HON DA “:3 =- :__. R51 000 PARTS LIST OWNER’S MANUAL WARRANTY The HS 1000 engines and kits have no warranty. No waranty is also made with respect to vehicles and engines when they are powered by the engines or contain any of the kit parts, IMPIIRTANT NllTICE I These kit are intended for use In endure and T.T. formula class i races. Before using, make sure that they conform to the standards or regulations established by a sanctioning body 0 Operation on public streets, roads. or highway IS illegal. I Use gasoline of high octan rating. Pay special attention to statements preceded by the following words: i R \I u, : Indira/es a pouibflily of personal injury or lost aflife if instructions are not followed. CA UT ION 1 Indicates a possibility afequipmenl damage if inwuuionr are no! [allowed NOTE : Gives helpful information to make the job easier. FIIREWIIRIJ Thank you very much for purchasing the Honda RSlOOO Tuneup Kit. Based on the CBQOOFZ engine, this kit is a product of the finest skills and techniques avai|able. it is a top-performing racing kit with a proven reputa- tion of Honda dependability and quality as evidenced by the successive victories in the famous European enduro races in the past three years. A choice of three engines and others make the machine even more versatile under all conditions from enduro to super bike speed racing, © HONDA RACING SERVICE CENTER CORPORATION,1979. HIJW III USE THIS MANUAL This PARTS LIST/OWNER'S MANUAL con» Iains information which differs from that of Honda CBQOOFz, and reference ism be made to the base manual for complete information Flnd Ihe section you want on this page, then turn to the table of cements on page I of that sectIon. ALL INFORMATION, ILLUSTRATIONS. DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTINGI HONDA R.S.C. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANV OBLIGATION WHATEVERI NO PART OF THIS PUBLICATION MAY BE REPRO- DUCED WITHOUT WRITTEN PREMIS- SION. HONDA RACING SERVICE CENTER CORPORATION. [IIIIIIEIITS TUNE UP KITS GENERAL INFORMATION PARTS LIST OWNER'S MANUAL EHEH I. TUNE-UP KITS The Iolluwmg live kits are available. They meet all the requrrements tor a top~pertormrng racing kit: power, speed and dependability, They provrde all big-bore enthusiusts With a chance of engines best suited to their needs. VOLUME —5 rn ----C .N KIT K KIT—t7 0 FEATURES KIT A: (BORED-UPI ------- Featuring a total displacement at 996.5 cc, the kit is applicable to various races which limit engine size to 1,000 cc. The maximUm output IS 100 PS/94500 rpm (105 PS/DINII 105 PSI]? (I‘ll) PS DIN/l2). KIT B: (KIT A 6 POWERED-UP) ~~~~~~~ The kit is a powered~up version ol the Kit A to outperform competitors in races up to 1,000 cc. It turns out 115 PS/9.500 rpm (121 PS/DINI. 121 (75/9 (127 PS DIN/I2). KIT C: (KIT B 4' DRV SUMFI rrrrrr The kit is designed to conform to all the regulations established (or the TT Formula One Racing and (or various competitions in europe named as enduro. The dry sump lubrication keeps the bearings and other moving parts of the engine well lubricated and cooled under toughest racing conditions. The maximum output is an increadibly high 125 PS/9,500 rpm (135 FS/DIN). 132 PS/IZ (139 PS DIN/I2). KIT D: (CLOSE RATIO MISSION GEAR + DRY CLUTCH) - C-losed ratio transmission and dry type clutch to enhance the already outstanding Ieatures ol Kits A B and C KIT E: (SPEED RACE KITI ------- Speed racmg kit for use With Kits A. B and C, Allows greater banking on corners In sprint races where no lighting equrpment is used. CA UTION Alwayx replace the connecrmg rod and crankshaft bearings with those described In Page 316 when any of the kit parts it used. 2. GENERAL INFIIRMATIIIN SPECIFICATIONS TORQUE VALUES SPECIAL TOOLS PERIODIC REPLACEMENT PARTS SERVICE DATA WIRING DIAGRAMS 2—2 2—4 2—4 2—5 2—6 2—7 GENERAL INFORMATION SPEEIFICIITIIIIIS I Specifications—Kits C and D ENGINE Type Cylinder arrangement Bore and stroke Dicplacement ratio CompresSion ratio Valve Hall'l MaXImum horsepower MaXimum torque Oil capacity Recummended orl Lubrication system Intake valve Opens Closes Exhaust valve Opens Closes Valve clearance Dry weight Air cooled 4-stroke Vertical parallel Iour 67.3 x 69.0 mm (2.67 x 2.72 in) 996 cm3 (30.8 cu In) 11.0 I 1 Chain driven DD. .6. 