SUSPENSION/ STEERING SPECIFICATIONS--~-----.-~-~~-- REAR WHEEL/BRAKE/ SUSPENSION SPECIFICATIONS ------------- -~ IGNITION SYSTEM SPECIFICATIONS "" -~ TORQUE VALUES .................................... ., LUBRICATION & SEAL POINTS CABLE 81 HARNESS ROUTING -------------- -> EMISSION CONTROL SYSTEMS ---------- -- 1-8 1-8 ....1.8 .I..1.g --1-10 1-13 ~144 "147 1-1 GENERAL INFORMATION SERVICE RULES 1. out. my» mum . Clean parts in cleaning solvent upon disassembly. Lubricate any sl . After reassembly, check all parts Ier proper installation and operation . Route all electrical wires as shown on page 1-14, Cable and Harness Routing. Use genuine Honda or Honda»recommended pans and lubricants or their equivalents. Parts that don't meet Honda's design specifications may cause damage to the motorcycle. . Use the special tools designed for this product to avoid damage and incorrect assemblyr . Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. . Install new gaskets, O-rings, cotter pins. and lock plates when reassemblingr r When tightening bolts or nuts, begin with the larger diameter or inner boll first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified, 9 surfaces before reassembly. MODEL IDENTIFICATION 1-2 0 U i) The Vehicle ldennficalmn Number (VINI is stamped on (he left side of the steering head. The engine serial number Is stamped on the lower lefl side U! the crankcase. The model identification label IU.S.A‘I or (he saleiy Cerllllcahon label (Canada) is located on righl suite of the steering head, The carbuletor identification number Is stamped on [he rlghl side of the carburetor body as shown GENERAL INFORMATION CARBURETOR IDENTIFICATION NUMBER 1-3 GENERAL INFORMATION '04 — ’07: The Vehicle Emission Cnntrol iniormation Label is attached on the reverse side 0! the Iell side cover. EMISSION CONTROL INFORMATION LABEL After '07: The Vehicle Emission Control Information Label is attached h I I [I k U,S,A, [mm] ‘ AFTER ‘07: EMISSION CONTROL tot s eh tan or ( )or rontiorksiCnnade) .NFORMAT‘ON mam-(Canada) if, / [If EMISSION CONTROLINFORMATION LABEL (U.S.A. and Canada) The color label is anachad on the left side oi the main heme. When ordering colur~coded parts, elweye SDBCIIY the designated color code. COLOR LABEL GENERAL INFORMATION GENERAL SPECIFICATIONS ITEM SPECIFICATION DIMENSIONS Overall length 1,302 mm (51.2 in) Overall width 581 mm (22.9 in) Overall height 774 mm (30.5 In) Wheelbase 911 mm (35.9 in) Seat helght 548 mm (21.6 In) Foorpeg height 209 mm (8.2 In) Ground clearance 1‘6 mm (5.8 in) Curb weight 50 kg (110 lbs) ‘ Maximum weight capacity 40 kg (88 lbs) FRAME Frame type Badr bone Front eutpanaien Telescopic lork Front wheel travel 87 mm (3.4 ("I Hear suspension Swingarm Rear wheel travel 70 mm (2.3 in) Flaar damper Conventional type all damper From lira size 2.50—10 33.1 Rear tire site 2.50—10 33J Tlre brand (CHENG SHIN) From brake Front/Rear: c-reaA Internal expanding shoe Clutch operation system Transmission Primary reduction FInaI reduction Geet ratio lat 2nd 31d Gearshilt peltem Rear brake Internal expanding shoe Caster angle 25" 00' Trail length 32 mm (1.3 in) Fuel tank capacity (’04 — '07) 3.0 liter (0.79 US gal, 0.66 Imp gal) (Alter '07) 2.6 liter (0.69 US gal. 0.57 Imp gal) Fuel tank reserve capacity (’04 > ’07) 0.9 liter (0.24 US gel. 020 Imp gal) (After '07) 0.7 llter (0.19 US gel, 015 Imp gal) ENGINE Bore and stroke 39.0 x 41.4 mm (1.54 x1.63inl Dilplacement 49 cm’ (3.0 cu-inl Compreaaion ratio 10.0 : 1 Valve train Chain driven, OHC with rocker arm Intake valve opens at 1 mm (0.04 in) tin 7.5“ BTDC closes at l mm (0.04 in) lltt 12.5" ABDC Exhaust valve opens at I mm (0.04 in) Iitt 22.5" BBDC closes at 1 mm (0.04 in) lift 2.5“ BTDC Lubrication system Forced prauure and wet sump Oil pump type Trochoid Cooling Iystam Air cooled Air filtration Oiled polyurethane loam Crankshaft type Assembled type Englne dry weight 17.2 kg (37.9 lbs) Cylinder arrangement Slngle cylinder Inclined 30° tram venlcal CARBURETOR Carburetor type Piston valve Throttle bore 13 mm (0.5 in) DRIVE TRAIN Clutdt system Multi-plate, wet Automatic cantritugal 3-speed 4.058 (69/17) 2.542 (37/14) 3.272 (36/11) l.667 (25/15) 1.190 (25/211 Lelt foot operated return system, N —1 -2~ 3 1-5 GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) IT“ STANDARD SERVICE LIMIT Engine oil capacity At drainan 0.6 liter (0.6 US qt. 0.5 Imp qt) — Al dilemmva 0.8 liter (0.0 US qt. 0.7 Imp I21) Recommended engine all Pro Honda 6N4 4-strolre oil (USA enrl Canada) or equivalenl motor oil AFI ssrvlne Classification: 56 or higher JASO T 903 standard: MA Vlecoalty: SAE 10W-30 Oll pump rotor Tip clearance 0.15 (0.0061 0.20 (0.003) Body clearance 0.02 — 0.07 (0.001 — 0.003) 0.12 (0.005) Side clearance 0.10 — 0.15 (0.004 — 0006) 0.2010008) FUEL SYSTEM SPECIFICATIONS ITBJ SPECIFICATIONS Carburetor identification '04 and '05 USA, m number '0‘ - '07 Canada: '06 and '07 USA: PMZB After ‘07: PMZC Main e1 #58 Slow at 635 x '35 at negyaflfigfaltlcn ( 04 and 05 U.S.A.. 2", “may. from mp Air screw lnItIal opening MI! turns out Float level 12.7 mm (0.50 In) Idla lpeed 1.700 t: 100 rpm Throttle grip (res play 2.0 - 4.0 mm (1/16 - 3/16 In) CYLINDER HEAD/VALVES SPECIFICATIONS Unit: mm (in) ITEM STANDARD SVICE LIMIT Cvllndar communion 981—1,177kPa(10.0-12.0kgflnm’, I42 - - 171 pal) at 1,000 rpm Cyllnder head werpaga — 0.05 (0.002) Valve and Valve clearance lN/EX 0.05 x 0.02 (0.002 t 0.001) - veiva guide Valve Item OD, IN 4970 - 4.985 (0.1957 — 0.1963) 4.92 (0.194) EX 4.955 - 4.970 (0.1951 - 0.1957) 4.92 (0.194) Valve guide I.D. INIEX 5.000 — 5.012 (0.1909 - 0.1973) 5.03 (0.198) Slam<10 Oil (sidafiil) _ 0.3 9 . 17 1.1 (0.04) Cylinder-to-piston clearance _ 0.010 — 0.0470 (0.00 —0.0016) 7 0 15 (07.7006) ‘ Connecting Iod7s7rrlall7end ID. 7 7 7 13.016 -13.034(707.51g4 0.5131) ‘ 1103(05151 I Connecting rod-lo-plslon pm C|7e731737r17£e 0.016 — 0.040 (0.0006 — 0.0017671 7 0.12 (0.005] CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS 7 7 7 Unit: mm (in) 7 ITEM 7 7 7 s7T7A7N707ARD j SERVICE LIMIT 01mm disc lhidlness ‘ A 2.52 - 2.03 (0.099 - 0.106) 2.31009) 0 ' 9.32 A 3.118(01314 0.197) ‘ 3.0 (0.12) Clutch pIa'ie warpage ‘ — ' 0.20 (0.003) CemriIugaI cluich spring has Iengih ' 22410.88) ' 19.4 (0.76) ’ ’ Prirnary ems gear 1.0. ‘ 21.000 v 21021 (0.8268 7 0.327s) : 21.05 (70.329) Clutch csnIer guide ' ’ ' ‘ 16.988—1i006I0.6088 — 0.5595) 170410.071) . . ' 20.930 — 20.950 (0.3240 7 0.3249) ' 20.90 (0.023) Crankshaft 0.0. m clutch cenlér 911 e j 16.966 — 10." 0.0600 — 0.6097) "1 690101605) ALTERNATOR/CAM CHAIN TENSIONER SPECIFICATIONS Unir (nun) 7 7 ITEM 7 STANDARD i I S7EI7iy7IEE7LIMIT j Cam chain xensiuner 1 Bush rod 00. 7 7 11.905 - 12.000 (0.4715 - 0.4724) 11.94 (07.470) Spring 15ee7151g1171 7 7 7 71314.30) . 100 (9.9) GENERAL INFORMATION GRANKSHAFr/TRANSMISSION/KICKSTARTER SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT ) Crankshaft Side clearance 0.010 A 0.350 (0.0004 — 0.0138) 0.60 (0.0724) Radial clearance 0—0.012(0—0.0005) 0.0501002) ‘ 'FIurTmi [ _ 7 —77 7 7 010107.004) Transmission Gear ID. if 7 7 7 M3 7117016111043(0.6699 ~0.6710) I110 (0.673) 1 91 7 230207— 2310573 (0906; — 0.507s) _ 2371010909) C3 20.020 .053 (0.7832 -— 0.7395) 20.10 (0.791) Busing 0D. C1 7 22.979 — 23.000 (0.9047 — 0.9055) _ 22.93 (0.903) ‘ Busing 1.0. ' c1 20.000 7 20.021 (0.7074 7 0.7002) 200010.791) Gear-lo-bushing clearance C1 0.020 — 0.074 (0.0008 — 0.0029) 0.10 (0.004) Mainshafl 0D. M2 16.966 -16.954(0.6660 — 0.6687) 16.95 (0.667) 1790117rit7ershafl 0.1). (:1 19.959 — 19.580 (0.7358 — 0.7565) 19.54 (0.705) GBar—(o-shafl clearance 7 7 7 M2 7 7 0.032 ~ 0.077 (0.0013 — 0.0030) 0.10 (0.004) ‘ ‘ Gaul bushingrlo‘shek clenrenca CI 0.020 ~ 0.062 (00008 ~ 0.0024) 0.10 (0.004) ‘ Shift lork ‘ ID. 7 34.075 - 34.100 (1.3415 -1.3425) 7 34.14 (1.344) Claw thickness 4.86 — 4.94 (0.151 — 0.154) 4.60 (0.181) ) Shifl drum DD. 7 7 33.950 — 33.975 (1.3366 — 1.3376) 33.53 (1.336) FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS Unil' mm7(i7n) ITEM ,., 2 , SITififii. . Minimum lire Head depth C010 tire pressure i T100 1153 (1.00 k’gI/cm’fis psi)’ ’ Agde runout 7 7 v whee u): distance 7 7 )7 Wheel rim runout 1 Radial I_ — 4 2.010.118) 77 7 7 01171371 7 1 7 _ 7 — 7 2,010.05) Brake Brake (ever free play ( 10 — 20 (318 ~ 13/16) 7 7 7 — 7 Blake drum LD. 30(11) 7 80.5 (3.17) 7 7 7B7rak7e lining thickness 7 I 3.5 (0.14) 7 7 2.70 (70.03) ) Fork Spring free length ( 160.8 (6.33) £3.3(613) REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS , 2 . ,WUI‘JE FIE! E“) 777 777 77 7 7777 7 7 7 (7 STANDARD SERVICE LIMIT 1 Minimum (ireireaq dept!) 77 777 7 777 - 7 7757.701 MM 7 7 7 7 7 125 kPa (1.25 kgl/CH’TIB psi) 7 — Ax7|e run u! 1 — 7 0.2001003) _ Wheel rim-to»hub distance I 25 1.71.0 (I70 2 9.94) 7 ‘ — Wheel rim runoui 1 Radial _ — ‘ 2.010.031 _‘ 1 Axial ‘ 7 7 7 1 2.00108) Drive chain 1 Size/link 7 )7D24207MB7K17/78 71 — 77 ( Sled< 15—25(9/16~1)77 7 7 ' ' ’1 7 Brake Brake pedal free play 1 (3/8 ~13I16) _ — I ( 1 l Rreke drum ID. | Brake lining thidmess I 1-8 L- GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS ITEM ' ngspiflqnqu *Spark plug Standard CRGHSA (NGK) UZOFSR-U lDENSO) For cold climate [below 41=FIS°C) CRSHSA (NGK) UIGFSR»U lDENSOl ‘ For extended high speed riding CR7H§§ (NGK) 7777i WUZZFSFIVU [DENSO] if Spark plug gap i i’gniii Tun peak voltage 7 7 i Ignition pulse generator peak voltage Alternator exciler coineak voltage iflgnition timing ("F" mark) 650 — 0.70 mm [0.024 — 0.0281”) 100 V minimum 0.7 V minimum 100 V minimum 27" ETDC at idle 1-9 GENERAL INFORMATION TORQU E VALUES STANDARD TORCIUE TORQUE EASTENER TYPE i Mm "(maul “7”” FASTENER T‘IFE Mm "(gum let) 5 mm hex bolt and nut 4.9 (0.5, 3.6) 5 mm screw ‘ 3.9 (0.4, 2.9) 6 mm hex bolt and nut i 9.8 (1.0, 7) 6 mm screw 8.8 (0.9, 6.5) 8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head, small head) ‘ 9.8 (1.0, 7) 10 mm hex bolt and nut i 34 (3.5, 25) 6 mm flange bolt (8 mm heed, large flange) 12 mm hex bolt and nut 54 (5.5, do) 6 mm flange bolt (10 mm head) and nut 3 mm flange bolt and nut 10 mm flange bolt and nut - Torque specifications listed below are for specified Iasteners. I Others should be tightened t0 standard torque Values listed above. NOTES: 1, Apply oil to the threads, 2. Apply grease to the seating surface. 3. U-nut 4. ALOC bolt; replace with a new one. ENGINE MAINTENANCE * ' ' ’ THREAD TORQUE 77777 7 7 "EM aw DIA. (mm) N-m (kghn, ern) REMARKS Spark plug (’04 and '05) 1 IO 12 (1.21 9) Spark plug (After ’05) 1 10 16 (1.6, 12] Oil drain bolt 1 12 25(2.5,1B) Valve adjuster hole cap 2 30 12 (1.2, 9) NOTE 1 Valve adjuster lock nut 2 5 8.8 (0.91 6.5) Clutchadiuster lock nut 1 B 7 12 (1.2.79) 7 7 _ 7 ' LUBRICATION THREAD TORQUE '— 7 7 :5” my om, (mm) 7Nm tkgtmlm-n) “MARKS Oil pump mounting screw 3 6 l 7.4 (0.75. 5.5) Oil pump cover screw 3 5 4.7 (0.48, 3.5) i , 7 W V THREAD 7 TORQUE 7 7 n7” DIA.7(mm) N-m (kgirm, let) REMARKS — 7 7 2 5 12 (1.2, 9) CYLINDER HEAD/VALVES 7 7 THREAD TORQUE 7 "7E" 0'" om, (mm) Mm [kgI-m lht-Itl REMARKS Cylinder head cover nuUcap nut 1/3 6 1771.1, 8) Cylinder head right side cover bolt 2 6 9.8 (1.0, 7) Cam sprocket bolt 2 5 8.8 (0.9, 6.5) CYLINDER/PISTON THREAD 7TOR0UE 77 7 77'TEM my om. (mm) M!» (km-m. lM-It) REMARKS Cam chain guide roller pin bolt 1 8 9.3 (1.0, 7) 1-10 GENERAL INFORMATION CLUTCH/GEARSNIFI’ LINKAGE THREAD TORQUE ' EM 0'" DIA. (mm) N-m [inf-m, lbw) “EM‘R‘S Cluldt outer cover screw 4 5 4.4 (0.45, 3.3) Clutch lock nut 1 I4 42 (4.3, 31) Clutch assembly screw 4 5 5.9 (0.6, 4.3) Shift drum stopper arm bolt I 6 13 (1.3, 9) Shin return spring pin bolt 1 B 29 (3.0, 22) Gearshitt cam plate bolt I 6 17 (11 12) ALTERNATOR/CAM CHAIN TENSIONER THREAD TORQUE "E" ‘1“ nu. (mm) N-m (mm. mm) "MKS Flywheel nut ‘l 10 41 (4.2, 30) Cam chain tensionar scaling bolt 1 1d 23 (2.3. 17) Cum chain tsnsionar pivot bolt 1 B 15 (1.6, 12) CRANKSHAFI’ITRANSMISSIONIKICKS‘TARTER ‘ 111nm mnous l "5" °'“’ on. (mm) «m rum-m. Mn) “MARKS Shilt drum bolt l 1 6 12 (1.2, 9) ( FRAME FRAME/BODY PANELS/EXHAUST SYSTEM THREAD TDRQUE ( "EM ‘1'" on. (mm) m:- (mm. mm mum‘s Slda stand pivot bolt 1 10 - page 2-7 Muffler mountlng bolt 1 8 26 (2.7. 20) Exhaust pipe protector bolt 3 6 15 (1.5, 11) Exhaust pip. cover screw 4 5 5.9 (0,5, 4,3) l MAINTENANCE T THREAD venous l m ‘ “TV nu. (mm) Nan llqtm. mm "EM “(S l Fuel valve mounting bolt ‘ 2 s 9.8 (10, 7) FUEL SYSTEM THREAD TORQUE "EM 1 M" nu. (mm) N-m (Wm, mm m h “(S Connecting boot band screw l I 4 L0 (0.1, 0.7) ENGINE REMOVAL/INSTALLATION . THREAD TORQUE “E” l 0"" on. (mm) Mm (mm. mm “Emm‘s Engine hanger nut 2 B 31 (3.2. 23) FRONT WHEEUBRAKE/SUSPENSION/STEERING * mam: mucus l "’5" ‘ ‘3'" nu. (mm) N>mI|wl-m.lb1»fl) “Ma‘s Handlebar mounting nut ‘ 2 8 20 (2.0, 14) Englne stop switm holder screw 2 5 2.3 (0. 2.2) Brake lever pivot bolt 1 5 2.9 (0. 22) Brake lever plvot nut 1 5 2.9 (0. 2.2) Spoke nipple ‘ 23 BC 23 2.0 (0. 1.4) Front axle nut ( 1 I2 47 (4. 35) NOTE 3 Front brake arm nut 1 5 5.9 (0.6. 43) NOTE 4 Fork protector bolt 4 6 9.8(11), 7) Steeran stem nut 1 22 74 (7.5, 5:) Steering stem top "trend 1 22 - pugs 1240 1-11 GENERAL INFORMATION REAR WHEEUBRAKEISUSPENSION THREAD TORQUE 77 N " E” “Y 7 nu. (mm) N-m (mm, mm _ “MAN‘S Spoke nippIe 28 BC 2.3 2.0 (0.2, L4) ‘ Rsar axle rm! 1 12 47 (4.8, 35) \ NOTE 3 \ Driven sprocket nut 4 B 32 (3.124) ‘ NOTE 3 Rear brake arm nut 1 5 5.5 (0,6, 4.3) NOTE 4 Swingarm pivot nul 1 ID 39 (4.0, 29) NOTE 2,: ‘ Shock absovber mounting nul 2 I0 34 (3.5, 25) NOTE 3 ‘ Drive chain squgr nut 71 5 12 (1.2. 9) ~ng 3 IGNITION SYSTEM 7 i THREE TORQUE _ —" E" 7 0'" DIA, (mmAMm-ml lM-Il) "Emfixsi ‘ Ignition coil mauntjngflll 1 5 i 7 5. 0.6, 4.3) 1-12 L. LUBRICATION & SEAL POINTS ENGINE GENERAL INFORMATION LOCATION Cylinder bore surface Valve adjuster hole cap threads Connecting rod big end hearing Connecting rod small and inner surface Piston outer surface] piston pin hole and ring grooves Piston pin outer surface Piston ring (whole surface) Valve stern sliding surface Camshaft lobes Cam chain Cam chain guide roller inner surface Rocker arm inner and slipper surfaces Cam chain tensioner push rod (inside) Oil pump rotors Clutch center guide (whole surface) Clutch discs Primary drive gear teeth and inner surface Primary driven gear teeth Mainshaft sliding surface Countersheft sliding surface Transmission gear sliding surface, gear Ieeth and shifter groove Shift drum outer surface Kickstaner spindle sliding surface Other rotating and sliding area Each bearing rotating area Each oil seal lips Each O-ring FRAME LOCAHON Air cleaner housing cover mating groove Throttle grip pipe flange Steering head bearing and race sliding surface Wheel hub dust seal lips Wheel bearing cavities Brake panel anchor pin sliding surface Brake cam spindle and sliding surface Brake pedal pivot Fork dust seal lips Fork slider outer surface (slider guide sliding surface) Fork slider guide outer groove Fork spring whole surface Swingarm pivot nut seating surface Side stand pivot and slridingisurface Brakarcair'n dust seal Throttle cable outer inside Brake cable outer inside ’Rfi'fibar grip rubber inside Air cleaner connecting bootrto~housing mating area 7 MATERIAL Engine oil 7 MATERIAL Mum-purpose grease Enginejil Cable lubricant '7fima bond A or eguiifa- lent REMARKS pour 1 ~ 2 cm3 Fill with 1 —2 cmiipage10-7) Fill with 0.5v1 tzrriJ Anemia“ Apply 5 — 6 9 Apply 5 ~ 6 9 Apply 14 g 1-13 GENERAL INFORMATION CABLE 8| HARNESS ROU11NG AFTER '0‘] ONLY: CLAMP LEFT Arum. HOSE ,KU D—amm (0—0.12inI ‘- AIR c man HOUSING "l FUEL TANK ‘1‘: anamen HOSE ‘ FUEL HOSE PAINT MARKS FUEL HOSE BRAKE CABLE TMRO'I'I'LE CABLE THROTTLE CABLE W‘RE BANDS BRAKE CABLE ENGINE STOP SWITCH WIRE 1-14 GENERAL INFORMATION IGNITION SWITCH SPARK PLUG WIRE IGNITION SWITCH WIRE ENGINE STOP SWITCH WIRE IGNITION SWITCH ALTERNATOR WIRE ENGINE STOP SWITCH WIRE CRANKCASE BREATHER STORAGE TANK THROTTLE CABLE CLIP WIRE CLAMP ENGINE STOP SWITCH WIRE 5 — 10 mm ALTERNATOR WIRE WIRE CLAMP CRANKCASE BREATHER DRAIN HOSE cAfiBUREroR DHNN HOSE 1-15 GENERAL INFORMATION 1-16 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The US. Environmental Protection Agency (EPA). and the Calilornia Air Resources Board lCARB) require that off-road motorcycle comply with applicable exhaust emissions standards during its useful life. when operated and maintained according to the instruction provided. SOURCE OF EMISSIONS The combustion process produces carbon monoxide, oxides of nitrogen. and hydrocarbons. Controlling hydrocarbons and oxides oi nitrogen is very important because‘ under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it IS toxic. Honda Motor Co., Ltd. utilizes various systems to reduce carbon monoxide] oxides of nitrogen, and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of appropriate carburetor setting. no adjustments should be made except tor high altitude setting and idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate lrom the crankcase emission control system. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. BlawAby gas is returned to the combustion chamber through the air cleaner and carburetor. AIR CLEANER CRANKCASE BREATHER STORAGE TANK ‘— BLOWVBV GAS <2 FRESH AIR CRANKCASE BREATHER DRAIN HOSE 1-17 GENERAL INFORMATION SERVICING THE HONDA use. 0an Maintenance, replacement or repair of the emission control devices and systems may be periermed by any motorcycle repair establishment or individual liming parts that are 'certified' to EPA standards, PROHIBITED ACTIONS The iollowing prohibitions apply to everyone with respect to the engines emission control system You may not remove or disable any device or element oi design that may aiiect an engine's emission levels. This restriction applies beiore and after the engine in pieced in service. NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: US. Federal law prohibits, or Canadian provincial laws may prohibit the iollowing acts or the causing there oi: (l) The removal or rendering inoperative by any person, other than ior purposes oi maintenance, repair or replacement. oi any device or element of design incorporated into any new vehicle int the purpose oi noise control prior to ite sale or delivery to the ultimate purchaser or while it Is in use; (2) the use oi the vehicle after such device or element oi design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE FOLLOWING ACTS: 1, Removal oi, or puncturing oi the muiilar, baiilee, header pipes or any other component which conducts exhaust gases, 2‘ Removal oi, or puncturing oi any part oi the intake system. 3. Lack cl proper maintenance. 4‘ Replacing any moving pans oi the vehicle. or parts oi the exhaust or intake system, with parts other than those speciiied by the menuiscturer. FUEL PERMEATION EMISSION CONTROL SYSTEM IAFI' ER '07) This motorcycle complies with the Fuel Permeation Emission Control regulations oi the us. Environmental Protection Agency (EPA). Caliicrnia Air Resources Board (CARE), and Environment Canada (EC). The iuel tank and iual hoses used on the motorcycle incorporate luei permeation control technologies. Tampering with the fuel tank or iuel hoses to reduce or deieat the eiiectivenesl oi the luei permeation technologies is prohibited by iederal regulations REBUILT ENGINE When you rebuild your engine Including a me]or overhaul in which you replace the engine's pistons or power assemblies or make other changes that significantly increase the service Iiie oi the engine, your Honda will continue to comply with all emissions regulations ii you: — Make aura you are technically qualified to rebuild the engine and have the proper tools — Use only Genuine Honda pens or equivalents - Make sure to maintain all specifications as described in this Service Manual 1-18 2. FRAME/BODY PANELS/EXHAUST SYSTEM 332va mponMA'nON .......................... ,. 2.2 NUMBER TROUBLESHOOTING ----- -- 2-2 FRONT FENDER - - - - - - - - - - v ~2-5 SEA-r ........................ T, 2.3 EXHAUST sys-rEM,,. .T..2.5 FUEL TANK .................................................. H 2.4 SIDE STAND ................................................. “2.5 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL O Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can a cause a fire or explosion. I This section covers removal and installation ol the body panels, fuel tank and exhaust system. 