HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standard set by L).S. Environmental Protection Agency and California Air Resources Board. Performing the first scheduled maintenance is very II'I'IpOP tant. It compensates for the initial wear that occurs during the breakrin period. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 20 describe parts of the motorcycle, grouped ac cording to location. Find the section you want on this page, then turn to the table of contents on page 1 of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The sub- sequent pages give detailed procedures ll you don't know the source of the trouble, go to section 21 TROUBLESHOOTING. All Iniormation, illustrations, directions and spec- ilicltinna included in this publlcaflon are based on the latest product ininrmation availnhlu at the timl of an approval tor printing. HONDA Moron 00.. LTD. Reserve: the tlght to make changes at any tima without notice and without lncurrirlg any nullgatinn whalavl', I No part oi this publication may be produced with- out writtln permission, HONDA MOTOR (30., LTD. SERVICE PUBLICATIONS OFFICE I ENGINE CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM JIIL ENGINE REMOVAL/INSTALLATION \_. , 7 .— \_CYLINDER HEAD/VALVES CYLINDER/PISTON CLUTCH ALTERNATOR/STARTER CLUTCH Eaauaa CRANKSHAFT/BALANCER TRANSMISSION CHASSIS ELECTRICAL morn WHEEL/SUSPENSION] ; 7 STEERING REAR WHEEL/BRAKE/SUSPENSION HYDRAULIC BRAKE IEaEa FAIRING/EXHAUST SYSTEM I BATTERY/CHARGING SYSTEM Ila! IGNITION SYSTEM I El L: : :, ELECTRIC STARTER SYSTEM m LIGHTS/INSTRUMENTSISWITCHES I El I WIRING DIAGRAM E:l I TROUBLESHOOTING El INDEX Dare oi Issue: September, 1988 Q HONDA MOTOR CO., LTD 1. GENERAL INFORMATION GENERAL SAFETY 1 - 1 SERVICE RULES 1-1 MODEL IDENTIFICATION 1-2 SPECIFICATIONS 1<3 TORQUE VALUES 1-5 TOOLS 1-7 CABLE 8t HARNESS ROUTING 1-9 EMISSION CONTROL SYSTEMS 1-16 EMISSION CONTROL INFORMATION LABELS IU.S.A. only] 1-18 GENERAL snrm If the mgine malt be running to do torn: work, malt: «are the area it u'tll~l'trrlllatcrl. Never run thz engine in l1 closed area. The exhaait contain: prrimnnuc carbon monoxirlr gal that can mun lost It] consciousness and may [lead (0 death. AWARNING Casaiinc is (xtrzmelyflammable and i: cxplaxive under certain canal/lam. Work in a well renn'laud am with the rngln: slappedt no mu smoke or allow flame; or yparlt: in yaw working uraa or when gnmll‘n: it stated. Brake Illlsl may («main asbeflal‘. - Inhalltd asbevlntflllus have been found to must rttpiramr ry ditaau and tartar. Never use an air hat: or dry Imuh tu clean brake afltmblifin - In the United States, an an OSHA approved vacuum dean” or alternate mztllatl appravrd by OSHA dm'gned In minimize 1h: hazard cam-ed by airlmrne asbnlus fibers. SERVICE RULES m— - The balmy glue; olfupltniw gluzs: Imp sparks, name: and clgamm away. Pruvid: adzquz vznrllarlnn when aiming. ' The banery L‘Illllflllu Juifurifl tu‘ld (eltctmlyl‘c). Lamar: wllh .tkln or gym may cause sew-r: burnt. Wear prowl-tilt! clothing and a face shield. — If electrolyte gets on your Jilin. flush with water. — l/ elrclralyte gm in your (vet. fluth with water for at least I5 minute: and call a physician. ' Ellctmlyn is poisanaul'. — I/ mallow-ed, drlrllr large quantities a] water ar milk and/oila ‘ ith milk afmagnetrla or vegetable oil and call a physician. CAUTION - Um: engine oil m cause skin mum if repeatedly Iefl in t‘onlacl wilh (lu- skin for prolonged [terrorist Alllwtlgh this it unlikely art/ail you handle used oil on tl dill/y basis, i/ I; Ell” advisable [D thoroughly wash yaur imam with soap and watt-r as 3mm as [msu’ble after handl- mg um: all. It Use genuine HONDA or HONDArmccmmended parts and lubricants or (hell aqulvalent Parts that do not meet HONDA's des‘lgn spemllcatmns may damage the motorcycle, 2. Use the special too|s deslgned for thls product 3 use only metric tools when servicmg Ih'ls motorcyclet Metric bolts. nuts, and screws are not interchangeable with English fasteners. The use at incorrect tools and lasteners may damage the motorcycle. 4, lnstall new gaskets. Orrings, cotter nlns. lock plates, etc. when raasssmbllng. 5. When tightening a series 0' bolts or nuts, begin with the larger-dlameler or inner lmlts first and tighten to the specified torque dlagonallv, unless a particular sequence is spemlied. a Clean parts in cleaning solvent upon disassembly. Lubricale any sliding surfaces below reassembly. 7. After reassembly, check all parts for maps! lnstallation and uperatl‘un 1-1 GENERAL INFORMATION MODEL IDENTIFICATION '88: AFTER '33: The Irame serial number Is stamped on the right slde DI xhe The vehicle Identification numbev [VIN] is on the right Slda slaenng head, oi Ihe name pups. | I l IDENTIFICATION NUMBER The engine serial numbnr is stamped on me right crankr The cavbuvetor Idemiflcation number is stamped an the case. carbuvefiov bodv. 1-2 L—__— SPECIFICATIONS GENERAL INFORMATION < >: Calilornia modal ’ ITEM SPECIFICATIONS DIMENSIONS Overall length 2.I95 mm (36 4 in) Overall width 890 mm (35.0 In) Overall heigm 1,220 mm (48.0 In) Wheelbase 1,435 mm (56.4 In) Seal heigm 870 mm (34.3 in] . Ground clearance 255 mm (10.0 in] Dry weight 152 kgl335.1 Ibl Curb weight 168 kg (370.3 lb] FRAME Type Semirdouble cradle Front suspension, travel Telescopic fork, 220 mm (8.7 In] Rear suspension. travel Swing arm, I95 mm (7.7 inl . From [ire sixe 90:90—21 545 Rear tire size 120490 17 643 Cold tire Rider only ironl 150 kPa (1.50 kgi'cm7, 22 psi) "”55”“ Rear 150 kPa (LSO kgicmi, 22 psi) Rider and Front 150 kPa (1.50 kgi'cmz, 2 psi) “"9 passenger Hear 200 kPa (2.00 kg/cmz. 2 psI) me brake Hydraulic. Slngle disc Rear brake Inlernal expanding shoes Fuel capacixy 13 Illels 13.4 US gal, 2.9 Imp gall Fuel reserve capacity 2.5 liters (0.66 US gal, 0.55 Imp gall Caster angle 28"30' Trail 117 mm (4.6 in) Fork oil capacity 592 an (20.0 US oz, 20 B Imp ozl . ENGINE Type All cooled 4-sucka Cylinder arrangement . Single cylinder, 15“ IrICIII'IEd lrum VErtICBI Bore and stroke 100 x 52 mm I194 x 3.23 inl ‘ Displacement 644.0 cc (39.29 an In] Compression ratio 3.3 : 1 Valve (rain OHC, chain drive, 4-valve Oil capacity 2.3 lirers (2A3 US qr, 2.02 Imp qr) alter disassamhly 1.9 |i1ers l2.01 US qt. 1.67 Imp qt) aker draining Lubrication syswm Forced pressura and dry sump Air iiiiraiion Paper mm Cylinder compression 125 kPa (12.5 kglcm‘, 178 psil Imake valve Opens 5“ (ETDC) Closes 40“ (ABDCl}al 1 mm IHr Exhaust valve Opens 45n (BBDC) ' Closes 5° (ATDC) Valve clearance (cold) IN 0 10 mm (0.004 In] EX 0.12 mm I0.005 In] Engine dry weight 50 kg (110 lbl CARBURETOR Type Constam Vacuum, Single carburetor ID. number VEBlA . Main je1 #155 Pilot screw opening 3 lums our Floal level . 18.5 mm [07 in) Idle speed 1,300 1 100 rpm ‘1-3 GENERAL INFORMATION Iniiial Full advance Ignition timing ITEM SPECIFICATIONS DRIVE TFIAIN i Clutch Wet, multirplatc Transmission Erspeed constant mesh Primary drlven 2.028 169134) Final reduction 1000145515) Gear rariol 1666132112) ‘ Gear ratio ii 1.750128!16) Gear ratio ill I 250 l25420) Gear ratio N I 00012103) Gear ratio V 0 840 l2l.’25) Gear shin paItem Left foot operated reIurn system. 17N72737475 ELECTRICAL Ignition DC-CDI 3° BTDC at idle 28° BTDC ar 4,000 rpm Alternarur AC gsnararsr 0.15 kw!5,000 rpm Emery capacily 12V BAH Spark plug NGK ND Standard DPHBEA 9 X24EPR rUS F‘" 9‘95““ “'9" i DPRQEA—Q X27EPR— us speed riding Spark plug gap 0.8—0.9 mm 10.031vo.035 In] Fuse Main 20A Sub 10A x 2 + 15A Sianing system Electrical stater Headiight 12V 60i55W Tailibraka light 12V 32i3cp Front turn signalirunnmg light 12v 3ch x 2 ‘ Hear Iurrl signal light 12V 32:9 x 2 1 Meter lights 12V 1,7w x 4 ‘ High beam indicator 12V |.7W Turn signal indicator 12V 3.4W x 2 Neutral Indicator 12V SAW TORQUE VALUES ENGINE GENERAL INFORMATION ”EM O‘TY 0112,2522] TORQUE N-m lkg»m. lt-lbl REMARKS Crankcase drain plug 1 12 25 [2.5. 18) Oil lilter cover bolt 3 6 9 [0.9‘ 7) Valve adjusting screw lock mu 4 8 15 [1.5. 18) Cylinder head bolt 6 9 36 (3,6, 26) Apply ml to the threads Cam sprocket bolt 2 7 20 (2.0, 14) Apply a locking agent to the Rocker arm shall 2 14 28 (2.8, 20) threads Sub—rocker arm shaft (IN) 2 14 28 (2.8. 20) (EXl 2 12 23 (2.3, 17) Cylinder head cover bolt (8 mm) 1 B 23 (2.3. 17) (6mm) 1 6 10(1.0,7l (6 mm SH) 11 6 12(1.2,5) Spark plug 1 12 18 (1.3, 13) Cylinder bolt 4 1O 50 (5.0, 36) Apply pil to the threads Cylinder nut 2 6 10 (1.0, 7] Clutch lock nut 1 1B 110 (1 1 .0, 50) Primary drive gear nut 1 1a 110 n 1.0, 90) Gearshift cam bolt 1 6 12 (1,2, 91 Apply a locking agent to the threads Stopper arm bolt 1 S 25 (2.5. 18) Flight crankcase cover balllnut 11 E 12 (12, 9| Slarter clutch bolt 6 B 30 [3 0, 22) Apply a locking agent to the threads Flywheel bolt 1 12 125 [12.5. 90] Apply M052 paste to the threads Len crankcase cover bolt 7 6 12 [1.2. 9) Starter gear cover 5 6 12 [1.2. 9) Crankcass bolt 11 6 12 [1,2, 9) Center shllt fork boll 1 7 15 [1.5, 11) FRAME ITEM O‘TY JAR?“ TORQUE N-m lkgrm, fl-Ibl REMARKS . mm) 1 Down lube drain plug 1 10 35 (315, 25) Oil strainer nut 1 18 40 (4. 29) Oil hose flare nut 2 16 40 (4.0. 29) Fuel valve cup 1 — 4 (0.4, 3) Spoke 7 7 4 (0.4, 3] Engine hanger nut (10 mm) 5 10 (8 mm) 6 8 Skid plate bolt 3 6 Oil pipe llare nul 1 18 40 (4.0. 29! Handlebar upper holder 4 l 8 26 (2.5, 19] Handlebar lower holder 2 8 26 (2.6 15) Brake disc bolt 4 8 35 (3.8. 27] Front axla nut I 12 65 (6 5, 47) Front axle holder nut d 6 12 (1 Z, 9) Fork slidar socket bolt 2 i 8 2012 O. 14) Apply a locking agent to the 1 threads Lower lurk pinch ball 4 B 33 [3.3. 24) Fork cap bolt 2 — 23 [2 3. 17) Upper lork pinch bolt 4 B 28 [2 B, 20) Blake callper bracket bolt 2 8 17 (2,7, 20) Steering adjustment nut 1 26 5 (0.5, 3.6) Steering stem nut 1 24 100 (10.0. 72) GENERAL INFORMATION (AFTER ’88:] dsrds balaw. 2 I 8 l ITEM O'TY I $2533“ TORQUE [kg-m, rub) REMARKS Driven sprocket nut 6 10 46 (4.6, 33) Apply oil to the threads Rear axle nut 1 16 95 [9.5, 69l Brake arm nut 1 6 10 (1.0, 7) Shock absorber spring lock nut 1 — 9019.0. 65) Shock absorber mount nut l 10 75 (7.5, 54) Shock absurber lower mount halt 1 1O 45 (4.5. 321 Shock arm tu-shock link nut 1 10 45 (4.5, 32) Shock link-tn-swing arm nut 1 10 45 14.5, 32] Shock arrnntoelrame nut 1 10 45 (4.5. 3D Swinger!“ pivot nut 1 14 110 (11.0, 30) Bread valve 1 7 E l0.6, 4| Front brake caliper bracket bolt 2 8 27 [2.7. 20l Hanger pm 2 1O 18 (1.8, 13) Hanger pin plug 2 10 2.5 (0.15, 181 Brake lever pivot nut 1 6 6 (0.6,4) Apply oil to the threads Master cylinder holder bolt 2 5 12 (1.2, 9] Brake hose nut {master cylinder sidel 1 1O 35 (3.5, 25) Brake hose iuirfl nut 1 10 1411.4, 10] Brake pipe nut l 10 14 (1,4, 10) Brake hose bolt 1 10 35 (3.5, 25) Caliper pin bolt 1 B 23 l2 3, 17] Apply a locking agent to the threads Caliper bracket pin bolt 1 8 13 (1.3, 9] Apply a locking agent to the threads Exhaust pipe jolm nut 4 B 22 (2.2, 157 Exhaust pips protector halt Z 6 10 (1.0, 7] Apply a locking agent to the threads Muffler hand bolt 2 B 20 (2.0, 14) Mufllsr muunting bolt 3 3 25 12.5, 18) Side stand pivot bolt 1 10 50 (5.0, 361 Apply a locking agent to the threads Rear carrier mounting bolt 35 l3.5. 25] _l Torque specifications listed above are lor the most important tightening paints. ll a specification is not listed. lollow the stan- STANDAFlD TORQUE VALUES Toruue Values l Torque Values "em | N-m (kgrm. rub) ”9'" l N-m (kgrm. ft-Ib] 5 mm bolt and nut ' 5 [0.5, 3.5) 5 mm screw 4 (0.4, 3) 6 mm bolt and nut 10 i1 .0, 7i 6 mm screw I 910.9. 7) 6 mm bolt with 3 mm head 9 (0‘9, 7) 8 mm bolt and nut 22 (2.2, 16) 6 mm llango bolt and nut 12 (1.2, 9] 10 mm bolt and nut I 35 t3 5. 251 8 mm flange bolt and nut l 27 [2.7. 20: 12 mm bolt and nut 55 (5.5, 40) 10 mm flange bolt and nut 40 (4.0, 29) 1-6 1001.3 SPECIAL GENERAL INFORMATION DESCRIPTION TOOL NUMBER REFER TO SECTION Compression gauge attach merit Cam Chain tensioner holder Valve guide learner Universal bearing puller Bearing puller carch Bearing remover Remover handle Remover sliding weighl Needle race remover Bearing remover shah Fuller shah Assembly collar Thread adapmr Attachment, 78 x 90 mm Folk seal drivel Fork seal driver attachment Slaaring stern sucker Sleerlng stern dnvel Ball race remover Ball race remover atlachmanr Driver handle Driver shall Needle bearing remover Snap ling pliers Honda ballery tester Christie battery charger Adiustable pin spanner Steering hearing a‘tachmenl Bearing remover, 20 mm Remover handle Remover sliding weight D7908~KK60000 or equivalem commercially avarlabal in USA. 07973—M630002 01079737MG30003 0798475510000 Dr 07954—6570100lU.5.A,only) 0763170010000 07931 MKZOIOO 07936 ~MK50100 079367KC10100 07741—0010201 07GMC*MK50100 077467 0050100 07931 , ME40000 or 079317ME4000A 079317KF00100 07931 7KF00200 07GADVSD40101 07947—KA50100 079477KF00100 079167KA50100 0794674300101 or 07946—M300000 O7953—MJIOOOO 079537MJ00100 07553—MJ00200 079467 MJ00100 D73317MA70000 07914—3230001 07GMJ70010000 MC 10121‘2 07702—0020001 GN HT54 (U.SlA. nnlyl 07536—3710600 07936 3710100 0793673710200 or equivalent cummelcially available in U.S.A. Not available in USA. GENERAL INFORMATION COMMON DESCRIPTION TOOL NUMBER REFER TO SECTION Spoke wrench C. 53 x 8.1 mm 07701 —0020300 or equivalent commerclally available In Us A, 3 Float level gauge 07401 —0010000 4 Valve spring compressor D77 57 70010000 6 Valve guide remover, 66 mm 07742700I0200 or 0795476570100 6 Clutch center holder 0772470050001 or equivalent commercially available in U.S.A. 8 Gear holder 0772470010100 Nol availble ln U.SIA. B Flywheel holder 07725 70040000 clr equivalenl commarclally available ln USA 9 Rotor puller 07733 70020001 or 07933—3290001 (U.$ A. only) 9 Torx bit IT40) 0770370010100 or equivalent commercially available in USA. 9 Driver 07749—001000!) 10‘ 12. 13 Pilot, 35 mm 07746—0040800 I0 Attachment, 52 x 55 mm 0774870010400 ‘0 Pllot, 25 mm 07746 0040600 10 Attachment, 42 x 47 mm 07746—0010300 10. 12. 13 Pilot, 40 mm 07746—0040900 10 Altachmenn 32 x 35 mm 07746—0010100 10, 12, 13 Attachment, 62 x 68 mm 07746 - 0010500 10 Attachment |.D . 35 mm 0774670030400 10 Bearing remover head, l5 mm 07746—0050400 10 Bearing remover shalt 0774670050100 10. 13 Anachmem, 72 x 75 rum 07746 0010600 10 Pilot, 20 mm 07746—0040500 1O Pilmr 15 mm 0774670040300 12 Lock nut wrench. 30 x 32 mm 07716 7 00204007 or equivalent commercially 12 Extension bar 07716—0020500Iavnilable in U.S.A. 12 Bearing remover head, 17 mm ‘ 0774670050500 13 Attachment. 37 x 40 mm 07745 0010200 13 Pilot, 17 mm 07746 0040400 13 Anachmsnt, 24 x 26 mm 0774670010700 13 Film. 20 mm 07745—0040500 13 Film, 22 mm 07746—0041000 VALVE SEAT CUTTER DESCRIPTION TOOL NUMBER 1 REFER TO SECTION Culrer holder, 6.6 mm 0778170010201 Float cunev INIEX 38.5 mm I32“) 07730 0012400 N01 avallabls In U.S.A. Interior cuuer IN/EX 3715 mm [60"] 07780—0014100 Equivalent commercially 9 Seal cutter IN 40.0 mm [45°l 0778070010500 I available in USA Seal cutter EX 350 mm I45°I 0778070010400— TESTERS DESCRIPTION TOOL NUMBER REFER TO SECTION Dlgllal mulri-[es1er IKOWA) 0741170020000 or KS AHM732—0031U‘SA. only) Civcun raster ISANWA) or 07308 0020000 16, 17, IS, 19 Circuit tester (KOWAl TH—5H 1—8 — CABLE 8i HARNESS ROUTING Note the following when routing cables and wire harnesses: O A loose Wire, harness or cable can be a salety hezerd‘ Alter clamping, check each wire to be sure II is secure. I Do not squeeze wires againsl a weld or the and of a clamp. 0 Secure Wires and Wire harnesses 10 the frame with bands at the designated locations. Tlghtan lhe hands so that only the insulated surfaces contact the Wires or wire harnesses. Route harnesses so they are not pulled (em or have no tax cessive slackt Praiecr wires and harnesses with electrical tape or \ubing where they cantacl a sharp edge or corner‘ 0 Do n01 use Wires or harnesses with damaged insulation. Repair by wrapping them Wlth protective tape or replace them. i Reute wire harnesses 10 avoid sharp edges or corners. 0 Also avoid the projected ends of bells and screws 0 Keep Wire harnesses away lrom the exhaust pipes and ether hol part5. Be sure grommets are sealed in thelr grooves properly. Alter clamping, check each harness to be certain that ii Is not interfering with any moving or sliding parts After routing, check that the ere harnesses are not twisted or kinked. 0 wire harnesses routed a long the handlebar should not be pulled taut, have excessive slack, or lnlerlera with adjacent or surrounding pans in all steering positions 0 Do not bend or twist control cables Damaged control cables will not operate smoothly and may stick or bind. GENERAL INFORMATION O: CORRECT x; INCORRECT GENERAL INFORMATION III FRONT BRAKE (2) CLUTCH HOSE CABLE CABLES (3) TURN SIGNAL LIGHT RELAV [2) HEADLIGHT CONNECTOR (11 CDI UNIT (4) SPEEDOMETER CONNECTOR (BLACK) (5) SPEEDOMETER CABLE 1-10 k————_— GENERAL INFORMATION (2) FUSE BOX (4) CARBURETOR CHOK E CABLE r5) PURGE CONTROL VALVE (California model nnle (1) FRONT BRAKE I5] CLUTCH CABLE (8) PULSE GENERATOR (7) AIR INTAKE HOSE CONNECTOR '88: (3] HEAR BRAKE LIGHT SWITCH {ZI VACUUM TUBE CONNECTOR l1) FURGE CONTROL ,_ VALVE (Calilornva model only) I7) CARBURETOR (5] SEPARATOR [5D HEAR SHOCK ABSORBER OVERFLOW TUBE DRAIN TUBE DRAIN TUBE 1-11 GENERAL INFORMATION I3I CVLINUER HEAD COVER BHEATNER TUBE l2) THROTTLE .' CABLES *~ I1) REAR BRAKE LIGHT SWITCH WIFIE I4] TURN SIGNAL LIGHT RELAY (5) SPEEDOMETER CABLE . (a) CANISTER (California model unIy) (3) IGNITION SWITCH WIFIE [7) ENGINE STOP SWITCH CONNECTOR (WHITEI WIRE CONNECTOR (REDI ('II EATTERV POSITIVE (2) AIR INTAKE [3) BATTERY NEGATIVE HOSE WIRE WIRE [4) BRAKE LIGHT SWITCH WIRE 7 CONNECTOR GENERAL INFORMATION (31 REAR RIGHT TURN SIGNAL [2) CLAMPS LIGHT wnns r. \\ [II TAILEBRAKE LIGHT WIRE [4) REAR LEFT TURN SIGNAL LIGHT WIRE 1-13 GENERAL INFORMATION ”TE“ '33‘ (1) PURGE CONTROL VALVE (CBIIfOIHIE model DI'IIVI \ (3) REAR BRAKE LIGHT swwca couuzgoa CASE DRAIN TUBE L" [4) AIR CLEANER (2) AIR INTAKE HOSE p I ‘61 SEPARATOR (5) SHOCK ABSORBER DRAIN TUBE (2) TAILIBRAKE LIGHT l3) CLAMPS WIRE l1) REAR RIGHT TURN SIGNAL LIGHT WIRE “ (4) REAR LEFT TURN SIGNAL LIGHT WIRE 1-14 1 GENERAL INFORMATION (2) SPEEDDMEYER CABLE (3) PEEDOMETER CONNECTOR 1-15 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Enwronmental Protection Agency and California Air Resources Board (CARE: require manulacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January I, 1953 comply with applicable noise emis- sion standards for one year or 6,000 km (3,730 milesi after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributoi‘s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty II'I eflect SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Control al hydrocarbons is very Important because, under certain conditions. they react 1o form photochemical smug when subjected to sunlight. Carbon monoxide does not react in the same way, but ll is toxic. Honda Motor (20., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro carbonst EXHAUST EMISSION CONTROL SVSTEM Except Iur Calilornia: The exhaust emission control system is composed vi a lean carburetor setting, and no adiustrnents should be made except idle speed ediuatment with the throttle stop screw, The exhaust emission control system is separate from the crankcase emission control system. Calflornla only: The exhaust emission control system consists at a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. No adjustments to this system should be made. although periodic inspection of the components is racommoncad, The secondary air supcly system helps improve emission perlormanca. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the h . combustion c amber (2) AIR CLEANER (1 l BREATHER ‘BB: SEPARATOR ()2: Fresh air (4) AIR SUCTION +— Blow by gas VALVE (3) DRAIN PLUGS 1-16 I GENERAL INFORMATION AFTER '88: ER 111 3252320,: [2| AIR CLEANER (4) AIR SUCTION Q: Fresh alr VALVE «3| DRAIN PLUG .— Bmwm gas EVAPORATIVE EMISSION CONTROL SYSTEM [California model only) This model complies With Calilmnia Air Resources Board svaporative emission requirements. Fuel vapor from (he fuel tank and carburetor is directed into the charcoal canister where it is adsorbed and stared while the engine is stopped. When the engine is running and tha purge control diaphragm vaive is apan, fuel vapor in (he charcoal canis- tel is drawn inlo Ihe engine through the carburetor. Ill FUEL TANK (2] CARBURETOR (3) AIR CLEANER a; [5) DRAIN (S) CANISTER (4) FURGE CONTROL VALVE (P.C.V.) 1-17 — GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS (U.S.A. only) An Emission Camrnl InIormation Label is Iocated on the inside DI the rigm side caver as shown. h camains basic tune up specifications. (II EMISSION CONTROL INFORMATION LABEL EMISSION CONTROL INFORMATION UPDATE LABEL AIler making a high altitude carburetor adjustmsni Ipage 4-1 71, attach an update Iabel on me light side Irame down pipe. Inr s1vuc1‘iuns for obtaining the updata label are given in Sen/ice Loner No, 132, I'II EMISSION CONTROL INFORMATION UPDATE LABEL VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) The Vacuum Hose Ruu‘ing Diagram Label is on the inside of the left slde covar. Rnute the vacuum hoses as shown an (his Iabel. ’88: SHOWN. AFTER 'BB: Slmilav I1) VACUUM HOSE ROUTING DIAGRAM LABEL 1-18 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits Ihe following acts ro the causing lhereol: (1) The removal or rendering inoperative by any person other than for purposes of maintenance. repair or replace- monk, of any device or element of design Incorporated into any new vehicle Ior the purpose of n control prior to its sale or delivery to the ullimalo purchaser or while it' Is 'In use; or (2) the use 01 lhe vehicle aiter such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: I. Removal oil, or puncturing OI the muffler, balflesl haadar pipes or any other component which conducts exhaust gases 2, Removal oi, or puncturing oi any pan oi Ihe intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake syswm. With parts other than those specified by the manufacturer. 1-19 '4 2. LUBRICATION SERVICE INFORMATION 2-2 OIL PIPE INSPECTION 2-4 TROUBLESHOOTING 2~2 OIL STRAINER SCREEN CLEANING 2<4 ENGINE OIL LEVEL CHECK 2-3 OIL STRAINER NUT 2-5 ENGINE OIL CHANGE 2-3 OIL PUMP 2-5 I ENGINE OIL FILTER REPLACEMENT 2-4 LUBRICATION POINTS 2-14 [1| OIL OUTLET PIPE [3) OIL INLET PIPE [4? CHECK VALVE (6) OIL SCREEN I5] OIL PUMP 2-1 LUBRICATI ON SERVICE INFORMATION GENERAL 0 This section describes inspectinn and replacement 0! engine oil and the oil filter. the cleaning of the oil strainer and oil pump servicing procedures. CAUTION - Used engine oil may cam: skin cancer [frepealedly left in cohrucr wilh (he 5k in for prulunged periods. Allhvugh IN: is unlikely rut/(55 you handle used oil on a daily ham, 1: u ml! adviyable lo Ihomughly wash your hands with mp and mm as soon as post'- the my handling used oil. SPECIFICATIONS Oil capacity 2.3 liters [2.4 U.5. qt, 20 [mp qt) at engine assembly [.51 [mars (2.0 05. qt. 1.7 Imp qt) at all change 1.95 liters [2.06 u.s. qt, 1,72 Imp at) at ml and all filter change Recommended DII Honda 4-Streke Oil or equivalent API Service Classillcatlon: SE 0! SF VISCOSITY; SAE 10 W—AO or 20 W . 50 NOTE ' Use SAE 10 W—40 oil when the outside temperature is below 0" C (32° F). Other viscoslties shown in the chart may be used when the average temperar ture in your riding area is wlthm the indicated range. ITEM STANDARD SERVICE qur 0' pump up clearance 0.15 mm (0.006 m) MAX. ‘ 0.20 mm (0.008 in) 7 VOilpump eoqy clearance 6.15—0.21 mm (0.005 0.008 in] 0.25 mm (0.010 in) oil pump and Islesrance 00270.08 mrn [0.0014003 lnl 0.12 mm (0.005 In) on pump delivery Pump A: .5 iters (7.9 us. qlllmin. at 5,300 rpm 7 7 Pump 5: 10.0 liters no.6 us. qtlrrrrm. at 5,300 rpm TORQUE VALUES Crankcase drain plug 25 N~m [2.5 kg-rn, 1B It-lbl Down tube drain plug 35 N-m [3.5 kg»m, 25 [l-lbl Dll flller cover belt 9 N-m [0.9 kg-m, 7 ft-lb) Oil strainer nut 40 N~m [4.0 kg—m, 29 lt-lbl Oil inlet hose nut 40 N'm [4.0 kg-m, 29 It-lhl TROUBLESHOOTING Oil lav-I [on low - Normal oil consumptlon - Enamel oil leaks ~ Worn piston rings Oil contamination - oil not changed often enough . Faulty head gasket Low nil preuun - Faulty oil pump . Oil pump driven gear broken 2-2 — ENGINE OIL LEVEL CHECK Momma motorcycle upright on level ground. Stanthe engine and let it idle lor approximately 5 minutes, Stopthe engine then check the oil level with the oil filler Cap] Mick by Inserting it in until the threads touch the filler neck, Do not screw the cap in when making this check, lftheoil level is below the lower mark on the dipstick. lill to the taper level mark with the recommended oil ENGINE OIL CHANGE NOTE - Change the engine oil with the engine warm and the motors cycle on its side stand to assure complete and rapid drain- ing. Remove the oil liller cap and drain plugs on the frame down tube and the left crankcase. CAUTION - Used engine oil may came skin cancer if repeatedly left in corr- Iat‘i‘ wiih litt- skin for prolonged perinrtr. Ali/rough tho it urr» likely arr/m you handle used oil arr daily Limit. it is slill advis- able to rhmughly wuah your hands with soap am! waler atmon as possible idler handling med m‘li After that oil has drained, check that the drain plug sealing washers are in good condition. then install the plugs. YORCIUE: Crankoau drain plug: 25 Min (2.5 Ira-tn. 18 ltrlbl Downtube drain plug: 35 N-rn [3.5 kg-rn, 25 ft-lbi NOTE - ll maintenance is also scheduled for the oil lilter and the strainer, do these belore filling the lrame oil tank with oil. . the engine takes about 1.9 liters (2.0 0.8. qt, I .7 Imp qt) at oil change. But since only a portion ol that oil is held in the lrame’s oil tank, you cannot add the lull amount initially. Four one liter (1.05 US qtl of recommended oil (page 2-1) into the oil tank Install the oil liIler cap/dipstick Start the engine and let it idle tor a law minutes Stop the engine and add the recommended oil up to the upper level mark with the motorcycle upright. CRANKCASE OIL CHECK BOLT NOTE - The crankcase oil level check bolt is useful when checking the lubrication system; the oil pump adjusts the oil level so that the crankcase is always kept at the proper level. II this check shows otherwise, some portion ol the lubrication system is not working properly. Run the engine first, then stop the engine and wait a law min utes. Remove the oil check bolt The crankcase oil level is correct it the oil is lluah with the bottom at the check bolt hole. Install the oil check bolt. Re check the oil level with the oil filter cap/dipstick LUBEICATION t1) OIL FILLER CAP-i _ 7 [2i UPPER LEVE DIPSTICKWM l3] LOWER LEVEL LU BRICATION ENGINE OIL FILTER REPLACEMENT NOTE - Change the oil filter before filling the frame nil tank with nil. Remove the oil filter cover "am the right crankcase, then remove the I‘Iter clement. Discard the oil filter element. Check that the Bering on the oil Iiiler cover is in good candle (ion. Install the spring, new oil filter element and all filter cover. NOTE - Install the element with the ”OUT SIDE" mark lacing out. - Install the Evil filter cover aligning the tabs on the filter cover and right crankcase cover. Tighten the cover bolts, TORQUE: 9 N-m (0.9 kg-m, 7 {HM Pour in the recommended oil [page 2 3) re the upper level on the 1illter Capidipstlck OIL PIPE INSPECTION Inepem me oil pipes for damage, bonds or cloging and replace ii necessary. ReIer to the following page for oil pipe replacement. 