4 valve 91.9 KW (‘25 PSI/9.500 mm~| (rpm) 107 N-m (10.7 kg-m, 76.2 tum/7,000 rnIn-I (rpm) 6 liters (6.27 US qt, 5.28 Imp. qt.) TOTAL BOL D‘OR #40, SHELL SR #40, or its equivalent. Dry sump 35" (ETDC) at 1 mm im 40“ (ABDC) at 1 mm im 50" (BBDCl arl mm im 25u lATDCl at I mm lift IN ’ } 0.15mm [0.006 in) EX: B4.0kgl185|b] CARBURETION Carburetor type Float level Main jet Main air jet Slow air jet Jet needle Slow jet Air screw Needle jet Air funnel VBSIA, 32 mm (1.22 m) venturi bore 15.5 mm Pfl1#0 2nd: #128 FYI. #0 2nd: Blind #170,30 25D75 stage #42 24/4 turn out $2.6 (Breach dia) L=50 mm (1.963 in) ELECTRICAL Ignition timing Full advance Starting system Spark plug 36"/3,500 min“ (rpm) Starting motor R 2093 (NGKI GENERAL INFORMATION DRIVE TRAIN Clutch Transmission Primary reduction Gear ratio I II III IV V Final reduction Drv, multi‘plate 5-speed constammesh L346] 2.0556 113455 1.2400 1.0769 0.9642 2.2941 GENERAL INFORMATION TllRllllE VALUES ITEM o'zv Thread Dla mm Nm T025? Mb Cam holder 24 G 14 1‘4 11 Cylinder head 12 10 36 3,6 26 Cam sprocket 4 7 16 1,6 12 Crankcase 10 B 25 215 18 Connecring rod 8 B 36 3.6 26 Pulsar rotor 1 8 32 3.2 23 Primary drive gear 1 12 90 9.0 65 AC. generaror 1 12 70 7.0 50 Clulch center lock nut 1 16 40 4.0 29 Fasreners not lrsted should be lightened (0 standard torques listed below. STANDARD TORQUE VALUES Type F TORQUE ME TORQUE N~m Kg~m lt-Ib N-m Kg-m ft-lb 6 mm screw 7—10 0.7—1.0 5—7 6 mm llange hex bolt 10—14 104 ,4 7—10 6 mm hex bolt 3-12 0.8412 6—9 8 mm llange hex bolt 24—30 2.4—3.0 17—22 8 mm hex bolt 18—25 1.8v2.5 13—18 10 mm flange hex bolt 34—45 3,4-43 24734 10 mm hex bolt 30—40 10—40 22—29 SPECIll TfllllS Tool Name Parr No. O'ty Rel. page Valve Illxer holder 00001—‘492—RSC 1 4—9 Top gauge anachmem 00004—492—RSC 1 4—8, 4—9 Meter holder 00005»492—RSC 1 4—8, 4—9 PERIODIC REPLACEMENT PARTS GENERAL INFORMATION REPLACE EVERY: 'TEM FHE°UENCV 5,000 km (3,000 «HI 10000 km (6,000 ml) ' PISTON o ‘ PISTON RING‘ TOP 0 ' 2ND o ' OIL O CAM CHAIN, A o CAM CHAIN, a o ' CAM CHAIN TENSIONER, A o ' CAM CHAIN TENSIONER, B o ' CAM CHAIN GUIDE 0 ' CAM CHAIN GUIDE‘ 0 o BEARING (PRIMARY, MAIN AND COUNTERSHAFT) o ‘ CLUTCH FRICTION DISK o ' CLUTCH PLATE, 5 o PRIMARV CHAIN o VALVE STEM SEAL o VALVE INLET o EXHAUST o VALVE COTTER 0 ~ VALVE SPRING ouTER o ' INNER o PRIMARY DAMPER RUBBER o ' """" Consul! service data Io determlne H parts are to be replaced. _ _ GENERAL INFORMATION SERVICE DATA ITEM smnmnu SERVICE LIMIT Cvllndev ID. 673076131 mm (2 6692»2.6697 m) 67.9 mm (26732 ml man on. 67.72»67.75 mm I2.6561v2.6673 in] 67.7 mm (2.6653 In) Pmon pm hula I D. ISDDZ—I 5.005 mm I0.590&0.5909 In) 1504 mm (0.592! In) Pmon pm OD. I4.994—15.000 mm {05903—05905 In) 14.980 mm "1.5899 in} Flslon IIngvm-Iing groove clealance TOP/SECOND 0.030— .045 mm (00012—00018 In) 0.070 mm (0.0028 4") Fislon nrlg end gap 0,370.5 mm (0.01 Iii—0.0197 In) 0.70 mm (0.0276 In] Valve clearance INJEX. 015 mm (0.0059 In) 0.|370.17 mm (00051-00057 In) Valve guldIID. INJEX. 5.500—5.5|5 mmI0.2I65—0.217l in) 5.530mml01177ln) VaIvn sum CD. IN, 5 475—5490 mm (01155-01164 In) 5.470 mm (0.2153 In) EX. 5455—5470 mm (02148—1121 53 in) 5.440 mm (0 2142 In) Valve spvlng Ive: langxh INNEF) 38 44 mm (1.5l34 In) 36.9 mm (I .4528 In) OUTER 44 34 mm ”.7654 In) 43.05 mm (I 6949 m) Valve spring Ierlsmn INNER 20.3 1 L4 kgl25 mm (44.753 2 3 036 lbs/0.9843 In) # OUTER 4!,96 : 2 9 k9/285 mm (92 505 x 6 393 lbs/I I220 In) 7 CamshaIl-cam hoIdeI clealance 0.05—0.‘ 5 mm (00020-00059 in) 0.25 mm (0.0098 In) Connecllng Ind-crankshall Sldl clearance 0.I040,20 mm (00039410079 In) 0.25 mm (0.0098 In) CrankshaII-upper case sidz clearance (#2) O.l0»0 30 mm (0 0039~0 01 IE In) 0.35 mm (0.0) 38 m) Pulse CDII'VUIO' clearance 0.4—0.5 mm (0,0!57—0 (”97 In) 0.5 mm (0.0197 In) mnnecling lad small and ID. 15,016v!5.034 mm (05912—05919 In) (5.045 mm (0.5923 In) Clulch Iricllun dlsk Ihlckness 2.692~2.708 mm (0.I060#0.1066 in) 2.45 mm (0.0965 in) CIulch surlng he: lengm 33.6 mm “.3228 In) 1190 mm (1 2559 m) Clulch Snnng Ienslon 43.5 XII/23 mm (97.7 IDs/0.9055 in) Tvansrmssmn 9231 backlash 0.034~0.102 mm [D OOH-0.0040 in) 0 20 mm [0.0079 In] CIankshaIl ell :IeaIance JOURNAL 0030—0040 mm ID 00| 2*000‘6 In) 0050 mm [0.0020 inl CRANK PIN 0035-0045 mm (0 0014—0 0013 In) 0.055 mm (0.0022 in) Camshall juuvnal all cllavance CENTER 0.055—O.I39 mm (00033—00055 In) 0.24 mm (0.0094 In) MIDDLE 006240.109 mm (00024—00043 In) 0.21mm(0.0083ln) SIDE 0.040—0 032 mm looms—0.0032 in) 043 mm l0.007l in] GENERAL INFORMATION WIRING DIAGRAMS .NEE mad up Eco...“ “2:5 $50 *0 «En icoauum .@ .«EE mm; wn 339.3 3:; 32.5... 9:3 SE: 5505 us» :33 .um. 6552,32 to 35 icosuwm .@ #2.: OF .32 .n on Ezofi $33 9505 «:5 >553 .EEE mEtm: .0 my; .mcoauwm .e Hm‘_..UZ \ sign—.85 I II] I l» O I 5:559”: is a E x :5. n .5 m in a $6: I :1; , 53 a 25:: H a s . y: y: 3. .2: as: :2... 