0 Always replace the exhaust pipe gasket after removing the exhaust system from the engine. I When installing the exhaust system, loosely install all of fasteners. Always tighten the exhaust pipe joint nuts first, then tighten the mounting fastener, it you tighten the mounting Iasteners first, the exhaust pipe may not seat properly. ' Always inspect the exhaust system for leaks after installation. TORQUE VALUES Side stand pivot bolt See page 27 Muffler mounting bolt 26 N-m (2.7 kgf‘m. 20 let) Exhaust pipe protector bolt 15 N-m (1.5 kgfm, 11 let) Exhaust pipe cover screw 5.9 N~m (0‘6 kgI4m, 43 Ith) ’ TROUBLESHOOTING Excessive exhaust noise 0 Broken exhaust system 0 Exhaust gas leak Poor performance 0 Deformed exhaust system 0 Exhaust gas leak I Clogged muffler 2-2 FRAME/BODY PANELS/ EXHAUST SYSTEM SEAT REMOVAL Remove the two trim clips. Remove the two screws and bolts. Pull the seat assembly back and remove it INSTALLATION Install the seat assembly by inserting the prongs into the retainers on the frame. Install the bolts and screws and tighten them, Install the trim clips and lock them by pushing the center pin flush. TRIM CLIPS SCREWS SEAT ASSEMBLY BOLTS HETAINERS PRONGS 2-3 FRAME/ BODY PANELS/ EXHAUST SYSTEM TANK SHROUDS DISASSEMBLY/ASSEMBLV SCREWS FUEL TANK For fuel strainer 55% was see page 3-4 Remove the seat assembly (page 2-3)‘ Remove the breather hose lrom the number plate. Turn the luel valve OFF and disconnect the luel hose lrom the fuel valve. Remove the two bolts, washer and collar. Remove the fuel tank. Installation is in the reverse order 0! removal. SIDE COVERS REAR FENDER BREATHER HOSE FUEL TANK BOLTNVASH E R FUEL HOSE 2-4 FRAME/BODY PANELS/ EXHAUST SYSTEM NUMBER PLATE Remove the breather hose from the number plate‘ Remove the tender mounting bolt. Remove the number plate from the steering stem nut and front fender. Installation is in the reverse order of removal. FRONT FENDER Remove the three bolts and the trout fender. Installation is in the reverse order of removal. EXHAUST SYSTEM For spark alrester mam {21151156, refer to page 1A 19 REMOVAL Remove the seat assembly (page 2-3). Remove the exhaust pipe joint nuts. Remove the mounting bolt and the muffler. Remove the exhaust pipe joint gasket. INSTALLATION Install a new joint gasket into the exhaust port. Set the exhaust pipe onto the engine by aligning the exhaust pipe flange with the cylinder head studs, then install the joint nuts and the mounting bolt. Tighten the joint nuts. Tighten the mounting bolt. TORQUE: 26 Min (2.7 kgl-m, 20 lbf-iti Install the seat assembly (page 2-3) BREATHER HOSE FENDER 2-5 FRAME/BODY PANELS/ EXHAUST SYSTEM a MUFFLER SPARK ARRESTER MOUNTING BOLT 26 N-m (2.7 kgftm, 20 letI EXHAUST PIPE PROTECTOR 15 Nm (1.5 kgl-m,11 lbf-ftl 5.9 N-m10,6 kgl‘m, 4.3 Ith) EXHAUST PIPE COVER SIDE STAND U REMOVAL Support the motorcycle securely with a hoist or equivalent. Retract the side stand and remove the following: — Return spring — Pivot nut — Pivot bolt — Side stand FRAME/BODY PANELS/ EXHAUST SYSTEM INSTALLATION Apply grease to the side stand pivot and sliding sur- faces. install the side stand with the pivot bolt. Tighten the pivot bolt TORQUE: 3.8 MM (1.0 kgi-m, 7 lel) Loosen the pivot bolt 45 — 90:. Install the pivot nut and tighten it while holding the pivot bolt. ' Install the return spring. Check the side stand operation for lreedom of movement. 3. MAINTENANCE SERVICE INFORMATION- ‘ 3-2 MAINTENANCE SCHEDULE ---------------------- u 3—4 FUEL LINE .................................................... .. 3.6 THROTTLE OPERATION .............................. .. 3.5 AIR CLEANER ............................................... .. 3.7 SPARK PLUG -- I 3.3 VALVE CLEARANCE .................................... .. 3.9 ENGINE OIL .......................................... .. 3.10 ENGINE OIL STRAINER SCREEN ------------- ~ 3-12 ENGINE OIL CENTRIFUGAL FILTER-mun» 3-12 ENGINE IDLE SPEED ................................ .. 3.13 DRIVE CHAIN~- DRIVE CHAIN SLIDER ............................... ..3.15 BRAKE SHOE WEAR .................................. “3.15 BRAKE sverM ......................................... ..3.15 CLUTCH svs'rEM ....................................... “3.17 SIDE STAND SUSPENs|0N ............................................ “3.1a SPARK ARRESTER .................................... "3.19 NUTS, BOLTS, FASTENERS ---------------------- "349 WHEELS/“RES .......................................... ..3.20 STEERING HEAD BEARINGS 3-1 MAINTENANCE SERVICE INFORMA110N GENERAL 0 Place the motorcycle on a level eurIece belore eteninp any work. I Geeollne is extremely flammable and Il explosive under certain conditions. Work in a well ventilated area. Smoking or allowing llemee or “will! in the work area or where the gewllne ie stored can cause a fire or explosion. I The exhaust oantaine poleonous carbon monoxide gas that may cause lose of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system In an enclosed area. SPECIFICATIONS I'M SPECIHCAWS Standard CHSHSA (NGK) U20FSR-U (DENSO) Spark plug For cold climate (below 41°FIS°Cl CRSHSA (NGK) u15an-u (DENSO) For extended higflpeed riding CR7HSA (NGK) 1 U22FSR»U (DENSO) Spark pluggap 0.00 — 0.70 mm (0.024 - 0.015 In) . . At draining 0.6 liter (0.6 US qt. 0.5 Imp qt) E"“'"' °" "Pm" At dlueeembly 0.01119: (0.0 us gt. 0.7 Imp qt) Recommended engine oil Pro Honda 6N4 4—nroke oll (USA and Canada) or equivalent motor oil API service classification: 86 or higher JMO T903 standard: MA Viscosity: SAE 1ow-ao Engine idle speed 1.700 t 100 rpm Throttle grer lreepley 2.0—4.0 mm (ll16—3I16in) IN 0.05 t 0.02 mm (0.002 :t: 0.00! In) “M “mm” ex 0.05 2 0.02 mm (0.002 t 0.001 (11) Drive chain sladr 15-25 mm (916—1 In) Drive chem size/link DID DIDdzOMBKifla Brake lever lreeplay 10 - 20 mm (3/3 —13/16inl Brake pedal lreeplev l0 — 20 mm (SIB - Iii/16 in) . Front 2.5040 33.1 T'" "" Rear 2.5010 33.1 Tire brand Front C-iBGA Fleer C-lm . Front 100 kPe (1.00 kgI/cm’. 15 pll) T'” ‘" “mm a... 125 We (1.25 k item’. 13 Del) Minimum tire tread depth :00: :2) TORQUE VALUES Fuel velve mounting bolt Spark plug ('04 and '06) Spark plug (After ‘05) Valve edlueter hole cap VeNe edlueter Iodr nut Oil dreln bolt Clutm adjuster lock nut Rear axle nut Spoke nipple use N-m (1o kgl-m, 71111-0) 12 N-m (1.2 kgl~m, 9 111m) 10 N-m (1.5 tat-m. 121111-11) 12 NM (1.2 kgt-m, 9 1014:) u N‘m (0.9 kgI~rn, 11.5 Ibl-Itl 25 N-m (2.5 tot-m, 10111141) 12 um (1.2 kgl-m, 9 Ith) 47 Mar (4.11 kgtm. :15 101-111 2.0 N-m (0.2 kgi~m, (um-1:) Apply engine oil to the threads U»nut L TOOLS MAINTENANCE Spoke wrench, 4.1 x 4.5 mm 07701-0020100 or equivalent commercially avail- able in U.S.A. Valve adjusting wrench, B x 9 mm 0770870030100 or equwalem commercially avail- able in USA. Valve adjuster B 07708-003040!) or 07908-KE90200 (U.S.A, only) 3-3 MAINTENANCE MAINTENANCE SCHEDULE ‘04 AND '05 Perform the Preaide inspection in the Owner's Manual at each scheduled maintenance period, I: Inspect and Clean, Adjust, Lubricete or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricata. WHICHEVER INlfiAl; I FREQUENCY COMES MAINTE- REGULfiZflE‘m‘ENANC‘E FIRST NANCE REFER To F’m’i ‘ I970 600 am .300 7 PAGE @ 7km7 7 150 1,000 2.70670737qu 4,ooT)I 9 ITEMS NOTE MONTH I s 12 13 24 ' ’- fFuEL LINE 7 ’ " ' - THROTTLE OPERATIQN 77 ’ ‘TAEITIIKNER 7 ' N0TE1 '7 *’ SPARK PLUG 7 7 7 -' VALVE CLEARANCE 7 I ENGINE OIL R 7'" ENETNfil’IL STRAmEfi' WEN 7 7" i 7 ‘ " ENGINE QILCENTEEUGAL’fiIZTEe 777 7 7 7 7 " ENGINE IDLE7s7I=EED7 7 l I 77 7 7 NOT“ LL I. L: Evarvi'mo mi (500 km) ‘ I NON-EMSSlON RELATED ITEMS EMSSION RELATED ITEMS .- NOTES: DRIVE CHAIN :efAKE ngE7' BRAKE SYSTEM Jr 3 rnonths C SPARK ARRESTER S BOLTS, FAerNsljs7 7 77 w E Every 1,060 mi (1,606 kin) or evew 100 qperating hours _I'— Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified. In the interest of salary, we recommended these items be servich only by an authorized Honda dealert 1. Service more frequently when ridden in wet or dusty conditions, 3-4 MAINTENANCE AFTER '05 Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. Replace. A: Adjust. L: Lubricate. WHICHEVEH INITIAL FREQUENCY COMES MAlNTE- REGULfiZflfiUfiENANCE FIRST NANCE aspen To mi 717g so 1.2007 1,800 2,100 PAGE 3' 7kg} 7’ 150 1,000,26001737000'4300‘7 l ITEMS NOTE 1 s I 12 ‘ 15 24 ‘ ‘ jFUEL LINE 7' " W ' i ‘ "W I 1 i I 345 7 THfifi'iLE79FERATI0N ‘ ' ‘ I I 3-6 AIR CLEANEII ' _‘ NOTE I ' ’ ' ' ' 7 c : a-zj SPARK PLUG 7 I I 3—3 f‘va7LI7E CLEZRANCE 7 7 ' ‘ I i I 3-9 ' ENGINE OIL ‘ ' ’ R a 3ro " ‘ENmE 0IL§7IRAINER SCREEN ' l c 3:27 " ENGINE OILCENTHIFUGKE'FILTER 7 ' 7 A ' 7 C I 7:: ’ 59-12 7 :[ENGINE IDLE SPEED 7 j 7 I 7 7| I7 7_ I 777I777 3-13 I ‘ |, L: Eve 300 mi (500ka DRIVE CHAIN NOTE 1 I, L 07: mums 37-13 ” pRIVEEfiAIN7ngEfi7 7 7 7 " I *I" ' I ' I 345 f BRAKE SHOE WEAR 7 7 7 77 I I I I 345 BRAKE sverNI7 7 I I7 I I 7I7 3-15 CLUTCH SYSTEM ' ' ‘ I I ' I I ‘ I 347 7 jsTIj'E 's'TANn 7 7 ' ' ’ j 7 ’ l I i ii 'é-fi 7 ' ~suflNSION 7 7 7 7 7I7 ‘77 _ I 7 3.13 C: Eve 1,000 mi (1,600 km) or every 7 ~ SPARK ARRESTERi 7 7 W 100 operating hours 7 3-19 7 BOLTS, FASTENERS ' ‘ I I" " I 7 349 ‘ :WHEELS/TIRES " I ’ Z I fl ' I : I _ I _ 3-20 7 ‘ " STEERING HEAD BEARINGS I ' I 7 I 7 7 I 3.270 , ,, Should be serviced by an authorized Honda dealer, unless the owner has proper tools and Service data and is mechanically qualified, " In the Interest of salety, we recommended these items be serviced only by an authorized Honda dealer. NOTES: 2. Service more frequently when ridden in wet or dusty conditions. 3-5 MAINTENANCE FUEL LINE check the fuel line tor deterioration, damage or leakage. FUEL IJNE Replace the fuel line it necessary. FUEL STRAINER SCREEN Turn the luel valve OFF and disconnect the luel hose. Place a drain pan under the luel hose and turn Ihe luel velva GM to drain the luel tank. After the tank has drained completely. remove the two bolts and collars, and remove the luel valve and strainer screen. Wash the lust strainer screen in non-flammable or high flesh solvent, . . . . . . STRAINER Check the O-rlng ls In good condltlon, reinstall the fuel valve. SCREEN Tighten the luel valve mounting bolts to the speci- fied torque. TORQUE: 5.: MM (10 kgr-m, 1 mm) After installation, check tor luel leaks. THROTTLE OPERATION Check lor smooth throttle grip full opening and _ automatic lull closing in all steering positions. 1-0 - 4-0 mm "/16 ~ 3/15 "ll Check the throttle cable and replace it it it is deterio— rated, kinked or damaged. Lubricete the throttle cable, It throttle operation is not smooth. Measure the tree play at the throttle grlp flange. FREE PLAY: 10- 4.0 mm (1/13 - 3/16 In) MAINTENANCE Throttle glip lree play can be adjusted 3| the upper end ol the throttle cable. LOCK NUT Remove the dust cover from the adjuster ' Adjust the lree play by Ionsenlng the lock nut and L turning the adjusterl Tighten the lock nut and install the dust cover prop- erlyl Recheck the throttle operation ADJUSTER “ DUST COVER AIR CLEANER Remove the two screws and the air cleaner housing cover. L Remove the air cleaner element holder and element 7 I lrom the housing, ‘ ELEMENT [ HOLDER Wash the element in non-flammable or high "ash ’ ’ 50””le pomt solvent, and let it dry thoroughly. 5005919 0m . . . solvent thoroughly Oul ‘ Soak the element In Pro Honda Faam Filter Oll or excess Oil equwalenl, and squeeze out any excess oil. ‘ K» ‘ l .y (f\ ,1 ‘ , b l r/ o \ ’ 2 ‘ V V PRO HONDA l w‘l’s"‘” FOAM 5° "3'" FILTER OIL l 3-7 MAINTENANCE Reinstall the air cleaner element and the element holder by aligning the cutout with the proiection on PROJECTION the housing, ALIGN GROOVE 7 Apply grease into the mating groove in the air cleaner housing covar. Align the gmme m Install the housing cover and tighten the screws. Ylie cover Wit/l [HE DIG/Ethan all me housmg CUTOUT HOLDER ELEMENT .‘i SPARK PLUG REMOVAL Clean alaund me Disconnect the spark plug cap. spHIli plug base mm compressed av nelpre ramov mg arid ue Sula Inspect or replace as described in the maintenance that no deans l5 schedule (page 3-4). allowed to enter me mmoilsnon mama DE! Remove the spark plug using a spark plug wrench or an equivalent. SPARK PLUG PLUG CAP INSPECTION Check the following and replace it necessary lrec~ ommended spark plug: page 32): CENTER ELECTRODE - Insulator for damage - Electrodes for wear - Burning condition, coloration: ~ Dark to light brown indicates good condition. — Excessive lightness indicates mellunctioning ignition system or lean mixture. — Wet or black sooty deposit indicates over-rich mixture. j INSULATOR SIDE ELECTRODE Clean the spark plug electrodes with a wire brush or ‘—¥ ’l special plug cleaner. ( Check the gap between the center and side elec- { . trodes With a Wire-type leeler gauge. 5.1 ll necessary, adjust the gap by bending the side l 4 electrode carefully, ‘ 0.60 — 0.70 mm SPARK PLUG GAP: otso —o.7a mm (mm- 0.oza in) ‘09“ ‘ “23 ‘"’ T0 prevent damage to the Cr/IVHJEV head, ha/Imighlen [he spark Ding Deters using a wrench to ngnsn I'D the Specified (Diane MAINTENANCE Install the spark plug inthe cylinder head and hand tighten, then torque it llilflg a spark plug wrench. TORQUE: ’04 and '05: 11 NM (1.2 kgf-m, 9 Ihlh) Altar '05: ISM-m (1.6 kgI-m, 12 Ibis") Install the spark plug cap to the spark plug. SPARK PLUG CAP VALVE CLEARANCE inspect and art/us! ma valve clearance mm» m W1ng i5 mm (below 95 ‘F/ 35 (l INSPECTION Remove the valve adjuster hole caps. Remove the left crankcase cover (page lD-4). Turn the crankshaft counterclockwise and align the "1" mark on the flywheel with the Index notch on the Ian crankcase. Make sure the plston at TDC (Top Dead Center) on the compression stroke. This posation can be obtained by confirming that there is slack in the rocker arm. If there is no slack, rotate the crankshalt one full turn counterclockwise and match up the "T" mark again. check the clearance by inserting 3 “59'” gauge ’FEELE-R GAUGE between the valve adjusting screw and valve stem, VALVE CLEARANCE: IN/EX10t05 : 0.02 mm (0.002 : 0.001 in) 3-9 MAINTENANCE ADJ USTMENT Adjust by looseninu the lock nut and turning the ; adiusting screw urrii there is a slight drag on e ADJUSTER fooler gauge. TOOLS: Volvo ldjum'ng wrench, 0710843030100 8 x 9 mm (Equivelent oom- merdelly mil- nhle In use) Valve Idjumr B OWN-0WD or MKESOZW (USA. only) TORQUE: 8.8 N'm (0.9 hf-m. 6.5 leI) Recheck the valve clearance. Check that valve adjuster hole cap O-ring is In good condition, replace iI necessary. Coot the O-rings with clean engine oil and install them in the valve adjuster hole caps. Apply clean engine oil to the threads, install and tighten the valve adjuster hole caps to the specified torque. TORQUE: 11 Ni!“ (1.2 huh". I but) install the left crankcase cover (page 104!) ENGINE OIL OIL LEVEL INSPECTION Support the motorcycle in an upright position on level ground, Start the engine and let it idle Ior 3 — 5 minutes Stop the engine and wait 2 — 3minutes. Hold the motorcycle in an upright position. Remove the oil tiller cap/dipstick and wipe it clean. Check the oil level by inserting the oil filler cap/dip- stick into the all liller hole without screwing it in. The engine contains a sufficient amount of oil i! the oil level is between the upper and lower level marks on the dipstick If the level is near or below the lower level mark. add the recommended all up to the upper level merk‘ RECOMMENDED ENGINE OIL: Pro Honda Gmmke oil (USA. and Canada) or equivalent motor oil API urvlol eieulfleetion: 56 or higher ‘_ use T m mud-n1: MA LOWER LEVEL Vitcoehy: SAE towan UPPER LEVEL 3-10 MAINTENANCE ' Other viscositias shown in the chart may be used when the average temperature in your riding area is within the indicated range. Reinstall the filler cap/dipstick, ~30 -2o -I 0 n 10 20 :0 4o 50": L__A—A—I—I—L—J___J ~20 0 20 ‘0 GD 60 100 m'F ENGINE OIL CHANGE L‘mngo we Snglns Warm up the engine. “MW” "'9‘" Stop the engine and remove the oil Iiller cap/dip W5”?! and [’78 slick motorcycle an in vol ' ground In assure complete draining OIL FILLER CAP/DIPSTICK Ramova tho drain bolt and sealing washer, Drain the all completely. DRAIN BOLT/SEALING WASHER Check that the sealing washer on the drain bolt is in good condition, raplacs iI «canary. Install and tighten the drain bolt. TORQUE: ZS Ni"! (2.5 huh", II but] SEALING WASHER DRAIN BOLT MAINTENANCE Fill the crankcase with the recommended engine oil. Om GAP/DIPSTICK OIL CAPACITV: . i ' 0.5 littlr (0.6 US qt, 0.5 Imp m) at d rig 0.3 litter (0.3 US qt, 0.7 Imp qt) at disassemny _-u * u :9 Install the oil filler cap/dipstick. Start the engine and let it idle for 3 — 5 minutes. Stop the engine and wait 2 ~ 3minutes. Hold the motorcycle in an upright position. Remove the oil filler cap/dipstick and wipe it clean. Check the oil level by inserting the ml filler cap/dipv stick into the oil filler hole without screwing I! in. Make sure there are no oil leaks. ENGINE OIL STRAINER SCREEN CLEANING Remove the right crankcase cover (page 9-5). Remove the oil strainer screen and clean It. Check the screen for damage and the sealing rubber (or damage or deterioration. Reinstall the oil strainer screen and righl crankcase cover (page 9-19). ENGINE OIL CENTRIFUGAL FILTER CLEANING Remove the right crankcase cover, ba|l retainer and clutch lifter lever (page 9-5). Remove the four screws and clutch outer cover. Do "oral/aw dusl Clean the DIulCI’I outer cover and inside oi the clutch 3 and dill ro enler the outer using a clean lint-free cloth. cranksha/r all pasr sage Do not use compressed air 3-12 MAINTENANCE Reinstall the clutch outer cover with a new gasket (page 9-14). ENGINE IDLE SPEED - Inspect and adjust the idle speed after all other engine maintenance items have been performed and are within specifications. I The engine must be warm Ior accurate idle speed inspection and adjustment. Warm up the engine Ior about ten minutes, Connect a tachometer Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,700 1100 rpm DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION Turn off the engine, place the motorcycle on its side stand and shift the transmission into neutral. Check the slack in the drive chain lower run midway between the sprockets. CHAIN SLACK: 15—25 mm (9/16 -1 in) NOTICE Excessive chain slack, 40 mm (171/2 In) or more, may damage the frame. ADJUSTMENT Loosen the rear axle nut. V Loosen the adiuster lock nuts and turn both adjust- ing nuts an equal number or turn until the correct drive chain slack is obtained. A-DJUSTING nut 14} 3-13 MAINTENANCE Make sure the index marks on both adjusters are INDEX MARK aligned with the index lines on the swingarm. Tighten the rear axle nut to the specified torque. TORQUE: 47 Mr“ (4.8 kgfrm, 35 IN“) Tighten hath lock nuts. Recheck the drive chain slack and free wheel rutav tion. Check the rear brake pedal Iree play (page 3-16). adjust if necessary. Lubricate the drive chain with t! 80 — 90 gear oil. Wipe off the excess oil. CLEANING INSPECTION AND LUBRICATION It the drive chain becomes extremer dirty, it should be removed and cleaned prior to lubrication. Remove the left crankcase cover (page 10-4). Carefully remove the retaining clip with pliers. Remove the link plate, master link and drive chain. Clean the chain with nan-flammable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubri» canting. Lubricate the drive chain with at so — 90 gear oil. i Wipe of! the excess gear oil. LUBRICATE W GEAR OIL (SAE Inspect the drive chain for possible damage or wearl Replace any chain that has damaged rollers, loose fitting links, or otherwise appears unserviceable. Measure the drive chain length between a span of 41 pins (40 linksl from pin center to pin center with ‘ the chain held taut and any kinked joint straight- ened. l senvrce LIMIT: 5|1mrnl20.1 in) I O 0 a9mewa NON-FLAMMABLE OR HIGH FLASH POINT SOLVENT ‘ WIPE AND DRY % i INDEX LINES It 80 OR 90) 41 PINS I40 LINKS) <3 3-14 MAINTENANCE Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. l Inspect the drive and driven sprocket teeth for wear i WEAR or damage. Replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condi- tion, or the new replacement parts will wear rapidly. Check the attaching bolts and nuts on the drive and DAMAGE driven sprockets. \ If any are loose, torque them. NORMAL Install the drive chain onto the sprockets. install the master link and link plate. MASTER LINK install the retaining clip so that its open end is uppor site the normal rotation of the chain. T ‘5“ PLATE RETAINING CLIP DRIVE CHAIN SLIDER Check the drive chain slider for wear or damage. Replace the drive chain slider if the wear limit guide i lug is worn out or it has been damaged. GUIDE LUG BRAKE SHOE WEAR Check the brake shares and brake drum ii the arrow on the indicator plate aligns with the " A " mark on the brake panel when the brake lever is applied Refer to page 12-13 or page 13-10 lor brake shoe \ and brake drum inspection. MAINTENANCE BRAKE SYSTEM FRONT BRAKE Measure the from brake levar lree play at the lip 01 the lever. FREE PLAV: 1D - 20 mm (3/8 —13/16in) Make sureme cub Adjust the brake lever free play by turning the ' autonmeadlusung adjusting nul. JO'NTP'N nu! rs seated on me jolnrpm REAR BRAKE Check the brake pedal free play. FREE PLAV: 10 — 10 mm (3/8 — 13/16 in) 10—20 mm (3/ 8—13/16in] ‘ . 