7 on pass pipe (page 6-3] Oil ourlar pipe (page 574, 5] — Oil inlet hose [page 5-4, 5) OIL STRAINER SCREEN CLEANING NOTE ' Perform this malntenance belara filling the engine wlth all. Remove the right crankcase cover (page 53). Remove the oil stralnar and clean it. Install and secure the all strainer with a bolt. Install the right crankcase cover [page 8-9). Fill the crankcase with the recommended oil [page 2»‘I ). (3) BOLTS NT [7’ SPRING I5] OIL FILTER ELEME (5) “OUT SIDE” MAFIK 2-4 V“ LUBRICATION 0“. STRAINER NUT ' V ' (1lélLOLT - NOTE - Clean the screen on the oil strainer nut belore filling the frame oil tank with oil. mmove the oil drain bolt on the trame down tube to drain the all. Remove the skld plats (page 52). Loosen the oil joint nut and dlscunnem the nose from the all strainer nut. Remove the oil strainer nm from me trame down tube. Clean the screen on the all stralnar nut in solvenr and blow dry with compressed air. Check that the 0 nng is in good condition, filinsulll and tlghten the all Strainer nut. TORQUE: 40 N-m (4.0 kwm. 25 h-lbl Connect the oil hose and secure ll wlth the nut. YOROUE: 40 N-m (4.0 kg-m, 29 h-lbl Reinstall the skid plate (page 5’5) l2] OIL STRAlNER NUT (3) (”KING Fill ma ull tank to the upper level with me recommended ml (page 2-1 I OIL PUMP REMOVAL Remove the following; — clutch [page 8~2l — all pump driven gear — orifice and 04an Remove the following: — bolL nut and oil pipe 7 oil pump attaching bolts and all pump LUBH|CATION CHECK VALVE (I) CUTTER PIN Remove the cotter pin, valve retamev, spring and check value from the check valve hnusing. Discard the removed coner pin. Inspect the valve and valve bore for sconng or camamination. ”I CAP Clean or replace as neczssary‘ [2) VALVE Install the check Valve, spring and valve retainer into ‘he check valve housing, and secure mom with a new cone: pin, (3) VALVE RETAINER [5| SPRING (4) COTTEFI PIN DISASSEMBLY m sanws Remove the oil pump screws. Remove the lollowing from me oil pump body. ‘1’ COVER A 70" pump cover A —Ou(er rotor A ilnner rater A 2-6 lUBRICATIO N hmove me following: (1) LOCK HN ‘ . I2] WASHER —|nek pin —lhvust washer Slplrate the ail pump body 1mm the oil pump cover B. [1) PUMP BODY 12] SHAFT flumava the following from the cover E. —Ofl pump shaft and lock pin -Innev rotor B —0utar rotor B INSPECTION Mn: 0 the tip clearance butweon the inner and omer rmor Al. CEIVICE LIMIT: 0.20 mm [0.008 in) Measure the clearance bmween the outer rotor A and the pump body. SERVICE LIMIT: 0.25 mm (0.010 In] LUBRICATION Wipe oil Irom the rotors and pm a piece of nlasflgauge across (I) PLASTIGAUGE Ihom as shown. Install the on pump cover A and (ighten the nil pump screws. Remove the on pump cover A and measure the width of me plashgauge. The widest thickness determines the pump and clearance. SERVICE LIMIT: 0.12 mm (0.005 In]. Measure the up clearance be1ween me inner and oulev rotor as with the pump shah installed. SERVICE LIMIT: 020 mm (0.005 in] 2-8 Manure Iha clearance between me outer mm: B end the pump 3 body, SERVICE LIMIT: 025 mm (0.010 in) Measure the end clearance of pump 8. SERVICE LIMIT: 0.12 mm (0005 In) AFTER ’83: Replace the oil seals II they show any signs of wear or dame anal NOTE - When removing me all seal, nme which surlace ol the oil seal Ieces um. Install new oil seals into the holes squarely m the specified depth fmm the cum: surIaces as shown SPECIFIED DEPTHS: 0.5— 1‘1 mm (032070.043 In! LUBRICATI 0 N (1) COVERT; 0.571,1 mm (00204043 in! [2) OIL SEALS l1) PUMP BODV 0,571.1 mm (0.020 0.043 in) ‘ , LUBRICATION ASSEMBLY (1) DDWEL PIN (SHORT) (2) DOWEL PIN (LONG) N (5) CHECK VALVE 13] PUMP SHAFT (7] SPHING QM (4, THRUST WASHER [8| VALVE RETAINER (5) CUTTER PIN \ 0/ I (9] PUMP COVER A / [10) OUTER ROTOR A [12] LOCK PINS _ 0 111] INNER ROTOR A (13] OIL PUMP BODY (14) INNER [15, omen ROTOR E ROTOR B [IGI PUMP COVER B AFYER '88' [7) PUMP COVER A (3) INNER ROTOR B (21 OUTER ROTOR B (1) PUMP COVER B {9) CHECK VALVE (10) SEALS 2-10 LUBRICATION hm!" the outer lotov Bin the oil pump cover B wllh the punch (1) PUNCH MARK .(2) PUMP COVER E mark an the rotor lacing inside CAU'HON Before im/allall‘on. poor {lu- dmn engine nil inla Me all puss hole in [hr 01'! pump body H mm! [he mlflowa um of the all pass halt- in the check valve homing side a: turning the pump shaft. Install the inner rotor Bin the pump covel B. [1) PUMP BODY (2} SHAFT Insert the lock pln through the all pump shaft, and insert the xhalr through the inner ro1or and pump cave! with the lock pin aligned mm the groove in the inner rotor Install the oil pump body anlo 1he pump cover E. Insert the dowel pins through the pump body and pump cover (I) INNER a. ROYOR A Install the tnlusl washer onto the pump shalt. Insert the luck pin through the hole in the shaft, Install the inner rotor A onto the shalt, aligning its groove with Ihl lock pint Ilutall the cult)! rotov A with the punch malk on the rotor laced l“ PUMP COVER A . l - [2 PUNCH. ”“55": outside. ’ Install the pump cover A onto the pump body LUBRICATION Tighten the all pump screws securely. AFTER ‘88: CAUTION - Before install-men. pour the clam engine all into the oil pass hole in the oil pump body 3 until the all flows out of the oil pass hole in the check valve housing side a: turning the pump shaft counterclockwise INSTALLATION Install tho at 1:: with a new O-ring imo the righl crankcase Install the oil pump onlo 1ha right crankcase. Tighten me we oil pump bolxs loosely Apply clean engine oil (0 new O-nngs. Install 1hs Dil pipe with the new O—vings. Tighten ma oil pipe nut and oil pump bolts securelyl l1] SCREWS 2-12 LUBRICATION Apply clean engine oil [0 a new O-ring. , -(1) D Inmll the orifice with the new O-ring, Install the oil pump driven gear onto the oil pump shaltr Install the lallowing: —clutch Ipage 6-5) —right crankcase cover [page 3-9) Fill the engine with the recommended ml (page 2-3]. AFTER '83: After intsllatlon, suppurt the motorcycle upright on firm, level ground and start the engine and let lt ldle hat a minute. Loosen the oil pipe butt on the rlght crankcase cover (page 3-10} and check that (he oil (lows Gut. Tighten tha oil pipe halt. TORQUE: 12 MM (1.2 Itg-m. 9 ft~lbl 2-13 LUBRICATION LUBRICATION POINTS Unless Otherwise specified, use general purpose grease. Apply oil or grease «2 any other sliding surfaces not shown here. CONTROL CABLE LUBRICATION Pencdrcallv msconnect me mmnla and cluxch cables at their upper ends. Clean the cable and mount In the mmuls and clutch lever, then nil lhe cable ends and relnstall. It Is n01 nec essary u: all the cables. il a cable begins to bind, il mus! be re placed, '33: SHOWN, AFTER 'EE: Similll SHOCK ABSORBER UPPER MOUNT BUSHING 7* , — I SAE It 80 OR # 80 \ GEAR OIL \ DRIVE CHAIN BRAKE CAM / WHEEL BEARINGS DUST SEALS .fil SHOCK ARM PIVOT NEEDLE BEARINGS SHOCK LINK PIVOT NEEDLE BEARING: DUST SEAL COLLARS SlDE STAND PIVOT WHEEL BEARING Grease new wheel beanngs and dust seals before installa- tion. Do not relnslall used wheel hearings or seals. NOTE Some souvces of Mos: paste grease wnh 40% or more molybdenum are: - Molvkore“ Grn Paste manufactured by Dow Corning, USA. v Honda Molv 451D.S.A.only) ' ROOOI ASP manufactured by Rocol Limited. UK, - Rocnl Paste manufactuled by Sumico Lubrlcant, Japan. Any other manufacturer's paste grease flquivalnm m the above may also be used. THROTTLE GRIP a BHAKEICLUTCH LEVER PIVOT BOLTS ffim ',/7 STEERING HEAD ” , / BEARINGSJ’DUST ’ SEAL SPEEDOMETER GEAR! DUST SEAL BRAKE PEDAL PIVOT SWING ARM PIVOTFDUST SEALSJCOLLARI NEEDLE BEARINGS 2-14 3. MAINTENANCE SERVICE INFORMATION 3-1 BRAKE FLUID 3-10 MAINTENANCE SCHEDULE 3-3 BRAKE SHOE/PAD WEAFI 3-1 0 FUEL LINE/FUEL STRAINER 3-4 BRAKE SYSTEM 3-1 1 THROTTLE OPERATION 3-4 BRAKELIGHT SWITCH 3—1 1 CARBURETOR CHOKE 3-5 HEADLIGHT AIM 3-1 2 E AIR CLEANER 3-6 CLUTCH SYSTEM 3-1 2 SPARK PLUG 3-6 SIDE STAND 3-1 3 VALVE CLEARANCE 3-6 SPARK ARRESTER [U.S.A. only] 3-13 CVLINDER COMPRESSION 3—7 SUSPENSION 3‘14 CARBURETOR IDLE SPEED 3-8 NUTS, BOLTS, FASTENERS 3-1 5 DRIVE CHAIN 3-8 WHEELS/TIRES 3—1 5 DRIVE CHAIN SLIDER 3-10 STEERING HEAD BEARINGS 3—15 SERVICE INFORMATION 3 GENERAL 3 Englne oil level check Page 2.3 EngIne oil change Page 273 Page 2-11 Engine oil slrarner nut cleaning Page 2 5 b Engzne oil finer replacemen! SPECIFICATIONS ENGINE Spark plug; Plug gap: 0.5 0 9 mm (0,031 0.035 my Plug type: Standard For extended high speed riding ND NGK ND NGK X24EPR-U9 DPRBEA-S x27EPHrus DPFISEAVS VaIve clearance, INTAKE: 0.10 mm (0.004 in) EXHAUST: ' Throrrle grip Iree play: Carburetor Idle speed: CyIinder cumpressiun: FRAME Choke valve travel: Chain slider service limil. Drive chain slack: Rear brake pedal free play: Clmch lever Iree plav' Tire pressures (rider onle‘ Front' Hear: ’ T‘rre size- From: Rear: 0.12 mm (0.005 In] 276 mm ma 1:4 m] 1,300 1 100 rpm 125 kg-cm’ [177.75 pen with me mm exhaust valve clearance about 1 mm (0.04 m] 10— 11 mm (0.39 O 43 inl 3 mm (1’8 inl 30740 mm I171! 7175/81n) 20—30 mm I4!8—l-l!4 In) 10720 mm rare 3” In) 150 kPa (1.5 kgr'cm’, 22 psi) 150 kPa (1.5 kg/cm’, 22 psiI 90:90—21 54$ 120590717 645 3-1 MAINTENANCE TORQUE VALUES Fue‘ cup Valve adjusting scraw lock nur Roar axle nm Spoke nippla TOOLS Special Compression gauge attachment Common Spanner C, 5.8 X 6.1 mm 4 N-m10.4 kg-m, 3 R-Ib) 25 N-m12 5 kgrm, 18mm 55 N~m19 5 kg m, 69mm 4 N-m [o 4 kgrm, 3 ma) O7908—KK6000070! equivalent commelcially available In USA. O7701—0020300—or equlvalenr commercially available In U SA. 3—2 MAINTENANCE MAINTENANCE SCHEDULE Perform the PRERIDE INSPECTION 51 each scheduled maImenance period. 1: INSPECT AND CLEAN. ADJUST. LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN H: REPLACE A:ADJUST LILUELICATE \7 FREQUENCY ODOMETEFI READiNG [NOTE 11 )I l "“\-s.\7 x 1,000 mi 0.6 . 4 i a 12 16 20 24 Rafe, ITEMS7 \\-~\~ NOTES )1 1,000 km 1 5.4 12.3 19.2 25.15 32.0334 m page L ' FUEL LINE I | l 374 ~ FUEL77$TRAINER SCREEN I 7 7777 77 7 c . c (7: c c c 374 _ ~ THROTTLE OPERATION : I 1 1 3-4 m ~ CAREURETOR-CHOKE l | I I 3.5 5 LJ'R CLEANER 7 7 (NOTE 21 c c R c 0 R7 376 '= ‘ CRANKCASE BREATHER (’88) (NOTE 3) c c c c c c 4-7 g SPARK PLUG 7 7 7 . R R R R R R 736 E - 7VALVE CLEARANCE7 I I | | 1 I I 3-6 77 I: ENGINE OIL R EVERV 2.000 mi 13,200 km R 2-3 5 ENGINE OIL FILTER 7 R7 R R R 2.4 "’ ' ENGINE OIL STRAINER g SCREEN7IN7I7JOWN TUBE I c c c 2'5 1 CAHEUHETOR IDLE SPEED | | | I I I I 3-8 . :EgggsARV A71R SUPPLY I 7 7 I 7 I I “9 “ i Ezziaztigzzizim mm 1 ;- DRIVE CHAIN (NOTE 51 EVERY eoo 111111.000 km) I, L are _ DRIVE CHIAIN mom I I I I I I 340 I g BRAKE FLUID (NOTE 7) I I R _I77I I R 3.10 ‘ g BRAKE SHOE/PAD WEAR I I I I I I 3710 B E77RAKE SYSTEM 7 I I I I 341 ‘ L; * BRAKE LIGHT SWITCH I I I 3-" g - HEADLIGHT AIM 7 7 777 7 ,L, I I 3-12 5 CLUTCH SVSTEM l I I I I I I I 34; I 3 SIDE STAND I I I 343 E 3 ' SUSPENSION , I I I 3-1477 : * SPARK ARRESTER (NOTE 6i c c I c c c c 3713 g 1 NUTS, eons, FASTENERS (NOTE 51 7 I I ! I I 3-147 7 1 . WHEELstEs (NOTE 51 I I I i l I I I 3-15 H STEERING HEAD BEARINGS I I I I 3-15 ‘ Should be serviced by an authorized Honda dealer, unless the owner has propertools and service dale and is mechanically quaIIIied, ‘ ' In the interesi of safety, we recommend these items be serviced ONLY by an authorized Honda dealer. NOTES: 1. At higher odometer readings, repeat 81 lhe lrequencv interval established here. . Service more Vrequencly when riding in unusually wet or dusiv areas. . Service more frequently when riding in rain Dr at full thrunle. . California type only. . Service mnre lrequenlly when riding OFF-ROAD. . USA only. . Replace every two years, or a! indieaied odometer interval, whichever comes first. Replacement requires mechan- ical skill. \Immbun 3—3 — MAINTENANCE FUEL LINE/ FUEL STRAINER Check the luel line lor damage, cracks or fatigue. and replace ll necessary, Turn the fuel valve "OFF". Remove the fuel cup, O-ring and strainer screen and drain the gesnline into a suitable container - Gasoline is extremely flammable andlt uplnrrlve rrrrdzr r-irrar‘rr pendulum. Work in it well ventilated Area. Do Iml minke or allow flame: or spark: in the wnrk area. Wash the cup and strainer screen in clean nonrflammable or night flash point solvent Reinstall the screen, aligning the index marks on the luol valve body and strainer screen. install a new Orting into the fuel valve body. Reinstall the fuel cup, making sure the o g is in place, Hand tighten the fuel cup and then torque it to specification. TORQUE: 4 N-m (0‘4 kg-m, 3 ft—lb) CAUTION - Do not overriglrten the fuel cup. Alter installing. tum the lusl valve "ON“ and check that there are no fuel leaksv THROlTLE OPERATION Check that the throttle grip opens smoothly to lull throttle and iully closes automatically in all steering positions, Make sure there is no deterioration, damage, or kinking in the throttle cables, and that the throttle grip lree play is 27 6 mm (1 (8—1,!4 in) at the throttle grip llange. Throttle grip free play can be adjusted at either end ol the lhronle cable Replace any damaged parts before beginning this adjustment, Minor adjustments are made with the upper throttle cable adr luster, Adjust "at? play by loosening the lock nut and turning the ad- iuster. Tighten the lack nut. Recheck thmltla operation (l) FUEL VALVE l2] FUEL LINE 3-4 MAINTENANCE ”adjustment is made with the iower adiuslett tree play by loosening the lock nut and turning the nor that adjustment. tighten the lock nun noeheck the throttle operation. Bounce any damaged parts. ll necessary. CARBURETOR CHOKE Check that the choke lever moves smoothly Lubricete the choke cable 1' the operation IE not smooth Ramve the fuel tank lpage 4-3). Loosen the choke cable nut and disconnect the choke cable from the carburetott Maasuls the choke valve stroke moving the choke iever from the full open posttion to the close posnion. Ohnkl valvo stroke: 10—11 mm ID.39~0743 in] I! the Choke valve stroke is out of the standard. adjust by Ions ('l) LOCK NUT (2) ADJUSTER suing the luck nm and turning the adjuster. \ / . Operate the choke lever and make sure the choke valve stroke ls within the Slandatd. Connect the choke cable to the carburetor and tighten the choke cable nut. Tighten the adjuster lock nut Connect the choke cable to the carburetor and tighten the choke cebie nut. Insteli the fuel tank (page 4-3). seat and slde cover (page 15 1), MAINTENANCE AIR CLEANER . . . imam Remove the left Elde cover. Remove the air cleaner cover screws and the cover, Unhook the upper element retainer from lhe lower relainer. and remove the element. According to the maintenace schedule, clean the element by applying compressed air from the outslde and il necessary, rer place the elemont with s new one. Install the element in the reverse order of removal, SPARK PLUG Disconnect the spark plug cap and rsrnuve the spark plug, Visually inspect the spark plug. Discard it it the insulator is cracked or chipped. Measure the spark plug gap with a wire-type ieeler gauge. Adjust the gap by bending the slde electrode carefullyt SPARK PLUG GAP: 03—03 mm 10.031—0.035Inl K, L, 08 0.9 mm ‘ (003170.035 in) RECOMMENDED SPARK PLUGS X24EPR~U9 I ND Slandard , — , DPRBEA-9 NGK Fur extended high x27EPR-u9 ND Make sum the sealing washer is in good condition Install the ‘ spark plug. tighten it by hand , then tighten with a spark plug wrench. Connect the spark plug cap. I VALVE CLEARANCE NOTE ~ Inspect and adjust valve clearance while the engine is cold 135“C195"Cl. speed riding DPRSEAVS l NGK L 'ILI'IHT-llvll'NGTl-OLE CAP l2] NOTCH Remove the luel tank [gage 4-3l. Remove the crankshaft and timing hole cans. Remove the valve adjuster caps. (4) CHANKSHAFT HOLE CAP Rotate the crankshali counterclockwise to align the "T" mark on the flywheel with the notch on the lelt crankcase cover‘ 3-6 lSl “T” MARK Malta sure the piston is at TDCtTop Dead Centerl on the com- msion stroke. Check the clearance at the left exhaust. and lelt and righr htake valves by inserting a fealer gauge between the adjusting Icrew and the sub-rocker arm, NOTE - When checking the clearance, slide the Ioeler gauge trorn the inside out In the direction of lhe arrow. Valve clearance: Intake: 0.10 mm (0.004 in] Exhnuar 0.12 mm (0.005 in! Adjust by loosening the lock nut amt turning the adjustlng screw until there IS a slight drag on the Ieeler gauge. Hold the adjusling screw and tighten the lock nut. TORQUE: 25 N-m (2.5 kg-m, 18 fi-lbl Right exhaust valve: NOTE I Special care must be taken when measuring valve clear- ance at the righl»hand exhaust valve, The Half-decompressor slighrlv lifts the right hand, exhaust valve when the crankshaft position is belore compressmn TDC. Tharetore it is necessary to position the crankshalt where there is no valve lift in order to obtain the correct valve clearance. CAUTION - Ulhe crunkshq/‘I plotted the "T” marl: (aligning mark). mute the t'mnhhq/l t'ounlrrt‘luck win» again and align i! with the “T“ mark. This must be done (0 prevent the rmrway drt'onr~ [)MKSOI svsrcmjmmfunm'om‘ng and to obtain the carrot! valve L‘learance. After tightening the valve adjusting lock nut, recheck the valve clearance. Install the removed parts in the reverse order of the removal. CYLINDER COMPRESSION Before measuring cylinder compression. edlust the right ex- haust valve with the valve clearance approximately 1 mm (0.04 in) (page 3 6). Warm up the engine. Stop the engine and remove the spark plug. Install the attachment to the compression gauge. TOOL: Compression gauge attachment 07908—KK6000 or oquivalenl cummrcially available in U.S.A. Connect the compression gauge Position the engine stop switch OFF. Open the throttle grip all the way, Crank the engine with the starter motor until the gauge stops rising. Check the gauge reading NOTE - Check that there is no leakage at the gauge connection. finessron; 121s ltglcm l177.75 psi] MAINTENANCE MAINTENANCE Low compression can be caused by: . Improper valve clearance adiusrment - Valve leakage ~ Leaking cylinder head gasket - Warn piston rings or cviinder High compression can be caused by: - Carbon deposits in the combustion chamber or on the piston head. NOTE - After inspection, reinstall the spark plug and adjust the valve clearance (page 3-6). CARBURETOR IDLE SPEED NOTE (1) THROTTLE STOP SCREW - Inspect and adjust idle speed alter all ether engine adjust- ments are within spec' "cations. The engine must be warm _ tor accurate idle inspect‘ n and adjustment. Ten minutes at ‘ stop and no riding is sufficient Warm up the engine, shift to neutral, and hold the motorcycle uprighlt Connect a tachometer, Turn the throttle stop screw to obtain the specified idle speed. IDLE SPEED: 1.300 t 100 rpm DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION - Neva inspect or adjust the drivt chain while the engine is run- nlhg. Turn the ignition switch OFF, plane the motorcycle on its side stand and shift the transmission into neutral, Check dnve chain slack in the lower run midway between the sprockets‘ STANDARD SLACK: 30—40 mm I1»1l4—1—5I8 inI DRIVEN CHAIN ADJUSTMENT Loosen the rear axle nut, fl 5, _ at”... . ____, Loosen both look nuts and [um both adiusling nut: as "8625- . (2) ADJUSTING NU v- i Salyt CAUTION . Br sum the index mark: a] the same posiliun are aligned wit the rear edge: of the swing arm holes. Tighten the rear axle nut. TORQUE: 95 Man [9.5 kg-m. 69 R4!” S the d‘ 1 nt ' t h d . nug 3 INS er I] 3 up BQEII’IS 1 B SWII’Ig arm en caps (4)4INDEéMAHKS Tighten both lock nuts. 3-8 k—_— ,_ ; IQI'EQCK‘ NUT v v"‘*"" MAINTENANCE We». chain weer label. It lhe red zone on the lebel aligns with the errow ol the chain adjuster after the chain has been Kfiltrated. the chain must be replaced. When the drive chain becomes extremely dirty, it should be ‘7 decried prior [0 lubrication. i Remove the rear wheel (page I3-3l, Remove the drive sprocket cover and chain cover Clean the drive chain with a non-flammable or high flash point and wipe dry. Lubricate only with SAE #30 or 90 gear oil Commercial chain lubricants may contain solvent: which could damage the rubber O-rings. (l) WlFE DRY W 29” .. 12) LUBRICATE SAE #80 or #90 7EGEAR OIL 7 ‘ lrlepect the drive chain and o-rlngs lar possible wear or dam- r 099‘ Replace the chain if it is worn excessively or damage. l i (1) MASTER LINK (2) O-RINGS Inspect the sprocket teeth 1m excessive wear or damage. Ree piece It necessary. Drive sprocket replacement: page 574 Driven sprocket replacement: page iii-5,6 NOTE . Never install a new drive chain on worn sprockets or a worn chain on new sprockets. Bath chain and sprockets must be in good condition, or the new replacement chain or sprockes will wear rapidly. Reinstall the rear wheel (page 13-7) and chain cover. [H GOOD 12] REPLACE We/Ae A 3-9 MAINTENANCE DRIVE CHAIN SLIDER Check the chem slider for wear or damage. Replace the dnve chaln slider it the thickness exceeds the 59,, vice Iimit. SERVICE LIMI'I: 3 mm (1/8 in] CAUYION - I] the dram slider bemme: worn down ”trough m the turf/lg arm, the chain will wear against the swing arm BRAKE FLUID m coven Check the from brake iluld reservoir level. If the level Is near the lower level mark, remove the cover and dlaphragm Flll [he reservoir with DOT 3 or DOT 4 BRAKE FLUID m the upper level. {2| scnswe ’ \ XA K; Check the entire system lor leaks, if the level ‘ls low. CAUTION - IJn mu remnve the mvcr unlil lilt- handlzbar has been lurm-d so lhal (h? mxervnlr I: level, - Avoid operating the brake lever Wllll the cap rPllde. Brake fluul Will xqm'r! (Jul 1/ Ike lever Li pulled, - Du rm! mix lily/mm [ypt's ujfllllll. May we nul t‘ompluible I UPPER LEVEL with each Other. I I Relel to sectlon l4 lor brake bleeding procedures. BRAKE SHOE/PAD WEIIR BRAKE PAD WEAR Check the brake pads Ior wear by looking though slu‘ indicalr ed by arraw cast on the caliper assemblyt Replace the brake pads if the wear line on the pads reaches the edge ol the brake disc (page 144) CAUTION - Always realm 1m- brake pads in pairs In mm evcrt Am [Mat- WW. 3-10 — MAINTENANCE BRAKE SHOE WEAR "‘ .. W ' '(ZJIARROW Mace the brake shoes if the arrow on the indicator plate light with the “A” mark an the brake panel when the brake is wlild. BRAKE SYSTEM BRAKE PEDAL HEIGHT Loosen the lock nut and adjust the pedal height by turning the newer bolt. Tight» the lock nut. Adjust the brake pedal free play. BRAKE PEDAL FREE PLAY NOTE - Adjust the rear brake pedal free play after adjusting the bvake pedal height. Measure the rear brake pedal free play‘ WEE PLAY: 20—30 mm (3/4—1-1I4in) Adjust the free play by turning the adjustev. BRAKE LIGHT SWITCH NOTE . Perfurm this adjustment after adjusting brake pedal height and free play. The brake light should go on when the brake pedal is de- pressed 10 mm [3/8 in). Adiust by turning the adjusting nut. CAUTION - Do not mm the switch body (2) SHE/35E LIGHT SW23 3-11 MAINTENANCE HEADLIGHT AIM (1) VERTICAL ADJUSTER Adjust vertically by turning the vertical adjuster. Tum the adjuster counterclockwise (clockwise) to direct the beam dawn. Adjust horizontally by turning the hurizantal adjuster. Turn the adjuster clockwise (counterclockwisel to direct the beam toward the right side 0' the rlder, NOTE - Adlust the headllght beam as specified by local laws and / regulation. [2» HORlZONTAL ADJUSTER - A n Improperly adjrured headlight ma y blind oncoming drivers. ur it may [all In light (Ill mad far a .mfc distance. CLUTCH SYSTEM Measure the clutch lever free play at the lever end. FREE PLAY: 10720 mm lam—314 in) 10720 mm (3J873l‘1il Adiust as fellows; [1| LOCK NUT [2| ADJUSTER Minor adjustments are made with the upper adjuster. Pull the cover back. Loosen the lock nut and turn the adjuster to obtain the speck fied lree alavt Trghten the luck nut and install the cover. Check clutch operar tum. Major adiustments are made with the lower adjusting nur Ir majm adjustment is reuuired, turn the upper adiuster in all the way and back out 1 turn. Loosen the lock nut and turn the lower adiusting nut ta obtain the specified lree play, Tighten the lock nut, Check clutch operationr 3-12 MAINTENANCE SIDE STAND Ail) WEAR MARK Chuck the rubber pad on the side stand lor deterioration and war. Rial-cc the rubber pad if wear extends to the wear line. Chuck the side stand operation: Whon lowerd. the stand should move easily to the first siop, [2) SM? STA D RUBBER than luck lurward to support the motorcycle! when the pad 7M touches the ground and the weight of thn motorcycle is sup ‘ / I ' pound, A thn the motnrcvcle is raised, the stand should automatically _ 3. move to the firsr 5min, ihen retract easily when kicked. , I4| RETFIUCTED (3) FIRST CLICK II the side stand does not operate smoothly, disassemble and (—4) RETURN SPRIN W check the side stand assembly as following procedure: Remove the return spring at the retracted position. Remove the pivm bolt and side stand. Check the Iollowmg parts: — Inside a! the DIVD‘ and pivot collar (or wear or damage, — Pivot dust seals Ior damaget Lubricars the plvot area with clean grease and reassemble tho :ida standi Apply a locking agent to the bolt threads Tighten the pivot bolt securely. (5) PIVOT BOLT TOH°UE15D N~m (5.0 kg-m, 36 fi-lbl CAUTION . bum/I rhe dim seal with in mar/t T141? faring mi - Make sure Ihai ihc dust .teal lip .tpring n- mated on rhi- oiiisidt‘ 0/ [he duxl .mal lip: securely. Check the side stand operation as indicated above SPARK ARRESTER (U.S.A. only) m MUFFLElrLlDS Remove the muffler lid Start the engine and increase rpm‘s to blow csrhoh out of the exhaust pipe while momentarily creating exhaust system back manure by blocking the and n1 lhe muiiier with a shop towel Repeat until carbon stops coming out - Do not perfnrrn this operation while the exhaust pip: is hot. - Per/arm rhb uperau'lm in a well ventilami area, free from fire hazard. ' Us: adeuuar! eye (irritation. (2.) BOLTS MAINTENANCE Aftel cleaning the spark atrasler, install the mufller lid and gas [H GASK T ket. NOTE ~ Check that the mulfler lid and gasket are in good condition and the bolts are tightened securely SUSPENSION FRONT Check the action ol the from suspension by compressing it several times With the hunt brake applied Check the entire fork assembly lor signs of leaks or damage Replace any components which are uniepaiiabla. Tighten all nuts and bolts to their specilied torque values, - [)0 nm‘ ride a whirl: with [dully rutptnsiun. Loon. worn or damaged Suspension parts may affect “ability and rider um— IrtII. REAR Check the action at the rear suspension campunems by Cami pressing the suspension several times. Check the entire suspension assembly, to be sure that all at the components are securely mntlmcd and that none are dame aged or distorted Tighten all nuts and bolts to their speCiiied torque Place the vehicle on a support to raise the rear wheel. Move the rear wheel Sideways with force to see if the swmg arm pivot m wheel beatings are worn. Replace if excessively worn, Check the entire suspension system to be sure it is securely mounted and not damaged or distorted. Tighten all nuts and bolts to their specified torque values. 