5:; " 9m: 5:: 5:5 2:5; 5:: \x 55; x , nu .3: [no < _ § \ I . ~ umE \\ F: / a Uh x, \ ‘ 4 . 525 Save u M / A”. \. a x z x _ ‘ I \ KoK ‘ a ., a 6:5 h i + + in x «a a W _ r 2-7 MEMO PARTS LIST 9: RS 1000 PARTS llST 1. BORE UP KIT A 3— 2 2. POWER UP KIT B 3— 4 3. HIGH POWER UP KIT C 3— 8 4. DRY CLUTCH & MISSION KIT D 3—14 5. SPEED RACE KIT E 3—18 I 6. PACKING SET K 3—20 7. MAINTENANCE PARTS L 3—22 c The tune-up parts for R5 1000 engine are installed in the engine based on CBSOOFL I This pans list indicates RS 1000 pans exclusively, All other parts not listed herein are the same as CBQOOFZ. 1. “RE UP 1111 A Ref. No. Part No. PARTS LIST Description Reqd. No. RS 1000 Rumarks ommNm-mhmm—n 12 13 14 15 16 17 18 19 20 21 06120~NA1-000 1 1000~NA1~000 12100»NA1-000 121931492000 12251 -NA1~000 13101-491010 131 1 1493000 131214911000 13131 u493-000 13141-493000 13210~NA1~000 15921300970 15922-300970 16013-425405 16027-425671 37511-300370 90036492010 90047-492000 90442-028000 90443- 1 07 -000 913011287000 991 02-393- 1020 99102-393-1050 991023931080 BORE UP KIT A CRANKCASE SET CYLINDER COMP. [67.8 mm) . GASKET, chinder (0.3 [I GASKET, cylmder head PISTON (67.8 mm) PIN, piston RING, piston top (67.13 mm) RING, piston second 167.8 mm RING, piston ml (67.8 mm) ROD COMP., connecrlng . BOLT, all pressure NUT, oil pressure LINK SET B, choke JOINT SET A, fuel CONNECTOR, oSI pressure prpe BOLT, stud, 8 x 128.5 BOLT, flange, 7 x 80 WASHER, sealing, 8 mm NUT, cap, 8 mm . O-RING, 69.8)! 2 JET, secondary main, #102 ..... JET, secondary main, #105 JET, secondary min, #108 ubbnn a.._._._. PARTS LIST 1. RIM UP KIT A BNAI—Al 3-3 PARTS LIST 2. POWER llP KIT B Refi . , Raqd. No. Rumirks No. P‘" "°' D'“"""°" RS 1000 (Divnned parts from other kit) 06140-NA1-000 POWER UP KIT B 1 1 HOOGNAI-DOO CRANKCASE SET ..... 1 A 2 12100-NA1-000 CYLINDER COMP. (67.3 mm). 1 A 3 12193492000 GASKET, cylinder (0.3 l) . I A 4 12251-NA1-000 GASKET, cylinder head . 1 A 5 13101-493010 PISTON (67.8 mm) ..... 4 A 6 13111-493-000 PIN, piston ....... 4 A 7 13121-493000 RING, piston lop (67.8 mm) . 4 A 8 13131-493000 RING, piston second (6718 mm) 4 A 9 13141493000 RING, piston 0111673 mm) 4 A 10 13210-NA1-000 ROD COMP., connecting 4 A 11 13610-NA1-000 CHAIN, primary (1 inch) 1 12 14100-492000 CAMSHAFT, inlet 1 13 14200-492000 CAMSHAFT, Exhaust 1 14 14401-NA1-000 CHAIN A, cam ..... 1 15 14402-493000 CHAIN E, cam ..... 1 16 14751-492000 SPRING. valve outer 16 17 14761-492000 SPRING, valve inner 16 18 14775-422000 SEAT, outer valve spring 16 19 14776-422000 SEAT, inner valve spring 16 20 15921-300970 BOLT, oil pressure 1 A 21 15922-300970 NUT, OII pressure .. 1 A 22 16018-425405 LINK SET 5, choke 1 A 23 16027-425671 JOINT SET A, Inn! 1 A 24 16216-NAI-000 FUNNEL, air. 4 25 17256-429000 BAND, insulator 4 r PARTS LIST 2. PIIWER IIP IIII II Raf. . , Raqdu No. Remarks ND- Port No. Dficr'mw" RS 1000 (Divened pans from Mlle! kill 26 18231492000 JOINT, exhaust pipe 4 27 18233-425000 COLLAR, exhaust pipe joint 6 28 18291254000 GASKET, exhaust pipe 4 29 18310-NA1—000 PIPE 1, exhaust 1 30 18320-NA1-000 PIPE 2, exhaus! I 31 18330-NA1-000 PIPE 3, exhaust 1 32 18340-NA1-000 PIPE 4, exhaust 1 33 18345-NA1»000 JOINT A, exhaust pipe 2 34 18345NA1-000 JOINT B, exhaust pme 1 35 18350-492000 MUFFLER SET 1 36 22401-493000 SPRING, cluxch 6 37 23803~NA1~000 SPROCKET, drive HST) I 38 30751492000 CORD. high tension 4 39 31900-492410 PLUG, spark, R2097 #11 4 40 37511300870 CONNECTOR. otl pressure pipe ...... 1 A M 90035-425000 BOLT, stud, 8 x 55 B 42 90036491010 BOLT, stud, B x 128.5 10 A 43 90047-492000 BOLT, Ilange, 7 x 80 .. 3 A 44 90442-028000 WASHER, sealing, 8 mm 10 A 45 90443-107000 NUT, cap, 8 mm .. 10 A 46 91304287000 O»RING, 69.8 x 2 4 47 99102-393-1250 JET, secondary man, #125 4 99102-393-1300 JET, secondary main, #130 4 99102-393-1350 JET, secondary mam, #135 4 JET, secondary main, #140 A 99102-393-1400 PARTS LIST 2. POWER llP KIT B (1) PARTS LIST 2. PflWER UP KIT B (Z) ENAIABZ 3-7 PARTS LIST 3. HIGH PIIIIEII lIP IIIT I: Raf. , , Read. N01 Rumuks e n N . No. ' ° D""'""°" RS 1000 (Divorted pans 170m other kit) 06150-NA1»000 HIGH POWER UP KIT C 1 11000~NA1~000 CRANKCASE SET 1 A, B 2 11210492000 PAN, oil 1 3 11351492000 COVER, lIf! slde , 1 4 ”643-492-000 COVER, drive chain 1 1 5 12100~NA1~000 CYLINDER COMP. (67.8 mm), 1 A, B 6 12193-492000 GASKET. cylinder (0.3 t) 1 A, B 7 12251 -NA1-000 GASKET, cylinder head . 1 A, B B ISDOD-NAl-OOU CRANKSHAFT COMP. (1-1/4 Inch). 1 9 131014193010 PISTON (67,8 mm 4 A, B 10 13111-493000 PIN, piston 4 A, E 11 13121493000 RING, piston mp (6716 mm) . 