3-16 L Make sure me cur- our on ma adjusting nut is seated on the join! pm. CLUTCH SYSTEM Adjust the brake pedal tree play by turning the —r adjusting nutt ADJUSTING NUT It the clutch does not operate properiy, adjust the following: Loan" the clutch adjuster lock nut and turn the adjusting bolt one lull turn clockwise. Slowly turn the adjusting bolt counterclockwise until resistance is lelt. Turn the adjusting bolt ilfl turn clockwise from this position, and tighten the lock nut while holding the adjusting bolt. TORQUE: I2 N-m (1.2 him, 9 IbMti Check that the clutch is not slipping and is properly disengaging by operating gearshift pedal, SIDE STAND Support the motorcycle on a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly lor lreedom of movement and lubricate the side stand pivot il net:- eeserv, SIDE STAND MAINTENANCE JOINT PIN 3-17 MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check Ihe aclion of the fork legs by operating the Iron! brake and compressing the from suspension several times. . Check the entire assembly for signs oI leaks, dam~ age or loose Iasleners Replace damaged components which cannot be repaired. Tighlen all nuts and bolts. Relar to page 12~1510r fork service. REAR SUSPENSION INSPECTION Supporl the molorcvcle on safety Slant! or bux and raise me rear wheel of! the ground. Hold the swingarm and move the rear wheel side ways wuh lame to see il the wheel bearings are worn. Check lor worn or loose suspension plvol compo- nanls by grabbing Ihe swingarm and anempung to move [he swingarm back-end-lorlh. Check each Iastener ol the swingarm and shock absorber. if any are Iooseness is noted. Also, shack (he DIVOI bushlngs lor wear or damage. Check the acuon of the shock absorber by cams pressing il several limes. Check the enme shock absorber assembly for Slgns o! leaks. damage or loose Iasleners. Replace damaged componenls which Cannol be repailed. Tighten all nuts and bolts. Refer la page 13-12 Io! shock absorbs! and lo page 13714 swingarm service. 3-18 MAINTENANCE SPARK ARRESTER Remove the three bolts, spark arrester and gasket from the mufller. SPARK ARRESTER/GASKET Use a soft brush to remove carbon deposits from the screen mesh, being careful not to damage it The spark arrester must be free of breaks and holes. Replace if necessary SCREEN MESH Install the spark arrester with a new gasket into the ‘ muffler. i Tighten the three bolts securely. ARRESTER BOLTS NUTS, BOLTS. FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-10). Check that all safety clips, clamps and cable stays are in place and properly secured. 3-19 MAINTENANCE WHEELS/TIRES Tire pressure should be checked when the tires are COLD, RECOMMENDED TIRE PRESSURE AND TIRE SIZE: FHGNT ' Wan :fifigfiflg ' 100(1.oo,15) tzslusnsr mm ’ ' ' 2.50.103 inn-10 33.1 TIREBLAND 7 - 7 ‘(CHENG SHL V C-mA 7 man Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels Iur trueness (refer to page 1273 and page 13-3) Measure the tread depth at the center at the tires. Replace the tires when the tread depth reaches the Iuliowing limits. MINIMUM TREAD DEPTH: FRONT/REAR: 3.0 mm (0.12 in) Tighten any loose spokes to the specified torque. TOOL: Spoke wrench, 4.1 x 4.5 mm 07701 — 0020100 [Equivalent com» mareially avail- able in U.S.A.I TORQUE: 2.0 NM (0.2 kgl-m. 1.4 [bf-ft) STEERING HEAD BEARINGS L that the can Support the motorcycle securely and raise the front Ira! cable's tit: not wheel ofl the ground. interfere With Men. dielJa' lolrnrorl Check that the handlebar moves freely Irum side to side. If the handlebar moves unevenly, binds, or has ver- tical movement, inspect the steering head bearings lpage IZAIBI. 3-20 4. LU BRICATION SYSTEM L L LUBRICATION SYSTEM DIAGRAM 4-2 TROUBLESHOOTING------~<-~~-m-w-u-~-w~-~----4-3 b sanwcfi INFORMATION 4.3 OIL 4-1 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM CAMSHAFI' PISTON OIL PUMP (—— \—.— CRANKSHAFI’ OIL THROUGH MAINS FT OIL FILTER ROTOR COUNTEHSHAFT OIL STRAINER KICKSTARTER LUBRICATION SYSTEM SERVICE INFORMATION GENERAL Used engine oil may cause skin cancer it repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible alter handling used oil. 0 The oil pump service requires engine removal. - The service procedures in this Section must be pertormed with the engine oil drained. - When removing and installing the oil pump. use care not to allow dust or dirt to enter the engine. I ii any portion at the oil 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 oil pressure is correct. SPECIFICATIONS ., Unit: rnmlinl ITEM 7 STANDARD SERVICE LIMIT Engine oil capacity ' At draining 7 7 0.6 mar (06 U$gt. 0.5 Imp qt) 7 — At disassemoly 0.3 liter (0.3 US qt, 0.7 Imp qt) - Recommended engine oil ‘ Pro HondeGNAA—stroke oil (USA. and ~ Canada) or equivalent motor oil l AFI service classification: 56 or higher JASO T 903 Standard: MA l Viscosity: SAE ioweo l 7 7 7 Oil pump rotor 73p clearance ’ 0.15 (0.006) l 0.20 (0.008) Body clearance 0.02 — 0.07 (0.001 — 07.9709) ' 7012719th5) [ Side clearance 0.10 ~ 0.15 (0.004 r 0.006) 0.20 (0.000) 7 TORQUE VALUES Oil pump mounting screw 7.4 Not (0.75 kgivm, 5.5 |th) Oil pump cover screw 4.7 N-m (0.4a kgi-m, 3.5 lbi-fl) TROUBLESHOOTING Engine Oil level too low, high all consumption - Normal oil consumption - External oil leak Worn piston ring or incorrect piston ring installation - Worn cylinder - Worn valve guide or stem seal 0 Oil pump worn or damaged Oll connminnlort I Oil not changed often enough 0 Worn piston ring or incorrect piston ring installation 0 Worn valve guide or stem seal - Clogged oil strainer screen LUBRICATION SYSTEM OIL PUMP REMOVAL Remove the clutch assembly (page 9-6). When the oil pump is ready to be disassembled. loosen the pump cover screws. Remove the three screws and oil pump assembly. Remove the rotor shaft collar from the crankcase DISASSEMBLY Remove the three screws and oil pump cover. SCREWS Remove the oil pump shah. then remove the inner and outer rotors Irom the oil pump body. INSPECTION Ila/Iypoll‘nrlo'me Temporarily install the outer and inner mlors mm on Hump Is mm: the oil pump body, Deva/III ms spea- lred germs mm lap/dc? mg ml Measure the tip clearance between the Inner and [IIHVIIV (75 an JISSPN' outer rotors. my SERVICE LIMIT: 0.20 mm (moon in) Install the oil pump shah, Measure the pump body clearance between the outer rotor and pump body. SERVICE LIMIT: 0.12 mm (0.005 ill) 4-4 LUBRICATION SYSTEM Measure the side clearance using a sIraight edge and feeler gauge. SERVICE LIMIT: 0.20 mm (0.008 in) ASSEMBLY OIL PUMP BODY OUTER ROTOR OIL PUMP SHAFT \ INNER ROTOR OIL PUMP COVER Install the inner and outer rotors into Ihe oil pump body. Install me oil pump shan aligning the Ilal surfaces of the shaft and inner rotor‘ Fill the oil pump with 0.5r1 cm’ aI engine oil. 4-5 LUBRICATION SYSTEM Install the oil pump cover and tighten the screws to the specified tarque. TORQUE: 4.7 MM (0.48 kghu, 3.5 letl INSTALLATION Install the rotor shaft collar into the crankcase. Install a new gasket onto the oil pump body. Install the oil pump into the crankcase while align- ing the pump shah groove with the cam chain guide spindle lug. Install and tighten the three screws In the specified torque. TORQUE: 7.4 N‘m (0.75 kgfrm, 5.5 lbl‘ft) Install the clutch assembly (page 9714). 5. FUEL SYSTEM COMPONENT LOCATION - SERVICE lNFORMAflON ............................ I, 5.3 TROUBLESHOOTING 5.4 AIR CLEANER HOUSING ---------------------------- .. 5.5 CARBURETOR REMOVAL .......................... .I 5.5 CARBURETOR DISASSEMBLY-~- -~5-7 cAnBunE-ron AssEMBLv .......................... ..5.9 CARBURETDR INSTALLATION AIR SCREW ADJUSTMENT-mumm-~~w--u-~~5-13 CRANKCASE BREATHER ........................... ..5.14 5-1 FUEL SYSTEM COMPONENT LOCATION 1‘0 N'rn (0.1 kgf-m, 0.7 lbf-ft) 5-2 SERVICE INFORMAHON GENERAL 0 Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gawllne II atcrad can cause a lira or explosion. and drain the carburetor. I After removing the carburetor. wrap the intake port at the engine with a lhop towel or cover it with piece of tape to [air Refer to page 2-4 tor fuel tank removal and innallatlon. When disassembling lual aystern parts, note the location at the O-rim. Replace them with new one: on raaesemblv. Before disassembling the carburetor, place the Initabla container under the carburetor drain hose. Loosen the screw vent any lorelgn material lvorn dropping Into the engine. FUEL SYSTEM SPECIFICATIONS i‘TETVI SPECIFICATIONS Carburetor identification ’04 end '05 U.S,A.. PM“ number '0‘ — '01 Canada: '06 and '07 U.S,A: PMZB After '07: PM2C , Main lot #58 Slow lot «as x ‘35 arm”, :Ifll‘gpfeltlon l 0‘ and 05 USA. 2m mm "om mp Air screw initial opening 1-1/2 turns out Final level 12.7 mm (0.50 In) Idle speed 7 r [.730 1 100 YE"! Thloltla grip lreeplay 7 2.0 - 4.0 mm (1/16 - 3/16 in) TORQUE VALUES Connecting boot band screw 1.0 MM (0.1 kgl-rn, OJ ital-l!) TOOL Carburetor "out level gauge Pilot acraw wrendi (D type) Pilot screw wrendi guide WWI-0010000 07KMA-MSGOIOI 07PMA-M2201I0 .,,/// / or 07KMAvMN9A100 lU.S.A. only) / Q/ FUEL SYSTEM TROU BLESHOOTING Engine cranks but won‘t start I Too much luel getting to the engine — Air cleaner clogged v Flooded carburetor - Intake air leak - Fuel contamhated/deteriorated - No fuel to carburetor 7 Fuel strainer clogged — Fuel hose clogged — Float level mlsadjusted — Fuel tank breather hose clogged Lean mixture Fuel jets clogged Float valve laultv Float level too low Fuel line restricted Carburetor air vent hose clogged Clogged luel strainer screen Intake air leak Throttle valve faulty ........ Rich mixture 0 Choke lever in CLOSE position 0 Float valve laulty - Float level too high 0 Airiats clogged ' Air cleaner elemenl contaminated 0 Flooded carburetor Engine stalls, hard to start, idles roughly 0 Fuel line restricted - Ignition malfunction I Fuel mixture too lean/rich 0 Fuel coniaminame/deteriorated - Intake air leak 0 Idle speed misadjusted I Float level misadjusted O Fuel tank breather hose clogged - Air screw misadjusted - Slow circuit clogged Aflerhurn when Inglne braking is used - Lean mixture in slow circuit Bukfiring or misfiving during acceleration - Ignition system mallunction I Fuel mixture too lean Poor pedormenca (drive-bility) Ind poor luel economy I Fuel system clogged - Ignition system malfunction 5-4 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL] INSTALLATION - ReVer to page 3—7 for air cleaner alemem service, BOLT/GROUND TERMINAL Disconnect the crankcase Dreamer hoses Loosen The connecting two! band screw. Remove the bolt and the air cleaner housing assem» bly. Ar WSYEUHIIDN, Installaflon is in the reverse order of removalv secure me ground eye/N war m an cleaver hnusmg mounnng narr HOLDER ELEMENT ‘ CARBURETOR REMOVAL THROTTLE VALVE Remove the SeaVshrouds/side cover/rear lender assembly [page 2-3). Loosen the carbu retor [ops CARBURETOR TOP 5-5 FUEL SYSTEM Remove the carburetor top and throttle valve from THROTTLE VALVE the carburetor Remove the throttle cable from the throttle valve . V . SPRING whale compressmg the throttle valve spring, Remove the jet needle retainer and jet needle, JET NEEDLE RETAINER Check the throttle valve and jet needle lcr scratches, wear or damage. THROTTLE VALVE ’/ RETAINER r l "\ / W. JET NEEDLE 5-6 FUEL SYSTEM CARBURETOR BODY Loosen the drain screw and drain the fuel from the .( float chamber into an approved gasoline container. Disconnect the fuel hose, air vent hose and from the carburetor body. Loosen the carburetor connecting boot band screw. Remove the carburetor mounting bolts, carburetor and insulator. \ v _e BOLTS CAHBtJ .1 r ‘/ INSULATOR CARBURETOR DISASSEMBLY Remove the dram hose. FLOAT CHAMBER DRAIN HOSE Remove the screws and float chamber. SCREWS Remove the screw. Remove the float pin, float and float valve. FLOAT Inspect the float for deiormallon of damage. ‘ \_ SCREW FLOAT VALVE 5-7 FUEL SYSTEM Hand/e an lets wrlh care They can us My be scored 0/ scratched Damage to me an SCVGW seat will occur m the an screw is trphrened agarnsl the sear After ‘05 U SA , After '07 Canada Inspect the float valve seat lor scores, scratches cloggan and damage Check the tip 0' the float valve where it contacts the valve seat ler stepped wear or contamination Replace the valve it the tip is worn or contaminated Check the operation 01 the float valve. Remove the lallowing: — Main jet — Needle let — Throttle atop screw and spring Turn the air screw in and carelullv count the num- ber olturne until it seat: Ilghtly. Make a note el this to use as a ralerence when reinstalling the air screw. Remove the air screw and spring. TOOLS: Pilot Icrew wrench (D Wl WKMLMSMM or B7KMA-MN9A‘IM (U.S.Ar only) Pilot screw wrlndt guldo FNMA-M2201” Inspect each Jet lpr wear or damage and replace it necessary. Clean the iets with cleaning solvent and blow open with compressed air. FLOAT VALVE VALVE SEAT MAIN JET NEE'DLE JET I THROWLE STOP SCREW AIR SCREW 5-8 FUEL SYSTEM CARBURETOR ASSEMBLY AIR SCREW (AFTER '05 USA” AFTER '07CANADA) ‘ AIR SCREW (’04 AND ’05 U.$.AI. '04 — '07 CANADA) THROTTLE STOP SCREW SPRING O-RING NEEDLE JET MAIN JET SPRING DRAIN SCREW O-RING FLOAT VALVE SEAL RING CLIP SPRING RETAINER JET NEEDLE (AFTER '05 U.S.A., AFI'ER '07 CANADA) JET NEEDLE (‘04 AND '05 USA. 0mm; l . FLOAT CHAMBER 0" ‘ “7 CANADA) THROTTLE VALVE Blow open each air and luel passage in ma carbure- lar body with compressed air. Handle all lers wrm lnslall me lollowing: THROTTLE 53” may ca" “5' — Throttle slop screw and spring STOP SCREW W he smredar _ Need” .e‘ scratched _ Main 18“ Insrall me sir screw mm the spring and ramrn it to its original position as noted during removal. NEEDLE JET Mar ‘05 USA, SPRING Afler 07 Canada TOOLS: Pllol mow wrunch (D (We) omMA-msmm or / wxmmuoo ) IU.S.AI only) /> Pllat Icnw wrench quid! WPMA—MZZO‘IO SPRING MAIN JET AIR SCREW Perlorm the air screw adiusxment procaduro if a new air screw is installed (page 543). FUEL SYSTEM Hang the lloat valve onto the float arm lip. Install the lloat pin through the float, then Install the float/float pin to the groove on the carburetor body. Install and tighten the screw. FLOAT LEVEL INSPECTION - Set the float level gauge so that it is perpendicu- lar to the float chamber face and in line with the main jet. With the float valve seated and the float arm just touching the valve, measure the float level with the special tool as shown. TOOL: Carburetor "out level gauge own-0010000 FLOAT LEVEL: 127 mm [0.50 in] The lloat cannot be adlusted. It the lloat level is out at specification, Inspect the float valve and valve seat. ll the lloat valve and valve seat are normal, replace the lloat assembly. It the llaet valve and valve seat are abnormal. replace them and recheck the lloat level. Install a new O~ring into the carburetor groove prop» erl . Install the lloet chamber. Install and tighten the float chamber screws. Install the drain hose. FLOAT FLOAT PIN FLOAT CHAMBER g OVRING FLOAT CHAMBER SCREWS SCREW FLOAT VALVE FLOAT LEVEL GAUGE DRAIN HOSE 5-10 ‘. FUEL SYSTEM CARBURETOR INSTALLATION CARBURETOR BODY Install the new O-rtngs into the insulator and carbu- ' I CAREUHETOR \. L k. '04 and 05 U S A '04 - 07 Canada Afler 05 U SA After 07 Canada '5 L retor body grooves. Install the carburetor body to the air cleaner con necting boot and the insulator between the men» Iold and carburetor, then install the mounting bolts. Tighten the connecting boot hand screw. TORQUE: 1.0 Ntm (0.1 kgfm, 0.1mm) Tighten the mounting bolts, Connect the fuel nose and air vent hose. ' FUEL HOSE“; THROTTLE VALVE Install the needle clip on the let needle. CLIP STANDARD POSITION: 27d groove Imm top After '05 U.S.A. and After '07 Canada models can not adjust the needle clip position. 5-11 FUEL SYSTEM Install the jet needle into the throttle valve and secure it with the needle retainer. THROTTLE VALVE '/ RETAINER JET NEEDLE Check the seal ring is In good condition, replace it ' necessary. Install the throttle valve spring onto the throttle cable. Connect the throttle cable to lhe throttle valve whlle compressing the throttle valve spring. Install the throttle valve into the carburetor body. aligning its cut-out with the throttle stop screw. 5-12 FUEL SYSTEM Tighten the carburetor top securely, CARBURFIOR TOP After installing the carburetor. check lar the (allow mg: 7 Engine ldIB speed (page 3-13) \ — Throttle gnp tree play (page we) AIR SCREW ADJUSTMENT IDLE DROP PROCEDURE \ 0 The air screw is Ianory pro-set. Adlustmenl is not necessary unless the carburetor is over- hauled or new all screw is installed I The englna must be warm Ior accurate adtust- ment. Ten minutes 0! stap-and-go rtdtng is suffi- cient. 0 Use a tachometer wllh graduatrons ol 50 rpm or smaller that Will accurately ind-Cate 50 rpm change. My 05 u s A Am” 0765mm Adjust the our screw usmg the lollowing tools. TOOLS: Pllot «row wrench (D WP.) 07KMA-Msomo1 or 07KMA-MN9AIW . (USA. only] L Pllot ear-w wrench guide o7PMA-MZ20110 Damege to wear 1. Turn the air screw clockwise untll It seats Ilghtly. , , ' screw seat Ml and then back It out to the specrhcetton gwen. THROTTLE 5T0? SCREW “5‘” ’I "'5 5” INITIAL OPENING: l<1l1 turn: out screw 15 ugmenea egamst the seat 2. Warm the engine up to operating temperature 3. Stop the engine and connect 5 tachometer according to the tachometer manufacturers instructions. 4. Start the engine and adiust the Idle speed with the throttle stop screw. IDLE SPEED: L700 : I00 rpm 5. Turn the an screw in or out slowly to obtain the mam” \ highest engine speed. FUEL SYSTEM CRANKCASE BREATHER Remove the crankcase breather hose plug and empty any deposits H the deposit level can be seen in the breather hose. Install the crankcase breather hose plug and secure it with the Clip securely. CRANKCASE BHEATHER DRAlN HOSE PLUG 5-14 6. ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 5.2 ENGINE REMOVAL SERVICE INFORMATION 5-3 ENGINE INSTALLATIONmm~-~~~~~ww--~-~-~----6-6 6-1 ENGINE REMOVAL/INSTALLATION COMPONENT LOCATION 26 Nm (2.7 kgf-m, 20 [bf-ft) 12 Mr“ (1.2 kgf-m, 5 IN“) 6-2 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL During engine removal and installation, support the motorcycle securely using a hoist or equivalent. Support the engine using a jack or other adjustable support to ease of engine hanger bolts removal. The following components can be serviced with the engine installed In the frame. » Alternator/cam chain tensioner (page 10-3) — Clutch (page 976) A Cylinder/piston (page 8-3) v Cylinder head/valves (page 73) r Gearshift linkage (page 9-16) — Oil pump (page 474) O The crankshaft. transmission and kickstaner require engine removal for service (page 11-3). SPECIFICATIONS 7 ifi 7 7 ' : ' ’ 'ercficfifoWs Engine dry weight fl 7 17.2 kg (37.9 lbs) Engine oil carpagityiatig’iisasisemplyii 0.8 liter (0.3 US gt, 0] imp qt) ‘ TORQUE VALUES Drive sprocket fixing plate bolt 12 N~m (1.2 kgllml S IbI-ft) Engine hanger nut 3| N!" (3.2 kgtrm, 23 lbI-ft) Muffler mounting bolt 26 N~m (2.7 kgllm, 20 Ithl 6-3 ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil [page 3711). Remove the lollowing: 7 Exhaust system (page 2-5) — Left crankcase coverlpage10-4l Disconnect the spark plug cap from the spark plug. Disconnect the ignition pulse generator and alterna» tor connectors. CONNECTORS Disconnect the crankcase breather hose from the crankcase. Remove the followtng from the clamp: — Carburetor drain hose 7 Crankcase breather hose to loosen the drive chain [gage 343) Remove the following: 7 Fixing plate bolts 7 Fixing plate 4 Drive sprocket Supper! the molar cycle SECWEIV Durmg engrrle assembly remaval, hold we engme Secure/y and be carem no! In dam» age me frame and englne. Remove the following: - Intake manifold bolls — O-ring — Brake pedal return spving ENGINE REMOVAL/INSTALLATION » Four bolts and foolpeg bar FOOTPEG EAR Remove the engine hanger nuts. HAN—GER NU?S'/BOLTS Place a floor jack or other adjustable suppon under the engine, Remove the hanger bolts and Ihe engme from the frame. 