3-14 ***.— MAINTENANCE r Grease the swing arm and shock linkage pivot bearings through their grease nipples. NllTS, BOLTS, FASTENERS Tighten the bolls, nuts and fasteners at the intervals shown In the Maintenance Schedule IPage 3A3). Check that all chassus nuts and bolts are tightened to their core tect torque values image 175 and 6]. Check all cotter plrls and salary clips, WHEELS/ TIRES TIRE PRESSURE NOTE . Tire pressure should be checked when the tires are COLD. PRESSURE, FRONT: 150 ltPa (1.5 kg/cm'l 22 psi) REAR: 150 km: (1.5 kg/cmz. 22 psi) SIZE: FRONT: 90150—21 54S REAR: I20/90—17 645 Check the tiles lav cuts, embedded nails. or other sharp ab- jams. Tighten the wheel spokes periodically. More frequent inspec» tion is necessarv when ridlng elf-read. TORQUE lfronllrearl: 4 N4" IDA lt-Ib. 3 lt-Ib) TOOL: Sparta-l C. 5.3 x 6.1 mm 07701—0020300 Equivalent commercially available in U.S.A. STEERING HEAD BEARINGS NOTE - Check that the control cables do not interfere with the rate than DT the handlebars. Bursa the tram wheel off the ground and check that the handlebars rotates freely. IV the handlebars moves unevenly, bind or have vertical move- ment, adjust the steering head bearings by turning the steering head adiustment nut With a pin spanner. (page 12-20). FUEL SYSTEM 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING FUEL TANK AIR CLEANER CASE CRANKCASE BR EATH ER CARBURETOR PILOT SCREW ADJUSTMENT (IDLE DROP PROCEDURE) 4-1 HIGH ALTITUDE ADJUSTMENT +2 IU.S.A. only) 4-17 4_3 PURGE CONTROL VALVE INSPECTION (California modal) 4-17 4-4 SECONDARY AIR SUPPLY SYSTEM 4-6 (California modal) 4-1 9 4-7 4-1 6 I SERVICE INFORMATION GENERAL mi - Gama": I: extremely flammable and I; explosive under certain conditions. Work In a well ventilated um. do nut milk: or allow llama or spark: in the W0”! mu m where gasoline is norm. 0 When disassembling the fuel system parts, note the locmmns oi the O-rings. Replace them with new ones on reassembly, O The carburetor floal chamber has a draln screw "131 can he loosened to drain residual gasoline. CAUTION - Do not bend or win control cab/a. Dumugnl can/ml cables will m7! operate smoothly and may slick ur bind. NOTE - ll vehicle is to be slored (or more than one monlh, drain the lloat chamber. Fuel leh In lhe lloat chamber may cause clogged Jets resulting in hard Starling or poor driveability. SPECIFICATIONS Fuel tank capacity Fuel reserve capacily 13.0 Illels l3.43 US gal. 2.85 Imp gal] 2.5 Iller510.66 US gal, 0.55 Imp gall < >: Calilornia model Throttle bore 42.5 mm identification No‘ VEB1 A Float level 18 5 mm (073 in) Maln iel «155 7 Slow jet 7' #43 V idle speed 7 1,300 1 100 rpm Throttle grip tree play 2 6 mml1l8—1!4inl Pilot screw opening 3 mm: out All' cut-off valve operating pressure 390 1 20 mm Hg TOOL Common Float level gauge 07401 70010000 FUEL SYSTEM TROUBLESHOOTI NG Englne ‘rurn; But Won't Start ~ No luol In tank ‘ No luel to cylinder - TDD much fuel getting to cylmder ~ No spark at plug [ignition mallunction or fouled spark plum - Air cleaner clogged - Improper throttle operation Engine ldles Faster. Roughly. Stalls. or Runs Poorly - late speed incorrect - Ignitlon malfunctlon - Rich mixture ' Lean mixture ~ Arr cleaner clogged - Arr leaking into manilold . Fuel contamrnatsd . incorrect arr screw adlustment - Fuel tank breather tube clogged lCaIIlotnia model cnlv‘l ~ Faulty purge control valve - Faulty emisslon control system hoses Lean Mlxture - Carburetor fuel lets clogged - Fuel tank breather tube clogged - Fuel filter clogged ' Fuel tuhe klnkad or restricted - Float valve laulty - Float level too low - Vacuum stuck piston Rich Mixture - Worn or damaged starter valve - Float valve faulty - Float level mo hlgh - Carburetor arr jets clogged - Sticking lloat - Dirty arr cleaner - Vacuum diaphragm damaged Idle Speed Too High . Incorrect throttle slot) screw adjustment - Faulrv choke valve ~ Starter valve stuck open Engine Does Not Slow Down Smoothly - Incorrect pilot screw adjustment Engina Lacks Puwar at Low and Idle Speeds - lncorrect air screw adjustment After burning during decelerallon - Faulty Ignition system . Faulty alt cut all valve . Lean mixture (California model only:] : Faulty secondary alr supply system : Faulty noses of the emission control system Poor parlormsnoe (drlvaahllitvl and poor fuel economy - Clogged fuel system - Faulty lgnltlan system - Dirty arr cleaner [Calrlormla model onlv'l : Faulty purge control valve - Faultv noses in the emission control system El. TAN K VMOVAL Move the sida covers and seat (page 15-2). Tundra fuel valve OFF and dlscunnec1 the luel tube at the luel Me. i (kaolin: i: untmely flammable and u lxplan'w under cmaln undiliam. Walk In a well Ventilated um, dn no! smuke or . wow flame; or spnrlu in the work area or where gasoline is A land. Remove the nght and left lronL larrlng maunting screws. Pul the lairing studs out of the gramets of the luel tank. NOTE - When removing the fairmg, be careful not to break them. Remove the fuel tank moun1lng bolt and remove the luel tank by sliding i1 backward. Check that luel flows out of the luel valve freely, H llow is re stricted, clean the luel strainer [page 34L INSTALLATION Install the luel tank In the reverse order of remuval. NOTE - After assembling, make sure there are no (Us! leaks. . Do not avenighten the fuel valve nut. (1) FUEL FILTER Q 4 N-m 40.4 tum Va) 3 h-Ibl a @ F UEL SYSTEM lzlfiNk FUEL STRAINER SCREEN FUEL SYSTEM AIR CLEANER CASE , m rust REMOVAL Remove the side covers and seat lpage 15-2], Remove the rear lender lpage 15-5] Remove the battery from the air cieaner case (page 16-3). Loosen the arr cleaner case duct band Disconnect the separator-to-arr cleaner case tube. [2) BAND Disconnect the regulatoI-‘rectifler 3P connector Separate 1h9 ' W W“ HARNESS wire harness item the holder on the air cieaner case. ‘ Remove the air cleaner elment cover by removing three screws. Dlsconnact the starter rainy switch connector. Disconnect the negative and positive battery cables at the starter relay switch. Remove the ait cleaner case from the frame as shown, Check the air cleaner case for cracks or other damage. Refer to page 376 for the air cieaner service. (1] AIR DUCT FUEL SYSTEM INSTALLAT|ON Installafion is the reverse order of removal. Rout: the wire hamess propevly (page 1711 and 12]. (2) AIR CLEANER ELEMENT a «h E [3| AIR CLEANER [4) AIR CLEANER CASE COVER g CASE FUEL SYSTEM CRANKCASE BREATHER |NSPECTION Check the crankcase breather tubes lor secure connection Check the crankcase nmalhev tubes and separatov 101 damr age, cracks, deterioIaIion or blockage Heler la page 1711 [0! correct crankcase Dreamer tube roulr mg '88: 5$ 40 fit NE W H] SEPARATOR ‘3) BREATHER HOLDER i? [2) DRAIN PLUG FUEL SYSTEM AFTER 'BB: 14] TO- AIR CLEANER CASE (1 I SEPARATOR (2) THREE WAY JOINT fig 13} BREATHER (5) FROM HOLDEFI CRANKCASE CARBURETOR REMOVAL Remove the fuel lank (page 473) Disconneu the crankcase breather 1ubes and nu” ma sepalar xor out a! me rubber holder‘ Loosen the nut and disconnect the choke cable ax the carburer tar. FUEL SYSTEM Check the valve and needle for wear or namage ‘ . " VALVE If necessary, replace the starter valvsl Compress the spring into the choke valve nut and remove the choke valve lrom lhe choke cable Install a new choke valve in Ihe reverse order of removal Remove the throttle cable holder by removing two screws Disconnect (he rhmulo cables from the [hlnltle drum. - ’ 3(2) CABEEHOVLDER- n I_. Loosen the air cleaner case duct band, (1) lNSULATOFl ~. Zl CAHBUHETOR Remove the carburetor lnsulator mountlng bolts and remove the carburetor from the left side With the carburetor Insulator. DISASSEMBLY (I) AIR VENT TUBES (2) FUEL TUBE Loosen the carburetor insulator band, Remmra the «allowing parts mm the carburetor. Carburatnr insulator 7 Fuel lube —Air vent tubes ioverlluw tube l3l OVERFLOW { TUBE l5) BAND l4] INSULATOR 4-3 . ‘ We ma thronle stop screw. For» the lour screws, float chamber and Dvrlng. Hamel/e the lollow'lng. — llorlt pin — "all — float valve — baffle plate Inspect the float valve and valve seat 'or wear or damage. Remove the following. 7 mm let — needle jet holdel — nnsdel jet — slow iet Turn the pllot screw ln and carefully countlhe number ofturns before it seats lightlyt Make a note of this to use as a relerence when reinstalling the pilot screw. CdUTIDN . Damage lo lhe [Ii/0! SCINV seat will occur (/ Ihr.’ pl'lar screw is tighrcrwd againsl the soul Remove the pilot screw. [1) SCREWS (2] NEEDLE JET HOLDER [ll NEEDLE JET —\ FUEL SYSTEM [2) FLOAT CHAMBER ‘3‘ B‘EEEEEELAIE 13] MAIN JET [EELEIILO‘E'SCREW 4-9 FUEL SYSTEM Remove the vouawing. 7 four screws 7 vacuum chamber cover — cnmpvessiun spring Inspect the vacuum piston far wear, nicks or other damage. Make sute the piston moves up and down Ireely in the piston bore. Remove the aiaphvagmlvacuum pustan‘ Push the iet needle holds: and Kum il clockwise 90 degrees with an 8 mm socket. Then remove the needle holder, spring and J9! needle from the vacuum piston Inspect the iet needle for excesswe wear at the up or mher damage. Check Var diaphragm for [ear or damnaration. Remove the followmg — twu screws air cm off valve cover 7 spring — diaphragm Check the diaphragm and spring for wear, damage 0: deterior rationv (3i DIAPHRAGM! VACUUM PISTON, , (1) JET NEEDLE ' (2 SPRING [3) NEEDLE HOLDER (4) DIAPHRAGM! VACUUM PISTON I1] 5 REWS 4-10 Move the two screws and carburemr Imk arm. Draw out thl carburmor link shalr with its spring. Check the Imk arm and link shah {or hands or other damage Chuck the spring and roller for wear or damage‘ Nth: linkshan, spring and roller are drrty, clean them Ihrough- Iv. Insert the link shah with the spring and secure the link arm with two screwsV Chuck the link shall and arm for smooth opevaoon when turnr ing the 1hrot|le drumr Blow compressed aIr lhrough each jet ta be sure it is clean. FUEL SYSTEM (”LINK ARM 141 LINK SHAFT ‘ [3) spams [1) LINK ARM {2) LINK SHAH (4) ROLLER I) LINK ARM. (3) SPRING ‘ FUEL SYSTEM ASSEMBLY (7) DIAPHRAGM: VACUUM PISTON (2) AIR CUT OFF VALVE COVER (5] LINK ARM (1 ) VACUUM CHAMBER COVER (6) LINK SHAFT (B) FLOAT VALVE (9) FLOAT [10! FLOAT PIN / / I [11] FLOAT - CHAMBER 2W [4| DIAPHRAGM a (21) STARTER % VALVE K I23I SPRING \4‘ \,v' (20) JET NEEDLE [13> NEEDLE JET / (14) NEEDLE L/ JET HOLDER Ia PILOT I221 JET NEEDLE (19) THROTTLE ‘ ’ sanw HOLDER STOP SCREW '16] MAIN JET (15) BAFFLE » ”7, SLOW JET PLATE I121 DRAIN SCREW Install the diaphragm, spring and an cut-o" valve Coven I1) SPRING «2) SCREWS Secure the air cut-off valve with two screws. NOTE - Be careful not to pinch the dIaphragm between [he carbureV (or body and air cut-01f valve cover. . Install rho dIaphrugm wI‘th its valve side [Droiecticn side) lacing the carburetor body. 4-12 mull the pilot screw and screw in until it seats lightly. Return the pilot screw to its original position as noted during removal. NOTE - Install the pilot screw by reierlng to the pilot screw adjust- mom on page 4-17. IIITIAI. OPENING: 3 turns out CAUTION . Damage to the pile: .tcrew seat will acrur t'flhe pilot scmw is lighlened against the teat. Install the needle jet. needle jet holder. main jet and slow iet. Set the float valve Into the valve seat, Install the float, aligning its tenge With the gap ol the float "Ive. Insert the lloet pm and install the balfle piste. SM the Heat level gauge above the main jet perpendicular to the carburetor body edge. heline the carburetor body edge. holine the carburetor slowly and measure the float level when the lloet tang just contacts the fleet valve. FLOAT LEVEL: 18.5 mm 10.73 In) TODl: Fhot level gauge 07401—0010000 Replace the float it necessary. Install the float chamber with a new Orrlng. Secure the float chamber With the tour screws. Install the throttle stop screw. FUEL SYSTEM (2) NEEDLE JET HOLDER [1 l NEEDLE ' JET 15) TANGS .‘Wu. . 18.5 mm [0.73 In) (41 FLOALCMMEER r3: TflBOfLLE 51ng soggy/v 4-13 FUEL SYSTEM Install the jet needle, spring and jet needle holder to the vacuum pistun. Push the jet needle holder in and turn it 90 degrees counter- clockwise. (2) DIAPHRKGME m, vacuuM PISTON Install the diaphragm/vacuum piston, aligning the tab 01 the di» aphragm With the cut out in the carburetor and with the vacuum piston held up to almost full open so it does not pinch the diaphragm on the chamber cover. Install the compressron spring into the diaphragm/vacuum piston with the tight cuil pitch down. Install the vacuum chamber cover, aligning the groove in the cover with the tab at the diaphragm. and secure the cover with at least two screws heiere releasing the vacuum piston. (3| ALlGN Install the remaining screws and secure the vacuum chamber cover by tightening the screws. CAUTION - Do nut pinch the diaphragm an the vacuum chamber rover. . Tighten one screw with the lube (lamp nuling its position as shown, Install the following parts to the carbureter. (1) AIR VENT —Air vent tubes TUBES ioverllew tube # Fuel tube NOTE - Secure each tube and with a tube clip. i3l OVERFLOVl rue: lnnall the carburetor Insulator, aligning its tabs with the pro- jection an the carburetor, and tighten the insulator bend se- curely. (6) ALIGN (5) BAND [4) INSULATOI 4-14 h-_— FUEL SYSTEM ALLATION ‘m the lelt sidee install the carburetur with the carburetor m7 “or, mite :arburetclr intake hare into the air cleaner case ducr, dtightan the duct band securely. ficure the carburetor insulator onto the cylinder head with m bolts. Connect each throttle cable to the throttle drum. Secure tho cable holder on the carburetor With two screws. Connect the chuke cable to the narhuretm. and tighten the drake valve nut Inmll the separator into the rubber band, and connect the crankcase breather tubesl Saturn each tube end with who clip Rotate the air vent tube, overflow tube currently, referring lo m- 1-t1. hstall the tollowing parts, - Fusl \ank (page 4-3) — Seal, side covers (page 15-2) After installation adjust the following - throttle grip free play [page 3-4) — carburetor Idle speed lpage 3*Bl ’ Stunthe englne, and check fur inhaling alr around the carbure- ml. l1) INSURETOR-‘l (WERBKE [CABLE ‘\ A;~.....~.V (2) C .BURETOR' 4-15 FUEL SYSTEM PILOT SCREW ADJUSTMENT (IDLE DROP PROCEDURE) NOTE - The pilot screw is factory preset end no adjustment is nec- essary unless the pilot screw Is replaced [see page 4rBl tor removal. CAUTION - Anyfarrl'blt- run-mp: m ramava (ha pilut mew 11mm mp will cause screw breaka I. Turn the pilot screw clockwise until it seats lightly and back it out to the speciflcatmn given. This is an initial setting prior to the final oilut screw adjusts mant. INITIAL OPENING: 3 turns out 2 Install the carburetor (page 4-l5l and warm the engine up to the normal operating temperature Stop and go riding for it) minutes is sullicient. 3. Adjust the idle speed by turning the throttle stop screw. IDLE SPEED: 1,300 : 100 rpm 4, Turn the print screw in or out sluwlv tD obtain the highest englne speed. 5. Readjust the idle speed with the throttle screw, 6. Tum the pilot screw in gradually until the engine drops 100 rpm. 7. Turn the pilot screw 1-1/2 turns open Irorn the position oh- teined in Step 6 8. Readiust the idle speed with the throttle stop screw. 9. Apply Lactite 601 or equivalent to the inside of the limiter cap Install the limiter cap onto the pilot screw so that its tab rests against the Ilaat chamber stop so it can be turned clockwise only. Thls will prevent adjustment in the counter clockwise direction which lichens the fuel mlxture. NOTE - Be careful not to turn the pilot screw when installing the limiter cavt (2i PILOT g/scaew I J «« l 9&[Lbiai WASHER (ll SPRING (4i OVRING (1) P1L6T scneyg l2) LIMITER CAP 4-16 H ALTITUDE ADJUSTMENT SJL ONLY) the vehicle is to be operated continuously above 2,000 (6,500 leet), the carburetor must be readjusted as lollows pinpmve driveaaility and decrease exhaust emissions. .erm up the engine to operating tempeiature. Stop and go driving for 10 minutes is sufficient. hum the pilot screw clockwise 1:2 mm . ‘uet the idle speed to specification, with the throttle stop mw. LE SPEED: 1,300 2 too rpm i... Thit adjustment must be made at high altitude to ensure proper high altitude operation, Much the Vehicle Emission Control lntormation Update lehel ‘pl thown. See SL#132 for information on obtaining the label, huts - Do not attach the label to any part that can be easily te- ‘ moved from the vehicle. - Opemliun u! an altitude lower than 1,500 meters (5.0001191; with the carburetors adjusted [or high altitude: my came the engine is idle roughly and stall. When the vehicle is to be operated continuously below 1 .500 was [5,000 feet); turn the pilot screw counterclockwise 1/2 turn to its original position and adjust the idle speed to IDGEI'i- "lion. Be turn to do this adjustments at law altitude Wllh the engine It normal operating temperature. PURGE CONTROL VALVE INSPECTION (California model) NOTE - The purge control valve should be inspected it hot restart is difficult. Check all Iuel tank, Purge Control Valve [PCV) and chacoal liter hoses to be sure they are not kinked and are surely con- nected. Replace any nose that shows signs of damage or deter violation. NOTE - The PCV is located above the breathet sepaiator Remove the fuel tank (page 4-3). Disconnect the PCV hoses from their connections and remove the PCV from its mount. Refer to the routing level on the inside oi the left side cover. FUEL SYSTEM IZI PILOT SCREW i1i PILOT SCREW CAP [3) CARBURETOR I'll VEHICLE EMISSION CONTROL UPDATE INFQRMATIQN LABEL mint naval C... m. ‘ (e WK! mum Al lllGIl ALTITIM, “" VBIIEII EKISSINI MITIDL Imflllflilol UPDATE llflS mm Ills IHJt musuii ll) IIRDVK [Ilssllll mm nmtmu AlTlTlIl'K PERFMI‘IDE IDMSTMIII INSTRUCTIONS ARE AVAILAIIE AT Vlllll IIITKDIIZED mm KARI. '88: SHOWN, AFTER ‘58: Similar WCUUM PIKE ROUT'NO MAM 4-17 FUEL SYSTEM Connect the vacuum pump to the 45 mm (0.18 In] 1.0. hose that goes to the carburetor body Apply the specrlied vacuum to the PCV. SPECIFIED VACUUM: 250 mm 19.8w Hg The specified vacuum should be maintalned Replace the FCV if vacuum is not maintained. TOOL. Vacuum/Pressuer pump A937X—0417XXXXX m Vacuum pump STrAH-ZBO-MC7 IU.S.A. nnlvi Remove the vacuum pump and connect it to Ihfl vacuum hose that goes to the carburetor Body. Apply the specified vacuum to the FCV SPECIFIED VACUUM: 250 mm (98 in) H9 The specified vacuum should be maintained. Replace the PCV i1 vacuum is not maintained. TOOL: Vucuumanssure pump A937X-041-XXXXX or Vacuum pump ST-AHvZGO-MCT (USA only) Connect a pressure pump lo the 8 mm 103‘ In] |,D. hose that goes to the chacoal canister. While applyan the specified vacuum to the PCV hnsu that goes to the carburetor body. pump air through the canlster hose, Alr should llow through the PCV and out the hose that goes to the carhuretur budyu Replace the PCV :1 air does not How out. CAUTION - Tu prev-cm damugn m the purge mntrul r-ulve. dc no] use high air pressurr Jam's. Use a hand operated air pump only. TOOl: Vacuum/Pressure pump A937X-041-XXXXX or Vacuum pump ST-AH-ZED-MC7 Pressul. pump ST-AH72557MC7 (USA. only) Remove the pumps, install the PCV its mount, route and rer connect the hoses according to the routing label. [4| T0 CARBURETOR BODY / [5| TO CHARCOAL CANISTEH (—j III PURGE CONTROL VALVE [3) CARBURETOR BOD V 07‘. (2) VACUUM PUMP (2) VACUUM PUMP 4-18 F UEL SYSTEM ORDARY AIR SUPPLY SYSTEM “1 (2) AIR max: liiornia model) ‘ YSTEM INSPECTION pun the engine and warm it up the normal operating tempera— Inn. iiaoonnect the secondary air intake hose from me air shame pov- iv. v I Check the secondary air intake purl is clean and he. or caihdn /§ mm" [4| SUPPLY 'l HOSE (3) REED VALVE AFTER '88: Check the secundarv ail intake hose lei clogging. deterioration l 1 «damage and replace li necessary. i check the need valve in the air suction valve [ASV] if the intake his: or supply hose is damaged by exhaust gas, Connect the vacuum pump to the vacuum tube. ‘ TOOL: i Vacuum/Pressure pump A937-o41-xxxxx or ‘ Vemum puma ST-AHAISOJAC‘I i (U.S.A. only) Sun the engine and open the throttle slightly tn be cannin that air is sucked in through the air intake hose. ii an is not drawn in, check the air supply hose and vacuum 1 tube lei clogging. With the an a running, gradually vacuum to the Asv. Check the a intake hose stops drawing air, and that vacuum does not bleed. “gum”? MAM WWWE “Ill-Illa SPECIFIED VACUUM: 300—360 mm (11.8— 14.2 In) Hg m'm'm m m w Mail is still drawn in, if the specified vacuum is not maintained, replace the ASV with a new one. Ii ailerburn occurs on deceleration, even when the secondary 8‘! supply system is nermal. check the air cut on valve for cor- rect vacuum operation FUEL SYSTEM REED VALVE INSPECTION Disconnect the air supply hoses lrom the reed valve cover 07 the ASV. DISCOI’N’IGCI the vacuum tube and air imake hose lrorn the ASV and vemove me ASV mounting balls and ASV. Check the reed valve (or damage or wear, and replace if neces- saw Replace the reed valve with a new ane if the seat rubbe! is masked 01 damagad, or N there is any clearance between the seat rubber and valve, CAUTION . Do not dimmpmhlc Ihc med valve anemhly or bend the reed Muppw. - I/ the Hopper. reel! arm! is faulry, replure 1hr rm! valve m an assembbu Assemble and install (he ASV in (he reverse order of disassem- blvs‘removal NOTE - Aher installing. make sure the alr and vacuum tubes are correctly conneclad (page 1711 and 1-14)‘ (1) AIR SUCTION VALVE IASV) 4 12] REED VALVE E3) REED ( ‘ (4] REED STOPPER % 4-20 ENGINE REMOVAL/INSTALLATION SO N-m (6.0 kg-rn, 34 Man (3.4 kgvm, 25 h-lb) 43 fl-Ib) 40 N~m [4,0 kgrm, 29 ft lb) 60 N-m (6.0 kg-m. 43 mm 5. ENGINE REMOVAL/ INSTALLATION SERVICE INFORMATION ENGINE REMOVAL 5-1 ENGINE INSTALLATION 5-2 5-3 SEUICE INFORMATION GENERAL 0 During Iemnval and inmnauum support the vehicle with suitable blocks. 0 Fans vequiring engine removal Ior servicing: Cranksha II Crankc ase Balancer Tiansmlssinn SPECIFICATIONS Engine weight Oil capac itv TORQUE VALU ES Engine hanger nut: 10 mm nut 8 mm nut Oil pipe flare nut Oil hose Hale nut Search 10 Secflan 1o Secnon 10 Sachem 1 1 50 kg (110 lb) 1,9Iite7512.01 US qt. 1‘67 Imp qt) at draming 2.3 liters [2.43 us m, 202 Imp qt) eker disassembly 60 N-m (6'0 kg-rn, 43 mm 34 Nvm [3.4 kg-m, 25 IK-Ib) 40 N~rn [4,0 kgrm, 29 Itrlb) 40 N-m [4.0 kg m, 29 I‘l-lb) ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Remove the vollowing‘ — seal and slde covers (page 152] fuel tank lpage 4-3) righl and left (airings {page 15-2) Disconnect the lollowing: [1D BRAKELIGHT — cylinder head cover blemher tube SW'TC“ , alternator CDI'II'ICC‘D! 7 pulse generator connectol Remove the following: — exhaust pipes (page 15-7] — brake pedal (page 13-1 I) skid plate — brakelighl switch DisconneCt the lollowlng: — clutch cable at the clutch lilter arm , spark plug cap 7 starter motor cable Loosen the time chain adjuslet lully lpage arBl. Remove the following; 7 cavburetclr (page 4-7) m CLUTC dlive sprocket cover and drive sprocket CABLE, gaatshih pedal — \ool box 7 oil outlet pm: 0 inlet hose engine hanger nuts. bolts and plates Remove the engine from the right side of the frame. Remnve [he tetalnlng plats, oil lulm hose and all inlet plpa (3) JOINT HOSE 5-2 ENGINE REMOVAL/INSTALLATION INE INSTALLATION (1] O-HINGS "7! clean engine oil to a new O-rings. the new O-rings. install the on joint hose and oil inlet pipe the engine 'flal the retnining plate and secure it with two belts r but-II the engine from the right side of the frame. ‘MII the top engine hanger plates, and tighten the bolts and I'm. TORQUE: 10 mm nut: 60 N~m (6,0 kg-m, 43 h-lb) 5 mm nut: 34 MM (3,4 kn-m. ZEOt-lhl I i (3) HANGER AT lnetall the front engine hanger plates, and tighten the bolts and mm. Imtall the front lower hanger bolt with the collar and tighten the nut. 13] HANGER TORQUE: 10 mm bolt: 60 Mom [6.0 Its-m, 43 fl-lbl PLATES 5 mm bolt: 34 Ill-m [3.4 kavm, 25 lt-Ibl Install and tighten the real lower engine hanger bolt and nut. 11) 3 mm BOLTS AND, Inna" the rear upper engine hangar plate. and tighten me a NUTS mm bolts and nuts loosely, lrmatl the callers, 10 mm bolt and nut, than tighten the 8 mm bolts and 10 mm null TORQUE: 10 mm nut: 80 "an (6.0 ltg-m. 43 ft-lb) 8 mm belt: 34 N-m (3.4 kg-m. 25 ft—lb) 441 1°11?!