4 A, B 12 13131-493000 RING, piston second (67,8 mm) 4 A, B 13 13141-493000 R1NG,pis{on oil (67.3 mm) 4 A, E 14 13210-NA1<000 HOD COMP., connecting 4 A, B 15 1361D-NA1-900 CHAIN, primarv (1-1/4 inch). 1 16 14100-491000 CAMSHAFT, inlet 1 B 17 14200492000 CAMSHAFT, exhausx 1 B 18 14401-NA1-000 CHAIN A, cam . 1 B 19 14402-493000 CHAIN B, cam . 1 B 20 147514192000 SPRING, valve outer 16 B 21 14761492000 SPRING, valve inner 16 B 22 14775422000 SEAT, outer valve spring . 16 B 23 14776-422000 SEAT, inner vaIve sprxng ‘ 16 B 24 15100-492000 BODV COMP., oll pump , 1 25 15136-491000 GASKET, Iefl slde cover . 1 26 15150-300000 SCREEN, oil strainer 1 27 15153-492000 BODV, oal screen .. I 23 15232-492000 SPRING, relief valve , 1 29 15311-492000 BODY, ml path . 1 30 15367-492000 BODY, oil iulnt . 2 PARTS LIST 3. IIIIIH PIIVIER UP 1111 C 22' Pm No. Description Road. No. RS 1000 (Divnmd pans Irom othor kit) 31 15512-492000 GRING, 21 x 3 2 32 15515492000 JOINT, oil hose 2 33 15921‘300-970 BOLT. oil pressure 1 A. B 34 15922-300970 NUT, oil pressure 1 A B 35 15100-NA1-000 CARBURETOR ASSY. . 1 36 1621E‘rNA1-000 FUNNEL,air ..... 4 B ' 37 17256-429000 BAND, insulator 4 B 30 18231492000 JOINT, exhaust pipe 4 E 39 18233-425000 COLLAR, exhaust pipe joint I 8 B 40 18291-254000 GASKET, exhaust pipe 4 B 41 18310-492000 PIPE 1, exhaust 1 B 42 18320-492000 PIPE 2, exhaust 1 B 43 18330492000 PIPE 3, exhausr 1 B 44 18340-492000 PIPE 4, exhaust 1 B 45 18345~NA1~000 JOINT A, exhaust pipe 2 B 46 18346‘NA1-000 JOINT B, exhaust pipe I 5 47 18350492000 MUFFLER SET 1 B 48 22401-493000 SPRING, clutch, 6 B 49 23112-492800 SPROCKET, primary (1-1/4 inch) 1 50 23160»NA1-000 BASE COME, primary tensioner ...... 1 51 23175-492-000 PIPE COME, primary [ErlSIOI'IEf ....... 1 52 23130492000 BODY COMP., tensioner valve 1 53 23803-NA1~OOD SPROCKET, drive NET) 1 B 54 30371-NA1-000 COVER. polnt . 1 55 30372-NA1-000 GASKET. pom! cove 1 56 30751-492000 CORD, high 1EI'ISIOI'I 4 B 57 21900492410 PLUG, spark, R2097 #11 4 E 58 31110-492000 ROTOR COMP, 1 59 37240-300970 TACHOMETER ASSV. 1 60 37260-300970 CABLE ASSY‘, tachometer ....... 1 ‘ - 3. HIGH POWER IIP KIT 6 PARTS LIST Ref. , , Roqd. No. Remarks Nor P‘" "n' D“"'”"°" RS1000 (Divan-d pom from other kit) 61 37511-300970 CONNECTOR, oil pressure pipe 1 1 A, B 62 90031-NA1-000 BOLT, slud, 10 mm 12 63 90035-425000 BOLT, stud, 8 x 55 B 64 90036—492010 BOLT, stud, 8 x 128.5 , 10 A, B 65 90047-492000 BOLT, flange, 7 x 80 . 3 A, B 66 90066492000 BOLT. flange, 6 x 69 r 3 67 90067-492000 BOLT. flange, 6 x 76 , 1 68 90442-028000 WASHER, seating 18 mm , 10 A, B 69 90443-107-000 NUT, cap, 9 mm 10 A, B 70 90483-492000 WASHER, 13 mm 1 71 90702-492000 PIN, dowel, 18 x 49 1 72 91304-287-000 O-RING, 69.8 x 2 4 A, B 73 91304-612000 O-RING, 20 x LE 1 74 91305492000 OvfllNG, 17 x 3 ., 2 75 92030-12000 EIOLT, drain, 12 mm 1 76 94109-12000 WASHER, dram, 12 mm 1 77 9430108140 P|N A, dowel, 8 x14 . 2 78 957000601000 BOLT, flange, 6 x 18 . 4 79 9570001502200 BOLT, flange, 6 x 22 14 BO 95700-060250!) BOLT, flange, 6 x 25 'l 81 9570006032-00 BOLT, flange, 6 x 32 5 82 95700-06045-00 BOLT, flange, 6 X 45 6 53 95700-06055-00 BOLT, flange, 6 x 55 2 64 991023934250 JET, semndary mam, #125 4 B 99102-393430!) JET, secondary mam, #130 4 B 99102-393-1350 JET, secondary mam, #136 4 B 99102-393-1400 JET, secondary main, #140 4 B 85 BEARING, connecting rod 6 86 BEARING, crankshaft 10 — . PARTS LIST 3. HIGH PllWER llP KIT 0 (I) PARTS LIST 3. HIGH PM!“ “P KIT C (2) RNA! —C2 3-12 3. HIEH PM!“ "P KII I} (3) PARTS LIST PARTS LIST 4. DRY ELUTCH 8- MISSIUN KIT [1 R51. ”0- Pm No. Dmrimion Road, No. RS 1000 Rum-7k: 06220-492000 1 11342-492010 2 1 11143-492010 3 22101-492000 4 22110-492000 5 22120492000 6 22202492000 7 22203-492000 8 22322-492000 9 22350-492000 0 22360492020 11 22401-492000 12 22405492000 13 22815—300000 14 22946—492000 15 22847-492010 16 22870-492010 17 231 013-492-000 IE 231 16492-300 19 23211-492010 20 23220-492010 21 23411-492010 22 23431-492010 23 23451492010 24 23460-492010 25 23470-492010 26 23481-492010 27 23491-492010 28 23501-492010 29 24610492000 30 24652-492000 DRY CLUTCH 81 MISSION KIT D COVER, righ! crankcase COVER, dutch. OUTER. clutch GEAR COME, secondary driven CENTER. dutch ...... PLATE A, clutch DISK, cluxch friction PLATE B,clulch .. PLATE, clutch pressure PLATE, clutch liftzr SPRING,cquch COLLAR, plate boss SPRING, clutch lever THREAD ASSV., lifter PIECE, clutch liner .. CABLE COMP.,c|utch GEAR, pnmarv drivE ...... COLLAR, pnmarv sprocket MAINSHAFT, Iransmussuan (1ST) . COUNTER SHAFT, transmission (34T) ...... GEAR, countershah low (37Tl GEAR, mainshalt second (22T) . GEAR, mainshafl Khlrd (2ST). GEAR COMP‘, countershah mud (31T) GEAR COMP” mainshah fourth (ZST) . GEAR, countershaft fourth (28T1 , GEAR, mainshafl hfth (ZBT) GEAR, wuntershafl mm (27T SPINDLE COMP., gearshift PIN, gearshm return spring 1 _.