6-5 ENGINE REMOVAL/INSTALLAHON ENGINE INSTALLATION Install the engine onto the frame in the reverse order of removal. HA\N‘GER NU S/BOLTS : A - Note the Installation 01 the hanger bolts. All bolts are installed from left side. ‘ I The lack height must be continually adjusted to relieve stress Irom the hanger bolts. Tighten the hanger nuts to the specified torque TORQUE: 31 Mm (3.2 kgf‘m, 23 IM-fl) Install the tour bolts and Iootpeg bare FOOTPEG BAR Install the brake pedal return spring. SPRING U Replace the intake manifold 04mg with a new one, Install and tighten the intake manifold bulls. 6-6 ENGINE REMOVAL/INSTALLATION Install the tollowing. - Dnve sprocket e Fixing plate - Fixing plate bolts TORQUE: 12 Mr“ (1.2 kgf‘m. 9 Ibis“) Adjust the drive chain slack (page 3-13]. SPROCKET Connect the crankcase breather hose to the crank- case. BREATHER HOSE 5 Connect the ignltlon pulse generator and alternator Connectors. Connect the spark plug cap to the spark plug, Install the tallowtngv v Exhaust system (page 275) — Leh crankcase cover (page lo-El Fill the recammended engtne OII [page 311]. 6-7 7. CYLINDER HEAD/VALVES COMPONENT LocAT|0N ......................... .. 7.2 CAMSHAFr REMOVAL ................................ ..7.6 SERVICE INFORMATION ......................... n 7.3 CYUNDER HEAD .......................................... ..7.7 TROUBLESHOOTING -------------- u CAMSHAFr INSTALLATION .................... “7.18 CYLINDER COMPRESSIOM- ~~ 7-1 CYLINDER HEAD/VALVES COMPONENT LOCATION ’04 and '05: 12 Nm (1.2 kgf‘m, S Ith) Aher '05: 16 N-m (1.6 kgi‘m, 12 Ibf-ft) 8.8 NM (0.9 kgf-m, 6.5 |th) CYLINDER HEAD/VALVES SERVICE INFORMATION GENERAL - This section covers service at the cylinder head, valves and camshaft. The cylinder head, valves and camshaft services can be done with the engine installed in the Irame. 0 When disassembling, mark and store the disassembled pans to ensure that they are reinstalled in their original loca- tions. Clean all disassembled parts with cleaning solvent and dry them by blowing them OH with compressed air before inspection. I Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cyl» inder head. Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Refer to page 10-6 for cam chain lensioner service. SPECIFICATIONS Unit: mm (in) 1 ITEM 7 7 STANDARD i kCylinder compression 98171.17? kPal10.0—12.0kgf/cm7, 142 — 77— 17717osii7a7t71,000 rpm ' Cylinder head warpags _ Valve and I Valve clearance IN/EX 0.05 : 007210.002 01) valve guide kValva stern 0.0, ' 7IN _ 4.970 e 4905101957 7 0.136;) ' 4.955 — 4 970 (0 195 0 957) 7 ‘ r 7 V 913) 7 . Stem-legume clearance j IN ‘ 0.015 — 0.04727 (@9196 — 0.0017) 0.08 (0.003) EX 0.05710 00g 002217 77 01010004) 7Va|7ve seal width |l§ll7E7X7 13 (07.05 — 0.05) 2.0 (0.08) Valve spring miengm 7 lN/EX ' 33.34 (1.313) 31.9 (1.25) l Rocker arm/ 1 Rocker arm |.D. IN/EX ' 10.000 — 10015103937 — 0.39473) 7 1010(03901 shell Rocker arm shaft 0.0. IN/EX ' 9.970 0. 7 ‘ Camshah Cem l'obe'heiéh’i ' ' IN ' 20.003 0 123107975 — 0.7922) V EX j 19,994 - 207.1174 (0.7072 A 0.791197 7 7 19.55717th7 7 7 TORQUE VALUES Cylinder head cover nut/cap nut 11 N-rn (1.1 kgftm, 8 let) Cylinder head rihl side cover bolt 9.8 Nrrn (1.0 kgf-rn, 7 lbfrfti Cam sprocket hall 8.5 N-m (0.9 kglrm, 6.5 Ith) CYLINDER HEADNALVES TOOLS Valve spring compressor Valve spring compressor mad» Valve guide reamer, 5.0 mm 07757-0010000 men! 07984-MA60001 ‘ 0795940030101 l or 07954vMA6000D (USA only) Valve guide driver, 5.0 mm Valve sealicuner, 24 mm (45°IN) Valve seal cutter, 205 mm (AS‘EX) 0794Z-MA60000 ‘ 07780-0010600 07780-0011000 l ‘ ’0 O l av equivalent commercially avail- or equivalent commercially avail- able in U.SiAi able In USA Flax Cutler. 21.5 mm (32°EX) Fla! cuner, 24 mm (32"IN) ‘ Interior cine, 22 mm (50°IN/EX) 077800012300 ‘ 077000012500 l 07780—0014202 l or equivalent commercially avail- or equivalent commercially avail» or equivalent commercially avail- able in U.S.Al able in USA. able In USA Cutter holder, 5 mm ‘ i 07781-0010400 or equivalem commercially avail- able in USA. '7-4 CYLINDER HEAD/VALVES TROUBLESHOOTING I Engine top-end problems usually affect engine periormance. These problem can be diagnosed by a compression test or by tracing engine noises to the top—end with a sounding rod stelhoscooe. - if the performance is poor at low speeds. check (or white smoke in the crankcase breather hose. It the hose is smoky check for a seized piston ring (page 3-5). Compression too low, herd starting or poor parlonnence at low speed - Valves: — Incorrect valve clearance — Burned or bent valve ~ Incorrect valve timing — Broken valve spring — Uneven valve seating - Cylinder head: — Leaking or damaged head gasket - Warped or cracked cylinder head - Warn cylinder, piston or piston rings (page 8-5) Compression too high, overheeting or knocking 0 Excessive carbon build-up on piston crown or on combustion chamber Excessive smoke - Cylinder head: ~ Worn valve stem or valve guide ~ Damaged stern seal 0 Worn cylinder, piston or piston rings (page 3-5) Exce e noise - Cylinder heed: — Incorrect valve clearance — Sticking valve or broken valve spring — Damaged or worn camshaft — Loose or worn cam chain — Worn or damaged cam chain — Worn or damaged cam chain tensioner (page 10-7) — Worn cam sprocket teeth — Worn rocker arm and/or shalt I Worn cylinder, piston or piston rings (page 8-5) Rough ldle - Low cylinder compression "1| CYLINDER HEAD/VALVES CYLINDER COMPRESSION Warm up the engine to normal operating tempera» ture Stop the engine and remove the spark plug [page 3» B). ' CQMPRESSION GAUGE Install a compression gauge. Shift the transmission in neutral and open the choke lever. Open the throttle all the way and crank the engine with the kickstarter until the gauge reading stops rising. COMPRESSION PRESSURE: 981 — |,l77 kPl [10,0 - 12.0 ligflcm‘, 142 — I71 psi) Low compression can be caused by: — Blown cylinder head gasket — Improper valve adjustment 4 Valve leakage — Worn piston ring or cylinder High compression can be caused by: 7 Carbon deposits in combustion chamber or on piston head CAMSHAFT REMOVAL Drain the engine oil (page 3'11) ' ‘ LEFT flex/ER Remove the lollowing: ' ’ - Valve adjuster hole caps [page 3-9) 7 Left crankcase Cover image 10-4) - Sealing bolt, tensioner spring and tensiener push rod to loosen the cam chain tensioner (page 10-6) Disconnect the spark plug cap, Loosen the cylinder head side cover 6 mm bolt. Tap the head of the 6 mm bolt and release the cylin- der head left side cover from the cylinder head. Remove the 6 mm bolt, sealing washer and cylinder head lelt side cover. Turn the crankshaft counterclockwise, and align the " O “ mark on the cam sprocket with the index notch on the cylinder head. Secure the Cam Remove the bolts cam sprocket and dowel pin. Mam mm a piece :7! wire in prevent ll from lie/ling mm me Cylinder DOWEL PIN 7-6 CYLINDER HEAD/VALVES Loosen the valve adjusting screw fully to make a valve clearance maxumum (page 340). Temporarily Install the cam sprocket bolts into the camshaft and remove the camshaft from the cylin- b der head while holding the rocker arms. INSPECTION Turn the outer vaces of the each camshaft bearing with your finger. b The outer race should turn smoothly and quletlv. Also check that the bearing inner race Ills tightly on the camshaft. Replace the camshaft assembly If the outer race does not turn smoothly and quietly, or if it fits loosely on the camshaft. Using a mtcrometer, measure each cam lobe height. ‘ SERVICE UMITS: IN: 1166 mm (0:174 in) EX: 19,65 mm (0,774 in) CYLINDER HEAD REMOVAL Remove the following: — MufflerlpageZ-Sl ~ Camshaftloage 776) Remove the Intake manifold bolts‘ L, Remove the O-ring. CYLINDER HEAD/VALVES R—'I Remove the lollowing: HEAD COVER CAPTJUTs/WASHE — Cap nuts/sealing washers — Nullsealing washers — Cylinder head cover 7 Sasha! Remove the cylinder head mounting boll and cylin- der head, Remove the vuuuwing- » Gasket r Dowel pins — Collar — O-ring O-RING/ COLLAR DISASSEMBLV Remove me spark plug (page 38). Remove the bolts and cylinder head ugh! sida COVBL RIGHT SIDE COVER Temporavily install a 8 mm bolt lo the rocker arm shah and remove the rocker arm shahs and rocker 6 mm boll ROCKER ARMS arms. I. ROCKER ARM SHAFI’S r .— ‘— 7-8 CYLINDER HEAD/VALVES m preve'v' ms of yen, n as nm comp'ess me valve sprmgs move than necessary zo remove me form’s Malk 51/113715 flu! mg msassembly so Ins-y can be placed mm m may ongma/ ’ucahons Anna aamagmg me 9.25m su/race Remove the valve spring comers using me special quls as shown TOOLS: Valve spring comprnssor 07757-001000!) VIIve spring compmssor attachment 07959‘KM30101 ATTACHMENT Remove [he Iollowmg: — Spring relainer STEM SEAL — Valva spnng — Valve 7 Valve sprung seal — Slem seal SPRING \ 0\ RETAINER SPRING SEAT INSPECTION cquuen HEAD Remove carbon deposils from me combustion COMBUSTION CHAMBER chamber. V. Check the spark plug hole and valve areas Ior cracks. Check the cylinder head for warpage with a slraight " edge and Ieeler gauge. 1! SERVICE LIMIT: 0‘05 mm (@002 In! 7-9 CYLINDER HEAD/VALVES 1/ Either ruckef arm ream/ES serwce or replacement mspecl me cam lobes for Scoring, Chipping or flat SDGIS ROCKER ARM/SHAFI’ Inspect the rocker arm slipper surIacas lor wear or damage. Also check that the all holes are not clogged. Measure the rocker arm LD. SERVICE LIMIT: IN/EX: 1010 mm [0398 In) Inspect the rocker arm shaft Ior wear or damage, Measure the O,D.oI the rocker arm shaftt SERVICE LIMIT: IN/EX: 9.91 mm [0.390 In) VALVE SPRING Measure the (res length of the valve springs SERVICE LIMIT: lN/EX: 31.8 mm (1.25 In) Replace the springs it they are shorter than the ser- vice limit. VALVE inspect each valve [or bending, burning or abnor~ mal stem wear, Check valve movement in the guide. Measure and record each valve stem O.D‘ SERVICE LIMIT: IN/EX: 4‘92 mm (0,134 in) 7-10 name the salve seats whenever the valve gdeS are replaced wage z m L, Do not use a rural Io near me cvlmder 71930, It may cause wam'ng CYLINDER HEAD/VALVES Ream the guides to remove any carbon deposits belore measuring the guide. Insert the reemer from the combustion chamber side of the head and always rotate the reamer clock- Wise. TOOL: Valve guide rumor, 5.0 mm VALVE GUIDE REAMé‘n OTMMAWOM or 07384-MA60WD [USA only) Measure and record each valve guide LD. SERVICE LIMIT: IN/EX: 5.03 mm (0.198 in) Subtract each valve stem OD. Irom the correspond- ing guide ID. to obtain the stem-to-guide clearance. SERVICE UMITS: W: 0.” mm (0.003 in) EX: 0.10 mm (0.004 it the stem‘to-guide clearance is out at specification, determine il a new guide with standard dimensions would bring the clearance within tolerance. It so. replace any guides as necessary and ream to tit II the stemvtmguide clearance is out at specification with a new guide, also replace the valve. VALVE GUIDE REPLACEMENT Chill new valve guides in the Ireezer section at a refrigerator tor about an hour. Heat the cylinder head to 212 — 302 "F [100 ~150 C) with a hot plate or even. VALVE GUIDE DRIVER Support the cylinder head and drive out the valve guides out of the cylinder head from the combus- tion chamber side. TOOL: Valve guide driver. 50 mm omz-Mnmoo Coat new O-rings With engine oil and install them onto new valve guides. While the cylinder is still heated, drive the new guides m the cylinder head from the camshaft side until they are Iully seatth TOOL: Valve guide driver, 5.0 mm (Wm-MAW Let the cylinder head cool to room temperature. 7-11 CYLINDER HEADNALVES Ream the new valve guide after installation. Use cumng all on Insert the reamer from the combustion chamber VALVE GUIDE REAMER the learner dullng side of the head and always rotate the rumor clock» mls opererlon wise, TOOL: Valve guide rumor, 5.0 mm 07984-MA800M or 07984-MA80000 (U.S.A. only) Clean the cylinder head thoroughly to remove any metal particles. Relace the valve seat (page 7-12). VALVE SEAT lNSPECTlON/REFACING Clean the intake and exhaust valves rhoroughly to .— remove carbon deposits. - flAND'LAEING 790'” Apply a light coating of Prussian Blue to the valve seat. Lap the valves and seats using a rubber hose or other hand-lapping tool. The valves Cdnllfll Remove and inspect the valves. “9 37W“ "3 “M Inspect the width 0! each valve seat. 3:9 is nulned DI badly me or ll ll SIANDARD: 1.0 - 1.3 mm [0.04- 0.05 in) 59"”‘3’5 1’19 595' SVICE LIMIT: 2.0 mm (0.0! in] ‘ unevenly lap/ace me valve ii the seat is tau wide, too narrow or has low spots, the seat must be ground. f I I 1.0 ~ 1.3 mm (0.04 — 0.05 in) VALVE SEAT REFACING a - Follow the retacing manufacturer‘s operating instructions. - Be careiul not to grind the seat more than neces- say. ‘ 450 G ‘V \ » ’ . :7 3m 32: v 60' 7-12 Use a 45‘ sear euner to remove any roughness or irregularities from the seal. TOOLS: Seat emf. 24 mm (45: IN) 077000010600 Sen cutter, 20.5 mm (45: EX) OHIO-0011000 Cm holder, 5 mm 077810010400 or equlvnlem comm-"idly mil-III- In U.S.A. Use a 32" or 30C cutter to remove rhe lap 1/4 oi the existing valve seer material. TOOLS: FII! cuttlr, 24 mm (32" IN) 077000012500 Flat tuner. 21.5 mm (32" EX] 0770043012000 Cuner holder, 5mm 07701-001040!) er equiv-lent eommueilllv Ivuillhlo In U.S,A. Use 3 60C curler, remove 1/4 oi me existing valve seat material. TOOLS: Interior armor, 22 mm (60: IN/EX)07700-0014202 Cutter holder, 5 mm 07101-001040!) or equIv-lent commemillly avail-bl. in USA. Using a 45“ seal cutter, our the see! to the proper width. VALVE SEAT WIDTH: 1,0 — 1.3 mm (0.04 — 0.06 In) Make sure that all pitting and irregularities are removed. CYLINDER HEAD/VALVES ROUGHNESS i OLD SEAT WIDTH OLD SEAT WIDTH 1.0713 mm \ (0.04 — 0.05 in) 7-13 CYLINDER HEADNALVES Excess/vs lapplng pressure may deform or damage MS SEE! Do not allow lapping cam- Bound IO ENE! I’VE If the contact area is too high on the valve, the seat must be lowered using a 32“or 30“ flat cutter. CONTACT T00 HIGH OLD SEAT If the Contact area is too low on the vaIve, the seat VIDTH , must be raised using a 60“ interior cutter. ’ 30a/ 32a ’ L CONTACT TOO LOW OLD SEAT WIDTH -’ U L 5°“ After cutting the seat, apply lapping compound and engine oil to the valve lace, and lap the valve using g LAEPING 1.9% A light pressure. Change the angle of lapping tool frequently to pre- vent uneven seat wear. guides After lapping, wash all residual compaund off the cylinder head and valve‘ ASSEMBLY CYLINDER HEAD RIGHT SIDE COVER ‘ 9.8 Ni“ (1.0 kgi‘m, 7 lbivfti ROCKER ARM SHAFT W SPRING SEAT STEM SEAL a’ ROCKER ARM 8’ V GASKET g n1 Q & VALVE GUIDE VALVE SPRING SPRING RETAINER VALVE COTTEFlS CAMSHAFI’ 7-14 CYLINDER HEAD/VALVES Clean the cylinder head assembly with snlvenr and VALVE blaw through all oil passages with compressed air. g STEM SEAL I f : Install the valve spring seats. Install new stem seals. Lubricate the valve stems with engine oil and insert SPRING the Valve into the Valve guide. To avoid damage to the stem seal. turn the valve slowly when inserting, Install the valve springs with the tightly wound coils . facing the combustiun chamber, Install the valve spring retainers. \ RETAINER SPRING SEAT Toprevenllass 0/ Install the valve Cutters using the special tool as (Miran. no nor shown. compress the valve spnng more man TOOLS: Necessary Valve spring compressor 07757-0010000 Valve spring compressor attachment 07959-KM30101 ATTACHMENT VALVE SPRING COMPRESSOR Supnon‘me cv/m» Tap the valve stems gently with two plastic ham— der head above me mars as shown to seat the valve cotters firmly. work bench so ma: the valve heads wrll no! cunracr anyr (lung that cause damage Apply engine oil to the rocker arm inner and slipper surfaces. Install the rocker Install the rocker arms and rocker arm shafts. arm shah mm It: threaded end (early the ngm srde $ [ROCKER ARM 5i frs 7-15 CYLINDER HEAD/VALVES Install a new gasket unto the cylinder head right side cover. RIGHT SIDE COVER Install the right side cover onto the cylinder head. v GASKET Install the right side cover bolts to the specified BOLTS torque. TORQUE: 3‘8 Nrm [LO kgltm, 7 let) RIGHT SlDE COVER INSTALLATION Clean off the gasket material from the cylinder sur- MATING SURFACE lace. J Install the folluwing: 7 New Orring — Collar 7 Dowel pins — New gasket GD ‘4 O-RING/ COLLAR 7-16 L CYLINDER HEAD/VALVES lnsla/l the cvllnder NEEU cover with us arrow mark ramg {10mm Route the cam chain through the cylinder head and install the cylinder head. . at GASKET v ~ . 4f Install a new gasket onto the cylinder head and then ‘ install the cylinder head cover. HEAD COVER ARROW install the following: CAP NUTS — Cap nuts/new sealing washers - NuUnew sealing washer 0 Note the position oi the washers and nuts. Tighten the cylinder head cover nuts to the specified torque. TORQUE: 11 Na!“ (1‘1 kgflm, 9 Ith) install and tighten the cylinder head mounting bolt. It the cylinder was removed, tighten the cylinder a mounting bolt. v COPPER WAsHER NUT/SEALING WASHER Install a new O-ring into the groove in the intake maniiold. Install and tighten the intake manifold bolts. install the lollowmg: 7 Spark plug [page 38) — Muffler [page 2-5) — Camshaft (page 7-18) 7-17 CYLINDER HEAD/VALVES CAMSHAFT INSTALLATION Apply clean engine oil to the camshaft lobes and .7! CAM SHAFT‘ } bearings. Install the camshaft intn the cylinder head with its cam lobes facing the combustion chamber while holding the rocker arms. Turn the crankshaft counterclockwise and align the "T" mark on the flywheel with the index notch on the left crankcase. Install the dowel pin and cam sprocket. Install the cam spracket with its " O “ mark with the index notch on the cylinder head. Install and tighten the cam sprocket bolts to the specified torque. TORQUE: 3.8 MM (03 kgf‘m. 6.5 "3"!) DOWEL PIN Install the cylinder head left side cover onto the cyl- inder head with a new gasket. LEFT 5'“ COVER V GASKET 7-18 CYLINDER HEAD/VALVES Set the tab on the side cover against me left side 0! I“ ‘ the stopper on the cylinder head. §EAUNG ASHER ’9 (I: LEFT SIDE COVER Install the 6 mm bolt with a new sealing washer into the cylinder head and tighten it. Tighten lhe two light side cover bolts it the cylinder head was disassembled. TORQUE: 9‘8 Min (to kgl-m, ‘l let) Install the spark plug cap. Install the tansioner push rad, spring and sealing bolt (page 10-7). Adjust lhs valva clearance (page 3-10). Pour the Iecommandsd engine oil (page 3‘1 l ), SEALING BOLT 7-19 8. CYLINDER/PISTON COMPONENT LOCATION ........................... I. 3.2 SERVICE INFORMATION ............................ .. 3.3 TROUBLESHOOTING .............................. .. 3.3 CYLINDER REMOVAL ................................. ,. 3.4 plSTON CVLINDERIPISTON INSPECTION ............... as n PISTON INSTALLATION .............................. “3.3 CYLINDER INSTALLATION .......................... “3.3 8-1 CYLINDER/PISTON COMPONENT LOCATION 9‘3 N-m (1‘0 kgl-m, 7 Ile) CYLINDER/PISTON SERVICE INFORMATION GENERAL I The cylinder and piston service can be done with the engine installed in the frame. I Camshaft lubrication oil is fed to the cylinder head through an orifice in the cylinder head, cylinder and crankcase. Be sure that this orilice is not clogged and thal the O-rings and dowel pins are in place beiore installing the cylinder, SPECIFICATIONS Unit: mm (in) ITEM ’ STANDARD ' 1 52111110: um‘r’ ylmder ’7 (.0. T' ’ 7*39005 - 39.01fifi56 71.5350) 39.05 (1.537) ‘ j @Lround T ‘ ' ' ~ ' 0.1010004) T 7Taper 7 010 (0.004) 7 V Warpage 7 7. V — 0.05 (70002) i Piston, pis- ton mark direction "N mark iacinaEw’rd the intake side - ‘ ton rings tori 0713. 