“ eons ENGINE RE MOVALI INSTALLATION Install the oil outlet plpe, and tighten me oil pipe Hare nut. .ZlH OUTLET TORQUE: 40 Nfln [4.0 ku-m, 29 H-Ibl Install the oil pipe/pulse genalawr wna clamp and fairing stays, and secure them with bolts. Connect the oil outlet plpe and joint hose, and Ihe oil inlet pipe to the oil s1rainer nul. Tighten the "are nuts. TORQUE: 40 Mom (4.0 kg-m. 29 ft-lbl [3| INLET FlFE Install the drive sprockel and retaining plate over the counter (3’ CQYER shah, and 1igh1en the bolts Ins‘all the drive spvocket cover and secure it with two DOIISV Install the gearshift pedal aligning lhe punch marks on the pedal and gealshik spindle, and xighten the anL (3) BOLT 5-4 ENGINE REMOVAL/INSTALLATION TOOL BOX Illthu tool box, aligning the boss on the bottom 01 the tool with the gromot. Secure with a bolt. lthc skid plate and secure it with three bolls. dun. following parts in the reverse order of lamoval. Starter motor cable Sunk plug cap Gulch cable Btdtelight switch links pedal (page 1341) , ‘ Exhaust pipe (page 15-7) 4- Pusa generator connector — Alternator connector ‘— Cylinder head cover breather tube - Fuel tank (page 473) - Right and left (airings (page 154] - 5m and side covers {page 15-2) Minn (he lollowings: — Drivu chain [page 3-8] - Blake nodal (page 3-10) — Brakslight switch [page 11 I) — Clutch lever free play [page 3-1 I) Start the engine and check the following: - Exhaust pipes for leakage - Oil pipes/hoses lor leakage CYLINDER HEADNALVES 23 N-m (2‘3 kg-m, 17 mm 10 Mom (1.0 mm. 7 ft~|bl ‘0 NM “.0 kg-m fl/ 7 mm . a" 12 N-m (1,2 Kg-m, 9 lt-lb) 23 Morn (2.3 kg-m. 17 (HI: 28 N~m (2.5 kgrm. 20 h-lb) 20 N-m (2.0 kg-m, 14 h-lbl 28 N-m [2,8 kg-m 20 fi-Ib) 1B N~m [L8 kg-m, 13 frlb) 36 N-rn (3.8 kg-m‘ 26 hrll 6. CYLINDER HEAD/VALVES .. ~SERVICE INFORMATION 6—1 VALVE SEAT INSPECTION AND rTROUBLESHOOTING 6-2 "EFAC'NG 6'12 CYLINDER HEAD COVER REMOVAL 6-3 CYL'NDE“ HEAD ASSEMBLY 6'15 CYLINDER HEAD COVER CYLINDER HEAD INSTALLATION 6-16 DISASSEMBLY 0-4 CAMSI-IAFT INSTALLATION 6-17 CAMSHAFT REMOVAL 6-5 CYLINDER HEAD COVER ASSEMBLY 6-18 CVLINDER HEAD REMOVAL 6-9 CYLINDER HEAD COVER CAM CHAIN TENSIONER REMOVAL 6-9 'NSTALLAT'O" 6‘19 CVLINDER HEAD DISASSEMBLV 0.1 0 SERVICE INFORMATION GEIERAL o This woman :Dvevs maintenance of the cylinder head, valves, camshaft, rocker 31m: and sub-rocker arms. These proce- dures can be performed wirh the engine In the frame. 0 Coal the camshall hearings with clean engine oil 10 provide initial lubrication. O Poul clean engine oil 17110 the Oil pockeu in “we cylinder hand In lubricate 1he Cam. 0 Belors assembly. apply molybdenum disulfide grease lo camshaft Ioumals 10 provide ‘Inixlal lubrICatlan, ITEM STANDARD SERVICE LIMIT Cylinder compression 10.57125 kglcm2 (l49.3l—177.75 as” 31.155» 31.315 mm [1.2266712329in1 31.05 mm (1.222 in) 7 31’091TSI'25‘ mm (12241711304 in) ‘ 31.00 mm (1.220 In]— 31.10I 31.341mm(1.2244 1.23391n] 30.48 mm (1.2001n1 31072731312 mm (12233—12323 In] 30.45 mm 11.199in1 0.04 mm [0.002 in) 11500—11513 mm [04523-04535 in) 11.55 mm [0.455 in) 8.000v8.015 mm (0.3150—0.31561n1 3.05 mm 10.317 in) _ 7000—1015 mm (01756702762 in] 7.05 mm (0.275 in] MAGS—11.484 mm10.4514A0.4521 inI 11.41 mm 10.449 in) 73697—1972 mm10.3137—0.31381n1 7.92 mm [0.312 in) fl Camshaft l '33: IN Cam lobe height EX AFTER '88‘ IN _ EX Hun 0m Mkar arm LD. Sub-rocker arm LD. IN . EX Rocker arm shah 0D. Sulrrockel arm shah OD. IN EX 6 96946372 mm (02744—02745 in) 6.92 mm (0.212 in) Rocker arm shalt-tn-arm clearance 0015—0052 mm (0.0006v0.0020 in) 0.14 mm (0.006 in) Sub-rocker arm shah-(07mm clearance 0013—0043 mm (00005—0001 7 in) 0.10 mm (0.004 in] Valve spnng Free length lnner 35.1 mm (1.38 ml 34.1 mm 11.;4in1 Oursr :16 mm 11.4211) 350 mm11.381n1 Preioadnengih Inner 6.14 x 0.4 kgIZB mm “3,536 1 0.03 1011.1 In) _ 7 _ . Omar 11.3 E10 119131.51 mm (20.01 at 2.20 11111.240 In) — Valve Srem 0.0. IN 057570.590 mIrI 102539—02594 In) 5.50 mm (0.253 In) Ex rises—6.575 mm 102585702585 in) 0.55 mm10.2581n) # Gulde I.D. _IN 5.500 6.615 mm [01598—02604 In) 6.63 mm10.161 in) _ EX 6.6007566 111111102590. 0.2004 In) 6.63 mm [0.261 in) Smmiurguide IN 0010—0040 rnm (0.0004»0.0016 In) 0.060 mm (0.0024 IL ‘ Osman“ ex 003070.055 mm 100012-0002: ln] 0.080 mm10.0031 in1_ Valve face wldth lN 1.207105 mm 10047—0073 in) 2.8 mm 10.10 inl Ex 0.9—1.7 mm [0.04—0.67 In) 2.4 mm 10.09 in) Cylrnder Werpage — 0.10 mm 10.00411) head Valve seat width IN/Ex 1.2—1.4 mm (0.05—0.06 In) 2.0 mm (0.03 in] 6-1 CYLINDER HEAD/VALVES TORQUE VALUES Cylinder head bolt Cam sprocket bolt Rocker arm shaft Subrmcker arm shall [lNl (EX) Cylinder head cuver ball (E mm) (6 mm} (6 mm SHl Spark plug Engine hanger plate nul (8 mm! (10 mm) Oil pipe bah TOOLS Special Cam chain tansloner holder Valve guide reamer Cnmmon Valve spring compressor Valve guide remover, 65 mm TROUBLESHOOTING 30 Nm (3,6 kg-m, 22 lt-lbl 20 N~m (2.0 kg-m, 14 ft-lb) 23 N‘m l2.8 kgem, 20 mm 23 N~m (2.8 kg-rrlt 20 ft-lbl 23 N~m [2,3 kgrm, 17 film 23 N-m «2,3 kgrrn, l7 ll-lb) 12 N-m (1.2 kg-mt 9 ft-lb) 10 N-rrl [1,0 kgrmt 7 hrlb) 15 ern [1.8 kg-m‘ 13 lt-lb) an N-rn [3.4 kg m, 25 ft lb) so N-m [6.0 kgrm, 43 rub) 10 N-rn [1.0 kg-m, 7 fl-lh) Apply oil to the threads Apply a locking agent to the threads 07973— MG3000Z or 07973 W MG3000S 07984 55‘0000 0r 07934—657010C(U25.A,onlyl 07757—0010000 07742—0010200 or 0793476570100 Engine toprend problems are usually performancerelatad and can usually be diagnosed bv a compression test. Engine nurses can usually be traced to the mp»and With a sounding rod or stethoscope. Low Compression - Valve ilncorrect valve adjustment —Burned or bent valves ilncarrect valve timing , Broken valve spring ' Cylinder head Leaking or damaged head gasket —Warped or cracked cylinder head - Cylinder and piston (Refer to Suctien 7) - Faulty decompressor cam High compression - Exessive carbon buildrup an plston head or combustion chamber - Decompressnr does not oparaie or is damaged Excessive Noise - Incorrect valve adjustment - Slicklng valve or broken valve spring - Damaged or worn maker arm or camshaft ' Loose or worn cam chain - Worn or damaged cam chain tensicner - Worn cam sprocket teeth - Faulty cam chain tensmner Poarldllng ~ Compression too low ' Faulty decompressor cam 6-2 CYLINDER HEAD/VALVES TUEE “DER HEAD COVER REMOVAL -"—‘ ' ' " ‘ > ' ’ [4| aRéAT'E'R'i the lollowing camponents; Hank (Page 4-3) , mo: and cavbumor insulator (page 4-7 and Bl Dlplpe bolts, sealing washers and oil pipe Cylinder head cover breather tube Spark plug cap -Chllch cable clamp -wne hanger plates -upul hole caps Remove the crankshaft hale cap and timing hale cap. Turn the crankshaft and align the “T“ mark on the flywheel with the index notch on me [91: crankcase cover when on (he «Impression stroke (page 3-6). Move the cylinder head cover bolts. NOTE - Loosen the bolts indicaled by lhe arrows. Remove these bolts after removing the cylinder head cover, Slide the cylinder head cover to 1hr: intaks Slda and remove It. Hemnve 1he balls from [he cyllndel head cavar. CYLINDER HEAD/VALVES Remove rhe dowel pm: and head cover gasket 'fifiOWEL PrNs V CYLINDER HEAD COVER DISASSEMBLY Remove the tape! hula caps from the cylinder hand coverr Remove me sub-rocker arm shans, sealing washers, wave “WHAFTS washers and subvrocker arms from the cylinder head cover. ' ' , (3) SUB-ROCKER ARMS U] SHAFTS AND WAVE WASHERS Remove me rocker arm shafts. copper washers and rocker l“ COPPER WASHERS - (21 ROEKER ARMS arms lrum the cylinder head cnvsr. ' ‘ ‘ ' ‘ I3] SHAFTS CYLINDER HEADNALV ES —. Pu. PIPE INSPECTION (I) OIL PIPE BOLTS (he oil pipe and DII pipe bolts for bands or clogging fail the condition 01 the sealing washers. k. (2) SEALING I3] OIL PIPE WASHER 1...“..‘fi/ . PCKER ARM INSPECTION . hpecr the rocker arms and sub-rocker arms lor wear or damV II!- NOTE ' If any rocker arms require servicing or replacemem. lnspecl the cam lobes for scoring, chippll’lg or flat sporsr Measure the ID. of the rocker arms and subrrocker arms. SERVICE LIMITS: Rocker arm 11.55 mm (0,455 in) Sub-rocker arm: IN; 8.05 mm ID.317 inI EX17V05 mm [0.277 In] ROCKER ARM SHAFT INSPECTION Impact the rocker arm and sub-rocker arm shalrs Ior wear or damage. Measure each shaft 040. SEKVICE UMTS; Rocker arm mm: 11.41 mm (0.449 In) SMIHocIor lrm shaft: IN: 7.92 mm [0.312 In) EX: 8.92 mm (0,272 In) Calculate rhe rocker armrrorshall clearance $ERV|CE LIMIT: 0.14 mm (0.006 in] Calculate 'rhe subrrocker arm-m-shaft clearance, SERVICE LIMIT: 0.08 mm (0.003 In] CAMSHIIFI' REMOVAL Remove the cam chain (ensiuner shah bolL CYLINDER HEAD/VALVES Push down the tensioner lever usmg a screwdriver and insert ’TENSIONER H0 the pin oi the tensioner holder into the hole of the rensionar to hold the tensionar. Slowiv release the tensioner unrii the (col rests against the cyl- inder head casting. TOOL: Cam chnln tensioncr holder 07973—M630002 or 07973 — MG30003 Turn the crankshaft and remove the cam sprocket holrsi CAUTION - Eu careful not drop the bolts mm the tron/mu remove the cam chain irom the sprocket. HOLDER Suspend the cam chain with a piece oi wire to prevent it from falling into the crankcase. Remove ‘ha camshaft, cam sprocket and tensroner holder. Separate the cam sprocket from the cam sprocket holder and Em TENS‘ONER Remove rho camshaft baaring set pins, reverse decompressor csm stopper and spring. (2) CAMERAFr 6-6 MSHAFI' BEARING INSPECTION the outer race of each bearing wirh your finger. Yhe bear should turn smoothly and quietly. Also check mar rhe nring inner race fits 1ightly on [he camshan. IN» outer races do not turn smoothly and quietly ar Inner a fit loosely on the camshaft, replica the bearings. eplace lhe camshaft bearings in pairs. Move the bearlngs lrom the camshaft. CAMSHAFT INSPECTION I pluck each cam lobe lor wear or damage. Measure each cam lobe height. ”VICE LIMITS: lmnlra: 31.06 mm (1.222 lnl Exhlufl: 31.00 mm (1 .220 In) Support both ends oI lhe camshalt with blocks. Ensure the camshaft runout WIIh a dial indicator. Aclual runom Is 1/2 of the total indicalur reading. SERVICE LIMIT: 0.04 mm [0.002 In) DECOMPRESSOR SYSYEM DISASSEMBLY Frass the cam sprocket holder of! [he camshalr. Remove the 1hrust washer, one way clutch, reverse decom- oressur cam and decompressov cam wkh spring. NOTE - Do not confuse tha cam spring with the clutch spring, CYLINDER HEAD] VALVES [ll BEARINGS I; B % [II SPRING l7] CAMSHAFT (5) THRUST WASHER (5) CAM SPROCKET HOLDER @0055. (ZI DECOMPRESSOR CAM (3) REVERSE DECOMPRESSOH CAM (4) ONE WAV CLUTCH CYLINDER HEAD/VALVES INSPECTION Check me one way clutch oulov, rollers and splings for wear or damage, Check both decompressor cams f0! well! 01 damage. leplace if necessary. lnspscl the cams’ sliding surlace on (he camshuh for scoring or wean DECOMPRESSOR SYSTEM ASSEM BLY Lubricate bmh decampressm cams, on: way clumh and the thrust washer wilh oil, then install me decompressov cam with us spring, onto the camshaft. Inslall the reverse decompressor cum and me one way clulch with a pin. Install lhe the thrust washer. Press We cam splockm holder onto the camshalt alker aligning the lug an the camshaft with the indentation Dn 1he cam sprocket holder. Be sum the! (he one way clutch ouwr rmates ln one dllec‘ion only. (1 I3] ROLLERS l OUTER A' ‘1 (2) SPRINGS YT» hEVERSE DECOMPRESSOR CAM I5] DECOMPRESEIEB RAM (2| ONE WAY CLUTCH [3) ROLLEmsPHING (4) PIN 12] LUG (1) INDENTATIDN ,Eyilndev head belts E LINDER HEAD REMOVAL m eons > me lollowing components: Exhaust pipes lpage 15»7l ”emu... ma cover (page 6-3] Clmfluh [page 6-5i Cylinder head nuts . Loosen the belts in a crisscross pattern in two or more steps. Remove the cyllndsr head, CAUTION c He awful not to damage the 4y ind” hard mah‘ng surfanes. Remove the dowel pine, cylinder head gasket and cam chain guide. Inspect the cam chain guide for wear or damage. Replace the guide with a new one, i1 necessary. CAM CHAIN TENSIONER REMOVAL Remove the iensloner shaft. Remeve the cam chain tensions! and saving. CVLIN DER HEAD] VALVES i1] CAM CHAIN GUIDE CYLINDER HEADNALVES CAM CHAIN TENSIONER INSPECTION Insert the tensioner shalt into the tansioner and inspect the tensioner by turning the shaft. The tensinner shall turns clockwise Ireelv and should not turn counterclockwise. Check the tensioner lifter and tensioner shaft for excessive or abnormal wear or damage. CYLINDER HEAD DISASSEMBLY Uslng a valve spring compressor, remove the valve spring cutters, retainers. sprigs. spring seats and valves from the cyl- indal head. TOOL: VIM spring campnuor D7 757— 001 0000 CAUTION . To prevent loss of tension. du rm: mmprms 1er valve springs more (hurt necessary to rem-we the rollers, NOTE - Mark all parts to ensure that they are reassembled in their original positions. Remove the valve stem seals and discard them. N OTE . Whenever the stem seals are removed, replace them with newlyones. CYLINDER HEAD INSPECTION Check the spark plug hole and valve areas Iar cracks. Check the cylinder head tor waroage with a straight edge and a loeler gauge. SERVICE LIMIT: 0.10 mm "1004 in) 6-10 CYLINDER HEAD/VALV ES VE SPRING INSPECTION the free length of the inner and outer valve springs. LIMITS: HER: 34.1 mm (1.34111) WI'EI: 35.0 mm {1.38 In) pact each valve lor bending, burning. scratches or ovmal elem wear. luck valve movement in the guide, and measure and record valve stem 0.D. "we: mans: IN: e.5a mm 10.25“") . ex: 3.55 mm (0.253 in) ‘ Item the valve guides to remove any carbon deposirs belore mocking clearances. NOTE - II is Important that the reamer is always related In the same dlrecrion when iI is inserted or removed. TOOL: Viv. guide learner: 07984—5510000 or 01984— 65701 00 (U.S.A. only) i Measure and record each valve guide I.D. .. ‘ IEI'IVICE LIMITS: IN: 5.53 mm (0.251 In] EX: 8.63 mm (0.261 ml Calulele the valve slem-to-guide clearance. IEIIVICE LIMITS: IN: 0065 mm [0.0026 in) EX: 0.030 mm [0.0031 in) Ilrhe slem»lo-guide clearance exceeds the service limit, deter- mine il a new guide with standard dimensions would bring the dearanca within tolerance. If so. replace guides as necessary and ream to fit, |ls1em»ro»guide clearance still exceeds the service limit when new guide: are installed. replace the valves. NOTE - Relate valve sears whenever new valve guides are in» stalled. CYLINDER HEADNALVES VALVE GUIDE REPLACEMENT Chill the replacement guides in the freezer for almut an hour. Heal the cylinder head to about 130— 140°C (275A290"Fl with a hut plate ur a oven. Do not heal the cylinder head beyond 300°F [150“F]. Us. temperature indicator sticks. available from welding supply stores, to be sure the cylinder head is heated la the proper temperature. nil/Rive table's fiéihavifij - Tn avm'd burns, wear heavy gloves when handllng the heated cylinder head. CAUTION - Do not as: a torch in heat rlze (‘yllrlden I! may muse warping. NOTE . Tu clear the valve guides. set the cylinder head on proper blocks. Support the cylinder head and drive out the old guides [ram the combustion chamber side oi the cylinder head. CAUTION - Be careful not to damage the cylinder hen , TDOL: Valve guide remover. 3.6 mm 07742—0010200 or 07942—9570100 Place a new O-ring an the new valve guide Drive in the valve from the rocker arm side. Inspect the valve guides for damage. 1‘ '11 VALVE GUIDE EEAME TOOL: Valve guide remover. 6.6 mm 07742—0010200 or D7984— 3570100 Ream the new valve guides alter installation NOTE - Use cutting ail on the reahner during this operation. Always rotate the manner in the same diremian. Clean the cylinder head throu‘ghly [0 remove any metal panir clas. Relece the valve seat: (page 6-13). TOOL: Valv- guide reenter. 6.6 mm 07984— 5510000 or 07984— 357010C IU.S.A. only] VALVE SEAT INSPECTION AND REFACING Clean all intake and exhaust valve: Ihnmughly tn remove carbon deposits. Apply a light coating of Prussian Blue to each valve face‘Lap each valve and seat using a rubber hose or other hand-lapping teal. Remove and inspect each valve. CAUTION - Valves cannot be ground. If the valve face is burned ur badly wam ar if it cantacls the sear unevenly. replace the valve. 6-12 In. width 0! each valve seat. LIMITS: AXE: 2.8 mm [0.10 in) “8132.4 mm ID.DB in) nut is too wide, too narrow or has low span. the seat n b. gmund, V LVE SEAT CUTTERS a Valve Seat tuners, grinder or equlvalenl value saat lug equipment are recommended to correct a worn valve 1-,, I Follow the refacer manuInmmer's operating instructions. VALVE SEAT REFACING Up. a 45 degrae cutter to remove any roughness or IrnguIlfl- in from the seat. I NOT E ‘ Reface \he sent with a 45 degree cutter when a valve guide is replaced. I Us. a 32 degree cunel m remove the mp I14 01 the existing “Iva seat material CYLINDER HEAD/VALVES HI VALVE SEAT WIDTH 45° [1) SEAT CUTTER 32° (2) FLAT CUTTER I3] INTERIOR CUTTER [1| ROUGHNESSIIHREGULARITIES I1} OLD SEAT WIDTH CYLINDER HEADNALVES Use a 60 degree cutter to remove the bottom ‘lld of the old seat. Remove the cutter and inspect the area you have ralaced. Install a 45 degree linlsh cutter and cut the seat to the proper wrdth. Make sure that all pittlng and lrreguleritres are removed. Refinish i! necessary, Apply a thin coatrng cl Prusslan Blue to the valve seat. Press the valve through the valve qulde and onto the seal to make a clear pattern. NOTE - The location of the valve seat in relation to the valve lace rs very important to: good sealing If the contact area rs too hrgh on the valve. the test must be lowered uslng a 32 degree flat cutter. II the contact area ls too low on the valve, the seat must he raised usrng a 60 degree inner cutter. (1) OLD SEAT WIDTH B 50“ 0,971.! mm (003570.043 in) [II CONTACTY TOD HIGH [2| OLD SEAT WIDTH [U CONTACT TOO LOW l2] OLD SEAT WIDTH 60° 6-14 CYLINDER HEAD/VALVES ilh the seat to specifications] using a 45 degree finish cutting the seat. apply lapping compound 10 the valve and lap the valve using light pressure. lapping, wash all residual compound off the cylinder and valve. TE _ Do not allow lapping compound In enter the guides . INDER HEAD ASSEMBLY bull the valve spring seats and new stern seals. Mints each valve stem with Mars: pasre grease lpege 1-H) and insert the value into the valve guide. ‘ (a) curse ' SPRING 151 COTTERS’ mall the valve springs and retainers. NOTE - Install the valve springs with their narrower pitches lacing to the cylinder head. Replace the stern seals with new ones whenever they are lfll'l'loVBdt ‘ “ . H CYLINDER Install the valves inlo lhe valve guidesi turning them slowly ‘ ‘ HEAD so you do not damage the stern seals. Compress the valve springs using the valve spring compres- Ior. then install the valve collerS‘ CAUTION - Tn prevent {out a] termini, do not compress (ha valve springs more than neceuary Ia install the valve rollers TOOL: Viv. spring compressor 07757—0010000 lIi VALVE SPRING COMPRESSOR . CYLINDER HEAD/VALVES Tap the valve stems genfly mm a plasxic hammer to Iirmly sum the cutters. CAUTION ' Support the cylinder hand at») we {he work [much sulfate to pre- vml possible vulva damnga CYLINDER HEAD INSTALLATION (1: spam Ins‘all the spring on the cam cham tensioner aligning, the hole In me tenslnner with the spring end. (2) HOLE AND SPRING END Install the :am chain tensiuner ink: II’IE cvlinev head. Apply engine oil [0 a new Orring and install it in the groove of the cam chain tensianer shah. Insert the Iensioner shaft through the tensioner and imo the cylinder head. Insrau the cam chain guide, dowe‘ pins and a new head gaskeL 6-16 CYLINDER HEAD/VALVES the lollowrng parts: finder head Clmshaft bearing set pins Spring and reverse decompressor cam slopoer all to the cylinder head bolts and washetsr lithe cylinder head baths in a crlsscross pattern ll'l two or naps. [IE1 36N~m (3.6 liq-m. 26 Irlbl the cylinder head nuts. the exhaust pipes (page 1577] SHAH INSTALLATION oil to the camshaft bearings and install them onto the film ends with their sealed ends facing out. y MoSz paste (page 244) to the cam lobe surfaces and huh inurnal. 12] SEAL . , END 3 pushing down the tansioner's lever, set the cam chain ‘uner holder onto the tensiunet, aligning the pin of the with the hole in the tensloner. hilly release the lensioner lever until the holder rests against h cyllnder head casting M052 IDOL: M chdn IIns‘ionor holder 079737M530002 or 07973—M630003 Install the cam sprocket to the camshaft ever the right cam- “l TENS'ONER (2’ CAISHAF, Ihlft bearlng with the "OUT" mark facing the outside . “OLDER Inna“ the camshalt through the cam chain. Retrieve the crankshait hole cap and timing hole Capt Tum lhe crankshaft counlerclockwise and align the “T" mark on the flywheel with the index notch on the Ian crankcase novel. , llaii the cam chain over the cam sprocket chain so that ‘the tlming marks an the sprocket align with the uppar surface al the cylinder headt Install the cam sprocket onto the sprocket holder of the cam- shaft NOTE o Do not turn the sprocket when installing it onto the spmck at holder, Apply locking agent to the threads of the cam sprocket bolts Irid screw one bolt in loosely, [hen screw the other bolt in alter turning the crenkshah. lighten the sprocket bolts to the specified toruue. TORQUE: 20 N-m l2.0 kg-m. 14 fl-Ibl Romave the tensioner holder. CYLINDER HEADNALVES Tum the crankshaft countarciockwise 360“and align the ”T" mark on the flywheel with the index notch on left crankcase cover again. Make sure that the timing mavks on the cam sprocket align with [he uppal surface of the cylinosv head Align the holes in the cylinder haad and tensions! shait by turning the «manner shah clockwise. Install and tighten the bolt. CYLINDER HEAD COVER ASSEMBLY NOTE Each rocker arm is stamped with its letter code in the lunar tion as shown Install properiv. - Note the locations of the wave washers (H INDEX NOTCH / 12] TIMING MAFIKS 12) TAB 6-18 CYLINDER HEAD/VALVES each rocker arm in the correct position, relernng 10 the an page 6-18. all to the rocker arm shah sliding surlace. a locking agent to the threads of the rocker arm shalts. 1M copper washers. insert the rocker arm shafts through cylirder head cuver and rocker arms. and tighten them [0 unified torque. E: 28 N-m (2.8 Ira-m, 20 ft-lbl M051 paste (page 2-14) to the rocker arm slipper surr II the sub-rocker arms and wave washers in the ccrracr iom, referring to the IIIUSUBUDII on page 5-18. Duly oil to the subrocker arm shaft sliding surfaces. ~pr A locking agent to the threads at the sub-rocker arm Hts, then insert tham through the cylinder head cover and mucker arm with copper washersl Mun the sub-rocker arm shalt. WNOUE: INTAKE: 28 N-m [2.8 kg»m. 20 lt-lhl EXHAUST: 23 libm [2.3 kg-m. 17 ft-Ihl Apply M052 pasta [page 2714] to the sumocker arm slipper eracss. CYLINDER HEAD COVER INSTALLATION Paurclaan engine oil into the oil pockets in the cylinder head su that the cam labs: are submerged, Inmll the dowel pins and a new gasket. {M052} i2i COPPER [1i ROCKER fl [3) ROCKER ARM SHAFTS 12] SUBHOCKER ARM SHAFTS (4) SUB ROCKER ARMS ('2) SUB-ROCKER ARM SHAfiré' CYLINDER HEADNALVES <— Set the 8 mm bolt and 6 mm SH bolt on the head cover. men ' V, ' ‘ ' - v Hue cov'E'a slide the cylinder head cover over the cylinder head. - ’ <, Tighten the cylinder head cover bolrs. YOIOUE: 8 mm bolt: 23 Min (2.3 kg-m. 17 h—lb] 6 mm ban: 12 III-III l1.2 Ira-m. 9 h-lh) 6 mm SH bolt: 10 N-m (1.0 k947i, 7 h-lb) NOTE . Tighren the cylinder head cover bolls In a crisscross pattern in \wo or more step: Install and tighran me spark plug TORQUE: 18 N-m [1.8 kgvm, 13 fr-lh) Install the engine hanger plates, bolts and nurs. Tighren rhe nuts to ma specified torque. TORQUE: 8 mm bone: 34 N-m [3‘4 k9»m, 25 h-Ibl 10 mm bah: 60 N-m (5‘0 kg—m, 43 fi-Ib) lnsIBH the clutch cable clamp and tighten the bolt. TORQUE: 10 N-m ILD Ira-m. 7 lr-lb) Cunnecl the cylinder head cover bremher rube. and secure ir with the clip. Install the spark plug cap. Adjust valve clearance (page 3-5L Install lhe oil pipe with lour sealing washers, and tighten rhe OII pipe bolls. TORQUE: 10 Man (1.0 harm. 7 (HM Install the following components: 7 Carburetor Ipage 4-15) — Fuel tank Ipage 4-3l '. j — Sean and side cuvers [page 15-2) .. “um—W 6-20 —————— CYLINDER/PISTON 50 Nm I51) kgrm, 36 k-lbl 7-0 7. CYLINDER/ PISTON _ ICE INFORMATION 7-1 PISTON REMOVAL 7‘3 '. OUBLESHOOTING 7-1 PISTON INSTALLATION 7-5 CYLINDER REMOVAL 7-2 CYLINDER INSTALLATION 7—6 TN: section covers service ol the cylinder and piston. These procedures can he parlormed with the angina in the frame. 5 "in connecting rod small and ID. Exceeds the service limit, see section 10 for the crankshaft removal. ‘ CIFICATIONS ITEM l STANDARD SERVICE LlMlT E 1.0. 100000, 100.010 mm (33354—33374 I") 100.12 mm13.s421n1 ‘Taper — 0.05 mm 10.002 in) ' 001 or round — 0.05 mm 10.002 in) Warpage across top , 7 0.10 mm (0.004 in] ‘ Wan 0.0. at skirt 99350—99330 mm (33370—19362 1n) . 99.35 mm 13.931 inl Piston pin bore 24002—24008 mm 10 9450—09452 ml 24.03 mm 10.946 in) :i::‘:;‘£:‘“°‘°i“°" 0.002 41.014 mm 10.0001 —0.0006 in) 0.07 mm 10.003 inl Pinon ring and gap Top 02070.40 mm 10.0004 016 in) 0.50 mm (0.020 in] Second 0.35—0.55 mm [0014—0022 in) 0.65 mm (0.025 In) 011 lslde Rail) 0.1 0.9 mm 10.01404 ml 7 # Piston ring-to-gruove Top 0030 70.065 mm 100012700025 inl 0.12 mm 10.005 in] “3'3"“ l—Second 0.01 5—0.045 mm (0.0006—0.0018in) 0.12 mm 10.005 in) Cylinder-tD-piston clearance 0.027005 mrn 100003700020 m) 0.10 mm (0.004 in) 7 Piston pin 0,0. 23099—23395 mm 109444-7094“ inl 2336 mm 10.943 in]; Connacting rod small end f 24,020,240“ mm (09457—03455 in) 2407 mm (0.948 inl TORQUE VALUES Cylinder bolt 10 mm bolt: 50 N-m (5.0 kg-m,36 lt-lb) Apply oil to ma threads 6 mm SH bolt: 10 N-m (1,0 kgnm, 7 Il-lb) TROUBLESHOOTING Low or Unstabl. Comprouion Dverhoa‘ing - Worn cylinder or plstun rings - Excessive carbon buildnup on piston head or combus- - Faultv decampressor earn tinn chamber Elmssivo Smoke Knocking or Ahnulmll Noise 1 Worn cylinder, piston or piston rings - Worn piston and cylinder - Improper installation at piston rings - Excessive carbon build-up in piston head or combus- - Scored or scratched piston or cylindlr wall tion chamber NOTE - If the piston, rings or cylinder show excessive wear. check for dirt passing the air filter due 10 improper installation or seal- 7-1 CYLINDER/ PISTON CYLINDER REMOVRL - ‘ ' " , l1) aou‘él “ Remove the cylinder head (Section Bl. Remove the cam chain guide Remove the mo 6 mm small head bolls on the right side 01 the cylinder. Remove rhe loul cylinder mourning belle, Illeil remove the cyl- inner. NOTE - Loosen the balls in a crisscross pal-lam in two or more steps. Remove the dowel pins and cylinder gasket CYLINDER INSPECTION Inspecr ihe cylinder wall lor scratches and wear. Measure and recard 1he cylinder LDV at three levels in both an X and Y axis, Yake the maximum reading to determine the cyl- irrder wear. SERVICE LIMIT: 100.12 mm (3,942 in) Calculate the piston-te-cylinder clearance Take the maximum reading to determine the clearance. SERVICE LIMIT: 010 mm (0.004 in! Calculate the cylinder lor raper ai three levels in an X and Y axis. Take the maximum reading to determine the taper, SERVICE LIMIY. 