‘__._. _._._.__. Addzsu _._.m\._. _._._._.- PARTS LIST 4. DRY CLUTCH & MISSIUII IllI I] R51. Raqd. No. "0' Pan Nu. Dascliption RS 1000 Remarks 31 90013492000 BOLT. flange, 12 x 21 1 32 90457-492000 WASHER, Khrust. 16 mm 1 33 90458-492000 WASHER, thrust, 25 x 35 x 2 1 34 90459-492000 WASHER, thrust, 30 mm 1 35 90462-492000 WASHER, 12.2 mm 1 36 91009-492020 BEARING, Iadlal ball, 6003 ................ 1 37 91203~492~000 OIL SEAL, 35 x 50 x E 1 38 91204492-000 OIL SEAL. 46 x 65 x a 1 39 91206-492010 OIL SEAL,7X16x4 1 40 91209612003 OIL SEAL, 12 x 22 x 7 ................ 1 41 91301-283005 O-RING, 5 x 2.4.. 1 42 913027492000 O-RING, 15.5 x 4 1 43 9430108140 PIN A, dowel, 8 x 14 2 44 9451012000 CIR CLIP, external, 12 mm 1 45 95700-06016-00 BOLT. flange, 6 x 16 2 46 9570006025130 BOLT, flange. 6 x 25 9 47 95700-06032-00 BOLT, flange. 6 x 32 2 48 95700-06040~00 BOLT, flange. 6 x 40 5 49 95700-06045-00 BOLT. flange. 6 x 45 2 3-15 PARTS LIST 4. DRY CLUTCH 8: “188""! KIT D 8492—01 3-16 PARTS LIST MEMO 3-17 5. SPEED RACE lllT E Rel. Nu. PARTS LIST Part No. Description Roqd, NIL RS 1000 Remarks 05330~NA1-000 SPEED RACE KIT E ..... 1 11341-NA1-900 COVER, leh crankcase 2 11631-NA1-000 COVER,dvnamo 3 28105~NA1-ODD SHAFT, starter reduclion gear 4 30220-NA1-900 ADVANCER ASSV., spark 5 30300-NA1‘900 GENERATOR ASSY, puls 6 30371-NA1-900 COVER, pomL, 7 30372~NA1~900 GASKET, palm cover . 8 31900-4934 IO PLUG, spark, R2093 #11 9 90001-493000 PLUG, seal, 30 mm 1 10 90001-NA1-000 WASHER, plain", u , .. 11 90023-425000 BOLT, flange, 12 x 40 12 95700-06014-00 BOLT, flange, 6 x14 .0 13 95700-060250!) BOLT, flange, 6 x 25 .. 14 95700-060400!) BOLT, flange, 6 x 40 l, 15 95800-10025-08 BOLT, flange, 10 x 25 _._.;,_._. [ll 3 For (mung adjust 3-18 PARTS LIST 5. SPEED RACE K” E 3-19 E. PACKING SET 11 PARTS LIST Ref. _ . Reqd. No. Remarks Na. Part Nu. Description RS 1000 (Lnutnd position) 06190~NA1~000 PACKING SET K 1 1 12191-492-000 GASKET, cvlmder (0.5 11 1 12192-492000 GASKET,cv|mder[0.41) 1 12193492000 GASKET, cylinder (0.3 t 1 2 12251-NA1-000 GASKET, cylinder head. 1 3 15136492000 GASKET, 12h SldE cover, 1 4 15512-492000 O-RING, 21 x 3 ...... 2 011 hose jam! 5 30372-NA1>000 GASKET, pom! cover .................. 1 6 30372-NA1~900 GASKET, paint cover 1 For speed race 7 91203492000 OIL SEAL, 35 x 50 x 8 1 Clutch cemey 8 91204-492000 OIL SEAL, 46 x 65 x 8 1 R. cover 9 91206-492010 OIL SEAL, 7 x 16 x 4 1 Clutch lifter 10 91209-612003 OIL SEAL, 12 x 22 x 7 1 R. cover 11 91301183005 0~F1|NG, 5 x 2.4 .. 1 Clutch lifter 12 91302-492000 O-RING, 15.5 x 4 1 Mamshafl 13 91304287000 O~R|NG, 69.5 x Z 4 Cylinder 14 913044612000 O~RING, 20 x 1.8 1 Oil screen body 15 91305492000 O-RING, 17 x 3 2 0|1101I’II ban 3-20 PARTS LIST 6. PACKING SET K IIIIIII PARTS LIST 7. MMNTENAIICE PARTS l Rafi . . Read, No. Nni Parl No, Description RS 1000 Remarks MAINTENANCE PARTS L 1 13000-NA1»900 CRANKSHAFT (1-1/4 inch) 1 2 13205634010 NUT.connec1ing rod . 3 3 13213-422004 BOLT, connecting, rod 8 4 13215-492000 BEARING A, connecting rod 3 Red 13216-492000 BEARING B, connecting rod 5 Vellow 15217-492000 BEARING (2, connecting rod 8 Gm," 13218-491000 BEARING 0, connecting rod 8 Blue 13219-492000 BEARING E, connecting rod 8 Purple 5 13315492000 BEARING A, crankshaft .. 10 Red 13316-492000 BEARING B, crankshaft 10 Yellow 13317-492000 BEARING C. crankshafr 10 Green 13315-492000 BEARING D, crankshaft 10 Blue 13319-492000 BEARING E, crankshaft 10 Purple 6 15120-492000 ROTOR A, inner 1 7 15122-492-000 ROTOR A, outer 1 E 15125-492000 ROTOR B. inner 1 9 15126492000 ROTOR E. Duler 1 IO 15130-491000 GEAR, oil pump 1 11 16020-NAHJDD PARTS SET, carburetor revision ......... 1 Componem parts NOZZLE, main, #0 [4] (JET, secondary air (4)) BALL, sleel,¢2r3 (4) 12 23802>NA1~000 SPROCKET, drive (1ST) 1 13 31900-492420 PLUG, spark. R2097 #12 . 4 For endurance 31900-4934 20 PLUG, spark, R2098 #12 . 4 For speed 14 90065-492000 BOLT, flange, 6 x 65 ..... 