7 T ’ ' ’ 975'— 313.995(115344—1T5'352) 1 73.5.00 (1.531) [ Piston 0,0. rneestirement point is mm (0.3 in) iro7r7n bottom o7l skin 7- ( Piston pin bore (.0. 13.0702 — 1100805119 — 0.5121) V173.05(0.514) 7 ‘ giston pin 0.13. 12.994 413.000(0.511 0.5110) 12.90 (0.511) 77 Piston-to-piston pin afirfi’ ' 0.002: 1010 (0.0001 — 0.0005) ’ 70700 (0.003) Piston ring-to-ring Top/Second 0.015 » 0.050 (0.0005 - 0.0020) v0.12 (0.005) QIOOVS clearance . I’iston ri’nfi end fifOfiODII gap T 0.5 (0.02) l 1.1 (0:04) 7 7 7 iston cEaniflm’ 7 7 7 0.010 — 0.040 (00004 - 0.0016) ‘7 0.15 (0.000) Connecting rod small endl 13.016 — 13.034 (0.5124 — 05131) 713 08 (0.515) 1' Eflnectindrod-to-piston pin cifiw’nce’ : LOIS — 0.040 (0.0006 — 0.0015) T7 04 2 9.0075) TORQUE VALUE Cam chain guide roller pin bolt 9.0 NM (1.0 kgi-m, 7 Ith) TROUBLESHOOTING I if the performance is poor at low speeds, check Ior white smoke in the crankcase breather hose. if the hose is smoky, check for a seized piston ring. Cylinder camproulon is too low. or engine in hard to start I Blown cylinder head gasket - Worn, stuck or broken piston ring I Worn or damaged cylinder or piston Cylinder compression is too high. or angina overheats or knocks 0 Carbon deposits on the cylinder head and/or piston crown Piston sounds I Worn cylinder, piston and/or piston ring - Worn piston pin hole and piston pin I Worn connecting rod small end Excessive unqu - Worn, stuck or broken piston ring CYLINDER/PISTON CYLINDER REMOVAL Remove the cylinder head (page 7-7). Remove the cam chain guide roller pin boll, sealing washer and guide roller. Remove the mounting bolt and cylinder. GUIDE ROLLER Ramcva the following: — Rubber packing - Gasket — Dowel pins PISTON REMOVAL Do NOV lei me DlS Remove the pistan pm clip wnh pliers. PEN ‘ l r l/ , . . {mu/Mm 5 mm Press the piston pin out 0' the piston and remove my crankcase . Ihe piston. Donor damage the Remove the piston rings. nrslvn rings during removal 8-4 CYLINDER] PISTON CYLINDER/PISTON INSPECTION Inspect the cylinder bore tor wear or damage. Measure the cylinder ID. in X and V axis at three levels. Take the maximum reading to determine the cylin- der wear, SERVICE lJMIT: 39.05 mm (1.537 in) Calculate the pistoniorcylinder clearance, Take a maximum reading to determine the clear- ance. Reler to page 86 lor measurement at the piston 0D. SERVICE UMIT: 0.15 mm (0.006 in] Calculate the taper and out of round at three levels m X and Y axis. Take the maximum reading to determine them, SERVICE LIMITS: TOP Taper: 0.10 mm (0.00! in) l Out 0! round: 0.10 mm (0.004 in) The cylinder must be rebored and an oversize pis» tun lined it the service limits are exceeded MIDDLE Yhe lollowing oversize pistons are available: 025 mm (0.010 in) 0.50 mm (0.020 In) The piston to cylinder clearance lor the oversize pis- ton must be: 0,010 - 0.040 mm (0.0004 7 0.00I6 tn). Inspect the top of the cylinder for warpage. SERVICE LIMIT: 0.05 mm (0.002 In) Remove any carbon deposits from the piston nng grooves, using an old piston ring as shown. CYLINDER/PISTON Temporarily install the piston rings to their proper pasition with the mark facing up. Measure the piston ring-to-ring groove clearance with the rings pushed into the grooves SERVICE LIMITS: Yep: 0‘12 mm (0.005 in) Second: 0.12 mm (0,005 in) Inspect the piston Ior wear or damage, Measure the diameter 0' the piston at 8 mm (0.3 in) from the bottom at skirt and 90 degrees to the pis- ton pin hole. SERVICE LIMIT: 33.90 mm (1531 in) 8 mm (0.3 in) Measure the piston pin bore. SERVICE LIMIT: ‘106 mm (0514 in) Measure the 0.0. ol the piston pin. SERVICE UM": 12,98 mm (0.511 in] Calculate the piston-to-piston pin clearance. SERVICE LIMIT: om lllm (0‘00! in) 8-6 CYLINDER/PISTON Push the VlVIgS mo ME cylinder Wllh me lop a! me ms ran in he sure they are square/v m me CV/llrdt’l Measure the connecting rod small and LD SERVICE LIMIT: 1108 mm (0515 in) Calculate the connecting rod-to-pistan pin clear- ance. SERVICE UMIT: 0.12 mm (0.0M in] Insert the piston ring squarely into the bottom of the cylinder and measure the ring and gap. SERVICE UMITS: Top: 0.5 mm (0.02 In) Second: 05 mm I002 lnI Oil (side ml): 1.1 mm I0.“ in) PISTON RING INSTALLATION Clean the piston ring grooves thoroughly and install ' the piston rings. - Apply on to the piston rings. - Avoid piston and piston ring damage during installation. - Install the piston rings with their marking Iacing TOP “me up. - Do not conIuse the top and second rings. ‘. Space the piston ring and gaps I20 degrees apart ECOND FHNG Do not align the gaps in the oil rings (side rails]. After installation, the rings should rotate freely in the ring grooves. SPACER l l OIL RINGS 8-7 CYLINDER/PISTON PISTON INSTALLATION Clean oft any gasket materials from the crankcase WAGE su dace. Apply oil to the piston pin outer surface. Install the piston with its "IN" mark facing the intake side. Install the piston pin and secure it with new piston pin clips. 0 Do not align the piston pin CleS and gap with the piston cut-out. 0 Do not let the piston pin clips Ialt into the can- kcaset CYLINDER INSTALLATION Apply engine oil to a rubber packing, Install the dowel pins, new gasket and new rubber pecking. Coat the cylinder bore, piston outer suflace and pis- ton ring grooves with clean engine oil. Route the cam chain through the cylinder and install the cylinder while compressing the piston rings. I Avoid piston ring damage during installation. ' Do not let the cam chain Ia“ into the crankcase. GASKET \. s! CYLINDER CAM CHAIN Tlgnlen me my» as: mnlmnnq Dmv afier mslalmg me cvllndm Head Apply engine oil to the guide roller inner surface. Install the cam chaln guide roller, new sealing washer and pin boltl Tighlen the cam chain guide roller pin bolt to the specified \urque. TORQUE: 9.8 N-m (1.0 kgf-m, 7 let) Install the cylinder mounting bolt but do no! tighten it yel. Install the cylinder head (page 746). ‘, CYLINDER/PISTON r 0 QLIN'G WASHER v —— 9. CLUTCH/GEARSHIFT LINKAGE COMPONENT LocA‘nou ........................... .. SERVICE INFORMATION ........................... “ TROUBLESHOOT|NG .................................. n RIGHT CRANKCASE COVER REMOVAL-"~- 9-2 9-3 9-4 9-5 GEARSH|FT L|NKAGE ................................ “9.15 RIGHT CHANKCASE COVER INSTALLATION .......................................... “9.19 9-1 CLUTCH/GEARSHIFT LINKAGE COMPONENT LOCATION 17 N-m (1.7 ngm, 12 Ibf-ft) 13 N-m (1.3 kgf‘m. 9 Ibl-fl) % 42 NM (43 kgf-m, 31 Ith) 9-2 CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION GENERAL ' This section covers service of the clutch and gearshift linkage. All service can be done with the engine installed in the frame. I Use care not to allow dust or dirt to enter the engine. SPECIFICATIONS m W W 7 7" Unit: mmilinl :7 ITEM STANDARD l SERVICE LIMIT ‘ Clutch disc thickness l A 2.52 — 2.639993: 9,106) l 7 B 3.327148 (0,131 ~0.137) l CLICII plate warpage _ 7 — ntriiugal clutch spring Irea length 22.4 (0.88) V 4 19 4 (076) Primary drive gear Lu 7 7 _ 21.000 — 21:0 8276) 210 (70.71an Clutch center guide I.D. 16.988 — 17.005 ((15688 — 0.66%?) ' 17.04 [0.671) ‘ _ CD. 7 @930 — 20.950 (0.8240 v 08248) 20.90 (0.823) ‘ Crankshaft 0.0. at clutch centgrggide 16966 —16.984(o,6530 — 05637) W 7716:90 [0.656) 77 fl TORQUE VALUES Clutch outer cover screw 4.4 Mm (045 kgf-m, 3.3 lbf-ft) Clutch lock nut 42 Nrm (4.3 kgI-m, 31 lbirft) Clutch assembly screw 5‘9 N~m (0,6 kgim, 4.3 Ithl Shift drum stopper arm bolt 13 Nm (1.3 kgl-m, 9 ibf-fl) Shift return spring pin bolt 29 N-m (3‘0 kgl-m,221bf-l‘t) Gearshift cam plate bolt 17 N-m (1.7 kgI-m, 12 Ibf-ftl TOOLS 7 L700; nut wrench, 20 x 24 mm Extension bar Flywheel holder 07715-0020100 07716-0020500 07725-004000!) flar} ‘n’ Lli l , / l' w 7'; , / l \:\_////' um t// l \ »y or equivalent commercially avail» l or equivalent commercially avail- able in USA. able in U.S,A, ,,7,, i 9-3 CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Clutch slips when accelerating I Incorrect clutch adjustment I Worn clutch disc I Weak clutch springs I Faulty clutch weight I Transmission nil mixed with molybdenum or graphite additive Motorcycle creeps with clutch disengaged I Incorrect clutch adjustment I Clutch plate warped ' Faulty CIUlCh lifter I Faulty clutch weight I Incorrect engine oil weight Hard to shift I Incorrect clutch adjustment I Loose stepper plate belt I Damaged stopper plate and pin I Damaged gearshift spindle Transmission jumps out 0' gear I Worn shift drum stopper arm I Weak or broken shift arm return spring - Loose stopper plate bolt Ganrshlft pedal wlll not return I Week or broken gearshin spindle return spring I Eant gearshift spindle 9-4 CLUTCH/GEARSHIFr LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3711). Remove the footpeg bar [page 6-4). Remove the bolt and kickstaner pedal. Unhook the brake pedal return spring. Loosen the rear brake pedal adjusting nut and lower me brake pedal. Remove the eigm bolts and right crankcase cover. Remove the gasket and dowel pins. Remove the clulch adiusting nut, washer and 0 mTIwASHER/ORING ringr r Remove the clutch lifter/adjusting bolt assembly/4 CLUTCH LIFTER/ADJUSTING Boll 9-5 CLUTCH/GEARSHIFT LINKAGE Check me kickskaner oil seal for damage, replace if necessary CLUTCH REMOVAL ‘J Remove the right crankcase cover (page 9-5). BALL RETAINER Remove the ball retainer and spring. Remove the clutch lifter lever. Remove the oil (hrough and sprig. Remove the clutch liher cam pla‘ev Remove the screws and clutch outer cover and bearing. VJ ‘ Q I .3 " a y, ‘ ,_ , CLUTCH OUTER COVER/BEARING 9-6 CLUTCH/GEARSHIFT LINKAGE Straighten the rab of the lock washer. Hold the clutch ouler will] the flywheel, holder and FL—YWPEL HOLE remove rhe lock nu! uslng the speclal tools as 7 shown. ‘ TOOLS: Flywheel holder 077250044X!” (Equivalent cam- mercillly IvailahIe in USA.) Lock nu! wrench, 20 x 24 mm 077160020100 Extension bar 07716-0020500 (Equivalent com- p“! Iyavnilahle V ‘ "‘U'S’A" aTENSIONBAR V i 0 Remove the lock washer E, 14 mm lock washer and 14 rm"; L'OCK WASHER . clutch assemblvr , .3A r’ ,, s |Locr< WAergEj Bi? \ \.. ’ Remove the primary drive gear. 9-7 CLUTCH/GEARSHIFI' LINKAGE Remove the clutch center guide. CLUTCH CENTER GU|DE Remove the snap ring and primary driven gear irom I’SNAP MW - the mainshaft. ' Remove the collar from the crankshaft. DISASSEMBLY Remove the following: « Set ring — Clutch plate E ~ Clutch disc A — Clutch disc 5 4 Clutch disc A — Free springs — Clutch plate A Remove the clutch center and dnve gear outer. CLUTCH CENTER DRIVE GEAR OUTER 9-8 CLUTCH/GEARSHIFI' LINKAGE Remove the {our damper springs. Remove the four screws and plain washers, SCREWS, WASHERS DAMPER SPRINGS Remove the drive plate assembly and clutch swing; DRIVE PLATE ASSEMBLY CLUTCH SPRINGS Remove the clutch weight stopper ring. Remove the clutch weight/center ring. CLUTCH WEIGHT/CENTER RING STOPPER RING INSPECTIO N clutch lifter bearing Turn the inner race of the lifter bearing with your finger. The bearing should turn smoothly and freely with- out excessive play. Also check that the bearing [its tightly in the clutch outer cover. Replace the bearing if necessary. BEARING 9-9 CLUTCH/GEARSHIFT LINKAGE Clutch spring Measure the clutch spring free length. SERVICE LIMIT: 19.4 mm (0.76 in) Clutch disc Replace the clutch discs if they show signs of scor~ ing or discoloration. Measure the disc thickness of each disc. SERVICE LIMITS: clutch dlsc A: 2.3 mm (0.03 in) Clutch dist: B: 3.0 mm (0.12 In] clutch plats Check each disc plate (or warpage on a surface plate using a feeler gaugel SERVICE LIMIT: 0.20 mm (0.000 in) Primary drive gear/clutch center guide Check the primary drive gear and clutch center guide for excessive wear er damage. Measure the I.D.0I Ihe primary drive gear. SERVICE IJMIT: 21.05 mm ID. inI Measure the OD. and LB. 07 the clutch center guide. SERVICE UMITS: I.D.: 17.04 mm (0.671 in) 0D,: 20.90 mm (0.823 in) C C C 9-10 CLUTCH/GEARSHIFI' LINKAGE Crnnluhafl Measure the crankshaft CD. at clutch center guide. SERVICE UMsz 1630 mm (0.665 in) Drch gear amarlclu‘ch center Check the drive gear outer and clutch center for excessive wear or damage. CLUTCH CENTER DRIVE GEAR OUTER ASSEMBLY CLUTCH SPRING STOPPER RING CLUTCH WEIGHT/CENTER RING DRIVE GEAR OUTER FREE SPRING ‘Zmo ‘: CLUTCH DISC A I CLUTCH PLATE 3 _ _ ,. : CLUTCH OUTER DR|VE PLATE CLUTCH CENTER CLUTCH PLATE A CLUTCH DISC B SET RING 9-11 CLUTCH/GEARSHIFT LINKAGE Install the clutch weightlcenter ring unto the drive plate by aligning the ring end with the plate hole. CLUTCH WEIGHT/CENTER RING Install the stopper ring by aligning the ring end with the plate groove. I STOPPER RING Install the clutch springs onto the clutch outer holes. Install the drive plate assembly into the clutch outer DRIVE PLATE ASSEMBLY alignan Its bosses With the clutch sprlngs- SPRINGS Install the plain washers and screws. Tighten the screws in a crisscross pattern in 2-3 steps. TORQUE: 5.9 MM (0.6 ltd-m. 4.3 let] Install the damper springs as shown SPRINGS 9-12 Install the drive gear outer and clutch center. install the following: 7 Clutch plate A — Free springs — Clutch disc A — Clutch disc 8 — Clutch disc A ~ Clutch plate 3 Install the clutch disc A with its flat surface facing the clutch disc E, Install the clutch plate 8 with its chamfered side lacing the clutch disc A. install the clutch set ring with its chamlered side facing the clutch plate 8. CLUTCH/GEARSHIFI' LINKAGE DRIVE GEAR OUTER CLUTCH CENTER SPRINGS SET RING 9-13 CLUTCH/GEARSHIFT LINKAGE INSTALLATION Install the collar onto the crankshaft. Install the primary driven gear onto the mainshal‘t f and secure it with the snap ring. DRIVEN GEAR Apply engine oil to the clutch center guide and w install it onto the crankshaft. ' "7. EL—UTCH CENTER Gum? ' I Install the primary drive gear, Install the clutch assemny onto the crankshaft. Install a new I4 mm lock washer by aligning Its short tabs With the grooves in the drive plate. I? 14 mm LOCK WASHER 9-14 CLUTCH/GEARSHIFT LINKAGE Install the lock washer B with its “OUT SIDE“ mark lacing out. w” SIDE“ MARK 5 Us A. Locrw/Ae‘EnZ‘AO Install the lock nut. FWWpEL HOLDER Hold the clutch outer with the flywheel holder and tighten the lock nut to the spentiied torque using the special tools as shown. TOOLS: Flywheel holder 07725-004000!) (Equivalent com- melcielly Iveillble in USA) Lock nut wrench, 20 x 24 mm 077160020100 Extension bar 077160020500 (Equivalent com- mercially available in USA) TORQUE: 42 Mm (4‘3 kgl‘m, 31 IM-R) If the lock nut groove does not align with the lock washer tab, further tighten the lock nul and align. Bent up the tab of the 14 mm lock washer into the groove of the lock nut. Clean the inside of the clutch outer and outer cover (page 342]. Install the bearing and a new gasket onto the clutch v outer cover. 9-15 CLUTCH/GEARSHIFI' LINKAGE Install the clutch outer and lighten the screws to the U specified rorque. , TORQUE: 4.4 Mm (015 kgf‘mAJ lM-fl) Insrall the clurch liner cam plate. lns‘all the oil through spring and ml through. Install the spring, ball retainer and clutch lifler lever. Insrall (he righr crankcase cover (page 94m .76 I r - — e' n LIFTER LEVER BALL RETAINER GEARSHIFT LINKAGE REMOVAL Remove the clurch and primary driven gear (page 9- ' plNCH 30L? 6). , V I! sl‘a C/ean ma gsarshr/l Remove the plnch boll and gearsmft pedal. spmd/s end to m» van! (1!!! "l7!" emer- mg m crankcase GEARSHFT PEDAL T I d m CLUTCH/GEARSHIFT LINKAGE Remove Ihe boll, stopper arm and return springv BO LT Pull down the gearshift arm, men pull am the gear- shifl spindle from the crankcase. _GESHIFr sags Remove the boll and shift cam plate. Remove the dowel pins and gearshifl drum pins. '4 9-17 CLUTCH/GEARSHIFI' LINKAGE INSPECTION Check the gearshift spindle far bands or other dam- age. INSTALLATION Install the four gearshift drum pins and two dowel ‘ 0 pins. : Install the cam plate by aligning the pin hole with . Am“ the dowel pins and aligning the drum pin with the dent. Install the cam plats and tighten the bolt to the spec» ified torque. TORQUE: 17 Min (1.7 Ital-m,” Ibfltl Install the gearshift spindle into the crankcase by aligning the return spring ends with the spring pin while pushing down the gearshift arm and set the gearshift arm to the shift drum pins. ». n 4 » GEARSHFT SPINDLE 9-18 CLUTCH/GEARSHIFT LINKAGE lnstall the return spring and stopper arm as shown and tighten the bolt to the specified torquet TORQUE: 13 MM (1.3 Ital-m3 IhI-It) Install the gearshlh pedal so that it is same height as the Ioutpeg. Install the pinch bolt and tighten it. Install the primary driven gear and clutch assembly (page 9-16) PEDAL RIGHT CRANKCASE COVER INSTALLATION Install the clutch lifter plate/adjusting bolt into the right crankcase cover by aligning its pin with the hole in the crankcase covert CLUTCH LIFTER PLATE/ADJUSTmG BOLT Coat a new O-ring with engine oil and install it into the cover gram/e properly. Inslall the washer and lock nutt WASHER 9-19 CLUTCH/GEARSHIFT LINKAGE Install the dowel pins and a new gasket. Install the right crankcasa cover. Install and tighten the eight cavet bolts in a criss~ cross pattern ssveral steps. Install the kickstartet pedal as shown and tighten the bolt. Hook the return spring to the brake pedal and staring holding pin as shown, Install the footpeg her [page 6-6). Adjust the brake pedal free play (page 3-16). Pour the racammanded engine oil (page 341). Adiust the clutch (page 3-17). RETURN SPRING - 9-20 10. ALTERNATOR/CAM CHAIN TENSIONER L COMPONENT LOCATION ------------------------ -- 10-2 FLVWHEEL/STATOR REMOVAL --------------- ~-10-4 k4 SERVICE INFORMATION 10.3 CAM CHAIN TENSIONER .......................... "10.5 TROUBLESHOOTING -------------------------------- .~ 10-3 STATORIFLVWHEEL INSTALLATION 104: m 10-1 ALTERNATOR/CAM CHAIN TENSIONER COMPONENT LOCATION 16 N‘m (1.6 “Mn. 12 Ibl-fl) ALTERNATOR/CAM CHAIN TENSIONER SERVICE INFORMATION GENERAL I This section covers service of the flywheel, alternator and cam chain tensioner. All service can be done with the engine installed in the frame. - Refer to 14-3 (or alternator stator Inspection. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cam cham tensioner Push rod CD. > 11.97875;1g.000(0.47£3;0:17724l [0.470) 7 Sprinflee length 77111.3 (4.38) 100 (3.9) TORQUE VALUES Flywheel nut Cam Chain tansionar sealing bolt Cam chain tensioner pivot bolt TOOLS Universal holder 0772541030000 TROUBLESHOOTING Excessive engine noise I Worn or damaged cam chain tensioner 41 N-m (4.2 kgf—m, 30 lbI-II) 23 Nm (2.3 kgi-m,17lbI-ft) 16 NM (1.6 kgf-m, 12 Ibf-ftl Flywheel puller 07833-GE00000 (Not available in U.S.A,) or 07933-0010000 USA. only - Weak or damaged cam chain tensioner spring Loose cam nlllin I Weak or damaged earn chain tensioner spring - Improper push rod operation 1 0-3 ALTERNATOR/CAM CHAIN TENSIONER FLYWHEEL/STATOR REMOVAL Drain the engine on (page 3‘11). Disconnect the alternator and Ignition pulse genera- tor connectors. ALTERNATOR/IGNITION PULSE GENERATOR CONNECTOR Remove the bolt and gearshift pedal. Remove the three bolts and left crankcase cover Hold the flywheel usmg the universal halder and remove the flywheel nut TOOL: Universal holder 077250030000 Remove the washer. \ .i ' LfllXERSAL HOLDER 1 0-4 ALTERNATOR/ CAM CHAIN TENSIONER Remove [he flywheel using the special loo]. FLYWHEEL TOOL: ' Flywhul puller DNSJGEWOOO (Not available in U,S,AJ or Flywheel puller 0793341010000 (U.S.A. ONLY) Remove the woodrufl key. Remove the boll and wire clamp. Release the wire grommet lrom the crankcase groove. Remove the ignilion pulse generator mounting bolts and wrre clamp. Remove lhe stalur mounting bolls. Remove me Ignition pulse generalor and stator as an assembly. I! WOODRUFF KEV: . .