0.05 mm (0.002 in) and V axisi Take the maximum reading to determine the our of round [1l IN <::l( l2] TOP Calculate ma cylinder lor outrolrruund at three levels in an x ‘ senwce LIMIT: 0.05 mm (0.002 in) r l The cylinder must be rebared and oversize plsmll fined ii the .3] MIDDLE cylinder limits are exceeded. Yha [allowing ovarilz. pls‘on are available: 100.25 mm13.947inland 100.50 mm l3.957 in] (4) BOTTOM The cylinder must be rebored so lhat the clearance to an over- slre piston is 0.02 — 0.05 mm (0.0008 7 0.0020 In) 7-2 CYLINDER] PISTON Clean the cylinder gasket surface. Inspect the cylinder for transverse warpage across the tone NOYE - Measure the warpage using a straight edge and leeler gauge in the directions as shown. SERVICE LIMIT: 0.10 mm (0.004 in] PISTON REMOVAL Place e shop towel into the crankcase opening and remove the piston CIIpS and discard them, NOTE . Do not let the Cllps faII into the crankcase. Push the piston pln out and remove the piston. PISTON/PISTON RING INSPECTION Remove the piston rings from the piston NOTE ~ Do not damage the plston rings when removing them, Inspect the piston for cracks or other damage and the ring grooves for excessive wear or carbon buildrup. Insert the outside surface of the ring into the proper ring groove and roll it around In the groove to make sure that the ring has a free fit around the piston’e circumference and clean the ring grooves. CYLINDER/PISTON Install the piston rings into the piston ring grooves (page 7-5). Measure the piston ring-to-groove clearance, pushing the piston rings into the ring grooves. SERVICE LIMIT: Top/Second: 0.12 mm (0.005 inl After measurement, ramove the platen ring from the piston. Measure each piston ling and gap; using a piston, push the ring into the cylinder squarely to the position as shown and make the measurement SERVICE LIMITS: Top: 0.50 mm [0.0020 in) Second: 0.65 mm (0.0026 in) Measure the piston O.D. NOTE - Take measurement 107mm (0.4 in) from the bottom. and perpendicular to the piston pin hole. SERVICE LIMIT: 99.85 mm (3.931 In! Calculate the piston-ta-cylinder clearance by subtracting the piston OD. from the cylinder I.D. (page 7-2] SERVICE LIMIT: 0.10 mm (0.004 In) Measure the piston pin bore. SERVICE lIMIT: 24.03 mm (0.946 In) Measure the piston pin 0D. SERVICE LIMIT: 23.96 mm (0.943 in) calculate the piston»to-piston pin clearance. SEIIVICE LIMIT: 0.07 mm (0.003 in] / 7-4 CYLINDER/PISTON Measure the LB. 0' the connecting rod small end. SERVICE LIMIT: 24.07 mm (0.948 in) PISTON RING INSTALLATION Apply clean engine oil to the piston rings. , Install the piston rings into the piston ring grooves with the ‘r-J- m marks lacing up. \H] TOP RING . 1 NOTE //////I. _ ‘ (2) SECOND RING - Be carslul not to damage the piston and piston rings during : assembly. t l3] OIL RING Stagger the ring and gaps 120 degrees lrom each other as shown. Do not align the oil ring (side rail) gaps. — 7 NOTE , ..— . in (1) PISTON RING - To install the all rlng, install the spacer first. then install the ' §\ MARK side rails, 12!)“ After installing the rings, check that they rotate ireely without sticking. (7) SIDE RAILS (6) 20 mm (0.8 in} OR MORE PISTON INSTALLATION Cover the crankcase opening with a shop towel. Apply Mosz paste [page 2714] to the sliding surfaces of the plslon pm and connecting rod smeli end. Insert the piston pin through the piston and connecting rod, and secure them with new piston pin clips. NOTE - Install the piston with the mark “IN" facing the intake side. - Alter installing the piston pin clips. make sure that they are seated properly and the end gaps are not aligned with the cut-out in the piston. - Be careful not to lot the clips lali into the crankcase. Clean any gasket materiel trorn the cviinder base surface. CYLINDER/PISTON CYLINDER INSTALLATION Install the dowel pins and a new gasket Coat the outer surface of the piston and Inner surlace of the cylinder with clean engine oil. Position the piston at the The (Top dead center on eompres~ sion stroke), and install it into the cylinder while compressing the piston rings with your lingers, NOTE . Be careful not to damage the piston rings during assembly. - When the cylinder is haltway over the piston, route the cam chain through the cylinder, Apply oil In the cylinder bolls (lo mm) and washers, and tight- sn the belts in a crisscross pattern in two or more steps, TORQUE: 50 III-m [5.0 kg-m, 36 It-Ib) Tighten the cylinder balls 16 mm]. TORQUE: 10 III-m (1‘0 kg-m, 71MB) Install the cam chain guide NOTE - Fit the cam chain guide tab in the cylinder cut-out and push the guide until it bottoms in the crankcase guide hole. Install the cylinder head (page 6-15) 7-6 CLUTCH 12 N-m [1‘2 kgrm, 9 h-Ih) Z5 N-m12‘5 kgrm.16 fi’lblflg)ly / 110 N-m [‘1‘0 kg-m, @ so k-lh) . . @v 110 N-m (11.0 kgrm. 80 h-lb] 12 N-m (1.2 kgrm, 9 Irrlbl 8-0 8. CLUTCH SERVICE INFORMATION 8~1 PRIMARY DRIVE GEAR B»7 TROUBLESHOOTING 8-1 GEARSHIFT CAM 8-9 RIGHT CRANKCASE COVER RIGHT CRANKCASE COVER REMOVAL 8-2 INSTALLATION 8-9 CLUTCH 3-2 SERVICE INFORMATION GENERAL 0 This secrion covers removal and installatlon of the CIUICI‘L gearshift cam and right crankcase cover, All these operations can be parlormsd with the engine in the Irame 0 When the clutch discs are replaced, out new rises with engine all prior to assembly SPECIFICATIONS a ITEM STANDARD SERVICE LIMIT Clutch Lever he; pEVlEJever and) 10—20 mm lid/87 3m in) i 7 , fir Spring free length 44.7 mm l1,76 ini , 43.1 mm [1.70 in) Spring preloadllsngtn 30 at: 1.5 kgiZEJE mm I662 :t: 3.31 lbfl.12 in) — Disc thickness 2.92—3.03 mm [0.1 1 5—0. I 21 in) 2.6 mm [0 IO irL Plate warpage — 0.15 mm [0.006 in) Clutch outer |.D. 27000—271321 mm [1.06307I.0638 inl 27.05 mm [1.065 in) Outer guide OD. 26.959 23.980 mm [10630—10622 in) 26.91 mm (1.059 In) l.D. 21390722035 mm (0.86577118675 in) 22.05 mm [0.868 In) TORQUE VALUES Clutch lock nut 11O N-m [11.0 kg m, BO IHb) Primary drive gear nut I10 N~m [1 I .0 kg-m, BO lrrlb) Gearshilr cam bolt 12 N-m (1.2 kg-m. S l‘Hb) Apply locking agent to the threads Stopper arm boll 25 N-m (2.5 kgrm‘ 18 ft-lb) nghl crankcase cover bolt/nut 12 N’m (1.2 kg~m. 9 ftvlbl TOOLS Common Clutch center holder 07724—0050001 var equivalent commercially available in U.S.A. Gear holder 0772fi700101007Not available in U.5.A. TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch lever free play. Clutch Slips When Accelerating Excesalve LOUD! Preisuru ~ Nu free play - Clutch cable kinked, damaged, or dirty - Discs worn - Lifter mechanism damaged ' Springs weak Clutch Operation Feels Rnugh Clutch Will Nut Dinngago - Outer drum slots rough Too much "as play . Dirty clutch cable - Plates warped Motorcycle Creeps Wlth Clutch Dlsengaged - Too much free play - Plates warped C LUTCH RIGHT CRANKCASE COVER REMOVAL Drain oil from engine and oil tank (page 2-3]. Remove the following components: 7 Brake pedal [page 1340) on pipe (page a 31 Remove the right crankcase covar bolts‘ nuts and right crank- case covert NOTE - Loosen the bolts and nuts in a crisscross pattern in two ar more steps Remove the dowel pins and gaskar OIL SEAL REPLACEMENT Check for the uil sual for damage or deterioration. Remove the snap ring and oil seal. Install the new oil seal and snap ring. NOTE ' Make sure the snap ring is seated in the groove in the right crankcase cover. CLUTCH REMOVAL Remove the right crankcase cuvsr. Remove the (our clutch bolts and springs. NOTE ' Loossn the bolts in a crisscross pattern in two or more steps. 8-2 CLUTCH Remove the push rod tip and clutch like: rod Unslake the clutch lock nul wiIh a drill or grinder fiemove the clumh lock nm. plain washer and clulch center, holding wilh lhe clutch center holder. TOOL: Clumh comer holder 07724 —— 0050001 or oquiv-Inm commercially iVIIIIbIB in U.S.A. Remove the clulch outer and clutch outer guide. 12) CIUTCH OUTE M. .GJJIEL. _ Inspecl the clutch lifter rud far was! or damage. ”1 L‘FTER ROD Check the liner rod fur mraighmsss by rolling the rod on a flat surface, CLUTCH INSPECTION O CLUTCH SPRING Measure thc free length 01 each spring SERVICE LIMIT: 43.1 mm (1.70 in) Replace if shoner Ihan the service limit NOTE . Clutch springs should be rEpIacud as a set if one or more are beyond the service Ii O CLUTCH DISC Replace Ihe discs if they show signs of scoring or discolora- tion. Muasuve the disc thickness. SERVICE LIMIT: 2.6 mm [0.10 in) NOTE - Clutch discs and plates should be replaced as a set N any one is beyund xhe service limix. O CLUTCH PLATE Check lor plate warpage on a surface pIals, using a lealar gauge, SERVICE LIMIT: 0.3 mm [0.01 in] - PRESSURE PLATE BEARING Turn me hearing Inner race wilh your rmger. The bearing should turn smcmhly and quietly. Also check mar me outer race or the healing (its tightly in (he pvessura plate, Replace the bearing with a new ans, if necessary. (II BEARING 12) PRESSURE PLATE 8-4 CLUTCH O CLUTCH CENTER (1] CLUTCH CENTER Check the teeth of the clulch center lav wear‘ damage or ' cracks 12] TOOTH 0 CLUTCH OUTER AND OUTER GUIDE Check the slats In the outer drum for nicks, cuts or indentations made by the friction discs. Measure the LB. 01 the clutch outer and the 0.0. of the outer gutde. SERVICE LIMITS: Clutch outer I D ' 27.05 mm [1.065 in) Clutch outer guude 0 D: 26.91 mm (1059 in) I.D.: 22.05 mm (0388 in) Measure the mamshafl on at lhe clutch outer guide area. SERVICE LIMIT: 21.91 mm IOVBSS in) Calculale [he malnshah larclulch outer guide clearancev SERVICE LIMIT: 0.14 mm [0.006 In) INSTALLATION Apply M052 paste [page 2-141m the clutch outer guide sllding 5 surfaces. and Install the outer guide qur the mainshaitv \nstall the clutch outer over the miter guide. C LUTCH Insxall me clulch lock nut and tighten it, holding wm‘ clutch 5' center holder. x TORQUE: 110 N~m [1 1.0 kg-m, 80 H-lbl TOOL: Cluxch center holdor 07724—0050001 or cqulvalem commnrcially available In UlS.Al Stake the clulch luck nu! wilh a punch. Inscn the clutch lifter rod through the mainshah. Coal (he 7 discs and 6 plums with clean engine all and install them as shown‘ fill \\/\ (1) CLUTCH PLATE (6 pieces] [2b DISC {7 pieces) Install the clutch push rod tip imo the mainshah, (1) FUS ROD TIP ,[Zl CLUTCH DISCS AND PLATES CLUTCH -.— ,....,_._ , 2 w‘ _. Ins1all the pressure plate, clutch springs and clutch bolts, and “(1) CLUYCH SPRINGSfi . tighten me bolls in a crisscross pattern in two or more snaps. ‘ A D BOLTS ' “’r‘lrr PRIMARY DRIVE GEAR REMOVAL Remove the pulse generator by removing the bolts and gromel. Remove the lollowing components: — Clutch [paga 5-2) — Oil pump lpage 2-5l '(3) OIL PUMP Temporarily install 1he clutch outer, men inslall we gear holder between the primary drive gear and driven gear as shown. TOOL: Gear holder 07724— 0010100 Not available in USA. Remove the primary drive gear nut, men remove the gear holder and clutch outer. . l2l PRIMAR GEAFI NUT Remove the following: {(1) PRIMARY DRIVE — washer k‘GEA 7 oil pump drlve gear ‘ — pulse generaior rutur 7 primary drive gear CLUTCH INSTALLATION Install the primary drive gear ever the crankehalt. NOT E . the pulse generator rotor and oil pump drive geer will only go on in one position because of the extra wide aligning spline. Inelall the pulse generator rotor onto the crankshaft. Install the oil pump drive gear and washer onto the crenkshelt. NOTE - Install the washer with the "OUT SIDE" mark laclng om: .‘—————-. H] PRIMARY DRIVE tween the primary drive gear and driven gear as shown. GEAR NUT Install and tighten the primary drive gear nut. TORQUE: 1 1D N-m l1 1 .0 kg-m. BO ft-Ihl TOOL : Gear holder 07724—0010100 Not available in U.S.A. Remove the gear hnlder and clutch outer. r 3'» CLUTCH OUTER u, Install the lollawlng: ~ oil pump (page 2711) 7 clutch (page 8-5) Install the pulse generator and secure it with two bolts. and put the grumet into the groove in the right crankcase. NOTE - Remove any metal chips that may be stuck to the pulse generator magnet, CLUTCH GEARSHIFI' CAM REMOVAL Remove the following: v clutch [page 3—2) 7 bolt, washer, stopper arm and spring — bolt and gearshift cam INSTALLATION Install lhe gealshih cam on ma shilt drum, aligning the hole in the turn with the dowel pin. Apply a locking agent to the threads uf me gearshik cam Doll. izi STOPPEHW} GEAREHIFT and tighten u lo lhe specified turquer ;.~ ' ARM C M YOROUE: 12 "ml [1.2 kg-m. 9 fl-Ihl Install the spring, snapper arrn. washer and boll, holding the stepper mm with a screw driver. Tighten the stopper arm bolt. Insiall the clumh (page 8-5] RIGHT CRANKCASE COVER INSTALLATION Install the dowel pins and a new gaskel C LUTCH Inslall [he llghl crankcase cover. and install and figman the bolts and nuts m a crisscross pattern m two or move steps. TORQUE: 12 N-m11.2 I194“. 9 ft-lbl Install the lollowmg componentes: — Oil pipe [page 8720) 7 Brake pedal lpaga 137111 Fl” lhe engine and oil tank with vecommandad oil (page 2-2) Adjust the fallowings: 7 Clutch lever free play (page 3-1 2) Brake pedal free play {page 3711) 8-10 ALTERNATORISTARTER CLUTCH so N-m «30 kg m‘ 22 H lb) ‘ 12 N~rn (l.2 kg m, " 9!: lb] 12 Nm ”.2 kg-m, 9 it-lb) 9-0 9. ALTERNATOR/ STARTER CLUTCH SERVICE INFORMATION TROUBLESHOOTING LEFT CRANKCASE COVER REMOVAL LEFT CRANKCASE COVER DISASSEMBLY FLYWHEEL REMOVAL 9-1 STARTER CLUTCH 9—1 FLVWHEEL INSTALLATION LEFT CHANKCASE COVER 9-2 ASSEMBLY LEFT CRANKCASE COVER 9A3 INSTALLATION 9—4 9-6 9-7 SERVICE INFORMATION GENERAL 0 This section covers servicmg of the alternator and slanel clutch, These operatlons can be accomplished with the englne m the frame. 0 For alternator Inspectmn and troubleshaotlng‘ raver to Ihe seciton 16 and 17‘ SPECIFICATION ITEM STANDARD SERVICE LIMIT Starter dTIVEfl gear 0.Dl 51755—51768 mm l2.2738—2.2743 m] 57.66 mm (2.270 In] TORQUE VALUES Slaner clutch bolts Flywmml bolt Left crankcase cover bolt Starter gear cover TOOLS Common Flywheel holder Rotor puller Torx bit lT40I TROUBLESHOOTING so N~m (3.0 kg-m‘22 It-lb) Apply a locking agent to the threads ‘25 N’m (12.5 kgrm. 90 Mb) Apply M952 past: (page 2714) to the 1hreads I2 N‘m (1.2 kgrm, 9 film l2 N-m (1‘2 kg-rn. 9 It-Ibl 07725~0040000 or equivalent commerclally available in Ut$.Al 077337 002000! ar07933 3290001 lU.S.A‘ only) 0770370010I00 ar equivalanl commercially available in U.S.A. 5mm motor mm. but angina data: not crlnk: - Faulty starter clutch - Faulty starter Idle gears - Faulty starter driven gear Starter motor dos: not turn: ' FRUI‘V S‘SHSI’ 771010! ISGCIIDH 15) - Faulty starting CII‘CLIII (section 18) ~ Bound idle gears 9-1 ALTERNATOR/STARTER CLUTCH LEFI CRANKCASE COVER REMOVAL Remove the following: — five sucker bolls — starter gear cover — dawel pins " (2') REDUCTION 7 gasket ' GEAR 7 shalt, reduction gear and washer: — shalt, idle gear and washers Check lhe idle gear and reducfion gear for excessive wear or , damage. 3: , Remove the following: ‘ ' ' '. (2) SPROCKET — gaarshlll pedal covgn drive sprocket cover ‘ Dlscnnnecl [he neutral swilch wire hum the neutral swi1ch. Remove the bolts and Is" crankcase navel, NOTE - Loosen the belts in a crisscross pa‘tem in rwo or more SIEDS 9-2 ALTERN ATORISTA RTER CLUTCH Remove lhe 10l|0wlng. ' (Zl‘SH'I-(FT AND 3) DR|VE ; . EAR ' ‘WASHEES . G ’ ‘ — dowel pins — gasket - shalt, starter drive gear and washers Check the starter drive gear for excessive wear or damage. [4| DOWEL_P!N§ (Z) DUST " LEFI' CRANKCASE COVER DISASSEMBLY (1) urren ARM Remove the lollowings; — Clulch lifter piece Clutch lifter arm — Sprrng Check me dust seal lor damage or deterioration Check lhe needle beating fur wear or damage. (4) NEEDLE BEARING Remove me allamalol wire holder and glammetr (2l BOLTS Remove the three bulls and alternalur stannr. FLYWHEEL REMOVAL Remove the flywheel boll while holding me flywheel with \he flywheel hulder. TOOL: Flywhlcl hold-r 07725—0040000 or an elem commcvciallv avl bl. in USA. ALTERNATOR/STARTER CLUTCH i FLYWHE'ET Remove the flywheel using the rotor puller. TODL: Rotor pullar 07733—0020001 or 07933—3250001 (USA, only) STARTER CLUTCH REMOVAL/DISASSEMBLY Remove the followings: 7 Flywheel lpage 93) ~ Washer and starter driven gear — Woodruf key Remnve the needle bearing and washer, and check the needle bearing 'ur wear or damage. Inslall the stanor driven gear onto the flywheel and inspect the starter clutch by turning lha starter driven gear. The driven gear should turn counter clockwise freely and should not turn clockwise, if not so, replace the starter clutch. Alter inspection, remove the starter driven gear. ALTERNATOHISTARTER CLUTCH Loosen and remove the six lorx belts in e crisscross pamern in two or more steps. holding [he flywheel with the flywheel holder. [1 ) TDRX BIT TOOLS: Torx bit ”40] 07703—001010!) or equivnhm commemlally evnllahlo in USA. Flywheel holdlr 07725—0040000 or equivalent commercial“! avail-bl. in U.S.A. INSPECTION Inspect Ihe slaner driven gear for excessive wear or damage. Measure the CD. of the name: driven gear hub. SERVICE LIMIT: 5736 mm (2.210 In] Inspeci me one way clutch lor wear ur damage and replace if necessary. ASSEMBLY/INSTALLATION m CLUTCH (2) ONE WAV _ omen CLUTCH Insiall the one way clutch onto [he clutch outer so that file flange side faces flywheel. [3] FLANGE SIDE 9-5 L— ALTERNATO RISTARTER CLUTCH Apply locking agent to the threads or the tent butts. Tighten the tarx bolts in a crisscross pattern in two or more steps while holding the flywheel with the flywheel holder. TORQUE: 3D "-1" (3.0 Ira-m. 22 lt-lbl TOOLS: Torx hit (T40) 07703—001 01 00 at equlvalont commercially avllllble in U.S.A. Flywheel holder 0772540040000 in equivalent oommorelallv aveilabla in U.S.A. Install the starter driven gear onto the one way clutch, With the flywheel install the starter clutch assy, onto the crankshalt. FLYWHEEL INSTALLATION Wipe all oil a" the crankshalt and Item within the tapered hole ”1 the flywheel. Install the lollowing: — woodrulf key 7 washer — needle bearing Install the flywheel unto the crankshaft. aligning the woodrull key with the keyway. Apply Mosz paste to the threads at the flywheel bolt. Install the bolt and washer, and tighten the bolt while holding the flywheelv TORQUE: 125 Mm (12.5 lg-lll. 90 h-lbl TOOL: Flywheel holder 07725—0040000 or aquivnlm commercially avlilnbl. In U.S.A. I‘ll FLYWHEEL HOLDER (21 TORX BlT ’ 9-6 LEFI' CRANKCASE COVER ASSEMBLY ALTERNATOR STATOR INSTALLATION Install the stator onto the left crankcase cover and apply a locklng agent to the threads ol the stator mounting bolts, Tighten the three baits. Home the stator wire and install the wire grommet into the groove of the sewer as shown. CLUTCH LIFTER ARM INSTALLATION Install the spring onto the litter arm. Insert the lifter arm and hook the spring [0 [he Ielt crankcase covorv Turn the lilter arm and install ths IItter piece, aligning the groove an the litter arm with the bottom 0' the Iifiet piece. LEFI' CRANKCASE COVER INSTALLATION Install the following: — washer and shaft ~ starter drive gear NOTE - Install the starter drive gear with the "OUT" mark facing out. 7 washer Install the dowel pins and a new gasket. ALTERNATOR/STARTER CLUTCH l1 1 STATOR MOUNTING BOLT ' [2| HOLDER ‘ f/ 13) GROMMET l5] STATOR I [1) LIFTER IZI GROOVE 9' ARM . ALTE RN ATOR/STARTER CLUTCH Install the left crankcase cover and connect the neulral 5w‘nch ‘(1l BOL'I: ’ wire‘ ' ' ’ Fm lhe neutral switch wire into the groove of (he left crankr case covei. |nstall \he left crankcase cover with a clamp, and tighten the leh crankcase cover boks in a crisscross panern In two or more steps YOROUE: 12 N-m (1.2 kg-m, 9 h-lbl Install the dvive sprocket cover and secure il with Ihiee bolts Install the gearshill pedal, aligning the punch marks on the pedal and geavshill spindle. Secure Ihe pedal wirh a bolt. Install the shaft and idle gear with Ihe washers. Install the shah and reduction gear with the washers . .t3) PUNCH V ' MARKS 9-8 ALTERNATOR/STARTER CLUTCH Inslallthe dowel plus and a new gasket. Install the starter gear cover and secure it wlm the live bolts. TORQUE: 12 NJ" [1.2 Iw-ln, 5 fl-lbl CRANKSHAFT/BALA NCEH 12 N-m (1.2 kg-m, 91H!!! l2 N-m I1.Z kgrm, 9 hrlb) 12 N-m 41.2 kg-m. 9 mlb) 1 0-0 10. CRAN KSHAFi/BALANCER SERVICE INFORMATION 10-1 CRANKCASE BEARING ' TROUBLESHOOTING 10-2 REPLACEMENT 1°45 CRANKSHAFT/BALANCER CRANKCASE SEPARATION 10-3 INSTALLATION 10,1 0 BALANCEHICRANKSHAFT REMOVAL 10-4 CHANKCASE ASSEMBLY 10-11 I SERVICE INFORMATION GENERAL 0 The crankcase must be separated to service the cranksharz, conneming rod, transmission and balancer. 0 Remove the rallnwing pans before separating the crankcase. Engine Section 5 Oil pump Section 2 Cylinder head Sectlan 6 Cyllnderlpiston SectIon 7 Clutch Section 8 Alternator Section 9 SPECIFICATIONS m ITEM STANDARD SERVICE LIMIT Connecting rod big and side clearancer 0 USO—0.650 mm (0.0020‘ 0 0255 in) 0.80 mm (0.031 in] Connecting rod big and radial clearance 000670018 mm (00002700007 In] 0.05 mm (0.002 in] Crankshaft runout — I 0.10 mm [0.004 in) I TORQUE VALUE crankcase ball 12 Now! ”.2 kg-m, 9 [HM TOOLS Special Unlversal bearing puller 076317 0010000 Bearing puller catch 07931 ~MK20100 ' Iv lent c e I:‘ II Bearing remover 079367MK50100 °v7filai U 5"?" ' '3 V Remover handle D7936—KC10100 a a' a e n ' ' ' Remover sliding weight 07741—0010201 Needle race remover 07GMC—MK501OO Bearing remover shaft 0774870060100 Puller shaft 07931 ME40000 or 079317ME4000A Assembly collar 07931—KF00100 Thread adaptor 075317KF00200 Attachment, 78 x 90 mm 07GAD—SD40'IOI Common Driver 07749—0010000 Piloti 35 mm 0774670040800 Attachment. 52 x 55 mm 07746—0010400 Pilot, 25 mm 077467 0040600 Attachment. 42 x 47 mm 07746 70010300 Pllor, 40 mm 07746—0040900 Attachment, 32 x 35 mm 07746—0010100 Attachment, 62 x 68 mm 07746—0010500 ‘ Attachment, 35 mm ID. 07746—0030400 Attachment, 72 x 75 mm 07746—001060!) Pilot. 20 mm 07746—0040500 10-1 — CRANKSHAFTIBALANCER TROUBLESHOOTING Excessiva Noise - Crankshafl 7 Worn connecung rod bearings 7 Benr conneclmg rod 7 Worn cvankshafl bearmgs ' Ba‘ancev 7 Improper msmnamn 7 Wom balancer bearings 10-2 CRANKSHAFTIBALANCER CRANKCASE SEPARATION Remove the lollowingr bolt, collar and cam chnin tensioner — cam chain — cam chain drive sprocket 4) BOLT AND ' ' V , QQEEAWK: ' Inspect the cam chain tensioner iur excessive wear or dam- age. [1] CAM CHAVN TENSIDNEH Loosen and remove the right crankcase bolts. Loosen and remove the left crankcase bolts m a crisscross par tern in two or more steps. ORANKSHAFT/BALANCER Remove the right crankcase Irnm the left crankcase, (1) GASKET NOTE . Separate the right and Ielt crankcases from each other while tapping them at several locations with a soft hammer. CAUTION . Do not pry (he trankmve: apart wirh a 51' Remove the gasket and dowel pins. BALANCER/CRANKSHAH REMOVAL (1) BALANCER Remove the transmission (page 1 1»3). Insert a proper sized nail into the hoies in the halancsr. while plying the scissors gears with a sciewdrivel. Turn the balancer weight With the baiancer weight out of the crank weight. and paint on the belencer drive gear and driven gear Remove the balancer and pull am the nail. Using a hydraulic press. press the crankshaft am or the hair ”I CRANKSHAFT crankcase. Remove the left crankshaft bearing with a bearing puller it it comes out with (he crankshaft, TOOL: Universal bearing puller D7331 —DD1000O ar .qulvaiam cummorclally eveliabla In U.S.A. Bearing puller catch 07931 —MK2|)'IOO or equivalent cummercielly “Iii-bl. in U.S.A, (3) PILOT 20 mm or EQUIVALENT Discard the bearing CAUTIO N - Always replace the IE]! bearing with a new one if it comes with (he crankshaft. 1 0-4 CRANKSH AFTI BALANCE R CRANKSHAFI' INSPECTION Se! me crankshaft on a lruing stand or V biocks and measure the runoul using a dial Indicator. SERVICE LIMIT: 0.10 mm [0.004 in) Measure the side clearance ol the conneming rod big and with B feeler gauge. SERVICE LIMIT: 0.80 mm [0.031 lnI Measure the connecting rod big and radiai clearance. SERVICE LIMIT: 0.05 mm (0.002 in) BALANCER DISASSEMBLVIASSEMBLY '11 WASHER (2] OUTER DRIVEN GEAR» Separate the outer driven gear from the inner driven gear by re- moving the snap ring and cans spring washer. Remave the (our springs from the inner driven gear [3| SNAP RING 10-5 CRANKSHA FT/BALANCER Check the gears and springs for wear. damage or fatigue, and 11] SPRINGS [2| OUTER DRIVEN GEAR replace il necessary ‘ ' Install the tour springs into the inner drlven gearr 13] INNER DRIVEN GEAR Install the ouler driven gear onto the innal driven gear, NOTE - Position the punch mark on the outer gear between the punch marks on the inner gear. Install the cone spring washer and the snap ring securely. CRANKCIISE BEARING REPLACEMENT INSPECTION Turn Ihe Inner races with your finger. The bearings should turn smoothly and quietly. Also check that the outer races of the bearings Iil tightly in the crankcase. Replace the bearings if necessary. RIGHT CRANKCASE BEARING REPLACEMENT , (2) 'REMOVEH H_ANDLE Remove the right halancer bearing using the following tools ’ TOOLS: Bolling nmovar 07933—MK50100 ur aqulvelant commercially Ivllllbla In U.S.A. Remover handla 07935—KC10100 ur aqulvalam commercially available In U.S.A. Remover sliding wainht 07741 —0010201 or equivalent commarclally available In U.S.A. J31, .S'rIQ'NE £9251 10-6 CRANKSHAFT/ BALA NCEH Bend down me labs of the lock plate, and remove 1ha bah, lock plate and bearing stopper platel Discard 1he luck plate. Remove each bearing am of the right crankcase. Remove the all seal and dlscard It after removing me right crankshaft bearing, Apply clean engine oil tn the lip 01 the new right coumev shall oil seal and install it securely, Apply oil to each new bearings, and drive each bearing into the right crankcase. NOTE v Drive in the bearing perpendiculavlv to the right crankcasa. TOOLS: Crankshlll benrlng Dvivlr 07749 — 0010000 Afllchmnl, 72 x 75 mm 07746—0010600 Film. 35 mm 07746 — 0040800 Right mainshalt hearing Driver 07749—0010000 Attachment. 52 x 55 mm 07748—0010400 Film. 25 mm 0774570040300 (U BALANCE“ ‘2’ MA'NSHAFT BEARING BEARING Right oounlarshaft baring Driv-r 077fl9AOD‘I 0000 Attachment 42 x 47 mm 07745—001030!) Pllol. 