2 3-22 'I. MAINTENANCE PARTS l PARTS LIST PARTSLST MEMO 3-24 4. IIWNER’S MANUAL 1. CRANKCASE ASSEMBLY O BEARING SELECTION U CONNECTING ROD INSTALLATION 0 PRIMARV CHAIN TENSIONER AND OIL STRAINER INSTALLATION o TRANSMISSION AND SHIFT DRUM. SHIFT FORK INSTALLATION 2. PISTON INSTALLATION 3. CAMSHAFT INSTALLATION 4. VALVE TIMING 5. OIL PUMP INSTALLATION 6. CLUTCH INSTALLATION 7. IGNITION TIMING I PULSE ROTOR/GENERATOR INSTALLATION o IGNITION TIMING 8. CARBURETOR SETTING (FOR A AND B KIT) I AIR JETS a AIR CUT VALVE 0 MAIN JETS 9. AIR FANNEL INSTALLATION 10‘ BREAK-IN OPERATION 4—14 4—15 4—16 4—16 4—16 4—17 4—17 4—18 OWNER'S MANUAL 1. CRANKCASE ASSEMBLY 21 23 y . r ‘ l - BEARING SELECTION [ I l I; “I? I‘ I; x CRANKSHAFT BEARING J‘ JIl-ImI 1 J I] lgbl I Install the malnshaft and cauntershaft Into " TJBI‘F—A the upper crankcase. Install the lower crankcase and tighten them I ’1‘ J evenly In the sequence shown and m 2-3 steps‘ 24 4" NOTE 3:" Applv molybdenum drsulflde grease to Sgfigfigfim’s the thread and head of the ten crankshaft stud bolts, and flange ol the ten crankshaft holding nuts, SPECIFIED TORQUES: 8 mm nuts (Crankshaft): 21—25 N-m (2.1—2.5 kg-m, 15 15—1 8 ft-lh) 5 mm bolts (Crankcase): 21—25 N-rn, (21—2.!) kg~m, 15—1 3 h-lb) 6 mm bolts: 10—14 Nrm, (1041.4 kg-m, 7—10lt-lhl 10 mm bolts: 45—50 Nam, (4.5—5.0 kg-m, 33—36 h-lb) MeasUre the crankcase each Iournals LD. In x and Y axrs. Measure the crankshaft Each journals O.D. Subtract the crankshaft iomnal 0.0. from the crankcase journal LD. Select the replacement bearings from the table Whlch wrll grve the correct bearing clearance, OIL CLEARANCE STANDARD SPECIFICA~ TION 04130—0040 mm (013012410016 in) CRANKSHAFT BEARING INSERT TchK- NESS A (Red): 1.498—1t502 mm (03590—00591 in) 3 (Yellow): [Owl—1.498 mm “1053840590 in) C (Green): 1.4904494 mm “10587-00538 in) D (Blue): 1486—1490 mm (00585—00537 in) E (Purple): 1502—1506 mm (0,0591 410593 in) Separate the crankcase. Install the bearings Into the upper and lower crankcase. 4-2 OWNER'S MANUAL Reinstall the crankcase and tighten the nuts and bolts to the specified toroue. Measure the crankcase each journal |.D. Subtract the crankshaft journal 0,0. Irorn the crankcase journal |.D.. ll journal bearing clearance Is beyond the tolerance. select the replacement baanngs. CONNECTING ROD BEARING Install the connecting rod bearing cap to the rod, NOTE Align the code on the connecting rod With the code on the cap. ‘ Tighten the connecting rod bearing cap bolts. ‘ A§ TORQUE: 3.6 Item (26 tt-lb) Measure the connecting rod ID, and crank DII’I 0D. Subtract the crankoin 0D. lrom the con» necting rod |.D, Select the replacement hearing which Will give the correct crankpm bearing clearance. OIL CLEARANCE STANDARD SPECIFI~ CATION: 0035-04145 mm (0.0014—0.001B in) BEARING INSERT THICKNESS A (Red): 1498—1502 mm “10590—00591 in) B (Vellowl: 1.494—1.498 mm (03588—00590 in) C (Green): men-1.494 mm “10587—00588 in) CONNECTING D (Blue): 1486—1490 mm (0.0585-0.0587 in] ROD BEARING CAP E (Purple): 1502-1506 mrn (0.0591 —0.0593 in) Remove the connecting rod hearing cap. Install the bearings into the upper and lower crankcase, Reinstall the connecting rod bearing cap and tighten the nuts to the specified torque. _. Measure the connecting rod ID. and crankpin CONNECTING ROD BEARING OD. Subtract the crankpin OD, tram the connecting rod |.D.. l! the crankpm hearing clearance is beyond the tolerance, select the replacement bearing. r 0 CONNECTING ROD INSTALLATION Grind the :rankplns and journals with chrome oxidet Install the crankshalt bearings mm the upper and lower crankcase. Apply molybdenum disultide grease to the upper and lower crankshaft beanngst Install the crankshaft With the cam cham and pnmary Chall’l. lnstall the connecting rods and beanng caps. Apply molybdenum dIsuIlIde grease to the connectmg rod bearings. After Installing and tightening the connecting rod, check that the rod moves freely wnthout mum; Check the connecting rod Slde clearance. STANDARD SPECIFICATIONS: 0.10—0.20 mm (03039-00079 in) Check the crankshaft’toupper case side clearance at No. 2 journal, STANDARD SPECIFICATIONS: 010—030 mm (000394.01 18 in) OWNER'S MANUAL 4-4 ' PRIMARY CHAIN TENSIONER AND OIL STRAINER INSTALLATION Install the slipper base into lower case. Tighten the bolts securelyr insert the spring and plunger. Press the slipper down and Install the pint After installing the plunger, spring, washer and pin into the fluid valve. install the fluid valve assembly into the tensioner oil pipe. Tighten the nuts 0 TRANSMISSION AND SHIFT DRUM, SHIFT FORK INSTALLATION lnstall the primary, main and counter shaft assembly into the upper crankcase, install the shilt fork shaft, shilt fork and shift drum into the lower crankcase Clean the crankcase mating surfaces, Apply liquid sealant to the mating surface of the lower crankcase CA UTION Do rial apply sealant lo the area near the crankshaft