‘ 1 0-5 ALTERNATOR/CAM CHAIN TENSIONER Remove the screws and slate! base, Remove the O-rings from me crankcase Remove the O-rings hum the stalor base. CAM CHAIN TENSIONER REMOVAL Remove the stator base (page 10-4). Remove the sealing boll washer, lensioner spring and push rod. Remove the pivol boll. tensioner arm and tensioner roller, ‘ / . ITENSIONER ARM 10-6 ALTERNATOR/CAM CHAIN TENSIONEFI INSPECTION Measure the tensioner spring Iree length. SERVICE LIMIT: 100 mm (3.9 in) WVWV Check the push rod (or wear or damage. Measure the push rod 0.0. SERVICE UMIT: 11.34 mm (0.470 in) INSTALLATION Install the cam chain tensionsr roller. tensioner arm and pivot bolt. Tighten the [)1th bolt to the specified torque. TORQUE: 16 Nam [1.6 “1m, 12 thII Check the sealing washer is in good condition, replace if necessary. Install the SUN/1g with the tapered Install the push rod, spring, washer and sealing bolt. side facmg the push Tighten the sealing bolt tn the specified torque. “7" TORQUE: 23 NM (2.3 kgf-rrt, 17 lbI-h) SPRING BOLT/WASHER 10-7 ALTERNATOR/CAM CHAIN TENSIONER Remove the crankcase sealing bolt and washer. Fill the push rod with l~ 2 cm] of engine oil through the filler hale. Check the sea|ing washer is in good condition and install the sealing washer and bolt. Tighten the bolt securely, STATOR/ FLYWHEEL INSTALLATION Check the stator base oil seal lor damage, replace it necessary. Apply engine oil to the lip oi the oil seal. Apply engine oil lo new O-rings, install them into the crankcase grooves Apply engine oil to new Owing. install it into the sla~ tor base groove. Secaremlnalm Install the slalar base and lighten the screws damage we on seal securely. ups 1 0-8 ALTERNATOR/CAM CHAIN TENSIONER Install the ignition pulse generator and stator as an assembly. Install the ignition pulse generator mounting bolts and wire clamp. Install the stator mounting bolts 4 ! \- ‘w; v: k IgNITlON PULSE ENERATDR Set the wire grommet into the crankcase groove. Install the wire clamp and tighten the bolt. Clean any oil from the tapered portion of the crank- shaft and flywheel. Install the woodrufi key into the crankshaft gmovet Install the flywheel by aligning the key way In the flywheel with the woodruff key on the crankshaft Install the washer. 10-9 ALTERNATOR/CAM CHAIN TENSIONER Install the flywheel nut. Hold the flywheel using the universal holder and tighten the nut to the specified torque. TOOL: Universal holder 07725-0030000 TORQUE: 41 MM (4.2 kgf-m, 30 let) Install the left crankcase cover and tighten the three bolts. LEFT CRANKCASE COVER » GEAfiSHFT PEDAL PlNCH Eon ' "’5 m ""67 Install the gearshift pedal so that it is same height as the iootpeg. install the pinch bolt and tighten it. Connect the ignition pulse generator and alternator connectors. ALTERNATOR/lGNiTION PULSE GENERATOR CONNECTOR 10-10 11. CRANKSHAFT/TRANSMISSION/KICKSTARTER COMPONENT LOCATION‘ SERVICE INFORM/um” ........................ .. 11.3 TROUBLESHOOTING ............................... .. 114 CRANKCASE sapAnAnou ...................... .. 11.5 CRANKSHAFrum N1L6 TRANSMISSION .......... .. KICKSTARTER ........................................ .,11.14 CRANKCASE ASSEMBLV ------------------------ --11-15 11-1 CRANKSHAFTITRANSMISSION/KICKSTARTER COMPONENT LOCATION 12 Nm (1.2 kgl-m. 9 "7"!) 11-2 CRANKSHAFI'ITRANSMISSIONIKICKSTARTER SERVICE INFORMATION GENERAL 0 The crankcase must be separated to service the crankshaft. transmission and kickslaner. 0 The following parts must be removed belore separating the crankcase. — Alternator/cam chain lensioner (page 10-4) — Clutch/gearshift linkage (page 9-6) — Cylinder head (page 7-7) ~ Cylinder/piston (page 8-4) — Engine (page 6—4) — Oil pump (page 4-4) SPECIFICATIONS 7 7 7 U7nil: mm (in) ‘ 7 7 77777 ITEM 7 SERVICE UMI‘I’ Crankshaft Side clearance ‘ 7Radia| clearance , , 51:19"! ,1 Transmission Gear |.D. ‘ , 1 Busing 0.0. 7 Busing ID. 7 7 20.03 (0791) Gear -ro»bushing clearance 10“) 07704) W 7 16.95 (0.567) CountershahpD. 7 4 7 7 _ 7 7.77 7 . 7 7 19.94 (0.757)” 77 7gar-to-shaf1 glearflgg 7 7 7 M2 _ 0.03i— 0.0777(00013 — 0.003017 7 0.10 (0.004) 7 Gear bushing-m-shan clearance c1 0 020 . 7 2 (0 00703 — 000724) 07.19 (0.07047) 7 Shift fork 7 1.0. i 7 415 —1.3425) 34.14 (1.344) Clavyrhicknessi 7 7 i 7 77 794) 7 4.60 (0.131) sum drum 0.0. 7 33.959:373.7975 (1.3366 —1,3376)7 77 33.93 (1.336) TORQUE VALUE Shifl drum bolt 12 N-m (1.2 kgI-m, 9 (bf-ft) TOOLS ‘ Driver 7 Anawmenl 37 x 40 mm Film, 17 mm 07749-0010000 07746-0010200 077460040400 ,0», \ J‘: 11-3 CHANKSHAFT/TRANSMISSIONIKICKSTARTEH TROUBLESHOOTING Hard to shift - Incorrect clutch adjustment - Bent shift fork I Bent lork claw - Damaged shift drum cam groove - Incorrect transmission oil weight Transmluion jumps out 0! guy - Worn gear dogs or slots ' Ban! shift fork - Broken shift drum stopper Exmnlvo no!“ - Worn crankshaft big and bearing 0 Worn crankshaft journal bearing 11-4 CRANKSHAFI'ITRANSMISSION/KICKSTARTER CRANKCASE SEPARATION Refer {a SEN/Ce Remove the snap ring from the kickstaner spindle, ‘ WNW!” (page Unhuok the return spring and remove the retainer H- . 3; for removal of and Mum spring, necessary pans before senararmg me crankcase Remove the rubber cap. Remove the shift drum bolt and washer. BOLT/WASHER Remove the cam chain‘ Loosen the seven crankcase bolls in a crisscross ‘ pattern in 2 — 3 steps and remove them. Remove the clamp 11-5 CRANKSHAFT/TRANSMISSION/KICKSTARTER Place ihe crankcase with the Ian side down. Separate the righi and left crankcase halves. RIGHT CRANKCASE LEFI CRANKCASE 7 Remove the gasket and dawal plns. DOWEL PINS ix GASKET CRANKSHAFT REMOVAL Remove the crankshaft from the lefi crankcase. CRANKSHAFT If necessary, remove the cam chain guide spindle and guide sprockaL \ SPROCKET 11-6 CRANKSHAFT/TRANSMISSION/KICKSTARTER INSPECTION Measure the connecting rod big and side clearance with a healer gauge. SERVICE LIMIT: 0.60 mm (0.024 in) Measure the connecting rod big end radial clear- ance at symmetrical points as shown, SERVICE LIMIT: 0.05 mm (0,002 in) Turn the outer race of the crankshaft bearing with yourlinger. The bearing should turn smoothly and quietly. Also check that the Inner race 0! the bearing fits tightly on the crankshaft. Check the timing sprocket for wear or damage. if you are replacing the timing sprocket, align the valley of the spmcket teeth with the center of wear drufl key groove as shown. 11-7 CRANKSHAFT/TRANSMISSIONIKICKSTARTER TRANSMISSION Place the crankshaft on a stand or V-blocks and measure the runout using a dial gauge. The measuring locations are shown in the illustrar tion. SERVICE LIMIT: 010 mm (0.004 in) 30 mm (1.2 in) 26 mmllDinl INSTALLATION Install the guide sprocket and guide spindle. \SPROCKET « ' Pour 1 — 2 cm3 of engine oil into the connecting rod big end bearing. Install the crankshaft into the left crankcase, being careful not to interfere the connecting rod with the crankcase. Assemble the crankcase halves [page 1146). CRANKSHAFI REMOVAL Remove the kickstarter spindle (page 11-14). Remove the meinshaft, countershaft and shift drum as an assembly. 11-8 CRANKSHAFl’lTRANSMISSION/KICKSTARTER TRANSMISSION DISASSEMBLY Disassemble the mainshaft, countershah and shift MNNSHAFT drum. SHIFT DRUM "v COUNTERSHAFT TRANSMISSION INSPECTION Check the gear dogs, dog holes and teeth (or abnar— mal wear or lack of lubrication. Measure the ID. of each gear. SERVICE UMITS: M2: 17.10 mm (0,671 in) C1: 2310 mm (0.909 in) C3: 20.10 mm (0.791 in] Measure the ID. and 0.0. 04 c1 gear bushing. SERVICE UMITS: 0.0: 22.93 mm (0.903 in) I.D.. 20.08 mm (0.791 in) —> Calculate the c1 gear-ta-bushlng clearance. SERVICE UMIT: 0.10 mm (01mm) Check the shifter groove ol the shifter gear (or excessive wear or damage Measure the 0.0. of the mamshaft and countershah. M2 SERVICE LIMITS: A? M2 gear: 16.95 mm (0.667 in] AT C1 gear: 15.94 mm (0.785 in) Calculate the M2 gearatoashah clearance. ( SERVICE LIMIT: 0.10 mm (0.004 in) Calculate the CI gear bushlng~lorshafi clearance. SERVICE LIMIT: (110 mm ((1004 in) CI 11-9 CRANKSHAFI'ITRANSMISSION/KICKSTARTER TRANSMISSION ASSEMBLY Assembly is in the reverse order 07 disassembly. c EAR 25T :Gear sliding surface, gear 3 G ( ) leeth and shiher groove CZ GEAR (25Tl / C‘i’G/EAR (SST) COUNTERSHAFT M3 GEAR (2IT) M2 GEAR (15T) MAINSHAFT (M I: 1 1T) GEARSHFI' DRUM DISASSEMBLY Remove the guide pin clips. Remove the guide pins, men remove the shift Iorks. CUP SHIFI' FORKS GUIDE PIN Inspect the shin drum grooves for wear or damage Measure the 0.0. o! the shin drum. SERVICE UMIT: 33.93 mm [1.335 ill) 11-10 CRANKSHAFT/TRANSMISSIONIKICKSTARTER Measure the shift fork |.D. SERVICE UMIT: 34.14 mm (1344 in) Measure the shift fork claw mickness. SERVICE LIMIT: 4.50 mm (0.131 in) SHFT DRUM ASSEMBLY WASHER “\‘k SHIFI' FORK GUIDE PIN SHIFT DRUM 11-11 CRANKSHAFT/TRANSMISSION/KICKSTARTER Apply engine oil to the shilt drum outer surlacer Install the shift Iorks onto me gearshift drum. Install the guide pins and secure them with the clips‘ If the washer has been removed. install e new washer and bend the tab ta lock the washer. GUIDE PIN TRANSMISSION BEARING REPLACEMENT Turn the inner race of each bearing with your linger, The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Remove and discard the hearing it the race does not turn smoothly, quietly, or (its loosely in the crank- case. Remove the ceuntershaft oil seal. Drive the mainshuft bearing our ol the right crank- case. MAINSHAFT BEARING 11-12 CRANKSHAFT/TRANSMISSIONIKICKSTARTEH Drive the countershaft bearing out of the left crank- case. LEFT CRANKCASE: (x Vi Drive new mainshaft bearing into the crankcases DRIVER using the special tools as shown. , > TOOLS: Driver: 077450010000 Attachment, 3‘] x 40 mm: 077460010200 Pilot. 17 mm: 077464040000 Drive new countershah bearing into the crankcases using the same tools Apply engine oil to a new countarshaft oil seal lip. |nsta|l the countershaft oil seal. TRANSMISSION INSTALLATION Apply clean engine oil to the transmission gears and shift drumt MAINSHAFT Set the right fork into the M3 gear and the left fork into the C2 gear to assemble the mainshaft. countershaft and shift drum as shown. SHIFT DRUM/SHIFTFORKS 2.‘ COUNTEHSHAFT 11-13 CRANKSHAFT/TRANSMISSIONlKlCKSTAHTER Instafl the mainshafl, countershaft and shift drum as an assembly into the left crankcase. Rotate the shift drum to check the transmission operation. Install the kickstarter spindle (page 11-15). MCKSTARTER REMOVAL Separate the right and left crankcase (page 11-5) Remove the klckstnner spindle from the right crankr case. DISASSEMBLY Remove the washer. Remove the snap ring and starter ratchet/spring. Remove the snap ring, washer and starter pinion gear. KICKSTARTER SPINDLE SPRING WASHER RATCHET SNAP RING PINION GEAR SNAP RING . WASHER q 11-14 CRANKSHAFT/TRANSMISSION/KICKSTARTER _|NSPECTION Check the kickstarter spindle for bending. Check the friction spring for fatiguel K'CKSTARTEH SP'NDLE Check each part for wear or damage, replace il nec- essary. PINIDN GEAR STARTER RACHET/SPRING ASSEMBLY Assembly is in the reverse order a! disassembly. ’7I KICKSTARTER SFlNDLE WASHER Q PlNION GEAR SNAP RING WASHER FRICTION SPRING STARTER RATCHET SNAP RING INSTALLATION Install (he kickstarter spindle by aligning iis friclion spring wilh the groove in the lefl crankcase as ‘ K‘CKSTARTER SF'NDLE shown. Assemble the crankcase halves. ALIGN CHANKSHAFT/TRANSMISSION/KICKSTARTER CRANKCASEASSEMBLY Dress me malil‘ig Clean the crankcase mating surfaces hefole assem- su/lacas With an or/ bling. 5m" '( “Nessa” install the dowel pins and a new gasket onw the left Ia correct any mmw DOWEL PINS crankcase. roughness or may- ularmas Make sure rlvat the Install the right crankcase over the loll crankcase. RIGHT CRANKCASE gasket sraVs m mace Install the seven bolts With the clamp and lighten them in a crisscross panarn in 2 — 3 steps. Apply engine oil to the cam chain and install it. Install the washer and bolt to the shih drum, than tighten the bolt to the specified torque. TORQUE: 12 N-m (1,2 him, 5 IN!!! 11-16 CRANKSHAFT/TRANSMISSION/KICKSTARTER Install the rubber cap. Install the return spring and retainer onto the kick- staner spindle. Temporarily install the kickstaner pedal‘ Install the spring ends unto the retainer and crank» case lug as shown and press the retainer to set its edge against the stepped part at the crankcase while turning the pedal counterclockwise. Install the snap ring into the groove in the kick- staner spindle securely. 11-17 12. FRONT WHEEL/BRAKE/SUSPENSION/STEERING COMPONENT LOCATION.‘...‘....,.....‘......‘,.. 12.; FRONT WHEEL ....................................... "12.3 SERVICE INFORMATION ------- u 12-3 FRONT BRAKE >>>> -- ~->--12-13 THOUBLESHOOTINGNH.“ 12.5 FORK ‘ , . . ‘ ‘ ‘ ‘ . . . ‘ . . . ‘ . . , . . ‘ . . . . . . , . .4245 HANDLEBAR ............................................ .. 12.5 STEERING STEM ...................................... “12.13 12-1 FRONT WHEEL/BRAKEISUSPENSION/STEERING COMPONENT LOCATION 0 v) 74 Nm (7.5 kgf-m, 54 lbf-fl) 20 NM (20 kgf-m,14|bf-fl) 47 N~m (4.8 kgf-m. 35 Ibftfll 9.8 N-m (1.0 kgf‘m, 7 “arm 12-2 FRONT WHEEL/BRAKE/SUSPENSION/STEERING SERVICE INFORMATION GENERAL Frequent inhalation of brake shoe dust, regardless oI materlal composition could be hazardous to your health, I l 0 Avoid breathing dust panicles I Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. O A contaminated brake drum or shoe reduces sloppan power. Discard contaminated shoes and clean a contaminated drum wnn a high quallty brake degreaslng agenlv I When servicing the tram wheel, brake, fork or steering stern, support the motorcycle usan a safety stand or I’IOISL SPECIFICATIONS Unlt. mm Ilnl ITEM 7 SYANDARD ' SERVICE LIMIT Minimumtire tread depth » 3r0l0.12l r Cald tire firessure 100 kPa (1,00 kgI/cm’, 15 psil ‘i — ‘ Axle runout — ‘ 0.20 Io.0osl Wheel rim»tc~hub distance 6 a :10“) 25 : 0,041 ' — Wheel rim runoul Radial ' — 2.01008) Axial » ' 2.010 05) Brake ' Brake Ever iree play l0 — 2013/8 —13/lfil ' 7 Brake drum LD 80(31) 805l3.17l Brake linlng thickness 3.5(0 14) : 20mm) Fork ‘ Spllng Iree length I603 [633) 153,3 «5.23) TORQUE VALUES Handlebar mountmg nut 20 N m 42 o kgl m, 14 mm) Engine Slop switch holder screw 2.9 N-m10.3 kgl~m, 2.2 lbI-hl Brake lever plvol bolt 2.9 Nvm (0.3 kgI‘m, 2.2 IbIAftl Brake lever plvot nut 2.9 Nvm10.3 kglvm. 2.2 Ibthl Spoke nlpple 2.0 Nm (0.2 kgilm, L4 letl Front axle nul 47 Nm (4.0 kglvm, 35 lbI-fi) U-nuI Front brake arm nul 5.9 N m (o s kgl m, a 3 lbI-ft) ALoc bolt replace wlth a new one Fork prutector bolt 9.8 N-m no kgl m, 7 mm) Steerlng stern nut 74 Nm (7.5 kglm, 54 IbI-h) Steering stern lop thread See page 12-20 12-3 FRONT WHEEL/BRAKE/SUSPENSIONISTEERING TOOLS Spoke wrench, 4‘1 x 4.5 mm Bearing remover shalt Bearing remover head, 12 mm ‘ 0770143020100 1 07746-0050100 077460050300 / \ x or equivalent commercially avail‘ able in USA. Driver Anechment, 32 x 35 mm 7 ‘ Pilol, ‘2 rrim 7 07749-0010000 O774$0010100 077460040200 l 1 ‘ 8 Pin spanner Ea" race remuver ‘ Annulment, 37 x 40 mm 07702-0020001 07944-11 50001 0774841010200 (1 c/éy 0 Steering stern driver ‘ 07946-GC40000 or Steering slam driver 07946 MBODOOO with Steering stem driver anaahmem OMGWDOA ‘ (UlsAnnly) TROUBLESHOOTING Hard nearing I Faulty or damaged steering head bearings 0 Insufficient tire pressure I Steering stem top thread too tight Steers to one side or does not track straight I Bent (ark Bent axle Wheel installed incorrectly Faulty steering head bearings Bent frame Warn wheel bearing Worn swingarm pivot components Front wheel wobbiing 0 Bent rim - Worn front wheel bearings 0 Faultvtire I Unbalanced tire and wheel Wheel turns hard I Faulty wheel bearings - Bent {rant axle I Brake drag ..-o.- Sok suspension I Weak (ark springs - Tire pressure too low Stifl suspension I Ben! fork sliders Front Suzpensinn noisy I Damaged or bent fork sliders - Loose lurk lasleners Improper brake performance 0 Incorrect adjustment of lever I Contaminated brake shoes - Worn brake shoes I Worn brake cam I Worn brake drum I Improperly engaged brake arm serrations FRONT WHEEL/BRAKE/SUSPENSION/STEERING 12-5 FRONT WHEEL/BRAKE/SUSPENSION/STEERING HANDLEBAR REMOVAL Remove the lue) tank brealher hose from {he nqm- BREATHER HOSE BANDS her plale and [he number plaxe (mm the sxeenng slem nut. Remove xhe Wire bands. NUMBER PLATE Remove the two screws and engme stop switch/ [hronle housmg 4mm me handmban ENGINE STOP SWITCH/THROTTLE HOUSING Hscagws DISCOnneC! lhe lhrollle cable and remove the "mar lle gnp 9 Remove [he ran handlebar gnp. Remove the Mo nuts and handlebar. 12-6 FRONT WHEEL/BRAKE/SUSPENSIONISTEERING INSTALLATION Install the handlebar into the fork top bridge and t v tighten the mounllng nuts. ‘ TORQUE: 2|! N-m (2.0 kgf-m, HIM-1t) Clean the Inslde sur'ace ol the left handlebar grlp and the outStde surtace of the left handlebar. Apply Honda Bond A or equivalent to the InSldB surr lace of the left handlebar grip and to the outside surface 0' the left handlebarrWatt 3 7 5 minutes and Install the gnp. Allan 1h? aaneswn Rotate the grip tor even application at the adhesive. in my tor an new Uri/me “5mg Apply grease to the throttle gnp pipe flange and Install the throttle grlp onto the rlght handlebar. Connect the throttle cable to the throttle grip DIDE flange, Install the engine stop swrtch/throttle housing onto the handlebar. aligning the mating surface with the punch mark on the handlebar. Tighten the forward screw first, then the rear screw. TORQUE: 2.9 MM (0.3 kgf-m, 2.2 let) ENGINE STOP SWITCH/THROTTLE HOUSING SCREWS 12-7 FRONT WHEELIBRAKE/SUSPENSION/STEERING Secure the engine stop switch wire with the wire bands properly. Install the number plate over the steering stem nut ' and insert the breather hose into the hole in the number plate, Check the throttle grip operation and free play (page 36), BREATHER HOSE BANDS NUMBER PLATE FRONT WHEEL REMOVAL 0 Support the motorcycle securely usmg a salety — - ’— sund m a hoist BRAKE CABLE HODER FORK PROTECTOR Remove the brake cable lrom the cable holder on the fork protector. Remove the two socket bolts and lork prolector. Disconnect the brake cable lrom the brake arm. Remove the axle nut, axle and front wheel. Remove the side collar item the right side wheel hub and the brake panel lrom the left side wheel hub, 12-8 FRONT WHEELlBRAKE/SUSPENSION/STEERING INSPECTION Axle Set the axle in V-blocks and measure the runout. U Actual runout is 1/2 the total indicator reading, SERVICE LIMIT: 0.20 mm (0.00! in) U U Wheel belrlng Turn the inner race at each bearing with your finger. The bearings should turn smoothly and quietly. Also check that lha bearing outer race Ills tightly in the hub. Always replace the Remove and discard the bearings if they do not turn Dealings in pairs smuothly, quietly. or it they fit loosely in the hub. 9 Wheel rim runont Check the rim runout by placing the wheel in a turn- ing sand. Spin the wheel by hand, and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Rldlll' 2.0 mm ID.“ In] 2.0 mm (0.08 In) DISASSEMBLY Remove the dust seal from the right side wheel hub. FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the bearing remover head into the bearing. REMOVER SHAFT From the opposlte srdel Install the bearing remover shah and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Baring remover head, 12 mm (077me During remover shift 077450050100 ASSEMBLY RIGHTWHEEL EEARING(6201U) a DISTANCE COLLAR DUST SEAL LEFT WHEEL EEAHING(6201U) DRIVER ' NNVPV msxa/r me am Pack each wheel beaflng cavity with grease, 4 lmarmgs Once the Drive in a new leh bearing squarely with its sealed " » Manyng have been Side facing out. rpmaved the bear Install the distance collar and drive in a new righl mgs mus! be hearing using the same tools. removed mm new WE TOOLS: brim 017400010000 Attachment, 32 x 35 mm 077450010100 J Fliot, 12 mm 077450040200 1"»? BEARING h . AnAéHMEyr/PILOT 12-10 Du not get glease anta ma limo! sun /ar:e of the brake mum keen grease on me dlum FRONT WHEEL/BRAKE/SUSPENSION/STEERING Wheel center adjustment Place the rim on the work bench. l Place the hub with the right side down and begin lacing with new spokes. Adjust the hub position so that the distance from l the hub left end surtace to the side ol rim is 6.3 :10 ‘63 + 1.0 mm mm [0.25 2 0.04 in) as shown. No.2; * 004 in) TOOL: Spoke wrench. 