20 mm 07746—004050!) nghl balancor be ing Driver 07749—0010000 Amachmont, 42 x 47 mm 0775—0010300 .1, .I v- 3] COUNTERSHAF .. BEAB'NG. 2(4) CRANKSHAFT BEARING 1 0-7 CRANKSHAFT/BALANCER Install the bearing stopper plate and new lack plate, and secure them With a bolt. Bend up the tabs at the lock plale against the bolt. STOFPER F Ti; LEFT CRANKCASE BEARING REPLACEMENT ,1 ‘ [2) BEARING REMOVER Remove the Ian balancer bearing using the lollowing rcols. TOOLS: Bearing remover 07936— MK501 00 or equivalem commercially eveileble in U.S.Ae Remover handle 07936— KC‘I 0100 or equivalent comm- eveileble in U.S.Ae Remover sliding welgm D7741 —001OZD‘I or equivalem commercially ’ ' , I SWING WEIGHT available in U.S‘A. lllv Remove rho needle bearing and check It ror wear or damage, and replace il necessary. Remove the bull and bearing race stepper Remove the needle bearing race (mm the right crankcase using the following tools. TOOLS: Needle raee remover D7GMc—MK50100 E rlng remover shaft 07766—0060100 A him (31 BEARING RACE 1 0-8 CRANKSHAFTIBALANCER Remove the Ian countershalt bearing nil seal and discard it. Check the gearshifl spindle oil seal for weav, damage or Valigue, and replace it it necessary, Remove each bearing cm of the leh crankcase. Replace the bearing plate if necessary Apply oil Io each new bearing. and drive each bearing into the ' , . . (1) DRIVER ls“ crankcase. (2) A'I'I'ACHr NOTE , ‘, - ‘ MENT - Drive in 1h: bea ngs perpen 'culavlv [0 the la" cvankcase. TOOLS: Lm crankshaft bearing Dflvev 07749—0010000 Almchmem. 73 x 90 mm 07GAD—SD40101 Film, 40 mm 07748— 0040900 Le" mlinshaf! boating race DI'IVB' 07749—0010000 Amchmom. 32 x 35 mm 01748— 0010100 ‘ _ (1) COUNT RSHAFT [2D CRANKSHAFT Lm mummhan burlng BEARING . BEARING Driver onus—0010000 ’ ' Anachmm. s: x as mm 07746—0010500 Pilot. 25 mm 07146—040300 Left hullncer baring NV" 07749 — 0010000 Attachment. 42 x 47 mm 07748—001030!) » - " , 3| BALANCEREEARINQ 1 0-9 CRANKSHAFT/BALANCER Install a new cauntershafl oil seal in the left crankcase, and apply all to the oil seal lip. Secure 1hr: bearing race stopper plate with the bolt, Install the needle bearing into the bearing race. CRANKSHAFI/BAUINCER INSTALLATION Clean the crankcase mating surfaces before assembling and check for wear or damage. NOTE - If there is minor roughness or irregularities an the crankcase mating surfaces. dress 1hem with an all stone - Alter cleaning. lubricate the crankshaft bearings and other contacting surfaces with clean engine oil. Install the special tool into the thread end at the crankshaft. Posillorl the crankshalt into the left crankcase. Draw the crankshaft into the Ian crankcase with the following tools' [4) AT CEMEI‘IILD. , NOTE ‘ Draw in the Crankshaft, making sure the connecting rod is not compressed against the crankcase edge. l‘II PAINT MARKS TOOLS: Puller shaft 07931 — MEADDOO Assembly collar 07931~KF00100 Thread adaptor 07931 — KFDOZOO Attachment LD. 35 mm 07746—0030400 Insert a proper sized nail into the hole in the balancer, while prying the scissors gears with a screw driver. Install the balancer with the paint marks aligned, 10-10 Turn ‘he barancar, and make sure the punch marks on ma balr ancer drive gear and driven gear are aligned. Draw the nail out of the balancer, Install the transmission (section I1). CRANKCASE ASSEMBLY InnaII the three dowel pins and a new gasket. Assemble the righ1 and Isl: crankcases being carc'ul to align the dowel pins and sha't5‘ CAUTION ~ Dnn’r forte Ihr ('rrmlrcm halve: together; if (her: is evcessive form required. something i: wrong Remove Ihr: right flank- (we and check for mmrlrgned parts. Tighten the Ian crankcase bolts m a crisscross pattern in Kwo or more Slaps. TORQUE: 12 N-m (1.2 lug-III, S h-lbl Trghten the light crankcase bulls. TORQUE: 12 N-m (1.2 kgrm. 9 fl-lb} ORAN KSHAFT/BALANCER [1D PUNCH MARKS (I) GASKET CRANKSHAFTIEALANCER Apply a locking agent to the rhreads oi me tensioner bolt ‘ . I1] TENSIDN'ER Securo the cam chain tensioner with the collar and bolt. Install the cam chain drive sprocker and cam chain. NOTE - The cam chain drive sprocket wiH nnly ga on one posirmn because of extra-wide aligning spline. Reinsran ma rsmovod parts in the reverse order of removal (page w-n. '«2» CAM CHAI' 3» Rawflocry .‘ 10-12 TRANSMISSION 11-0 ll. TRANSMISSION SERVICE INFORMATION 11-1 TRANSMISSION DISASSEMBLV 11-3 ‘TROUBLESHOOTING 11.2 TRANSMISSION ASSEMBLY 11-6 SERVICE INFORMATION GENERAL I The crankcase must be separated (a service (he transmissmn. O The gearshik cam plate can be serviced with the engine install in the flame (Secfiun 8]. SPECIFICATIONS Shift fuvk ID. 511111 fork claw thickness ITEM STANDARD SERVICE LIMIT Gear I.D. I M4,'ci:1:752 29.020 23.041 mm (1.1031 - 1.10401n) 28.10 mm (7 Ioa InI M5 WW 28.000 28.021 mgfi.1024-1.71032in) EBB InrnIRI106 in) C1 25020-25041 mrn (0.9850-09859 in) 25.10 mm (0.985 in) my bushing M5 0 n, 27949-27990 rnrrI (1.1004-1.1016 In) 1 27.90 mm (1.099111) C1 0.0. 24904-25005 mm (09936—09944 in) ' 24.93 mm [0.981707 01 ID. 20020—20041 mm 10.7882-078901n) 20.01 mm (0,738 in) M4, (:3, (:2 0.0. 27979—29000 mmI1.1015—1.1024in1 27.93mm11.100 in) M4, (:3, (:2 1170.7 25020-25041 nnnIo 9850-0 9859 in) 25.10 mINESiBS in) Gear-to-bushlng clearance M5 0020—0072 mm (00008—00028 In) 0.10 mm (0.004 in) CI 0015-0057 mm (00006-00022 in) 0.10 mm (0.004 In) M4, c2, ca 0020—0062 mm (00009—0 0024 in) 0.110 mm (0.004 In) MaInshafl 0:0. M4 '7 V 24 972 24.993 mm (0 9331 0,98401n) 24.92 mm (0.981 In) Countevshafi 0.0. CI I 19980-19993 mm (07888-07871 in) 19.94 mm (0.785 in) C: 24972—24993 mm (0.9891 —0.9840 in) 24.92 mm (0.981 In) (:3 W, 24959-24930 mm (0.9325-09335111) 24.92 mm (0.9817in1 Shaft-m-geav clearance M4 ' 0.027 0.068 mm (0.0011 -o.0027 in) 0.10 mm (o 4 irT c2 W .. 0041—0082 mm (00016-00032 in) 6.15m"; (0.0 6 in) Shah-lo-bushing clearance (21 0.027—0.06| mm (00011—00024 in) 0.10 mm (0.004 in) M4.cz 0027—0069 mm (00011—00027 in) 0.10 mm (0.004 In) 11000—171018 mm (0.5512—:0.551 4.93-5.00 mm (0194-0 97 In) 14.05 mm (0.553 in) 4 Srnjm (0.18 in] 5M" Iork shah 0.0. 13366713384 mm (0.5498705506 in) 13.90 mm (0.547 In) TORQUE VALUE Center shifl fork bolt 15 N-m [1 5 kgrm, 1‘I "‘Ib) 11-1 TRANSMISSION TROUBLESHOOTING Ham to shift ~ lmplopev clutch adjusment. um much lree may ' Shift forks bent ' Shih iork shah bent - Shifl dvum groove damaged Transmlssion jumps om n1 gear ' Gear (1095 worn ~ Shllt Fork shah bam . Shlh drum stoppm broken . Smk forms) bem 11-2 TRANSMISSION DISASSEMBLY Separate the crankcase {section 10!. Pusmrhe gearshall plate in the direction (he allow shows, and remove the gearshift spindla. Bend down the labs uf the lock washer, and remove the bolt and Iack washer. Remova the following: 7 shIIK Iork shalt , shilr forks — shlk drum Remove me mainshah and countershaft as an asssmbly‘ TRANSMISSION GEAR/SHAFT INSPECTION Dwsasssmble the mainshafr and caunrershahv Inspect each gear for wear or damage. Check (he gear math for wear or damage. Check (he engagement dogs cl gears for wear or damage. TRANSMISSION (4) BOLT. AN LOCK WEE? (1) COUNTER- SHAFT I‘I) MAINSHAFT [2| COUNTERSHAFT TRANSMISSION Check each gear for excessive or abnormal weer. Inspect the ID. of each year. SERVICE LIMITS: M41110 mm (1.106 in) M5:28.08 mm (1.106 in] (21:25.10 mm (0.988 In] 03:28.10 mm (1.105 In] 02: 28.10 mm (1.106 in] Measure the LB. and 0.0. M each gear bushing, SERVICE LIMITS: .: 27.90 mm [1.095170 24.93 mm [0.931 in) 20.01 mm (0.788 In) M4. 03, OZ. 0.0.: 27.93 mm [1.100 In) M4. 03. OZ. |.D.: 25.10 mm [0.935 In) Calculate the clearance between the gear and bushing. SERVICE LIMITS: M5. CI: 0.10 mm [0.004 in) M4, C3. CZ: 0.11 mm [0.004in) Measure the mainsnalt 0.0.. SERVICE LIMIT: M4: 24.92 mm l0.381 in) Calculate the clearanc. between the mainshalt and M4 bush- ing. SERVICE LIMIT: 0.10 mm (0.004 In) Measule the counrevshafl D.D . SERVICE LIMITS: C1: 15.54 mm [0.785 in) 02, 03: 24.92 mm [0.931 In) Calculate the clearance between the gear or bushings and countershafl. SERVICE LIMITS: C1 bushing: 0.10 mm (0.004 In] C2 bushlng: 0.10 mm (0,004 in! C3 gear: 0.15 mm (0.006 in! 5‘; :r 11-4 TRANSMISSION SHIFT FORK/SHIFT FORK SHAFT INSPECTION Measure the ID. of the right and left shift Iork. SERVICE LIMIT: 1405 mm [0.553 inI Measure the thickness of each shih fork claw. SERVICE LIMIT: 4.5 mm I0.l8 in) Measure the 0.0. 0! the shift lurk shaft at the surfaces sliding wi1h the right and left shilt forks. SERVICE LIMIT: 13.90 mm (0.547 in) SHIFT DRUM INSPECTION [II SHIFT DRUM BEARING Turn the outer race of the shift drum bearing with your finger, The hearing should turn smoothly and quietly. Also check that the inner race or the hearing (it: tightly onto the shilr drum, Replace the bearing il necessary. Inspect the shirt drum grooves ior wear or damage. and re- place it if necessary, (2] SHIFT DRUM GEARSHIFT SPINDLE INSPECTION/DISASSEMBLY m RESET SPRING )SPINDLE Check the spindle «or bends excessive wear or other damage. Check the return spring and rassr spring larlatigue in damage (4) SNAP RING Remove the return spring. snap ring and reset spring (3) RETURN SPRING GEARSHIFT SPINDLE ASSEMBLY I l1r SNAP RING Install the snap ring, rorurn spring and wear spring. @/ [2) gig-{Ne (a) RETURN f0 SPRING 11-5 TRANSMISSION TRANSMISSION ASSEMBLY Apply clean engine on m the :IIding and volavlng suvlaces of J [1l SNAP RING the gears, bushings and shafts. Assemble the mainshafl and counter shah. NOTE - Install [he snap rings aligning their end gaps between the shah teeth as shown - Make sure the snap Iings ave seated securely in the grooves ‘ of the shafts, (2] SHAFT (3| M3 GEAR [ZOTI I2I M5 GEAR (25T) (4) M4 GEAR (23“ (5) M1 GEAR 112m [H M2 GEAR (1ST) % MAINSHAFT aka '3 @G um " @ng , 17] M5 GEAR BUSHING (6) M4 GEAR BUSHING [10) c5 GEAR I21n [12> c4 GEAR [13) c1 GEAR lBl c2 GEAR man ”1) ca GEAR 25m (23“ (32“ <9) COUNTERSHAFT ( hf. \‘ ' I D .yQH . 0©® (Mi) i. IE§® 1161C2 GEAR I15] (:3 GEAR l14lC1 GEAR BUSHING BUSHING BUSHING Align the hole In the M5 gem bushing with the hoIe in me mam ' Ill HOLES shah when installing, -‘ - Alter assembly, check the gears ler smnnth mtetmn and slid» ing on the sham 11-6 I Insull (he mainshait and coumershak imo (he Iek crankcase together Each shik1ork has an identification mark; "R", “C" (cantor), ”L", Insla|| each shift fork to the correct pasnion. Apply clean engine oil to «he slidIng and rmanng sunaces or (he shIh forks and Shih fork shall, and ‘he groove 0' [he Shlh drum, Inslall the shin drum. than inskalI the shift forks wilh their idenuhcanon marks lacing up, Insert the shin [ark shaft through the shm Iorks, and align the bolt holes In the center lock and shaft. InslaII and Ilghten the center shik Inrk bun with a new look washer, YOHDUE: 15 "ml ".5 kg-m. 11 [HI]! Bend up the tabs of lhc lock washel agamst the camel shifl fork ball, (2) COUNTERSHAET TRANSMISSION / (u MAINSHAFT III IDENTIFICATION MARKS l'II SHIFT FORKS TRANSMISSION Ahgn the retum spring with the pin bn‘t and mile” the gear shilt spindle while pushmg the guarsm'l glare m the drrecllon the arrow shows. Assemble the Clankcase [Seaman 10] Install lhe geavshlll cam, sloppy avm (page 89] and gearshift pedal. and check the uansmissmn for smooth operation, (17 SPINDLE zl'RETuéfibm’NG AND‘ P N BOLT 11-8 FRONT WHELL/SUSPENSION/STEERING 24 Nom (2.4 kg m, 17 n-lh) 100 Now (10.0 kg-m. 72 bel 28 N-rn12.8 kgrm, 20 n-lh) 33 N-m (3.3 kg-Vm 241mb) 65 N-m (6,5 kgrm, 47 hrlbl \ W 12 N-m [1,2 kgAm, 9 (Mb) 27 Ncm (2.7 kg-m, 20 h-lb) 12-0 12. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION TROUBLESHOOTING HANDLEBARS 12-1 FRONT WHEEL 12-2 FORK 12—3 STEERING STEM 12-5 12-10 12-17 SERVICE INFROMATION GENERAL 0 A box or work stand is required to suppon the motorcvie Brake dusr may contain arbmw. . lnhallrd arbcsms fibers have been found m cause respirazary divine and cancer. Never as: an air Iran or dry brush to clean bulk: dummies. - In the United Slater, me an OSHA approved vacuum cleaner or alternate method approved by OSHA designed m minimize the hazard mum! by alrbame asbemu fibers. SPECIFICATIONS ITEM STAN DARD SERVICE LIMIT Axle runoui 0.2 mm (0.0! in] Front wheel rim runuul Fork spring lrae length Radial ~ 2.0 mm (0.08 In] Axial 7 599.3 mm (23.59 in] 2.0 mm (0.08 In) 593.3 mm (23.36 In) Fork tube runuut 0.2 mm (00! In) From lork oil capacity 592 cc (20.0 US 01. 20.81rnp ozl Fork oil level 120 mm [4.7 in) TORQUE VALUES Handlebars upper holder Handlebars lower holder Front hub cover screw Brake disc bolt Frunr axle From axle holder rim Fork slider socket boll Lower rork pinch boll Fork cap bolt Upper fork pinch bolt Brake caliper brackel boll Steering adiusrmenl nut Steering sierrr nul TOOLS Special Fork seal driver Fork seal driver anachment Steering sum socket Steering slam driver Ball race remover — Ball race remover arrachment — Driver handle Adjusiable pm spanner Steering bearing atlachmem 24 N-m [2.4 kg-m, 17 h-lb) 24 N-m [2.4 kg-m‘ 17 h-lh) 1.5 N-rn (0.15 kg-m,1.1f1-|bl is N-mi1.5 kg-m, u lI-lbl 55 um [6.5 kg-m, 47 mm 12 N-m i1.2 mm, 9 fr-Ib) 20 N-m r2 0 kgrm, 14 lt-lb) Apply locking agem in the threads 33 NM i3.3 kg-m. 24 it-lbl 23 N-m (2.3 kgrm,17 firlb] 24 N-m12.4 kg m, 17 ilrlbl 25 NOV“ i2.5 kg-m, l8 It-Ihl 5 N-m i0.5 kgim, 3.6 flrlb) 100 N-m (10.0 kg-m, 72 I'l-lbl 079477KA50100 079477 KFOOlOO 07915—KA50100 07946—43001 01 or 07946—MEOOOOO 07953—MJ1000D or 07953~MJ1000A [U.S.A. only) 079.537 MJiolOD D7953vMJ10200 07702—0020001 GN HT54 lU,S.A. only) 12-1 FRONT WHELL/SUSPENSIONISTEERING Common aeanng remover head, 15mm 07746 0050400 ‘ Bearing remover shall 07745 70050100}? gfaugralengg’rmm'a‘” Driver onus—0010000 “3‘ E '“ ' ' ' Anacnmem, 32 x 35 mm owns—0010100 Pilot, 15 mm 07745Aooaoaoo Lock nul wrench. 30 x 32 mm 07716 0020400 r Extension bar 0771s foozosoojw' €f“;:"".°”fl “SWXmm‘al'V Anachmenr. 42 x 47 mm 0774670010300 3““ a "‘ ' ‘ ' TROUBLESHOOTING Hard Stealing . Steering adjustment too tight - Faulty steering stern bearings - Insufficient air in from we Sloan to One side or Doe: Not Track Stralght - Bent fork ~ Bent from axle, wheel installed incorrectly . Unequal oil quaniiry in lork tubes From Wheel Wobbling - Distorted rim - Worn from wheel bearings ‘ Loose or broken spokes . Faulty [Ire - Axle or axle holder not ngmened properly Soft Suspension - Weak fork springs - Insufficient fluid In fork legs Hard Suspension - Fork all level loo high - Fork tubels) be"! or lurk sliderlsl damaged Front Suspension Noise - Fork slider binding - lnsuflienr fluid in fork legs ' Loose fork fasteners 12-2 FRONT WHEEL/SUSPENSIONISTEERING HANDLEBARS (1) LEFT HANDLEBAFIS SWITCH REMOVAL Remove the lollowing pens: — Wile bands — Left handlebars switch Clinch/choke lever holder 7 Front brake master cylinder — Starter/engine stop switch 7 Throttle grip (6) CLUTCHr CHOKE LEVER HOLDER Hemove the upper holders and handlebars. g 5) Remove the lower holders it necessary. INSTALLATION Install the washers, lower holders and nuts it removed Place the handlebars on the lower holders by aligning the punch marks on the handlebars with the upper surface ol the lower holder. Install the upper holders with the punch marks lacing lorward Tighten the lorward balls firsts then the rearward. TORQUE: 24 N-m [2.4 kg-ln. 17 ft—lb) Tighten the lower holder nuts to the specified torque. TORQUE: 24 N-m (2‘4 kg-m, 17 [Hill Install the stanarrsngine stop switch by aligning [he pm with (1) STARTsEmfiNG‘NE the hole m the handlebars STOP CH Tighten the lorward screw first, then tighten the rearward. «41 PIN 31 Hope, WIR‘E mugs. _ [2) MASTER CYLINDER r3) THROTTLE <3an (4) STARTER: ENGINE STOP SWITCH l2) SCREWS 1 2-3 FRONT WHELL/SUSPENSION/STEERING ii the grips were removed. apply Honda Bond A or Honda Grip Cement [U.S.A. only) (a ihe inside surlaces of the grips and lo the clean suriace of the left handlebar and throttle grip pipe, Wait 3—5 minutes and install the grips. Rotate the grips lor even application cl llie adhesive. NOTE - Allow the adhesive to dry (or an four beiure using. Apply grease to the throttle grip sliding surlace and cable guide, Apply grease to the throttle cable ends, and cunnecl the throt- tle cable ends to the throttle grip. Apply 978859 to the throttle cable slider, and install the slider as shown. Assemble the throttle housing halves, and align the mating surface of the halves with the punch mark on the handlebars Tighten the upper screw first, then the lower one. install ihe master cylinder and position the master cylinder (1) MASTER lZi FUSHCKH held?! With "no" mark lacing up, and loosely install the holder CYL'NDEH M _‘ bolts. Align the edge of the master cylinder with the punch mark on the handlebars and tighten the upper bolt lirst, then the lower bolt. Connect the (rant stop swnch wires tn the switch terminals. Install the Ialt handlebars switch by aligning the pin with the hole in the handlebars, and tighten the iarward screw first, than the rearward screw. (l) HOLE _ _ .[2) LEFT HANDLEBARS ' V ‘ .» ' SWITCH I3l SCREWS ; (4) rfiiy 12-4 —_.L install the clutch/choke level holders and loosely Install the holder bolts, Align the mating surface at the clutch/choke lever holder With Iha punch mark on the handlebars and tighten the lmwavd screw first, then tighten the rearward screw. Connect the clutch switch wires to the switch terminals, Route the swutch wires and secure them with the wire bands lpage 1712) Adiust the following: — throttle grip nee play (page 3-4) clutch lever Ives play [page en). FRONT WHEEL REMOVAL Raise the hunt wheel all the ground by placing a box or work stand undev the engine. Disconnect the speedometer cable from the speedometer gearbox at the hem wheel, Loosen the axle holder nuts and then remove the hem axle. Remove the ham wheel lNSPECTION FRONT AXLE Set the axle in V blocks and measure the runcut. The actual runout Is i.’2 of the total reading. SERVICE LIMIT: 0.2 mm (0.01 inl WHEEL BEARINGS Turn the inner race of each bearing with yciuv linger. The bearings should turn smoothly and quietly. Also check that the heating outer race lits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly, quietly. or if they lit loosely in the hub, NOTE ~ Replace wheel hearings in pairs. For bearings replacement. see page l2-7. FRONT WHEEUSUSPENSIONISTEERING (1) HOLDERS [2| MATING SURFACE AND VPUNCH MARK [4) SCREWS ii i éeeebeEféR CABLE | (i) WHEEL BEARING FRONT WHELL/SUSPENSIONISTEERING WHEEL RIM RUNOUT Check the nm runout by placing the wheel on a truing standv Then spin the wheel by hand, and read the runout using a dial indicator. SERVICE LIMITS: RADIAL: 2.0 mm (0.08 irtl AXIAL: 2.0 mm (0.08 in) WHEEL BALANCING CAUTION - Wheel balance dirertly affect; the “ability. handling llfld over- all safety 0f the motorcycle Always (heck balance when lite lire are remavcdfmm the rim. NOTE . Fm optimum balance, the tire balance mark la paint dot on the sidewall) must be located next to the valve stem. Mount the from wheel in a inspection stand, Spin the wheel, allow it to stop. and mark the lowest (heaviest) part oi the wheel wnh chalk. Do this two or three times to verify the heaviest area If the wheel is balanced. it will not stop consistently in the same position To balance the wheel. Install wheel weights on the highest side of the tim, the side oppnsite to the Chalk marks. Add just enough weight so the wheel does n01 stop in the same posmon when it is spun. DD not add more than 60 grams. 1 2-6 FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY (1) GEAR BOX ’ Remove the speedometer gearbox from the ngm side 01 wheel hub‘ Remove the Gas! seal and speedomeKer gear retainer. Remove the Slde collar, lront brake dlSC, dusl seal and the hub (ll BRAKE D‘SC cover. ‘~ i3) DUST ‘ SEAL [4» HUB (50sz Remove the wheel beanngs and distance collar, YOOLS; Bearing removal hold 07746—0050400 or equivalent commercially availabll in UlS.A. Baring "mover shall 0774370050100 ar equivalent commercially avallable in U.S.A. NOTE . Replace the wheel bearing with a new one. whenever the bearing I: removed - Replace the wheel bearings in pairsl 12-7 FRONT WHELLISUSPENSION/STEERING ASSEMBLY ' Do not get great: on the brake dim or napping power will be reduced. (1) SPEEDOMETER GEARBOX \“ l2] SPEEDOMETER GEAR l [5) DISTANCE COLLAR 16) BEARING (7] DUST SEAL I8] SIDE COLLAR l3] DUST SEAL [Bl HUB BEARING l \s (4) BEARING (10) DISC Place the rim on the work bunch. Place the hub with the disc side down and begin lacing with new spokes. Adjust the hub position so that the distance from the dlsc oulr slde surlnca tn the side 01 rim is 22.25 mm (0 876 in) as shown. Tighten the spokes in 2 or 3 progressive slaps. TORQUE: 4 "cm [0.4 kgim. 3 h-lbl n nquivnlom commercially TOOL: A \ SPOKE WRENCH C. 5.8 x 6.1 mm 07701 —0920300 or $fi l mail-bl. in U.S.A. ‘ l , I» ‘ Pack new wheel bearings with grease. QLIEJ’ZD. 22 Drive in the light bearing first untll it sent: completely ~ 4 A (o gfs'm‘ Install the distance collar and drive in the Ieh bearing. ' NOTE - Install the bearings with their sealed ends lacing outside. . Drive the beavlngs in perpendlcularly lll DRIVER (2) ATTACHMENT AND PILOT TOOLS: Dtivot 07749—001000!) Attachment. 32 x 35 mm 07746A0010100 Pilot, 15 mm 07746—0040300 Check the wheel mnout (page 126). install the rim lock, rlm band, tube and tile NOTE - Install the tlrs with its directional arrow pointing in the di» tection of normal rotation lot toward metinn. 1 2-8 Apply a locking agent to the threads of the hub cover screws. and secure Ihe hub cuvar wllh tha screwsr Install \he brake disc with the stamped side laclng out, and secure the disc with four boltsr TONGUE: 15 MM (1.5 kg-m. 11 h-Ib) Apply grease m tha dust seal lips and inmll lt. Install the la" srde collar. Install the shims inm the speedometer gearbox. Apply grease to lhe inside surface cl the gearbox and gear teeth. and install the gear into the gearbox, Install the speedumaler gear retainer, allgning tabs n1 lha ra- rainal with me grooves in the wheel hub. Anplv grease to the dust seal lip, and install it into the wheel hub. Install the speedometer gearbox mm the dust seal, engaging the tabs of the gear mainer with the basses at the spaodomo- (er gear each other. FRONT WHEEL/SUSPENSION/STEERING ~m BRAKE DISC l2) BOLT [3) SIDE COLLAR [Bl Hua ‘ COVER «Al ousr SEAL l1] SFEEDOMETER GEAR FRONT WHELLISUSPENSION/STEERING INSTALLATION Place the front wheel between the lork legs. Fit the caliper over the brake disc. tuklng cave not to damage the brake pads. Clean the axle and holder, Install the axle through the speedcmarel gearbox and wheel hub. Set the sneedameter gearbox lab against the behind at the tang on the lork slider. ll you removed the axle holder, install it wllh "UP" mark lacing up. Install the axle holder nulS IOOSGIVV Tighten me front axle lo the spec'llied Iorquel TORQUE: 65 Man (6!. kg-m, 47 lt-lbl Cunnact the spaodomatsr cable to the gearbox, and secure it wnh the SCVSW. With the hem brake applied‘ pump the ham suspensinn up and down several times to seat the axle. Tighten the front axle holder nuts, the uppel nuts li-st, then the lower nuts In 273 steps, TORQUE: 12 N-m l1V2 k‘rm. 9 ftrlbl FORK REMOVAL (1) mom FENDER (3) FORK Remove the following parts. BRACE Front wheel (page 12-5) — Front fender 7 Fork blaca — Reflectors Ill REFLECTUHS 7 Speedometer cable clamp. — Blake hose clamp — Brake caliper (page 14-8) NOTE - It is not necessary to disconnect the bake hose. <4) SPEEDOMETER CABLE CLAMl= 12—10 FRONT WHEEL/SUSPENSIONISTEERING Loosen the upper fork pinch bolts first, men Iha lovk cap bol‘s. Holding the fork legs, loosen the Iowa! fork pinch bolis, then remove the 1am lags. ‘ y [3) UP PINCH BOLTS DISASSEMBLY Loosen ‘hs hoot band screws and remove the Vork boot and boot bands. Remove the [ark cap bait. . (1} FORK CAP BOLT . The cup bolts are under wring pressure. Um car: when rtmov- in; and wear 21! and face pmncn'un. [U SPRING |3I FORK Remove the spacer, spring seat and fork spling‘ SEAT SPRING Drain the [Mk fluid by pumping the fork tube in and out seveval times. Check the spacer and spring 333‘ fol weal or damage. FRONT WHELL/SUSPENSIONISTEERING Hold “12 fork slider in a Vista with son jaws or a shop lowel. I1] SOCKET BOLT Remove the Iork slider socket bolt. ' CAUTION - Do nor distort rhzfark slider in a vim Remove the fork piston and rebound spring. Remove the dust seal and circlip, CAUTION - Be can-[u] not to damage the fork lube. Pull the fork tube am until It stops. Then move il in and out. lapping the bushing lightly until the lurk tubs separates from the lork slider.The slider bushing WlII be Iorced out by the fork tube bushing. Remov: the oil luck piece Irom the fork slider. ) FORK TUBE ‘ BUSHING Remove the on seal, back-up ring and slider bushing from the fork tube, Do not remove the (ark lune bushing until inspection determi- nes it is necessary [page IZ-Iall (SJSL ER “ ~ ' ausmuo I4] OIL SEAL 12-12 4"»; FRONT WHEEL/SUSPENSION/STEERING INSPECTION Measure the Iork spring free lenglh, SERVICE LIMIT: 593.3 mm (23.36 in] Check me oil lock piece, rebound spring and fork tube pismn (I) OIL LDCK PIECE (2) PISTON ring for damage or wean RING Replace it necessary‘ (3) REBOUND SPRING Check the fork sllder, Iork lube and Iork piston cm scoring. . ‘2' FOR“ scratches, deIarmation o! excessive wear Replace any campunents which are mm 0! damaged. (3) FORK PISTQN Sal Ihe Iovk tube on V blocks and measure ma runout. The actual lunuut is 1I2 of the Imal Indicator leading. SERVICE LIMI‘I: 0.2 mm 10.01 In) 12-13 FRONT WH ELLI SUSPENSION] STEERING Visually ‘Inspecl me slider and fork lube bushings. Replace the bushings if there Is excessive scoring or scratch- I“ BUSH'NG ing. or if the teflon is worn so am rha coppar surface appears on more man 314 of the entire surlace. (2) BACK UP RING Check the back-up ring; replace it il Ihere is any distortion at the points shown. (3) CHECK POINTS I4) COPPER SURFACES ASSEMBLY (4) SPACER 131 WASHER m DUST SEAL I2] FORK aoor e‘ gar—41m FORK CAP Q‘\(11)o.rimc3 I18! CIRCLIP (l7) OIL SEAL [IGI BACK UP RING (5) FORK :‘Jr SPRING/,6 ./ I] " [6) PISTON I RING K [13> FORK was [7) FORK BUSHING (15) SLIDER BUSHING PISTON (Dd) <2 (81 REBOUND & SPFIING (14) FORK SLIDEH (9) OIL LOCK PIECE I110“. LOCK [2) #ORK ,(3) SLIDER , PIECE PISTO BUSHING , Insert the fnrk piston with [he rebound spring and with I15 piston ring side facing up. Apply ATF to a new oil seal lip. Install the slider bushing, hack-up ring and new all seal onto the Iork tube, NOTE . Install the all seal with rha marks 135mg up. 5.31 the oil lock piece onto the end of the lork piston. than (5, {mpg ‘5, BACKUP insen the fork tube imo the {ark slider. SLIDER RING (4) OIL SEAL 12-14 FRONT WHEEL/SUSPENSIONISTEERING Temporarily insrell the Iork spring, spring sear, spacer, washer (1) SOCKET BOLT and Iork cap bolt inko the fork tube. Place