bearings. - Do not let sealant/all into (he crank- case. For the upper crankcase, apply liquid sealant only where shown. OWNER’S MANUAL PRIMARY TENSIONER BASE V‘\ w FLUID VALVE ’« My" 9% PLUNGER \ SLIPPER SPRING \ l \ \ t TENSIONER OIL PIPE ‘\ PLUNGER - . f ,, am “I'm as ‘ SEIPPER l all OWNER'S MANUAL Assemble the crankcase halves, aligning the shift fork claws With gears. Tighten the bolts to the specmed torque valves [see page 4-2). NOTE - Make sure that the plain washers are under the llange of the ten crankshaft holding nut. Apply molybdenum disullide grease to the thread and head of the ten crankshaft stud bolts and flange ol the ten crankshaft holding nutst Tighten the upuer crankcase bolts to the specified torque, Install the Oll strainer into lower crankcaset Install a new gasket and the oil pan, OIL STRAINER SCREEN 2. PISTON INSTALLATIGN Install the piston rings, Space the piston my end gaps 120 degrees apart. NOTE Do not align the gaps in the oil ring . Install the dowel pinst Install the stud bolts. - oy’r_ 53m Pllfii; :‘ l‘ OWNEWSMANUAL - lns‘all the cylinder gaskei NOTE Use a 0.3 mm gasket. If the COmPIESSlOH I5 high, use 0.4 or 0.5 mm gasket. Apply molybdenum drsulfide grease to me connecting rod small ends. Install the piston, prsion pins and CM“. NOTE PDSIIiOn [he mark "T”oi ”in" on rhe piston (o the intake Slde. Do not allow piston pin clips to fall . anO the crankcase. Install the cam chain tensvoner. Install the cylinder and cylinder head. Fur cylinder head assembly, refer ta CBQDOFZ Shop Manual. 3. EAMSHAFI INSTALLATIIIN Grind each camshaft journal with chrome oxide. Attach a cylinder gauge to the #1 cylinder spark plug hole With the spemal tools. NOTE Use Honda scental CVLINDER GAUGE lP/N 0734241010000). Rotate the crankshaft clockwrse to bring the #1, 4 cyllnders at the Top Dead Center. SPECIAL TOOLS: Top Gauge Attachment: 00004—492-RSC Meter Holder: 00005—492—RSC Turn both camshahs so that the bunch marks on the Intake and exhaust cam sprockets are flush wrth the cylinder head surface as shown. Make sure that the Intake and exhaust cam lobes oi the #1 cvllnder are honzontal on the spark plug slde. After II’lSllemg the camshah. ad‘ust the cam chaun leflSlOneY as lollows Loosen the; front cam cham tensloner lock nut Loosen the front cam Ehaln tenslcner bolt 1/2 turn WhIIE rotating the crankshaft clockwrse. Tlghten the bolt and lock nut. Loosen the rear cam chain tensroner lock nut 1/2 turn rotatmg the crankshaft clockWIse. Tlghten the lack nut. whrle NOTE The tensioner wull automatically position llse” to orowde the correct tensxon when the lock nut or bolt l5 loosened. lnstall the exhaust cam charn guide attachmg plate and Oil Deal caps. Install the all line and cam chaln guide, Tighten the bolts In the sequence shown and In 23 steps. Full the all pockets tn the head With all so that the cam lobes are submerged. Adjust the valve clearance. OWNER'S MANUAL IN SPROCKET EX. SPROCKET \ CYLINDER l HEAD SURFACE . ”11/ r r 0 w (n \y <9 PUNCH MARK EX CAMSHAFT 1N CAMSHAFT CYLINDER HEAD SURFACE tmw "Mu No 1 CAM LOEES OWNER'S MANUAL 4. VALVE TIMINB Attach a cylrnder gauge to the #1 or :24 cylmder spark plug hole wrth the specral tools NOTE Use Honda specral CVLINDER GAUGE [P/N 07342—0010000). Rotate the crankshaft to hung the #1, #4 prston at Top Dead Center, Set the needle of the cylrnder gauge at zero Remove the #13 cylrnder exhaust Camshaft hotders Attach the specral tool. Insert the valve tifter rnto hole In the tool on the exhaust srde upsrde down. TOP GAUGE ATTACHMENT NO. 00005—11534st ‘ ‘ 5’ v Q Attach the Tap Gange Attachment to the dral gauge wrth the gauge hand slrghtlv restrng agarnst the valve Itfter. TOP GAUGE ATTACHME) NO. 00004- 492*RSC Loosely attach a 360—degree graUUator to the end of the rrght crankshaft as shown. Bolt a piece of wire to the crankcase where shown as a DOIHYEY. After making sure that the #4 piston rs at the Top Dead Center a! the compressron stroke, rotate the graduator to align the zero graduatron wrth the wire pornter. Trghten the gtaduator. OWNER'S MANUAL Rotate the crankshaft clockwnse. The needle of the indicator should regtster 1.15 mm when the correct timlng is Indicated r on the graduator inst beneath the pomter. NOTE 1.15 mm refers to the sum of 1 mm valve hft and 0.15 mm valve clearance. lntakevalve (Opens) 35"aTDc (Closes) 4o°AaDc Exhaust valve lOpens) so°asoc (Closes) 25°Amc Repeat the same procedure on the intake side. 5. llll PUMP INSTAlLATIDN Install the DII pump assembly. ahgning the all pump dowel pin wtth the crankcase dowel pin hole. Install