4.] x 4.5 mm 07101-00an00 1 (Equivalent com- mercially mull- Ible in U‘SAJ TORQUE: 10 NJ“ [0.2 kgh'n, 1‘4 IbMt) Check the rim runout (page 129). Apply grease to a new dust seal lips. then install it into the right wheel hub‘ INSTALLATION Make sure any grease is cleaned oft the inside ol the brake drum and brake shoes‘ BRAKE PANEL Install the brake panel into the left wheel hub. Install the side collar into the right wheel hub. 12-11 FRONT WHEEL/BRAKE/SUSPENSIONISTEERING Install the tron! wheel between the fork legs while aligning the brake panel groove with the boss on the left lurk slider. Apply a thin layer at grease to the front axle surlace Install the lmnt axle lrom the right side. Hold the axle and temporarily tighten the axle nut. Install the spring and joint pin and connect the brake cable. Install the adjusting nut. SPRING Adjust the lront brake lever lree play (page 3‘16). With the front brake applied, pump the lurk up and down several times to seat the axle and check brake operation. Tighten the axle nut la the specified torque. TORQUE: 47 Mn (4.! ltgl‘m, 35 lbfi-ft) Install the tork protector and tighten the sockel bolts. TORQUE: 9.8 Nrm (1.0 kgtm, 7 lM-ft) Install the brake cable into the cable holder. "BRAKE CABLE HOLDER PROTECTOR 12-12 FRONT WHEEL/BRAKE/SUSPENSION/STEERING FRONT BRAKE REMOVAL Remove the brake panel Irom the Iron! wheel (page 12-5). INSPECTION Measure the from brake drum |.D. SERVICE LIMIT: 80.5 mm (3.17 In) Measure the brake lining thickness. SERVICE LIMIT: 2.!) mm (008 inI DISASSEMBLY Remove the spving and bvake shoes Remove the null bolt and Make armA Remove the wear indicalor, dust seal and brake cam. CAM NUT DUST SEA'L 12-13 FRONT WHEELIBRAKE/SUSPENSION/STEERING ASSEMBLY WEAR INDICATOR PLATE BRAKE ARM DUST SEAL BOLTS BRAKE CAM SPRING BRAKE SHOES Apply greasn [0 the brake cam spindle. Install the brake cam into the brake panel. " BRAKE CAM Apply oil to a new dust seal and install it onlo [he brake panel. INDICATOR Install the wear indicalar plals onto the brake cam by aligning its wide tooth with the wide groove in the brake cam .7 ,\ ‘ ’I g DEE/lg 12-14 FORK FRONT WHEEL/BRAKE/SUSPENSION/STEERING Install the brake arm by aligning the punch marks on the arm and brake cam. Install a new brake arm pinch bolt and nut as shown and tighten it to the specified torque. TORQUE: 5.9 NM (0.6 kgtlll, 4.3 lM-hl NUT Apply grease to the anchor pin and brake cam slid- ing surfaces. SHOES Install the brake shoes and spring as shown. Wipe any excess grease of the brake cam and anchor pin. INSTALLATION Install the hunt wheel (page 12-11) SPRING DISASSEMBLY Remove the lront wheel (page 12-8). Loosen the brake cable nut and remove the brake cable lrorn the fork slider. Remove the dust see] from the fork outer tube by sliding it down. Remove the stopper ring. BERT: 6A_BL_E STOFFER RING DUST SEAL F“ FORK ASSEMBLY v/ I Remove the fork top bolt and washer and pull the fork slider down to remove the fork assembly. BOLT/WASHER 12-15 FRONT WHEEL/BRAKE] SUSPENSION/ STEERING Drive out rhe spring pin, using a 4 mm pin driver. , 7 PIN DRIVER Remove the following from the fork slider: — Fork spring/spring holders ~ Slider piston — Slider guide 7 Back up ring — Stopper ring 7 Dust seal INSPECTION Visually inspem each part (or excessive wear or PISTON SLIDER GUIDE FORK SLIDER a damage. & \ I - . DUST SEAL SPRING EACK~UF RING STOPPER RING Measure the {ark spring iree length. q SERVICE LIMIT: 1583 mm (6,23 in) 12-16 FRONT WHEEL/BRAKE/SUSPENSION/STEERING ASSEMBLY HACKVUF RING FORK SPRING/HOLDERS STOPPER RING Q \ DUST SEAL FORK SLIDER OUTER TUBE SLIDER PISTON SPR'NG P‘N SLIDER GUIDE Install the following onto the (ork slider: SLIDER Gums New dust seal (apply grease to the seal lips) I s s g . v < Stopper ring (with the chamlered side lacing up) — Back up ring - Slider guide (apply 5 v 6 g of grease to the slider guide sliding surface al the lork slider) D BACK-UP RING STOPPER RING SEAL Install the slider piston and fork spring/holders as shown. Align the pin holes in the piston, lork slider and spring holder so that the locating pin on the upper spring holder is facing inside of the fork slider and drive the spring pin to secure them, using a 4 mm pin driver, Be sure that the spring pin does not project oul ol the piston outer surface. SPRING/HOLDERS SPRING FIN Narrow PISTON 12-17 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Apply 5 — 6 g of grease to the slider guide outer groove. Pack the fork spring with 14 g 0! grease. Install the lork assembly by aligning the locating pin with the groove in the outer tube. Install the (ark top bolt and washer and tighten it. Wipe any excess grease of the outer tube. Install the stopper ring into the groove in the outer tube properly. Install the dust seal over the outer tube. BACK-UP RING BRAKE CZBL'E Wipe any excess grease o! the fork slider. Install the brake cable onto the fork slider and secure it by tightening the cable nut. NUT STOPPER Install the front wheel (page 12-11). RING STEERING STEM REMOVAL Remove the following: 7 Number plate [page 2-5) — Handlebar (page 12-6) - Front wheel lpage 1278] 7 Front lender [page 2-5] — Steering stem nut and washer. — Front top bolts and washers 7 Top bridge. ‘ V BO_LTS/WASHERS 12-18 FRONT WHEEL/BRAKE/SUSPENSION/STEERING AIM/{IVS ism tiemmgs mi v. as a so: Remove the steering stern 10p thread usmg the spe» cial mal. PIN SPANNER TOOL: Pin spanner 07702-0020001 Remove (he following: INNER RACE i 7 Upper bearing inner race — Upper bearing 7 Steering stem — Lower bearing STEM BEARlNG REPLACEMENT Drive out ihe upper and lower bearing outer races using {he special tool. TOOL: Ball race remover 079444150001 ‘ , ' OUTER RACE Drive new upper and lower bearing ouier races into me sieering head pipe using the special tool as shown. DRIVER TOOLS: Driver Attachment. 37 x 40 mm 077490010000 0774647010200 ATTACHMENT OUTER {RACE 12-19 FRONT WHEEL/BRAKE/SUSPENSION/STEERING Temporarily install the steering stem nut onto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem. Remove the lower bearing inner race with a chisel or equivalent tool. being careful not to damage the stemt Remove the dust seal and washer. Install the washer over the steering stern. Apply grease to a new dust seal lips and install it over the steering steml Install a new lower bearing inner race using a spe- cial tool and a hydraulic press. TOOLS: Steering nem driver 079466040000 or Steering stem driver o7mMBooooo with Steering stem driver Ittlchment 07946—664000A (USA, only] INSTALLATION INNER RACE/DUST SEALNVASHER STEM NUT STEERING STEM DRIVE—R TOP THREAD @<—— UPPER INNER RACE %<—— UPPER BEARING UPPER OUTER RACE LOWER OUTER RACE & LOWER BEARING DUST SEAL WASHER LOWER INNER RACE '61 :INNER/OUTER RACES BEARINGS v DUST SEAL FRONT WHEEL/BRAKE/SUSPENSION/STEERING | , , r2122; grease to upper and lower hearings and INNER RACE Insert the lower bearing onto the lower bearing '6 IBCEV r "‘58" the steering SKEITI into the steenng head plpe Install upper bearing, inner race and (up thread . , r u. r ; . r [V Hold the steering stem and tighten the stem lop thread to the Initial torque. mp THREAD TORQUE: 25 NM (2.5 kgt-m, 18 lhl-h) Move the steering stem right and left, lock-to-lock several times to seat the bearings Loosen the top thread. Retlghten the top thread to the specified torque. YOROUE: 2.9 N-m (0.3 kgf-m, 2.2 Ihf-itl Install the top bndgev lnstall the stem nut and lork top bolts with the washers and lighten them. TORQUE: 74 Mm (7.5 kgf-m, 54 Iblvh) Make sure that the steering stem moves smoothly, without play or binding WASHERS Install the touowmg: — Front lender (page 275) » Front wheel [page 1241) » Handlebar (page 12-7) — Number plate (page 245) 12-21 13. REAR WHEEL/BRAKE/SUSPENSION COMPONENT LOCATION ...................... ..13.2 REAR BRAKE senwc: INFORMATION 13-3 snocx ABSORBERw-u-m-w-wumm.~~-~-13-1z TROUBLESHOOTING ................................ n 13.4 SWINGARM ............................. N ....‘13.14 REAR WHEEL .......................................... n 13.5 BRAKE pEDAL ........................ .. “"4345 13-1 HEAR WHEEL/BRAKE/SUSPENSION COMPONENT LOCATION 34 Nm (3.5 kgf‘m. 25 law ' 34 Nm (3.5 kgf-m, 25 Ile) . 13-2 SERVICE INFORMATION GENERAL REAR WHEEL/BRAKEISUSPENSION CA ION Frequent inhalation of brake shoe dusl, regardless oi material composition could be hazardous (0 your heallh. - Avoid brealhing dust particles. - Never use an air hose or brush in clean brake assemblies. Use an OSHA-approved vacuum cleaner‘ - A contaminated brake drum or shoe reduces SIOpplng power. Discard cunlamlnaled shoes and clean a comaminaled drum with a high quality brake degreasing agent. - When servlcmg the rear wheel, suppon the motorcycle using a safety stand or hmsr. - Use genuine Honda rep|acemenl bells and nuts lor all suspension pivms and mounting poims, SPECIFICATIONS ITEM Minimum tire tread depth Cnld tire pressure Axle runout Wheel rim-ro-hub dlSlance Wheel rim runoul Drive chain Brake TORQUE VALUES Spoke nipple Rear axle nul Driven sprocket nul Rear brake arm nul Swingarm pivot nul Shock absorber mounllng nur Drive chain slider nut Size/link Brake pedal Iree play Brake drum ID. 80131] Brake lining thickness 125 kPa (1.25 kgf/cm’, la psu) 25 z 1.0 (1.0 :004i 3,5 (0,14I 2.0 N-m (0.2 kglm, IAIN-f1) A7 N'm 14.8 kgilm, 35 In! R) 32 N-m13,3 kgI m, 24 |le) 5.9 N»m10,5 kg! m, 4.3 lhI-fti 39 NM (4 O kgI-m, 29 mm) 34 N‘m13V5 kgi‘m, 25 leU 12 N-m IL? kgI-m. 9 IbI-It] SIANDARD DiD420MBKi/78 15 - 25 (9"6 — Ii 10 — 2013/8 713/16) Unil: mm (in) SERVICE LIMIT 3.0 (0.12) 7 ' 0.2010008) _ [clonal - 2.0 local 805 [3.17) 2.0 (0.08i U~nul U-nul ALOC bolt replace wnh a new one Apply grease to the sealing sudace/U-nul Urnul U»nul 13-3 REAR WHEEL/BRAKE/SUSPENSION TOOLS Spoke wrench, 4.1 x 45 mm Bearing remover shaft Bearing remover head, 12 mm 7 07701-0020100 o774e00501oo 07746-0050300 V/Vi / or equivalent commercially avail- able in U‘S.A. ‘ i 7 ~ , , . 7 7 Driver i Anechmenl, 32 x 35 mm Pilot, 12 mm ’ 07749-001000!) 077460010100 07746-004020!) TROUBLESHOOTING 0 San lulpemlon ' Weak shock absorber spring I Oil leakage from damper unil - Tire pressure too low Still lulporwlon - Bent damper rod 0 Damaged swingarm pivot bushings I Bent swingarm pivot O Tire pressure loci high Sloan Io one lids or dues not truck nr-ight - Bent rear axle - Axle alignment/chain adiuslmenl not equal on both sides Rear wheel wohhllng - Ben! rim ’ Worn rear wheel bearings Faulty rire Unbalanced fire and wheel Tire pressure too low Faulty swingarm pivot bushings 13-4 REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Suppon the motorcycle securely using a heist or ,——-- V _— .._' equivalent and raise the rear wheel off the ground. ADJUSTING ViUT " . BRAKE ROD’SPR'NG Remove the rear brake adjusting nut and disconnect the rear brake md lrom the brake arm, and remove the joint pin and spring. |_J_QINT PIN Lonsen the drive chain adjuster lock nuts and adjusting nuts. AXLE NUT Remove the axle nut and left chain adjuster. Push the rear wheel (onward and derail the drive chain from the driven sprocket. Remove the axle from the right side and remove the rear wheel. Remove the left side collar from the left wheel hub. Remove the brake panel from the right wheel hub. REAR WHEEUBRAKEISUSPENSION Replace the wheel bearing: in pelts lNSPEC‘nON Axle Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm [0.008 in) Wheel boning Turn the Inner race of each bearing with your finger, Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings it the races do not turn smoothly and quietly, or ii they fit loosely in the hub. Wheel rim runout Check the rim runout by pllcing the wheel in a turn- ing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE umn's: Rldlel: 2.0 mm (0.00 lnl Aid 2.!) mm (0.08 in) Driven modtct Check the condition oi the final driven sprocket teeth. Replace the sprocket if worn or damaged. - If the final driven sprocket requires replacement. inspect the drive chain and drive sprocket. - Never install a new drive chain on a worn sprocket or e worn chain on new sprockets. Both chain and sprockets must be in good condition or the replacement chain or sprocket will wear rapidly. 13-6 REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY Remove the nuts, bulls and driven sprocket. Remove the left dust seal. DUT SEAL ,r/I"~\ Wheel bearing IIMDVII Install lhe bearing remover head into the bearing. From the opposixe side install the bearing remover shaft and drive lhe bearing out of the wheel hub. Remove the distance collar and drive out the mher bearing. TOOLS: Bearing remover hand, 12 mm 077460050300 Bearing romover shun 07746—005010!) ASSEMBLY '6 DISTANCE COLLAR BEARING IGZD‘IU) @0, .6. BEARING (6201 U) DUST SEAL '6: 32 N-rn (3.3 kgl-m, 24 Ibl-n) DRIVEN SPROCKET W BOLTS REAR WHEEL/BRAKE/SUSPENSION Wheel belring inst-"flint! Never ,nsuu me am Pack each wheel bearing cavity with grease. DRIVER bearings, once the Drive in a new right bearing squarer with the Deermgshdve been sealed side facing up using the special tools as vernal/m1. m 5257- shown. mg must be TOOLS: Wm” Mug: Driver 077494010000 Attachment. 32 x 35 mm 077W10100 Pilot. 12 mm anmmzoo Install the distance collar and drive in a new left bearing using the same tools. ATTACHMENT/PILOT -5 A Wheel center Idlunment Place the rim on the work bench. Place the hub with the left side down and begin lac- l ing with new spokes. 25 t 1.0 mm l Adjust the hub position so that the distance lrom maroon") the hub right end suriace to the side oi rim is 25 z 10 mm (LO 1 0.04 in) as shown. TOOL: Spoke wrench, l.1 x 4.5 mm 07701—0020100 (Equivalent com- mercially Ivlll- ahle In U. . .) TORQUE: 20 N41! (0.2 kg1~m4 1.4 lM-hi Check the rim runout (page 13-6), Apply grease to a new dust seal lips and install il into the left wheel hub. Install the driven sprocket, bolts and nuts and tighten the nuts to the specified torque. TORQUE: 32 Min [3.3 Hull", 24 lM-h) 13-8 REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the left side collar into the left wheel hubt SIDE COLLAR install the brake panel into the right wheel hubt Place the rear wheel into the swingarm by aligning the brake panel groove with the swingarm boss‘ Install the drive chain over the driven sprocket. Apply thin layer of grease to the axle. Install the axle with the right drive chain adjuster from the right side. Install the left drive chain adjuster and axle nut. 13-9 REAR WHEEL/BRAKEISUSPENSION Install the spring onto the brake rod and the ioint |——-i V—-—- —| pin into the brake amL ADJUSTING liUT a AKE ROD/SPRING Connect the brake rod and install the adjusting nut. 7 Adjust the drive chain slack (page 3-13). fighten the axle nut to the specified torque. TORQUE: 47 N-rn (4.3 kgf-m, 35 Ihfrn) REAR BRAKE INSPECTION Remove the brake panel Iwm the rear wheel (page 13-5). Measure the rear brake drum l.D. SERVICE LIMIT: 30.5 mm (3‘17in) Measure the brake lining thickness SERVICE LIMIT: 2.0 mm (0‘0! in) DISASSEMBLY Remove the brake shoes and spring. SPRING 13-10 REAR WHEEL/BRAKE/SUSPENSION Remove the brake arm cover i1 necessary. CAM I'ARM COVER Remove the nut, bolt and brake arm, NUT \ Remove the indicamr plate, dust seal and brake cam. ARM \ '\ BOLT INDICATOR PLATE ASSEMBLY BRAKE ARM WEAR INDICATOR PLATE BRAKE SHOES 5.5 N-m (0,6 kgfvm, 4.3 lbl-fll BRAKE ARM COVER SPRING Apply grease lo the brake cam spindle. Install the brake cam inlo the brake panel, 13-11 REAR WHEEL/BRAKE/SUSPENSION Apply oil to a new dust seal and install it onto the brake panel. Install the wear indicator plate onto the brake cam by aligning its wide tooth with the wide groove in the brake cam. Install the brake arm by aligning the punch marks on the arm and brake cam. Install a new brake arm pinch bolt and nut as shown and tighten it to the specified torque. TORQUE: 5.9 N-m (0.6 Raf-m, 43 MR) Install the brake arm cover onto the arm, ALlGN e! eon \ Assemble the brake shoes and spring as shown and SPRING install them onto the brake penel‘ Wipe any excess grease oil the brake cam and anchor pin. Install the rear wheel (page 13-9). SHOCK ABSORBER REMOVAL Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground‘ Remove the seat (page 2—3). Remove the shock absarber lower mounting nut and bolt. 13-12 REAR WHEEL/BRAKE/SUSPENSION Remove the upper mounting nut and bolt and the NUT/BOLT shock absorber. SHOCK ABSORBER INSPECTION Visually inspect the for follawrng: DAMPER ROD SPRING a Spring for fatigue or damage. » Damper rod for bend or damage. — Damper unit for deformation or oil leaks, - Bump rubber for wear or damage. 7 Mounting bushings for damage, Replace the shock absorber assembly if necessary. BUSHINGS INSTALLATION Install the shock absorber Into the lrame and swingarm, BOLT/NUT SHOCKABSOHEER Install the upper and lower mounting balls from [he left side. Install the nuts and tighten them to the specified torque. TORQUE: 34 Mr" (3.5 kgltm, 25 Ith) BOLT/NUT 13-13 REAR WHEEL/BRAKE/SUSPENSION SWINGARM REMOVAL Remove the drive chain (page 3-14). Remove the rear wheel (page 135). CHAIN COVER Remove the bolls and drive chain cover. Remove the bulls and drive chain guard. Remove the shock absorber lower mounting nut and be". ‘ NUT/BOLT Remove the swingarm pivot nut, bolt and ‘ ‘/ _ SWINGARM swingarm. ' PIVOT NUT Remove the nut and Doll and the drive chain slider. ' NUT/BOLT CHAIN SLIDER INSPECTION Inspect (he swingarm ior wear or damage. ‘ Inspect the pivot bushings for wear or damage. BUSHINGS 13-14 REAR WHEEL/BRAKE/SUSPENSION INSTALLATION install the drive Chain slider and tighten the nut to the specified torque. TORQUE: 12 N-m (1.2 kgf-m, 3 let) N UT/BOLT CHAIN SLIDER install the swingarm over the frame, then install the pivot bolt item the right side and the shock absorber lower mounting bolt from the left side. Apply grease to the seating surface of the swingarm pivot nut. Install and tighten the swingarm pivot nut to the , specified torque. TORQUE: 39 Nm (4.0 Islam, 29 tht) Tighten the shock absorber lower mounting nut to the specified torque. TORQUE: 34 Mr" (35 kuf-m.25 IbMt) Install the drive chain guard and tighten the bolts. install the drive chain cover and tighten the baits. CHA'N COVER Install the rear wheel (page 13%). Install the drive chain (page 3-15). CHAIN GUARD BOLTS BRAKE PEDAL REMOVAL Remove the rear brake adjusting nut and disconnect JOINT W the rear brake rod lrorn the brake arm, and remove the joint pin and spring. REAR WHEEL/BRAKE/SUSPENSION Remove the comer pin, joint pin and brake rod. V)OINfiN BRAKE Ron Unhnok the brake pedal return spring from the brake pedaL Remove the cotter pin, washer and brake pedal. :COTTER PIN BRAKE PEDAL INSTALLATION Apply grease (o the pivul surface and insrall the brake nedal. 1nstall the washer and a new canar pin 10 secure me brake pedal. Install the return spring as shown. BRAKE PEDAL 13-16 REAR WHEEL/BRAKE/SUSPENSION Connect the brake rod to the pedal with the joint pin and secure it with a new cotter pin. V JO'NT PIN BRAKE ROD Install the spring unto the brake red and the joint pin into the brake arm‘ Install the rod to the joint pin with the adjusting nut. Adjust the brake pedal free play (page 3-16L 13-17 14. IGNITION SYSTEM svs'rEM DIAGRAM ................................... ,, 14.2 SERVICE INFORMATION .......................... .. 14.3 TROUBLESHOOTING ................................ ., 144 IGNITION SVSTEM INSPECTION ~~~~~~~~~~~~~ n 14.5 IGNITION COIL ........................................... N 14.7 IGNITION CONTROL MODULE ---------------- --14-8 ENGINE STOP SW|TCH IGNlTloN swn'c” ..................................... "14.9 IGNITION TIMING .................................... “14,10 14-1 IGNITION SYSTEM SYSTEM DIAGRAM ENGINE STOP SWITCH IGNITION CONTROL MODULE (ICM) IGNITION SWITCH SPARK PLUG EXCITER con. IGNITION PULSE GENERATOR ENGINE STOP IGNITION swrrcu swrrcu 9 9 9 9 I I I I W 0 DWI a W G M IW B G M HUI BUR M swrrcu cou'nuurrv l fig“ IGNIVION I M m swncn 5W0“ IGNITION IGNITION com n, E ,0 E OONTROL MODULE 1 FUN mm l OFF o--o or: 0-0 1 {03]— MM 6 m“ a sfmx TlGerofl ALTERNATOR PLUG Ls — PU E GENERATOR 1 4-2 I) J IGNITION SYSTEM SERVICE INFORMATION GENERAL When servicing the ignition system, always follow the steps in the troubleshooting sequence on page 144. The CDI ignition system uses an electrically controlled ignition liming system. No adjustments can be made to the Igni- tion timing. The ICM may be damaged it dropped. Also if the connector is disconnected when current is flowing, the excessive volt» age may damage the module. A faulty ignition system is often related to poor connections. Check those connections before proceeding. Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. For alternator and ignition pulse generator removal and installation, See page 10-3. SPECIFICATION ITEM SPECIFICATION §tjr1dard For cold clfiate (balow 41 :F/5°CI For extended high speed riding Spark plug CRGHSA (NGKI I UZOFSRvU (DENSO) CRSHSA (NGK) U‘ISFSR-U (DENSO) CR7HSA [NGKI U22FSR»U (DENSO) 0.60 Jojo {rim (0.024 — 0.023' in) Spark plug gap Ignition coil peak voltage Ignition pulse generator peak voltage 100 V minimum 0.7 V minimum 100 V minimum ‘ "'27°'BTD§ at idle Alternatquciterrcoil pgakvoltege IQL‘I‘L”! 'i'fljfliflflmflkl TORQUE VALUES Ignition coil mounting bolt 5.9 N«m (0.6 kgf-m, 4.3 Ibl-It) TOOLS u . Peak voltage adaptor with commer- cially available digital multimeter (impedance 10 Mfl/DCV minimum) Ignition Mate peak voltage tester MTPO7-0286 [U.S,A, only) 07HGJ—0020100 (not available in U.S.A.) 14-3 IGNITION SYSTEM TROUBLESHOOTING - inspect the following before diagnosing the system. — Faulty spark plug 7 Loose spark plug cap or spark plug wire connections — Water got into the spark plug cap (leaking the ignition coil secondary voltage) No spark at spark plug ( Unusual Endition ignition coil Low peak voltage. primary voltage pm or Profitable cause (check in numerical order) Incorrect peak voltage adaptor connections (System is normal it measured voltage is over the specifications with reverse connections). . The multimeter impedance is too low: 10 Mtz/DCV. . Cranking speed is too low (Operating force of the kick- starter is weak.) . The sampling timing of the tester and measured pulse were not synchronized. (System is normal it measured voltage is over the standard voltage at least once.) . Poorly connected connectors or an open circuit in igni- tion system. . Faulty exciter coil (Measure peak voltage), Faulty ignition coil. . Faultych (in case when above No.1~7 are normal). No peak voltage. Paakvoltaga is normal. but no spark jumps at plug. Exciter coil Low peamltage. 7 7 No peak voltage. ignition pulse Low peak/073799. 7 7 7 7 7 generator No peak voltage. 77 mum n dmNm dmeOI u N..N.. , Faulty i 77 77 7 7 7 7 77 77777 7 77 , The multimeter impedance is too low; 10 MQ/DCV, . Cranking speed is too slow (Operating force of the kick- . Faulty peak voltage adaptoT . faulty exciter coil. . The multimeter impedance is too low:'i0 Mif/DCV: . Cranking speed is too slow (Operating force of the kick- . Incorrect peak voltage adaptor connections (System is normal it measured voltage is over the specifications with reverse connections). , Short circuit in ignition switch wire or engine stop switch wire (Black/white). , Faulty ignition switch or engine stop switch. . Loose or poorly connected ICM connectors. , Open circuit or poor connection in ground wire (Green) of the ICM. , Faulty peak voltage adaptor. Faulty exciter coil. (Measure peak voltage). . Faulty ignition pulse generator (Measure peak voltage). . Faulty lCMiin case when above7No.1—78 are normal). . Faulty spark plug or leaking ignition coil secondary cur- rent ampere ' ion coil. starter is weak) . The sampling timing of the tester and measured pulse were not syndironized. (System is normal it measured voltage is over the standard voltage at least once.) . Faulty exciter coil (in case when above No.1 — 3 are normal). starter is weak.) . The sampling timing of the tester and measured pulse were not synchroniled (System is normal if measured voltage is over the standard voltage at |east once). , Faulty ignition pulse generator (in case when above No.1— 3 are normal). . Faulty peak voltage adaptor. . Faulty ignition pulse generator, 14-4 IGNITION SYSTEM INSPECTION If there is no spark at plug, check all connections for loose or poor contact before measuring each peak voltage. - Use recommended digital multimeter or cornv mercially available digital multimeter with an impedance at 10 Mn/DCV minimum. The display value differs depending upon the internal impedance ol the multimeter. I I! using peak voltage tester (U.S.A. only), follow the manulacturer's operating instructions. Connect the peak voltage adaptor to the digital multimeter, or use the peak voltage taster (U.S.A. only). TOOLS: Peak voltage tester MTPD7-0286 IU.S.A, onle or Peak voltage adaptor 07HGJ-0020100 Not available in USA.) with commercially available digital multimeter [impedance 10 Mfl/DCV minimum) IGNITION COIL PRIMARY PEAK VOLTAGE - Check all system connections before inspection. If the system is disconnected. incorrect peak volt- age might be measured. - Check cylinder compression and check that the spark plug is installed correctly. Disconnect the spark plug cap irom the spark plug. Connect a known good spark plug to the spark plug cap and ground the spark plug to the cylinder head as done in a spark test. With the ignition coil primary wire connected, con» nect the peak voltage adaptor or peak voltage tester to probes to the ignition coil primary wire terminal and ground. CONNECTION: Black/yellow terminal (—I — Body ground I4) Turn the ignition switch ON and engine stop switch I to "RUN". Shift the transmission into neutral. Crank the engine with kickstarter and read ignition coil primary peak voltage, PEAK VOLTAGE: 100 V minimum If the peak voltage is abnormal, follow the checks described in the troubleshooting chart (page 14-4). KNOWN GOOD SPARK PLUG IGNITION SYSTEM DIGITAL MULTIMETER \ 4 (v) PEAK VOLTAGE ADAPTOR 14-5 IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE - Check cylinder compression and check that the spark plug is installed correctly. Remove the seat assembly (page 2-3). Disconnect the 4P connector from the ICM. Connect the peak voltage adaptor or peak voltage tester probes to the connector terminals of the wire harness side. TOOLS: Peak voltage tater mmr-om (USA. only) or Peak voltage adaptor 07HGJ»0020100 with commercially available digital multlmeter (impedance 10 MQIDCV minimum) CONNECTION: Blue/yellow terminll l+l - Green l-l Shift the transmission into neutral. Crank the engine with the kicketarter and read the peak voltage. PEAK VOLTAGE: 0.7 V minimum II the peak voltage measured at ICM connector is abnormal, measure the peak voltage at the pulse generator connector, Disconnect the ignition pulse generator connector (Blue/yellow) and connect the peak voltage adaptor or tester probes to the connector terminal ol the ignition pulse generator side and ground. in the same manner as at the lCM connector, mea- sure the peak voltage and compare it to the voltage measured at the [CM connector. - lithe peak voltage measured at the ICM is abnor- mal and the one measured at the ignition pulse generator is normal, the wire harness has an open circuit. or loose connection. 0 ll both peak voltages are abnormal, (allow the checks described in the troubleshooting chart (page 14-4). IGNITION PULSE GENERATOR CONNECTOR 1 4-6 ALTERNATOR EXCITER COIL PEAK VOLTAGE I Check cylinder compression and check that the spark plug is installed correctly. l Remove the seat assembly (page 2-3]. Disconnect the 4F and 2F connectors from the ICM. Connect the peak voltage adapter or peak voltage tester probes to the connector terminals of the wire i harness side. TOOLS: Peek voltage tester MTPo7-0285 (USA. only) or Peek voltage adaptor n7HGJ-0020100 (Not available in U.S.A.I with commercially available digital multimeter (impedance lo Mfl/DCV minimum) CONNECTION: Black/red terminal (+1 — Green [-I Shift the transmission into neutral. Crank the engine with kickstarter and read the peak voltage. PEAK VOLTAGE: 100 V minimum II the peak voltage measured at ICM connector Is ' abnormal, measure the peak voltage at the alterna- tor Exciter coil connector. Disconnect the alternator exciter coil connector (Black/red) and connect the peak voltage adaptor or tester probes to the connector terminal of the exciter coil side and ground. In the same manner as at the ICM connector. mea sure the peak voltage and compare it to the voltage measured at the ICM connector. - It the peak voltage measured at the ICM is abnor- mal and the one measured at the alternator exciter coil is normal, the wire harness has an i open circuit, or loose connection, l - I! both peak voltages are abnormal, follow the I ' checks described in the troubleshooting chart (page 14-4]. IGNITION COIL REMOVAL/INSTALLATION Disconnect the spark plug cap from the plug. Disconnect the primary wires from the ignition coil. Remove the bolt and ignition coil. Installation is in the reverse order ol removal. Tighten the ignition coil mounting bolt to the speci» fied torque. TORQUE: 5.9 MM Ills kgf-m, 4.3 “if!” IGNITION SYSTEM IGNITION SYSTEM IGNITION CONTROL MODULE REMOVAL/INSTALLATION Remove the seat assembly (page 273), Disconnec‘ the Ignition Contml Module [ICM] 4? and 2P connectors. Remove the ICM Item the frame. Installation is in the reverse order of removalv CONNECTORS ENGINE STOP SWITCH INSPECTION Disconnect the engine stop swrtch connectors. check Ior continuity between the terminals. ENGINE STOP SWITCH There should be no continuity when the engine stop switch IS in the "OFF" posution and there should be continuity when the engine stop swttch is in the “RUN” position. 14-8 IGNITION SWITCH INSPECTION Disconnect the ignition switch connectors. Check for continuity at the connectors on the igni- tion switch side. There should be no continuity when the ignItion switch is in the "ON" position and continuity when the ignition switch is in the “OFF” position. REMOVAL/ INSTALLATION Discon heat the Ignition switch connectors. Release the labs on the igniuon swnch body and remove the ignition switch. Aiinsra/Iarion, align Installation is in the reverse order of removal. the guide on me ignition switch and groove on me flame ‘ TABS ' 4\ IGNITION SYSTEM CONNECTORS IGNITION SYSTEM IGNITION TIMING Read [he INSUUCV IIDns for nmmg Igm operanan Warm up the engine. Stop the engine and remove the left crankcase cave! (page 104). Connect the timing light to Ihe spark plug wire. Stan the engine and lel it idle. IDLE SPEED: 1.700 t 100 rpm The ignition liming is curred ii the “F” mark on fly» wheel aligns with the index notch on [he left crank- case. Increase the engine speed by turning the throttle stop screw and make sure the "F" mark begins to move clockwise. Install the left crankcase cover (page 103). 14-10 15. WIRING DIAGRAM wIRmG DIAGRAM ................................... I. 15.2 15-1 Z'SI. ENGINE STOP IGNITION SWITCH SWITCH | | | | BIIW G BIIW G G G T HIM—DI: a BIIW G BIIV BIIV G G BUN BIIR EIIR Bulv _I'I_ _I_I_ Bu/V BI/R SWITCH CONTINUITV ENGINE smp IGNITION swncN SWWC" IG E It: E RUN RUN OFF O-—O an: 0—0 com mm a coma aw 6 Bl BLACK 5 GREEN v YELLOW a RED au BLUE w WHITE C C IGNITION CONTROL MODULE @1qu Iaumou ALTERNATOR PULSE GENERATOR 003OZ-GEL-7000 C Q Q INVHDVIG BNIHIM WWSVIO SNIHIM 16. TROUBLESHOOTING ENGINE DOES NOT START 0R POOR PERFORMANCE AT LOW ls HARD 70 START .................................. “15.2 AND IDLE ENGINE LACKS POWER ------------------------- u 16-3 POOR PERFORMANCE AT HIGH SPEED~--16‘5 poon HANDUNG .................................... .45.; 16-1 TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START 1. Carburetor Inspection Check the fuel flow to carburetor. Is fuel reaching the carburetor? N0 — I Clogged Iuel line and strainer I Clogged fuel tank breather hose VES - GO TO STEP 2. . Spark Test Perform a spark test. Is there a good spark? NO - ' Faulty spark plug - Fouled spark plug I Faulty ignition control module 0 Broken or shorted spark plug wire 0 Faulty igniting pulse generator - Faulty engine stop switch or ignition switch - Loose or disconnected ignition system wires VES — GO TO STEP 3. . Spark Plug Inspection Remove and inspect spark plug. Is the spark plug in good condition? No - ' Flooded carburetor I Choke valve closed ' Air cleaner dirty YES - GO TO STEP 4. , Engine Stan Con ition Stan by following the normal procedure. Does the engine start but than stop? VES - - Improper choke operation - Carburetor incorrectly adjusled I Intake pipeleaking - Improper ignition timing (faulty ignition coil or ignition pulse generator) - Fuel contaminated NO — GO TO STEP 5. t Cylinder Compression Inspection Test cylinder compression. Is the compression normal? N0 - Valve clearance too small Valve stuck open Worn cylinder and piston ring Damaged cylinder head gasket Seized valve Improper valve timing 16-2 ENGINE LACKS POWER 1. Drive Tuin Inspection Raise wheel off the ground and spin by hand. Does the wheel spin freely? NO — - Brake dragging I Worn or damaged wheel bearings VES - GO TO STEP 2. . Tire Prmun Inspection Check the tire pressure. II the the presenter con-(.17 ND — I Faulty tire valve O Punctured tire VES - GO TO STEP 3. . clutchlmpmion Accelerate rapidly from low to second. Does the englne speed change locordirlgly when clutch is roluud? NO — 0 Clutch slipping - Worn clutch discs/plates - Warped clutch discs/plates - Weak clutch spring - Additive in engine oil YES - GO TO STEP 4. . Engine Parlormanoe Inspection Accelerate lightly. Dan the engine lpud inuuu7 N0 — - Choke valve closed - Ciogged air cleaner - Restricted fuel flow - Clogged muffler I Pinched fuel tank breather hose VES — GO TO STEP 5. . Ignition Timing Inspection Check the ignition timing. II the Ignition timing norm-I7 NO - - Faulty ignition control module 0 Faultv ignition pulse generator YES - GO TO STEP 6. . Cylinder Compression Inspectlon Test wlinder compression. Is the compression normal? N0 — - Valve clearance too small I Worn cylinder and piston ring - Leaking head gasket - Seized valve I Improper valve timing VES — GO TO STEP 7. . Carburetor Inspection Check the carburetor tor clogs. Is the carburetor clogged? VES — Carburetor not serviced frequently enough NO - GO TO STEP 8. TROUBLESHOOTING TROUBLESHOOTING 8. Spark Plug Inspection Remove and inspect the spark plug. I: the spark plug In good condition? No — 0 Plug not serviced frequently enough - Incorrect spark plug heat range YES — GO TO STEPSl 9. Engine Oil lnopoctlon Check the oil level and condition. In tho onginl oil In good condition? No — 0 Oil level too high - Oil level too low I Contaminated oi| VES - GO TO STEP 10. 10, Lubrlcatlon inspection Remove cylinder head cover and inspect lubrication I: the "In train lubricated pmporly? N0 — 0 Clogged oil passage - Clogged oil control orifice VES — GO To STEP 11. ,Ovlr Hunting Inopoctlon Check Ior engine over heating. 1 II the engine our honing? YES - - Excessive carbon build-up in combustion chamber I Use a! poor quality Iuel - Clutch slipping - Lean luel mixture 0 Wrong type at fuel N0 - GO TO STEP 12. 11. Engine Knocking Inupoction Accelerate or run at high speed‘ Does the engine knock? YES — - Worn piston and cylinder 0 Wrong type of fuel ~ Excessive carbon build—up in combustion chamber - Ignition timing too advanced (faulty ignition control module) O Lean 'uel mixture 1 6-4 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED 1. b L b Cerburetor Air Screw Inspection Check the carburetor air screw adjustment. Is the all screw correct? NO — (page 5-13) YES - GO TO STEP 2. . Int-ire Manifold Looking Inspection Check Ior leaks in the intake Maniiold. Is there looking? YES - - Loose carburetor mounting bolts ' Damaged insulator NO - GO TO STEP 3. . Spark Tut Fariorm a spark test, I: there 1 good spark? No v - Faulty or iouled spark plug I Faulty ignition control module 0 Faulty Ignition corl ' Broken or shorted spark plug wire - Faulty engine stop switch or ignition switch - Faulty ignition pulse generator - Loose or disconnected Ignition system wires YES - GO TO STEP 4. . Ignition Timing Inspection Check the ignition timing. II the Ignition timing nonnel? NO - Improper ignition timing (Faulty Ignition control module) POOR PERFORMANCE AT HIGH SPEED 1. Fuel Une inspection Disconnect the iuel hose at the carburetor. Does the fuel flow Ireely? NO - O Clogged fuel line - Clogged iuel tank breather hose ' Faulty iuei valve - Clogged iuel strainer YES - GO TO STEPZ. . Cerburetor Inspection Remove the carburetor and check for clogged jets. Are the 'ets clogged7 YES - Clean No — GO TO STEP 3. . Valve Timing inspection Check the valve timing. Is the valve timing W7 N0 — Cam sprocket not installed properly YES - GO TO STEP 5. . Ignition Timing inspection Check the ignition timing. 16-5 TROUBLESHOOTING Is the ignition timing norm-I7 N0 - - Faulty ignitinncuntrol module - Faulty ignition pulse generator VES - GO TO STEP 5. 5‘ Volvo Spring Inlpactlon Check the valve springs. L1 tlu vulva nprlng Ira length normal) N0 — Feultv spring VES — Not weak POOR HANDLING Steering in heavy - Steering stem adiusting nut too lighl - Damaged steering head bearings Either wheel I: wobbling - Excessive wheel bearing playl 0 Bent rim - Improper Installed wheel hub I Swingarm pivot bearing excessively worn I Bent frame The motorcycle pull: to one side 0 Faulty shock absorber - Front and rear wheel not aligned - Bent fork - Bent swingarm - Bent axle 16-6 AIR CLEANER AIR CLEANER HOUSING AIR SCREW ADJUSTMENT ALTERNATOR/CAM CHAIN TENSIONER SPECIFICATIONS BRAKE PEDAL BRAKE SHOE WEAR >15 BRAKE SYSTEM-w ~16 CABLE 81 HARNESS ROUTING- 1-14 CAM CHAIN TENSIONER 10-6 CAMSHAFI' INSTALLATION A 7-18 CAMSHAFT REMOVAL 7-6 CARBURETOR ASSEMBLY 5-9 CARBURETOR DISASSEMBLY- 5-7 CARBURETOR INSTALLATION: 541‘ CARBURETOR REMOVAL CLUTCH 9-6 CLUTCH SPECIFICATIONS 1-7 CLUTCH SYSTEM - 347 COMPONENT LOCATION ALTERNATOR/CAM CHAIN TENSIONER CLUTCH/GEARSHIFT LINKAGE CRANKSHAF‘r/TRANSMISSION CYLINDER HEADNALVES CYLINDER/PISTON ENGINE REMOVAL/INSTALLATION FRONT WHEEL/BRAKE/SUSPENSION/ STEERING ~ FUEL SYSTEM REAR WHEEUBRAKE/SUSFENSION- CRANKCASE ASSEMBLY CRANKCASE BREATHER- CRANKCASE SEPARATION CRANKCASE/TRANSMISSION/KICKSTARTER SPECIFICATIONS CRANKSHAFI CYLINDER COMPRESSION CYLINDER HEAD-~- CYLINDER HEADNALVES SPECIFICATIONS CYLINDER INSTALLATION CYLINDER REMOVAL CYLINDER/PISTON INSPECTIO CYLINDER/PISTON SPECIFICATIONS I DRIVE CHAIN ---- -‘ DRIVE CHAIN SLIDER ENGINE INSTALLATIO ENGINE OIL ENGINE OIL CENTRIFUGAL FILTER ENGINE OIL STRAINER SCREEN ENGINE REMOVAL ENGINE STOP SWITCH EXHAUST SYSTEM -- FLYWHEEUSTATOFI REMOVAL FORK- FRONT BRAKE FRONT FENDER - FRONT WHEEL 17. INDEX FRONT WHEEL/BRAKE/SUSPENSION/STEERING SPECIFICATIONS FUEL LINE FUEL SYSTEM SPECIFICATION FUEL TANK GEARSHIFT LINKAGE GENERAL SPECIFICATIONS HANDLEBAR IGNITION COIL IGNITION CONTROL MODUL IGNITION SWITCH IGNITION SYSTEM INSPECTIO IGNITION SYSTEM SPECIFICATIONS- IGNITION TIMING KICKSTARTER - LUBRICATION & SEAL POINTS‘ LUBRICATION SYSTEM DIAGRAM LUBRICATION SYSTEM SPECIFICATIONS MAINTENANCE SCHEDULE MODEL IDENTIFICATION NUMBER PLATE»««- NUTS, BOLTS. FASTENERS OIL PUMP~ PISTON INSTALLATION PISTON REMOVAL» REAR BRAKE REAR WHEEL REAR WHEEL/SUSPENSION SPECIFICATIONS RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKCASE COVER REMOVA SEAT-u SERVICE INFORMATION ALTERNATOR/CAM CHAIN TENSIONER CLUTCH/GEARSHIFT LINKAGE CRANKSHAFT/TRANSMISSION CYLINDER HEADNALVES CYLINDER/PISTON ELECTRICAL SYSTEM> ENGINE REMOVAUINSTALLATION FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEUBRAKE/SUSPENSION/ STEERING FUEL SYSTEM LUBRICATION SYSTEM MAINTENANCE REAR WHEEL/BRAKEISUSPENSION SERVICE RULES- SHOCK ABSORBER SIDE STAND SPARK ARRESTER- SPARK PLUG STATOR/FLYWHEEL INSTALLATION STEERING HEAD BEARINGS - STEERING STEM SUSPENSION SWINGARM - SYSTEM DIAGRAM ELECTRICAL SYSTEM > THROTTLE OPERATION TOROUE VALUES 17-1 INDEX TRANSMISSIONW- TROUBLESHOOTING ALTERNATOFIICAM CHAIN TENSIONER CLUTCH/GEARSHIFT LINKAGE CRANKSHAFT/TRANSMISSION CVLINDER HEADNALVE CYLINDER/PISTON v~ ELECTRICAL SYSTEM ENGINE DOES NOT START OR IS HARD TO START- ENGINE LACKS FOWERT- FRAME/BODY PANELS/EXHAUST SYSTEM-w FRONT WHEEUERAKE/SUSPENSIONI LUBRICATION SYSTEM POOR HANDLING POOR PERFORMANCE AT HIGH SPEED POOR PERFORMANCE AT LOW AND IDLE SPEED 16-5 VALVE CLEARANCE - WHEELS/TIRES WIRING DIAGRAM