the iork slider in a was with soh laws or a shop lawel. Apply slacking agem to the socket bolr threads and mrque (he Iork slider sockel bolt. TORQUE: 20 N-m (2.0 kg-m. 14 It-lb) Drive the oil seal inlo place using a fork seal driver and anach— l1) FORK SEAL DFWER merit. TOOLS: Fork uni driver o7sa7~xasoroo Fork seal driver amehmm own—“00100 (2) ATTACHMé T . Ins‘all the clrcllp and dust seal III CIRCLlF [2D DUST SEAL NOTE - Be careful not to damage the fork rube sliding surlace. - Make sure me :irclip is seated securely in the fork slider Q'ODVS. Remove me fork cap bolt, washer. spacer, spring sear and Iark spring. Pour in the specified amount oi ATF. SPECIFIED FLUID: A‘I’F CAPACITY: 592 cc (201) US oz. 20.8 Imp oz] (1) T, Slowly compress the lork leg up and down about live limes. (hen measure the oil level from the top oi the lube with ‘he OIL LEV L {ark leg fully compressed. L ' r‘ . /r NOTE . Make sure rhe oil level is me same in both fork rubos. l2] ATF STANDARD OIL LEVEL: 120 mm 14.7 in) “‘ 12-15 FRONT WHELLISUSPENSION/STEERING Wlpe any ml clf [he lovk spring, Install the lurk spllng ml!) the fork tube with lts nallow pllch end facing down, and lnstall me spring seat and spaceL (ll FORK CAP (2) O RING BOLT , . Apply ATF lo a new O-riug and lnslall II Onto the lurk cap boll. Put the washer onto me fork Cap bolt, and screw the cap bolt ll'l lhe lork lube. 7 «3| WASHER Install the fork boot wilh the breather holes lacing the rear. ll) FORK BOOT “,y l2! BREATHEl? HOLES ‘, Install the lower band with the screw head Vaclng am, and . . l nghren iL Loosely lnstall me upper band wuh the screw head laclng on! 13. BOOT BAND ‘ . lNSTALLATION Install me lurk legs through me steerlng stem and steenng top bridge, Allgn the tops ol Ihe lork lube and steering kop bridge and tighlen the lower lolk cinch bolls. TOROUE: 33 N-m (3.3 kg-m. 24 firlbl Tlghren the fork cap bolts to (he Specllled torque. TORQUE: 34 MM (23 kg-m, 17 lr-lh) Tighten the upper lurk pinch bolts to the speclfled torque YOROUE: 28 N-m (2.8 kg-m. 20 Il-lbl 12-16 FRONT WHEEL/SUSPENSIONISTEERING Install the make calipev and callpar bracket onto the leh lork I'll REFLECTORS slider. and secure the bracket wnh lhe bons‘ TORQUE: 25 N~m (2.5 ka-m. 18 fella) Secure the make hose wllh Ihe brake hose clamp. Secure the speedometer with the speedometer clamp. Insull the valleclms as shown. (41 SPEEDOME‘TER CABLE CLAMP Pull the fork hools up to the steering bouom budge, and tight (‘3 30m an we boot band screws BANDS Install the fork brace and front fender onto the lork legs and [U FFICINT FENDER secure mem with the four bolts, lnsmll (he lrom wheel (page 12710) (3] FORK BHACE STEERING STEM REMOVAL Remove the following: 7 handlebars Ipage ‘2»3I — ignman switch (page 196) 7 from wheel (page 12-5) smm nul cap — brake hose clamp FRONT WHELL/SUSPENSION/STEERING Remove 1he air guide plate and brake pipe attaching halts. . ('lJ AIR GUIDE PLAYE ' Remove the steering stem nut 11) EXTENSlO BAR TOOLS: Lock nut wrench, 30 x 32 mm 07715—002040!) or equivalent Bummlrciallv available in USA. Extension bar 07715 0020500 or equivalent commercially available in U.S.A, Loosen me upper fork pinch bolts and removn ins steering top Image. Remove the imk legs Hold the steering stem to prevent it imm failing‘ Remove the steering adjuslrnent nut‘ YOOLS: Steering stem socket 079167KA50100 Extension bur 07716—0020500 or or equiv: lent commercially Ivallahlo In U.S.A. Adjustable pin spannlr D7702— 0020001 (“DUST <2] UPPER iNN’En SEAL ‘ RACE Remove the following: — dust seal 7 upper bearing inner race upper heaving steering stem Check the dust seal, inner racer upper and lower bearings and outer races for wear or damage. Replace If necessary. Remcve the lower bearlng from the steering stem. (SlUPPER , :3. BEARlNG ‘ ' (“LOWERBEflmg 12—18 FRONT WHEEL/SUSPENSION/STEERING BEARING REPLACEMENT N OTE . Always replace the bearing and race as a sat, Remove the bearing inner race and dust seal from the steerlng stem. N OTE - Temporarily insrall the steering stern nut onto the sleerlng stem to prevent the stem threads from being damaged when removing lower inner race. Install a new dust seal onto the steering stern and press the lower bearing inner race mm the stem with the special tool, TOOLS: Steering stem driver 07946—43001 01 nr Not available in U.5‘A, Steering elem driver 07946—M300000 with Steering haerlnu emchmem GN HT54 (U.S,A, enlyl Remove the upper and lower cuter races using special tool. TOOLS: Bell race remover 07953— MJ1 0000 Not available in U,5.A, O7953—MJ‘IO‘IOO Not Ivallible In U.S.A. 07953— MJ10200 — Ball race remover attachment — Driver handle or Not evellable in U.S.A. Ball rec. remover 07953— MJ1000A IU.S.A. onlyl Drive new outer races into “18 staenng head. TOOLS: Drlver Attachment, 42 x 47 mm 07749—001 0000 07743—001 0300 (1) DUST SEAL (2) INNER RACE .r lal STEM NUT fl", m srzsmwé STE" DRIVER r (2) INNER Ritc‘E '. (é) nusr . SEAL \\ l LSEW'E'HWTARIBE ' ‘ A FRONT WHELL/SUSPENSION/STEENNG INSTALLATION '(1) io’w‘e‘a'iaEA—m—ra Pack a new bearing cavllies with grease. Install the lower haallng onto the sleallng stem, men insert the steering stem through the steering head. Inslall the upper bearing and bearing inner race. Apply grease to the dust seal, and install it onto 1hr; smevlng head. Install and tighten the steering adjustment nut to the specrlied , [1) STEERING STEM . torque. . SOCKET YOROUE: 5 N-m (0.5 kg-m, 3.5 hrlb) TOOLS: Stealing stem socket 07918— KA50100 or Adjustable pin spannol 07702 —— 0020001 Extension bar 07716—0020500 or equivalent commercially available in U.S.A. Turn the Sleellng stem lock to lock 5 76 times to seal the bear lngs, and check the steering slem lor uuiandrdown mover mam. Tighten the adiustrnem nut to the specified torque again‘ (ll TOP BRIDGE Install the steering top bridge and sleellng stem nut. Temporarily Install the fork legsv .- Tighten the steering stem nut to the specified torque. “ (3] LOCK NUT WRENCH TORQUE: 100 N-m 110.0 kn-m, 72 lt-Ihl TOOLS: Lock nut wrench, 30 x 32 mm 07718—002040!) or oqulvalent commercially avallable in U.SiAi Extension bar 0771670020500 m equivalent wmmnrcially avallibla In UiSiAi Secure the brake pipe to the steering bottom bridge with two bolts‘ lns1all rhe air guide plate with two bolls 12-20 FRONT WHEEL/SUSPENSION/STEERING mm” the following components: (1) BRAKE HOSE CLAMF‘ ‘ Fork lags cpage 12-16» 7 Brake hose clamp 7 Stem nut can 7 Ignition switch [page 19-7) Handlebavs lpage 1273) 7 From wheel (page 12710) [2) ‘S‘TEMJEUT CAP 12-21 REAR WHEEL/BRAKEISUSPENSION " 75 N ‘ _A_ND I’ll-0T REAR WHEEL/ BRAKE] SUSPENSION Install the damper rubbers. (1y DAMPER (2) DRIVEN FLANGE Apply grease lo a new Orring and lnstall lt onto the groove of RUBBER ' ‘ the wheel hub. Install the dnven flange. Apply grease to the dust seal hp and lnstall it. Install the axle collar. 4:. NEW”. . lNSTALLATION Install the brake panel on the wheel hub. Place the rear wheel between the swing arm and rail me drive chain over the driven sprocket LN! the rear wheel and Insen the tang on the swtng arm into the slot in the brake panel, then insert the rear axle from right side through swing arm. "Inna—5n. Loosely Install the axle nut. AXLE NUT Adjust the drive chain [page 3-8). Tighten the rear axle nut, TORQUE: 90 ”an [9.0 kg-m, 65 ft-lh) 13-8 REAR WHEEL/BRAKE/SUSPENSION Connect me bvake rod to the brake arm and Install the sums!- ing nut. Adjust the rear brake pedal Ivee play [page 371 I). REAR BRAKE INSPECTION Remove the rear wheel (page 13-3). Remove the lean brake panel. Measure the rear bvake drum I D. SERVICE LIMIT: 131 mm (5.16 in) Maasuve the lee! brake lining thickness SERVICE LIMIT: 2.0 mm (0.03 In) Replace the brake shoes if 1h|nnev than the sen/roe limit. DISASSEM BLV Remove the brake shoes and spnngs Irom the brake paneL NOTE . Mark the shoes to indicate (hair uviginal pusitians belore re- moving them, [2) SPRINGS HEAR WHEEL/BRAKEISUSPENSION Rsmuva the lolluwing pans «mm (ha brake panel: in aon AND ““Tymg}, DUST SEALS 7 Boll nut, and brake arm (2| lNDlCATDFl ' — Indicator plate ‘ Brake cam — Thrust plate — Dust seals Clean all parts thmughly. , file) BRAKE JRM. “SEW ffim ,6" ‘2l DUST SEALS (3) THRUST (4] BRAKE CAM PLATE HI INDICATOR PLATE [5) BRAKE SHOES [7| BRAKE PANEL (B) BRAKE ARM Apply grease to the dust seals. and install them into the brake panel. InsYaII lhe thrusl plate by aligning the pin on the brake panel wnh lhe slot In the plate, (3) DU§EEALS 13-10 REAR WHEEL/BRAKE/SUSPENSION Apply grease to the brake cam and install it. Apply grease to the anchor pin and thrust plate. mi Great! on m: brake lining: will reduce napping paiar. Keep grease off the brake (ruin/w Wipe exams great of] m: cum and anchor pin. Ins‘all the indicator plate onto the brake cam, aligning its [8b ‘ [H iNDICATOR I wirh cul~our on the brake cam. ' PLATE Install the brake arm by aligning the punch marks. Install the ball and tighten the nut nu ma spscrlied torque. TORQUE: 1O N-m (1V0 kg-m. 7 fi-lb) r‘ . (2) CUT-OUT (4) BRAKE ARM Posifiun the brake shoes In their original pusixions and inslall (U BRAKE the springs. SHOES Chzck the rear brake assembly Vor smoorh operation by moving ‘he brake arm. [2i SERINGS BRAKE PEDAL REMOVAL/INSTALLATION (1) BRAKE LiGHTNG Remove the following pans: — Brake adjuster 7 Brake rod lrom the brake arm Brake rod spring — Brake pedal return spring — Brake light switch spring 7 Bars pin. nu‘ and washer - Brake pedal \ Idl BETA PIN NUT [3) ROD 15D REHTURN SPRING A”? WASHER SPRING 13—11 REAR WHEEL/BRAKE/SUSPENSION [U BRAKE PEDAL (7) RETURN SPRING Apply grease toIhe dust seal lips and brake pedal plvot, and in stall \he brake pedal. lns’lall 1he fullowing pans: — Washer, nut and hem pin 7 Brake lrght switch spring Brake pedal return spnng 7 Brake rod spring 7 Brake rod to the blanks arm — Brake adjuster Adjust the brake pedal free play (page 3-1 1 I. SHOCK ABSORBER REMOVAL Halsa me rear wheel off me ground by pIscing a box or work stand under the engine‘ Remove the shock arm boll (shock link sxde] and shock absorbr er Iowa! mount bolt. Remove the right side cover (page 15 2) and shock absorber upper mount bolt, (2| BRAKE ROD IEIRETURN SPRING [ I ADJUSTER (4) SPRING M A ”(mum PIN (El NUT j .46»: (1: B'RAKE LIGHT SWITCH spams I3I ROD \ I WASHER, NUT 14 SPRING AND BETA PIN (2) UPPER MOUNT} [3| SHOCK ARMBOLT (SHOCK LII‘iK_SI_DEI 13-12 REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY (I) LOCK NUT Hold me shock upper moum in a Vise with soft laws or a shop towel. Remove the lock nut and adjusting nut. Remove the shock spring. (2) ADJUS NUT TING Check the spring for damage, and measure the spring (re: tengrh. SERVICE LIMIT: 235.1 mm (5.26 in) - Th: damper unrr ixfilled mu; imp}. in; ""714; Zign prenure, do not try to disassemnle. [H UPPER MOUNT BUSH‘NG (2) DAMPER RUBBER Check the damper unll 1or ml leaks or other damage and the damper rod for trueness. Check the sprlng seal stopper, spring saat, spring guide and 3 STOPPER damper rubber for wear or damage ( ) Check "19 upper mount bushing lor wear or damage [4D DAMPER ROD Mark me lo mm position as shown of the dampel Iud. Place the damper rod on a sca‘e and measure the force re quired to compress 1he damper 10 mm (0.4 in)‘ COMPRESSION FORCE: 33 kg (72.8 lb! I! the levee required is less than 28 kg [617 lb), gas is leaking. Examine the damper rod and replace the damper unit I! It Is bent or scaled. IO mm [0.4 in) REAR WHEEL/BRAKEISUSPENSION SHOCK ABSORBER DISPOSAL PROCEDURE Canrsv punch ‘he damper case 10 mark the drilling point, an proximately 160 mm (0.63 in» «mm the mp surface. In PLASTIC BAG ‘2' DR“ an I ‘ Wrap \he damper unit inside a plastic bag. \U/j Support the damper unit uplight m a vise as shown 16.0 mm (0.63 in) Through the open and of lhe bag, insert a dnll mutur wnh a sharp 2—3 mm (5I64 1fBinldriHbiL m— ' Do not MI: a dull Ilrill bi! which could caused build-up 11]qu- lee hut andprzmre [wide the damper. Itadlng m explndrm and stunt pzrgonal injun . - The Mach absorb" cnnmiru nimgzn gal and all under high pressure. Do not :lrlll any falthtr down the damper mat than (he mearunmmr givzn above. or you may drlll [mu m: nil chambzr: all Htaplnl under high pressure may came Km'aux personal injury. ~ Always wear lye pmrun'nn m avnid gating matal ylmvlngy In your my wlmv the gas premm is maxed. The planic bag i: only lutendtd to shleld you fmm 1h: (Malling gas. Hold lhe bag around the tin“ motor and brlelly run me an" momy inside 0.: bag; this will inllale the bag with air1vom mo <3) DAMPER UNIT motor and help keep [he bag from getting caught in the bit when you start. ASSEMBLY [2p LOCK [3) SPRING NUT SEAT U) AD%UST|NG 141 DAMPER UNIT ”U C3 16] spams (5) SPRING GUIDE \ 13-14 REAR WHEELIBRAKEISUSPENSIDN Install the spring, adjusting nut and lock nun [i Turn the spling adjusting run until the sorlng length is as speci- 42' LOCK NUT Had. A‘ DECREASE THE SPRING LENGTH a: INCREASE THE SPRING LENGTH Iii ADJUSTING NUT ’ I561: \ \ (3) SPRING LENGTH STANDARD SPRING LENGTH: 237.5 mm (535 In) K‘ MAXIMUM LENGYH: 239.9 mm (5.44 in) MINIMUM LENGTH: 235.1 mm [9.26 in) I NOTE - One turn 0! the adjusting nut changes the spring length by LS mm. 4 Hold the shock absorber upper mount in a wet: with solt Jaws or a shop towel. Using pin spanners, tighten the lock nu! while halding the adv iusting nut TORQUE: 90 N-m (9‘0 Its-m, 65 h-Ibl Install the breather tube [0 the seat stopper, Install the shock absorber to the lrarne with the blaalher lube toward the rearv Install and tighten the shock absorber upper mount huh and I'IUL (1) UPPER MOUNT BOLT TORQUE: 75 Nvm [7.5 kg-m, 54 lI-Ibl Install and [Ighlefl the shack absurbei lower mount bolt. TORQUE; 45 MM (4.5 kg»m. 32 h-lb} Install and tighten the shock arm-to-shock link bolt, TORQUE: 45 N-m [4,5 kg-m, 321t-lb) Install the right side cover (page 15-2lv (3) SHOCK ARM7T0~ Check the operallon ol the shock absurber (page 3-14) *510CK_L|NK BOLT SHOCK UNKAGE 'W'suock ARM-rd} (2) LOWER MOUN?” FRAME BOLT " , . REMOVAL Raise the rear wheel off the ground by placing a work stand or box under the engine Remove the following components: 7 Shank alm~to>shuck link bolt — Shcok |ink»lo»swing arm ImIt , — Sheet"? b l i5i SHOCK ARM~TO~ no: a star er ower mount bolt SHOCK LINK BOLT (3) SHOCK LINK-TO 7 Shock arm-to-liame bolt _ Shock am '4) SHOCK LLNK _ swwe ARM BOLT 13-15 REAR WHEEL/BRAKEISUSPENSION <5HOCK AHM> INSPECTION l1] DUST SEALS (2) NEEDLE BEARINGS Inspect the dusl seals, collars and needle bearings. Replace them il they have score marks, scratches, or exces- sive or abnormal wear. NOTE ' Be careful not to lose the needle rallals oi the shock an“ and llnk pivot needle bearings. - If the needle rollers are out of place, inspsct men for wear or damage and install into place using molybdenum disul- lide grease. (3) COLLARS ('ll COLLAR l2) NEEDLE BEARINGS [3) DUST SEALS _ 7. NEEDLE BEARING REPLACEMENT m ‘ (SHOCK LINK) xiii ‘ J». .-.- Drive the needle bearings out oi lhe shack arm and shock link. TOOLS: Driver shaft 07946—MJ00100 or Not available lll U.S.l\r Drivel 07749—0010000 Pilul. 22 mm 07746—0041000 gamma” SHOCK ABSORBER LOWER MOUNT BOLT PIVOT AND SHOCK ARM-TO-SHOCK LINK aon PIVOT '” DR'VER l2l INNER 50555 Pack a new needle hearings with multi purpose grease. Press the needle bearings into the shack arm untll the bearing outer ends are an a level wilh the shock arm inner edges. N OTE ~ Press the needle bearing an the stampegend, TOOLS: Driver 07749—0010000 Atlachmenl. 24 x 26 mm 07746—0010700 ‘4] ATTACHMENT (3) NEEDLE BEARINGS 13-16 REAR WHEEL/BRAKE/SUSPENSION SHOCK AfiM-TO»FRAME BOLT PIVOT l1) NEEDLE BEARING Pack a new needle bearing with multi purpnse grease. Measuring with a Vernier caliper, press the needle bearing into the shock arm 9 mm 10.35 in) below the outer edge of the shock arm. NOTE . - Press the needle bearing an the stamped and, TOOLS: Dflver 07749A0010000 Anachmdm, 24 x 26 mm 07748—0010700 1 DRIVER 3" '1 [2) BEARING I3] INNER SHOCK LINK-TO-SWING ARM BOLT PIVOT ( ) , \ EDGES l Pack a new needle hanrings wrth multi purpose grease, Fill the space between needle bearings with grease, Press the needle bearings into the shock link until the bearing outer end: are on a level with the shack link inner edges, NOTE - Press the needle bearing on the stamped end. TOOLS: Driver 07749—0010000 Attachment, 24 x 25 mm 0774570010700 (SHocK ARM) INSTALLATION 0 NOTE - Make sure that the needle rallers ol the needle bearings are a in position before installing the pivot collars, Apply multi purpose grease to the shock arm pivot collar sur- faces and dust seal lips. Insrall the collars and dust seals into the shock arm. - Open or short amount m was harness tor (wire harness sidm (page 16 G) ‘ ~ Loose or poorw cumact connector BATTERY VOLTAGE - Faulty regulamn‘reclmev 1 6-2 BATTE RVI CHARGING SYSTEM 3mm ’ The [pantry gin: off explnn‘vt guts: keep sparks. flames and cigarettes away. Provide adequate venn‘lan'on when charging. - The Imrmy contniru XIII/uric Bald (electrolyte). ('onlacl with skin or (ye: may came severe Dunn. Wear protective clothing and a lace :hlzld. — Iftlectwlyla gm on yuur skin. mm: with mmr — If electrolyte gm In your eyes; 11th wlrh water for nr law 15 minute: and call a physician. ~ Isrmmryre i! pnixonous. 7 If Jwallowtd. drink large quanllllex Inf water or mill: and follow with milk of mug/mull) or vegetable 0!! and call a physician. REMOVAL Remove the right side caver (page 15-2.. Disconnect the battery negetlve l~l cable first. men \he posi» tive (+) cable from The bauery Remove the ballery holder and baileryv TESTING NOTE - Reler m the Sen/Tc; Zena} #48 and me Operation Manual lor the Honda Banery Tester and the Chflsllfl banery Chatgr er for battery Testing Procedure. NOTE ‘ Use the Hands battery TaslerlBM»210)m tam (he battery. Remove the battery. Securely connect me (astev's posmva 1+] cable first, then connect the negatwe (-l cable. NOTE ’ For accurme \esl resuks. be sure (he lester‘s cables and clamps are in good working condition and that a secure cannemion can be made at the battery, Set the temperature swnch (0 "HIGH” or “LOW" dependmg on the ambient Temperature. HIGH: 15°C [80°Fl or higher LOW: 15”: IEO°H a! lowly Push in the "5,5 AhrB Ah" (as! button for three seconds and read (he condillon ol the banery on the meler, NOTE - Be sure to push the correct (as! bunonr For the hrst check DO NOT charge the banery belore res! mg. @7§:©©©@©©o u' u 16-3 BATTERY/CHARGING SYSTEM CAUTION [ - Team damage can raw/l fram overheating when: — [he It's! bullon is pushed in for more than three second: — lemme more than on: battery and 1h: layer is no! alluwed ID coo/for a! least one minute between mrs. — man' Man [an tam areperformed consecutively wilhruu aI- , c lowing at Iran a 30vminme ('uol-duwn per/0d, ,rTesl Buttons IE 00000 © © © The battery is OK if the meter reading registers m lhe GREEN _ 10718. H U If the matter leading registers in the VELOW or RED zone, charge the belterv. and retest and judge it m accordance wnh the chan heluwt Flm cheek: Grun ' OK Yellow, Rod : Charge VELLOW GREEN RED 2‘ 171D ”Y, *2 Socond chuck: vi; ‘. , *3; First chuck Yellow: \ .'I Gllln : OK _\ Yellow : Replace (4— Filn chock Red: Green : 0K Vallow : Recharge Rad : Replace 41 Thlrd chock: Green . 0K , , Yellow : Replace CHARGING NOTE - Use the CHRISTIE Battery Charger (MC 1012.’2l to charge the battery. Below operating the charger Be sure we area around the charger is well ventilated and clear ol flammable materials, heat, humidity, water and dust. Clean the battery terminals and position the battery as hat 7!. away lrom the charger as the leads wrll pavrniL Do nm place the battery below the charger gases from the battery may currade and damage the charger. Do not place the battery on mp 01 the charger. Be sure the air vents are nm blacked. m— - During operation. the thwgur will germane heal. ra avoid taming a fire. always clear 2h: wurk urea u/flummabh/ materi- nlr rue/I as gamlint, brake fluid. electrolyte, 0r doth (awe/s. Tum ‘he Power Switch to the OFF positron. 891 the Battery Amp. Hr. Selector Switch [0 the “5.5 to 90" position, 1 6-4 BATTERY/CHA RGING SYSTEM Set the Timer to the position indicated by the Honda Emery r Tester: RED-3. RED -2. or YELLOW —I, ll you are charging a NEW new battery‘ set the switch to the NEW BATT position. BATT TIMER 0 Attach the clamps to the battery terminals; RED to Positive. RED BLACK to Negative. CAUTION ~ A 1- 2 - Conner! Ihc barrcry cabIL'S only when HIE Pow-r S wirrh [i or ’ Turn the Power Switch to the ON position. YELLOW When the timer reaches the "Trickle" position, the charging ‘1 cycle is complete. Turn the Power Switch OFF and disconnect the clamps NOTE - The charger will automatically switch to the Trickle "rude alter the set cha 'ng time has elapsed. Re-test the battery using the Honda Battery Tester and re- charge iI necessaty using the above slaps NOTE - For accurate test results. let the battery cool tor at least ten minutes or until gassing subsides alter charging. lNSTALLATlON Install the battery onto the air cleaner case and secure it Wlll'l the battery holder and bolts Connect the positive I r— l cablcl 51, then connect the negative (7i Cable and cover the negehve H cable With the rubber , cover. [1) éfig'l'T'iVE . (2) cover: 2 Install the right side cover (page 15-2). CHARGING SYSTEM NOTE - With large cape ty circuits that exceed the rating or the fuse contained in the tester. measuring errors can be dan- gerousv - Before starting each test. set the tester at the high capacity ’ range first. and it to small capacity circults range in order that you have the correct range, LEAKAGE INSPECTION CAUTION [1) NEGATIVE (*I TERMINAL - When meant/lily yrlull (‘upm'lb' t'ln'lllls, keep ihe lgmfloll swilt'h uffi If the Swilt'h u .sudtlrrlly iurrm/ w. (luring u It‘bl. ilw [Ester/rm may blow. Check the battery ampere leakage before making the regulated ampere inspection Turn the ignition switch olf and disconnect the battery nega tive cable horn the battery Connect the tester between the negative cable and the nega- ’ tive battery terminal 12] NEGATIVE CABLE The ampere meter should indicate wrlhln 1 mA wlth the Ignlr tion switch OFF 16-5 E BATTERY/CHARGING SYSTEM REGULATED VOLTAGE INSPECTION NOTE - Be sure the battery is in good condition belore performing this test, Warm up the engine to normal operating temperature, Stop the engine. and connect the voltmeter as shown. Allow the engine to idle, and lncrease the engine speed gradu7 ally. The voltage should be controlled to 13.57155 V at 5,000 rpm. (1) BATTERV , CAUTION cable to flu- frame - Be careful rm! to coniacl the battery pom: while resting. REGULATOR/ RECTIFI ER INSPECTION Remove the fuel tank lpage 473). Disconnect the 3P connectors of the regulatorlrectilier from the holder. Check them lor loose contact or corroded terminals. If the regulated voltage reading is out of the specification, check the items between connector terminals (Wire harness side and alternator side), lollowing the chart below. ITEM TERMINALS STANDARDS l20°Cf68°Fl Batterx sharging line Red/While 4+) and Green l-l Battery voltage should come. Alternator coil line Yellow and Yellow D.l 1.0 l} NOTE Uflll: fl - The rasisiance values will be incorrect ii the probes touch From 6) el le v v v G your fingers. 6 Plot“ . Use one at the folio ' g recommended multltesters. Using another manulaoiura's equipment may not allow you to Bl 1° k 15 k ‘5 k ‘5 k 1° " obtain tha specified values This is due to the characteristic ~‘°° k ~50 k ~80 k ~80 k ~50 k of semiconductors, which have different resistance values nrw aa aa a. a. .. depending on the applied voltage. _ soo RECOMMENDED MUlTITESTERs: V °“ ~10 k " " a — 0741 1 —0020000 (KOWA Dlgltel type) 500 7 777 — KS—AHM—32—003 (KDWA Digital typl' ,s.At only] V °° ~10 k °° l W °" 7 073037 0020001 (SANWA Analogue type) 500 ‘ — TH —5H IKOWA Analogue typol V m ~10 x m m ‘ °° .. 1 lt 1 It 50:) 500 soc :ELSSZFEIMMW‘M range. G ~20 k ~20 k ~10 k ~IO it ~10 k Kowe: x 100 ll - An old battery stored in the multltester could cause inaccue rate readings, Check the battery it the multltester resistors lflcOerCIIVV - When using the KOWA multitester, remember that all lead lngs should be multiplied by 100. Replace the regulatorlrectiiicr unit it any one oi the IeSIsinnce values is abnormal 1 6-6 BATTERY/CHARGING SVSTEM REPLACEMENT Remove the rear lender (page 15-5), Disconnect the reguretor/rectitier 3P connector, remove the reguretorlrectifier |nstall the reguretar/rectifler in the reverse order or removal. ALTERNATOR INSPECTION Q NOTE t ' . Ill CONTINUITY - It is not necessary to remove the stator coil to make this tesrt Remove the seat and disconnect the alternator 3P connector 12] NO CONTINUITY Measure the resistance between the yeilow wire terminals and check for no continuity between each terminal and grnund, STANDARD: 0.1 — 1 .0 n (at 20°C/88°Fl Replace the stator if the resistance is out of specification or If there is continuity be1ween each yellow Wire terminal and ground. 1 6-7 IGNITION SYSTEM SYSTEM DIAGRAM (I) IGNITION (2] ENGINE STOP SWITCH (3) STARTER SWITCH (4) IGNITION COIL (5) SPARK (6) BATTERY (8) ALTERNATOR . [7) STARTER MOTOR “- STARTER SUB FUSE IGNITION SWITCH ELECTRIC 4—VTR \? STARTER R SYSTEM ENGINE STOP ‘ SUB r SWITCH USE mm BIIW Busy G El: G PULSE v1 OQGENERATDR d; e IGNITION BATTERV COIL CDIL UNIT IZVBAH .. — __ -— _ V L ': _ ‘_ SPARK PLUG BI Br I anew v -I o , ORANGE __ an -I Lb UGHT BLUE ? G - L1 ua-IT GREEN R w P , PINK II Gr IIIII aw 17. IGNITION SYSTEM SYSTEM DIAGRAM SERVICE INFORMATION TROUBLESHOOTING SYSTEM INSPECTIO N 1 7-0 IGNITION COIL 17- 1 PULSE GENERATOR 17—2 IGNITION TIMING 1 7-3 17-5 17-7 17-7 SERVICE INFORMATION GENERAL 0 When inspecting the Ignition system, check the system components and lines step-by-step according to the troubleshoot ing sequence on the man page. I Ignition timing cannot be adjusted since the CDI [Capacitive Discharge lgnitronl unit is nonradiuslahle. c For pulse generator removal and instailatlon, see section 8. e For alternator removal and mate llation. see section 9. O For spark plug gap inspection and adjustment procedure' see page 376. SPECIFICATIONS ITEM STANDARD Spark plug Standard DPRSEAS (NGK) X24EPR-UP (ND) For extended high speed riding DPRSEAS INGK) )527EPR-UP (ND) Spark plug gap ignition timing 0370.3 mm ((1031—0035 In] Initlai 5“ BTDC at idle Full advance 28° BTDC at 4,000 rpm i20°C/68°FI Ignition coll resistance Primary coil 0.4706 n Secondarv nail Iwithuut spark plug cap) 10.5—15.5 m Secondary coil (with spark plug cap) 14723 Id) Else generator resistance (20°CISB°FI 7 420—520 I) 7 TOOLS Circuit tester (SANWA) or Circuit tester lKOWAl or Digital multimeter IKOWA] 07308 7 0020000 TH » SH 0741 1—0020000 dr KS-AHM-31-003 lU.S.A. only) 17-1 IGNITION SYSTEM TROUBLESHOOTING Weak or no spark at plug OD SPA 1 Try spark test wlth known good spark plug. RK ~ WEAK OR NO SPARK 2. Check spark plug wire for lncse or pool con tact at the spark plug cap, then try spark test agem, WEAK OR NO SPARK 3, Check CDI um! connectors var loose or poor contact, then try spark lest again. NORMAL GOOD SPARK ABNORMAL Faulty spark plug - LDDSe or poor Contact nl spark plug cap . Lease or poor contact of CDI unit connectors. 4 Check the resistance, continuity and voltage at the CDI unit connectors of the wire harness sude (page 17 3), Also check the ignition secondary coil resistance (page ”-3. 4|. ABNORMAL 5. Check the related components In that pan or the abnormal lino Alter checking, Compare the measurements of (5) with those of 14L NORMAL ABNORMAL (DIFFERENT [SAME MEASUREMENTS) MEASUREMENTS] ———> - Faulty related components ALL NORMAL —>~ Faulty CDI unlL Pulse generator (page 17-4) electric starter system line [Y/Rl 7 ignition coil [page 17-3, 4] — lgnilion switch (page 19 6) — engine stop switch (page 193) ground wire {0) battery (page 1673) — fuse” 0A Lease or poor contact or the related component COUHQCYGIS Open or short Circuit In the wire harness be tween the related component and CD! unrt, 17-2 IGNITION SYSTEM SYSTEM INSPECTION NOTE - Check the system components and lines step-byrstap ac cording to the troubleshooting on page 17-2. - This method does not include an inspection 01 the ignltion timing advance system at the CDI unit. Remove the right fairing (page 15—2). Disconnect the CDI unit connectors and Check them for loose contact or corroded terminals. Measure the resiStance, continuity and voltage between conr nectar terminals of the Wire harness side as lollows: ITEM TERMINAL STANDARD Ignition coil primary coil , BIN andfiG 0‘4 661] [at 20°CI63“F) Pulse generator coil , EuIY and G 9207520 9 (at 10"C4'639Fl Ignition switch and engine stop switch (Turn the igr BI-‘W (-l and G H Battery voltage. nition switch 0N and the engine stop switch RUN) , , , Electric starter system line iTurn the ignition switch YIH H) and G H Battery voltage ON and push the starter switch] NOTE: Transmission must be in neutral IGNITION COIL INSPECTION Remove the fuel tank (page 43] Measure the primary coil resistance hetwaen terminals. STANDARD: 0.4—0‘5 t) (a! 20°CI68°FI Measure the secondary coil reSistancn with the spark plug cap in place by checking for continuity between the plug cap and green terminal STANDARD: 14—23 Itfl (at 20"CI68°FI IGNITION SYSTEM Remove the spark plug can lrom the wires and measure the secondary DOII resistance. STANDARD: 10.5—16.5 III] [at 20°C, 68"F) PULSE GENERATOR NOTE - It is not necessary to remove the luel tank and fairing to make this test, INSPECTION Disconnect the pulse generator wire connector (2P minilt Measure the resrstance between lha connector terminals. SYANDARD: 420—520 I! (at 20°C/88°F| IGNITION TIMING NOTE - The Capacllive Discharge Ign (con system is factory purse! and does not require adjustment. To inspect the Iunctlon or the CDI components, ignition timing inspection procedures are given more Warm the engine up to the nperatlng temperature Remove the timing hole cap Connect a tachometer and ti ing lightt Start the engine and allow it to idle. IDLE SPEED: 1,300 2 100 rpm Inspect the ignr on timing Timing Is correct iI the ”F" mark on the alternator rotor is aligned with the index mark on the left crankcase cover at Idle. Te check the advance. raise the engine speed to 4,000 2 100 rpm. The index mark should be between the advance marks ll the ignition timing is incorrect. perform the system inspec- tion image 1773]. (2) ADVANCE MAFIK 1 7—4 ELECTRIC STARTER SYSTEM SYSTEM DIAGRAM H) \GNmON S ITCH 2D STARTER SWITCH (4) STARTER H ELEY SWITCH [5) STARTER MOTOR STARTER HEADLIGHT SW'TCH FUSE 10 A —O/O—W/G——O"\’O-WE' DIODE G/R Gm-@—B METER/TAIL LIGHT FUSE I? ~04 0 GI ‘5 A RIEI * l l NEUTRAL '9 $ CLUTCH _ szTCH SWITCH , BATTERV 12 v 8 AH T MAIN FUSE 'GN'T'DN 20 A SWITCH ——O~/‘o—r1——o E BLACK I WIN Y . YELLOW D DRIVE BA BLLK LI LIOW ILUE G EIEEN L; LIM GREEN R ‘ ‘ WED P PIP“ W . ' mu: l'r ERNI 1 8-0 I) l) D) 18. ELECTRIC STARTER SYSTEM SYSTEM DIAGRAM 18-0 STARTER MOTOR 18-3 SERVICE INFORMATION 18-1 STARTER RELAY SWITCH 18-7 TROUBLESHOOTING 18-2 CLUTCH DIODE 18-3 SERVICE INFORMATION GENERAL 9 The surrey mmor can be lemcved wixh me engine in the IrameI SPECIFICATIONS mm (inI ITEM STANDARD ‘ SERVICE LIMIT sane: motor brush length 110—130(047—051) 6.5102767] ELECTRIC STARTER SYSTEM TROUBLESHOOTI NG N DTE - The starter motor could turn when the transmission is in neutral or the clutch disengaged, - Check the following items before troubleshooting the system. Main (20A] and sub (10A and 15A) fuses for burn. ~ Battery and starter motor cables let loose connectiont — Battery discharged. Starter motor do not turn ‘ 1-1. Check the starter relay swtlch lor opela- ‘CLICK' _ ,_ M. _ tron. You should hear the relay ‘CLICK‘ HEARD 1.2_ Apply battery vuhage to the starter motor when the starter switch buttnm is de- directly and chuck the operation, pressed (page is?) ’ TURN DD NOTTUHN ‘CLICK’ NOT HEARD - Loose or poorly con ~ Faulty starter motor tact cables 19399 1873] - Faulty starter relay switch (page 18-7) 2. C he neutral indicator tor function M». Faulty neutral switch (page 19 9) NORMAL 3. Check the starter relay sWitch voltage N0 VOLTAGE lpage l8-7l BATTERY VOLTAGE COMES #— ty (page 1377) NORMA L Startar motor turns ongina alowly ~ Low specific gravtty r Excessive resistance In circuit iSectiun 9] - Binding in starter motor shalt (Section 9) Starter motor tumst but angina does not turn - Faulty starter clutch (Section 5) - Faulty starter motor gears {Section 8] - Faulty starter motor or idle gear (Section 9) Stanar motor and engin- turns, but engine does not start - Faulty ignition system - Engine problems lSectlon 2m 7 Low compression — Fouled spark plug 4. Check the. starter relay switch lar continul- ABNORMAL . _—_.- Faulty starter relay switch - Loose or poorly contact connector 01 the neu- tral switch ~ Faulty ignition switch (page 19-6) . Loose or poorly contact canneclol ol the clutch diode - Faulty starter switch lpage 1978] . Faulty ciutsri diode [page 13-8) - Open or short circuit in wire harness ———>- Lease or poor contact at starter telav swrtch 1 8-2 ELECTRIC STARTER SYSTEM STARTER MOTOR ’ REMOVAL m ' With the Ignition min-Ir OFF. remove {he negativ! can]: a! the bunny before servicing the Martel motor. ’ Remove me clu‘ch cable holder from [he smner momr . Disconnect me sung! motor cahla. Remove 1he motor mounting bolls, s1anar motor, set rubber and mmor stay. DISASSEMBLY Remove the followmg components. — mom! case bolts 7 1mm cover and real cover — armamrs NOTE - Record the location and number of shims. ' (2) REAR ’ r31 BOLTS COVER INSPECTION Check for continuity From the cable terminal 10 each brush, CONTINUITV: NORMAL ELECTRIC STARTER SYS'IEM Check '0! continuiw from Khe cable (ermmal 10 [he from center No CONTINUITV: NORMAL Measure each brush length. SERVICE LIMIT: 63 mm (0.26 in) Inspect the commulamr bars for discoloration‘ The bars discolored In pahs mdicale grounded armature CDIIS. (1) COMMUTATOH BARS Check 10! continuity belween paws o! commutator bars. There should be continuity. 18-4 ELECTRIC STARTER SYSTEM Check Var conlinuuy between individual commumlnr bars and a. (he armature shaft. D There shnuld be no cominuiw‘ ' Check the dusi seal «:1 1h: front mum lor wear or Iatigue. l" DUST SEAL «2| FRONT COVER ASSEMBLY mCAsE INK/KL (2) SHIMS (3) ARMATURE [2| SHIMS . a) (4) SPRINGS [8) I’EHMINAL % 69% H1] FRONT . ‘ COVER . [9) WASHER (10) LOCK WASHER (7] INSULATED (6) O RINGS WASHERS 18-5 ELECTRIC STARTER SYSTEM Install the brush ho|der onto the rear ccvcl, aligmng the tang of III BRUSH HOLDER the holder with [he slm DI the lam cover [3) REAR coves £23599” Install the armature mm the mmnl case. (1) ARMATURE (2) names Inslall the slums m the same Iucatlon and number when disas I semhled. Install the 0»nngs on the motor caset Install the rear cover. allgnlng lts slal wnh the tang nl HIP. blush holdal. I4) SHIMS (3) ALIGN (H LOCK (Z) DUST Insull lhc shims m Ina Sam I ' , e ocallun and number when dlsas WASHER SEAL Sen] bled . Inslall lhe lock washcr‘ allgninq its tabs wllh the slots ol the front cover‘ Apply grease tn the rim! seal. Inslnll tho lmm covert (All SHIMS (3) FRONT COVER Align Ihe Index marks ol the from cover, cast) and rear cover ~ ‘1’ mo“ MARKS as shown Tighten the motor case bolts securely wltll Ihe O-nngs and Washelst Apply on m the Owing and install It Into the from east: gmove (3) OrFlINGS (2] BOLTS AND WASHERS 1 8-6 ELECTRIC STARTER SYSTEM INSTALLATION . Set the motor stay and set rubber onto the engine Install the slarre- motor on the rubber and stay. and tighten the mounIing bolts, NOTE . - Install the ground cable with one mounting bolt as shown. Connect the motor cable to the motor termlnal. Pul [he rubber cap on the termlnal. Connect the battery negauun cable, MIMI GRO-UND CABLE ' Install the clutch cable holder. alignlng lrs hole wlth the boss m CABLE Ho'LcrEr'i; on the starter moron and secure With the haltt ' ‘ ' STARTER RELAY SWITCH OPERATION INSPECTION Remove 1he real fender [page rte-53‘ Duprcss the starter switch button wlth the ignition ON. The coil is normal ii the starter mlav swrlch clicks VOLTAGE INSPECTION tween [he yellowsreu H) and ureem'red H wlles al the relay connector, The battery volrage should appear when the starter swrtch button is depressed with the ignition switch 0N and nnutml positron Perlorrrr lhe lollowing inspection l' the battery voltage appeared between the yellow-Wed and greenfred wnesr ’ I! [he swllch ‘CLICK' Is not heard, measure the Voltage be ELECTRIC STARTER SYSTEM CONTINUITY INSPECTION Remove the slallev relay swnch. Comwm an ohmmeter to the staner veIay swimh Imge tarmI nah; Connect a Iully charged 12 V bmrery posmve wure (o the start vr Inlay swnch Yellows‘Red wue Iermmal and barmrv negative wua to ma Greenfified wxre termmat Check rm cnnlmulw betwcen the starter reIay Swilch lemu- nals. There should be conunullv WMIIE 01912 V Ilellerv Iscnnncmcd to II]? manor relay swnch Yerrmrlals and should be no (,(mIInuL (y when the ballevy us rhsnmmaclcd CLUTCH DIODE NOTE - CIuIch dIUlIe Is loomed under Ihs seat, INSPECTION Check Ior contunuiw wilh an uhnmvuler NORMAL DIRECTION: CONTINUITY REVERSE DIRECTION: NO CDNTINUITY ‘BE SHOWN: 18—8 19. LIGHTS/lNSTRUMENTS/SWITCHES { SERVICEINFORMATION 19-1 IGNITION SWITCH 19-6 .3 v TROUBLESHOOTING 1 9-1 LEFT HANDLEBAR SWITCH 19—7 I HEADLIGHT 19-2 RIGHT HANDLEBAR SWITCH 19-8 STOP/TAILLIGHT 19-3 CLUTCH SWITCH 19-8 LICENSE LIGHT 19-3 BRAKE LIGHT SWITCH 19-8 [3 TURN SIGNAL LIGHT 19-4 NEUTRAL SWITCH 19-9 ‘ INSTRUMENTS 1974 HORN 1979 R“ SERVICE INFORMATION GENERAL 0 Some wires have diflercnt colored bands around them near the connector These are connected to others with cone spunding band colors. 0 Color code Bl: Black Er‘ Brown v: Vellaw o- Orang L: Blue Lb: Light blue at Han Lg: Light gluon W: White G: Green 0 All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting. 0 To isolate an electrical leilure, check the continuity of the electrical path through the part ” u A continuity check can usually be made removing the part Irom the motorcycle by simply disconnecting the WII’eS and con- necting a continuily tester or yoltmntar K0 the terminals or connectors SPECIFICATION Headligl l 12V 60-’55W smpiiaiuigm 12v 32130P Turn signal light Fronli'rear 12V 32i’CP x 4 License light 12V 40? Meter light 12V I.7W x 4 Indicator light High Imam 12V I.7W Newtral 12V 3.4W TROUBLESHOOTING D No lights come an when Ignition switch is turned on: Headlight beam dons no! shlfl when leLO switch it npar» n . Bulb at faull m burned out atad: - Faulty switch - Boom Filament burned out . Wiring lc Ihat component has an open circuit - Faulty dimmer swmch - Fusl‘! hlnwn - Wiring louse, broken or at Iault . Battery dead or disconnected All lighls come on. but dimly, when ignition switch is turned on: - Battery voltage low D - Wiring or switch has excessive resistance 19-1 LIGHTS/INSTRUMENTSISWITCHES HEADLIGHT , W. I1] BULB SOCKET BULB REPLACEMENT Dlsmnnect me headlight hulk) socket and pull the bulb covey off. Remove the bulb holder and hum. and msta‘l the new bulb ”'1 [he reverse order OI lemoval. CAUTION - near I? glow when "mm/[mu the halogen mu 4/ you “mu/wt] the hull) with your [wry hllfldl, dean :1 ml}: a dart: mummcd m/h u/whul w prev-cm it; early [JIIUVL‘V Note the top mark on the Xab of lhfi hull) covey when installation I“ BULB COVER N 12} ”TOP“ MARK \nstall thn hull) cover wnh the ”TOP" mark facing up Connecl Ihe bulb suckel to the bu‘b securely 1 9-2 LlGHTS/INSTRUMENTSISWITCHES REMOVAL/INSTALLATION Remove Ihe right and lefl faring: [page 1572]. Dwscnnnec‘t 1he headllght bun: connector, and remove the mounting bolts and haanugm. Insla“ the headligm In the revelse order of lha removal, Conneu (he bulb connector, and msraH the vighl and Inn iamngs (page 15-4). D3 STOP/TAILLIGHT BULB REPLACEMENT Remove the attaching screws and vaillighl lens. Replace [he bulb with a new one. mslall the sealing rubber m the groove, and secuve ma [allllghl _ (1) BULB \ens wnh screws LICENSE LIGHT BULB REPLACEMENT » Remove the mounting screws and \Icanse plate slay. LIGHT5/IN5TRUMENTS/SWITCHES Remove the nuts and bull) case. l1l BULB CASE Replace rhe bulb with anew one, and install the removed parts l‘l) BULB in the reverse order of me removal, TURN SIGNAL [Kim (13 scnew lZI aura BULB REPLACEMENT Remove the screw and lens. and replace me hulb wvth a new one. Rmnsrall lhe lens and secure wlth the screw. INSTRUMENTS BULB REPLACEMENT N UTE - Yuu can replace the bulb Wilh only me headlight plate re moved; It Is not necessary to remove 1he right and Iefl larlngst Refer lu 15-3 luv headlight plate removal 1 9—4 LlGHTS/INSTRUMENTSISWITCHES REMOVAL ‘5. Remove the headlight plate (page 1 5131 4 Disconnect the speedometev 9P connector. > 3 Disconnect the speedometer cable. Remove the two mounting butts and Speedometer DISASSEMBLY m CLAMPS Disconnect one clamp and remove the other clamp with the screw. ‘ Pull the bulb sockets out of the meter case. [2| BULBS LIGHTS/INSTRUMENTS/SWITCHES Remove the screws and disassemble the speedomelel. [II SCREW ASSEMBLY/INSTALLATION Assemble and insmll the speedometer in [he {averse order of vamovali I u IGNITION SWITCH INSPECTION Remove [he Iuel \ank [gage 4-3). Disconnect the ignition swim}: connector Ind check for contlr nuny betwsan the terminals. Continuity should exisl belween color coded wives indicated by O 70 marks. Color I R RIBI Position ON 0 i o OFFi' # LOCK 7 7 LIGHTS/INST}?UMENTS/SWITCHES DlsCDnneC‘ the ignirion switch connector. Remove the mounting bolts and ignltion switch. CONTACT BASE REPLACEMENT Cut the WIN; band and discard lt‘ Remove 1he allaching screws and cantact base. Install the new contact base, and seems ir wilh rhree screws‘ Clamp the ignition switch wlre with a new wlve band. Apply a locking agent to rm; ignirian switch mounring bolls. Install rho ignirion switch in the reverse order 0! lhe remavali and secure with bolts [2) CONTACT BASE (1) WIRE BAND TORQUE: 27 N-m [2.7 kg-m. 20 fl-Ihl LEFI HANDLEBAR SWITCH INSPECTION Disconnect the 9P counselor IWhi‘te) and check for conhnully, rsIering the below charts. The switch is nurmal if ihere IS conrinuiw helween 0—0 marks. (Bl SCREWS DIMMER SWITCH .. [U DIMMER (2) TURN SIGNAL ‘ \ SWITCH SWITCH I *7». Color ‘ ~ ‘ LJW w L Posiliorl Lo , 0 #0 , (tn ofioigo Hi 07" ifio TURN SIGNAL SWITCH \ Color (3) HORN SWITCH GlR LB 0 Posillon \ \ V _ L 7 o N H o l—o HORN SWITCH Color I LG El Position \ FREE , PUSH o ifi_o 1 9-7 LIGHTS/lNSTRUMENTSISWITCHES RIGHT HANDLEBAR , , -iiTENéTrTr?'éT0P swncri SWITCH 5 INSPECTION Disconnect the 9P connector Ited), and check lor continuity. reIering the charts below The switch is normal it there is continuity between CF? 0 marks ENGINE STOP SWITCH I2] STARTER SWITCH Color E“ R BII‘W Position [1) CLUTCH SWITCH OFF TERMINALS ¥RUN O 740 STARTER SWITCH ‘- Color V I R LIW WJ‘G Position .. FREE 0—» o PUSH ‘ G—— 740 CLUTCH SWITCH INSPECTION Disconnect the clutch swi‘ch wire connectors. Check lor continuity between the switch terminals. There should be continuity with The clutch lever pulled In and should be no continuity with the clutch lever released, Replace the clutch switch with a new one, if necessary. BRAKE LIGHT SWITCH FRONT ' Disconnect the switch Wires, and check lat continuity. The swutch is normal il there is continuity between the [elmlr mil: with tho Iron! brake applied, HEAR Remove the seat and disconnect the switch connector. Check for continuity. The swnch is normal i! there is continuitv between the termie nals withe rear brake applied. 19-8 LlGHTS/INSTRUMENTS/SWITCHES NEUTRAL SWITCH (1| LIGHY GREENFFS‘ED WIRE CONNECTOR. fit Remove the sear [page 15-2). Disconnect the Ilght green/red wire connector. Check the continuity betwaen the lrghl greenfred wire and ground wrth any gear posr'ion. There should be can‘inurty be1wean rhe greenlred wire and ground wrth 1he 1ransmissron m the neutral positron, and should he no continuity m any other gear pusrt‘ron. ‘1‘ norm r The horn is normal when It sounds by connecting 12V battery to the horn terminals. 19-9 20. WIRING DIAGRAM canclm=i1Nonoc a u. an. N Am @Ul! a?“ '38: 20- 1 WIARING DIAGRAM AFTER '88: 33 ‘3: ‘ N88 N "am 20-2 H 21. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEEDS POOR PERFORMANCE 21-1 AT HIGH SPEED 21-2 UNDERCHARGED BATTERV OVERCHARGED BATTERY 21-3 NO SPARKS ENGINE DOES NOT START OR IS HARD TO START 1‘ Check if fuel is getting to the carburetor GETTING T0 CARBURETOR 2, Try spark lest GOOD SPARKS 3 Tesl cylinder compression COMPRESSION NORMAL 4. Start by following normal starting procedure ENGINE DOES NOT FIFIE 5_ Remove spark plug DRY 6, Start with choke applied Probable cause NOT GETTING TO CARBURETOH ' WEAK OR NO SPARK—*~——>l LOW COMPRESSION —5 - ENGINE FIRES BUT—>- SOON STOPS . WET PLUG—D- No Iuel in Iuel tank Clogged iuel lube or fuel filter or luel 5trainer Clogged float valve Clogged fuel tank can breather tube Faulty spark plug Fouled spark plug Faulty C,D.|. unit Broken or shorted high tension cord Faulty alternator Broken or shorted Ignition coil Faulty engine slop switch Feuny pulse generator Poorly connemeu, broken Dr shore ed wires Valve clearance loo small Valve mick open Worn cylinder and piston rings Damaged cylinder head gasket improper valve timing Sruck decompressor cam Faulty reverse decompressor cam anarway clutch Seized valve Choke excesswely opan Carburetor air screw excessively closed Air leaking past intake pipe Improper Ignition timing (C.D.I. unit or pulse gonormur laully) Carburalor llooeea Carburetor choke excessively closed Throttle veive excessively open Clogged air cleaner element 21-1 TROUBLESHOOTING ENGINE LACKS POWER 1‘ Halse wheel 0” ground and spin by hand WHEEL SPINS FREELY 2. Check tire pressure with tire gauge PRESSURE NORMAL 3. Try rapid acceleration irom low to second ENGINE SPEED LOWERED WHEN CLUTCH IS RELEASED 4. nghlly accelerate engine ENGINE SPEED INCREASES 5 Check ignition (Imlng using [Iming light COFIFIECT 6. Check valve clearance CORRECT 7. Test cylinder compresslon using compression gauge NORMAL 8. Check carburetor for clogglng NOT CLOGGED 9. Remove spark plug NOT FOULED OH DISCOLOHED Probable cause WHEEL DOES NOT SPIN‘fl . FREELV - PRESSURE T00 LOW‘D- ENGINE SPEED DOES NOT—5‘ CHANGE WHEN CLUTCH l5 ' RELEASED - ENGINE SPEED DOES NOT——v' INCREASE SUFFICIENTLY ' INCORRECT‘. . INCORRECT——.. TOO LOWE - CLOGGEDE. FOULED 0R DISCOLORED—H . Brake dragging Worn or damaged wheel bearing Wheel bearing needs lubrication Dllve chain too tight Axle nut excessively ilghiened Punctured tira Faulty tire valve Clutch slipping Worn clurch dlsciplale Warped clulch disc-“plale Carburelor choke closed Clogged air cleaner Resrricled luel flow Clogged luel rank breather lube Clogged mulfler Faulw c D L Unl‘ Faulty pulse generator Improper valve adjustment Worn valve seat Valve skuck open Worn cylinder and plslon rings Leaking head gasket Improper valve timing Siuck decompressol cam Faulty reverse decompressor cam anarway Clutch Carburetor not serviced frequently enough Plug not serviced lrequemlv enough Use of plug with improper heal range 21-2 10. Remove all level gauge and check ml level and for dirty ail CORRECT l ‘l. Remove Ihe valve adjuster cover and inspect Iubricmion VALVE TRAIN LUBRICATED PROPERLY . Check if engine overheats l3r Accelerate or run a! high speed ENGINE DOES NOT KNOCK 0|L LEVEL |NCORRECT——> VALVE TRAIN NOT——O LUBRICATED PROPERLY OVERHEAYEDJD ENGINE KNOCKS———. POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition timing and valve clearance CORRECT 2. Check carburetor pilot screw adiuslmenl CORRECT 3. Check il air is leaking past intake pipe NOT LEAKING 4. Try spark lest GOOD SPARK lNCORRECT————’ INCORRECT———> LEAKING ———> WEAK 0R INTEHMITTENT———> SPARK TROUBLESHOOTING Probable cause . on level (00 high - Oil |nvel ‘00 low » Clogged oil passage - Clogged oil central orifice - Coniaminaied oil Faulty all pump - Excessive carbon buildrup in com- nustion chamber ‘ Use of improper quality of fuel - Clutch slipping - Fuel air mixture too lean - Warn piston ring and cylinder . Fuel air mixture loo lean . Use of improper grade of oil ~ Excessive carbon buildup in com- busiion chamber ' lgnition liming too advanced (Faulty C.D7I, unitl Pussiblo Cause - Improper valve clearance » Improper igniliun liming (Faulty CD I. unit] ~ Fuel air mixlure (on lean (To correct. screw out) - Fuel air mixture too rich (To currecl, screw in] - Dereriorated insulator O-ring - Loose carburetor ' Faulty, carbonized or wet spark plug - Faulty C.D.Iv unir - Faullv alternator - Faully Ignitiun coil - Faulty pulse generator 21-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED ‘l. Check Ignition timing and valve clearance CORRECT 2r Dlscunnecl fuel run: an carburetor 3‘ Remove carburetor and check for clogged let NOT CLOGGED 4. Check valve timing CORRECT 5‘ Check valve spring tension NOT WEAKENED UNDERCHARGED BATTERY 1, Parlorm the battery or electrical inspection (page 1674) NO LEAK 2. Sta lhe engine and perform the regulated voltage inspection (page 16-4] NOT REGULATED 3. Check the alternator Stator Coil contlnurty (page 16-5] NORMAL a. Measure the voltage between the redlwnite (H and green H terminals of the voltage regulator! rectifier REGULATED 57 Check the regulatelreetifler contlnunv (page 16 5) and hlack terminal of the regularon‘rectiller connector for loose Probable cause INCORRECT —- Improper valve clearance - Faulty C,D.l. unll - Faulty pulse generator FUEL FLOW RESTRICTED —>- Lack at Tue! in tank - Clogged fuel tube - Clogged luel rank breather tube - Clogged luel valve - Clogged fuel strainer CLOGGED *———>' Clean INCORRECT —~————>- Cam sprocket not Installed properly WEAK —-———> - Faulty Spllng Probable cause LEAK ——>- Loose, broken or shorted wire or connection - Faulty ignition switch REGULATED ——-—-b ' Faulty ballery OUT OF ORDER “fib ‘ Faulty stator call - Loosev broken or shorted yellow wires or their connections OUT OF ORDER —-—————~‘ Loose, broken or shorted redr‘white or green wires or their connections OUT OF ORDER —>- Faulty voltage regulator. rectifier NORMAL . Loose connector - Faullv alternator 21-4 TROUBLESHOOTING (I OVERCHARGED BATTERY i Measure the voltage belween the black (H and green [-) terminals cl ihe vollage regulalon‘ieciiliei when ignition switch 0N NORMAL READINGS . Check me vahage regulaturlreciilier connector Var loose [\IJOT LOOSE Pvabable cause OUT OF NORMAL ———>~ READINGS (11 712V] LOOSE N0 SPARKS . Replace ihe spark plug wim good one NO SPARK . Check the plug cap and high lension cord for loose NOT LOOSE . Disconnect the blacklwhi‘e wile ierminal and check me spalks while engine clanking N0 SPARK . Pal aim the ignirion system inspection (page 1773] OUT OF ORDER Me sure (he exalmr coil resistance {page 1 7-3] NORMAL . Measure the pu|se generamr resistance [page 17-4) NORMAL . Check the ignition Coll (page 1773] it. 8’ NORMAL Check [he CDI unit (page 17-3} NORMAL L— GOOD SPARK ————> - GOOD SPARK ———>. NORMA L OUT OF STANDARD———>I OUT OF STANDARD 4». RESISTANCE OUT OF ORDER ~%—->. OUT OF ORDER Broken black or gleen wire harness- as Loose connacmv Faully Voltage iegulatnn‘rectlliel Pmbabls causn Faulty spavk plug Loose plug can Faulty ignition switch of engine slop switch Broken or shulled Faulty excilov coil Faulty pulse generator Fatu Iglllhon coil Faully cm unil Loose iarminal connection Out of order pulse generaror air gap 21-5 L—__ .ua Air Cleaner ..................................... 36 Case ................ , 4-4 Alternator/Stanly Clutch Alternator Balancer!Crankshalt Removal Battery/Charging System Battery" ,t Brake Carper . Brake Fluid . Replacement/Air Bleeding . Brake Light Switch Fadi'Disc Shuei‘Pad Wear . System Brakelight Swflch Cable 5i Harness R0 9 1-9 Cam Chain Tensioner Remava 679 Camshalt Installation 6~17 Removal 5-5 Carburetor . 4~7 Choke 3.5 Idle Speed 3»B Charging System 16-5 Clutch 8-1, 8»2 Diode 18-8 Switch ‘33 System . 3-12 Crankcase Assembly..10-1 1 Bearing Replacement . l076 Brealher 4-6 Separation ,, 10-3 CrankshamBalancer Installation Cylinder Headr'Valves CyiinderiPismn . Cylinder Compression , V Head Assembly Cylinder Head Cover Assembly Disassembly Installation Removal Cylinder Head Disassembly Installation Removal Cylinder Installation . Removal Drive Chain Slider . Electric Starter System Emission Control lnlormat nlabels (USA. only) 1.13 Systems L16 Engine Removal nslallafion 5-! Installation 53 Engine Oil Change 23 Filter Replacement 2-4 Level Check 2~3 Engine Removal - Exhaust Pipei'Mufller FairinglEKhaust System . Fairing Flywheel Install 22. INDEX Flywheel Removal i 9-3 Fork. .12 10 Front Wheel SuspensionISteerIng 12-1 Wheel 1 2-5 Fuel System . 4-1 Line/Fuel Strainer l 3-4 Tank .. 4-3 Goarshilr Cam . 8-9 General Inlormation . 1-1 Safely t M Handlebar . 12-3 Headlight 1 9-2 Aim 3712 High Altitude Adjustment iu,5.A, only) . 4-17 Horn t, 1979 Hydraulic Bral