a new gasket and the dowel puns. Install the oil joint boltss 4-10 Install the ml pump cover. Install the Ovrings and all horse iomts, n OIL COOLING SYSTEM OIL comm 2% f '\l\ J‘ x11 ‘J mews 0 Oil Cooler The oil cooler should at least be SEHCK ARC 9809 [228.6 x 13-tube) in capacity. NOTE In no cases should the oil temperature be allowed to exceed 115°C. The minimum inside diameter of each Oll passage should be 12 mm, Use oil pump Joints whose thread diameter is 7/B”—l4—pitch (22.2 mm x 1.84 pitch). r 2 OWNER'S MANUAL cchoN / aegnrnzn \Nm m BREAVHER flux MW 1 s: on. um 5 m w NAME mm M, 1 2 ‘ Aunam m Slurp” mm. mum I'vunmn 7 m was: MI-ln 3 Ame-nu ans-m ills nose mL-wssu-m I Oil Pressure Gauge Use SMITH OIL PRESSURE GAUGE (6.5 kg/m2 , 92.43 mm1 L CA UTION Stop {he engme and ixolme the cause immediately J the oil pressure falls belaw 4 lag/cm2 (56,88 Ib/in‘ 1. 4-11 B. CLUTCH lllSTAllAllllll Install the washer and driven gear. Install the dowel puns and a new gasket. Drive The oil seal in the Fl. crankcase Coven lnslall the R. crankcase cover. Install [he followmg pans m the order llS‘ed. Washer - Clutch outer, aher dnving the all seal mt - Pressure plate and collar. ‘ DISkS (7), and plates 5 (6) alternately, - Plate A (1 l. - Clutch center. CA UTION 00 m7! apply oil or greaxe 10 (he dukx and plate: OWNERS MANUAL PLATE (Al PLATE [Bl DISK CLUTCH OUTER OWNER'S MANUAL Install the O-ring and washer. Position the lock washer as shown and Install it, Tighten the lock nut. TORQUE: 40 N~m (4t!) kgm, 29 h-lh) Bend the lock washer tab-up. Drive the Oil seal in the clutch lifter guidet Install the release beanng and clutch lifter guide into the clutch lifter plate, NOTE Apply grease to the insude of all seal thoroughly. Tighten the bolts in a criss cross patern in two or more “EDS. Install the clutch lifter thread assv Into the cover. Install the clutch lever SDI‘II’IQV Connect the clutch cable, Install the clutch cover. AdiUSI the clutch as follows. Loosen the lock nut, then turn the adjusting screw clockWIse until a slight resistance [5 felts From thls position, loosen the clutch adjusting screw counterclockwrse 1-1/2 turn, and then tighten the luck nut. 'I. IGNITION TIMING . PULSE ROTOR/GENERATOR INSTAL- LATION Attach a dial gauge to the #1 cvllnder with the specral toolt Bring the #1 pismn at the Tap Dead Center of the compressron stroke. Install the left crankcase cover, Attach the pulser rotor to the Ieft crankshaft with the #1 and M "T" marks are right up an the rotor shah. OWNER'S MANUAL CLUTCH LEVER SPRING 0 POINT GAP Install the pulser generator rotor wtth the "T” mark on the governor at the center of the window in the base plate. Align the lug on the rotor wnh the lug on the generator. Tighten the screws securely. Measure the norm gap. POINT GAP: 0.4—0.5 mm (00157—011197 in) . IGNITION TIMING Attach a graduator and wire pomter to the right crankshaft and crankcase (Page 4-9). Place a punch mark an the pulser generator base plate In line wnh the "T" mark on the governor. Rotate the crankshaft 15° counterclockwise. Check that the "F" mark IS alrgned with the punch mark on the base plate. Loosen the base plate screws and align the lug on the pulser generator wrth the lug on the rotor, Retlghten the screws. Apply the same procedure on the #2 and #3 cylinders. Reinstall and start the engrne. USII'IQ a stroboscoprc trmlng lrght, check the tgnmon tlmmg. Ttmtng Is correct A the wrre painter on the nght crankcase Is between 35 and 37°. OWNER'S MANUAL 4-15 OWNER'S MANUAL ll. CARBUIIEWII SETTING (Hill A MID B KIT) 5 AIR JETS Remove the vacuum cylinders from the car buretor bodies. Carefully lift the vacuum pistons out With the VACUUM CYLINDER COMPRESSION needle and compression spring‘ Carefully lift SPRING the seal ring oft Remove the air jet cover. VACUUM PISTON g/fiEAL RING Blind the secondary air jet in either of the a“ 6' ‘ 1 I followmg two methods: I 1. Remove the secondary air jet with a SEQONDARY AIR JET * screwdriver and by screwing a tapping screw as shown. CAUTION , Avoid damaging the carburetor body. I Press # U secondary air jet unto the vaccanr hole, # 0 secondary air jet: No. lSOZZ-NAIDOD PRIMARY 2, If the existing air jet is not removed, blind AIR JET the hole by soldering. Make sure that the hole of the air jet is plugged securelv. ‘ Install the removed parts in reverse order of v L disassemblv. 0 AIR CUT VALVE Remove the air cut valve cover and spring Remove the diaphragm and O-ringt Drive a 2.3 mm steel ball Into the air passage In the air cutoff value. 23 mm steel ball: No. 16023-NAl-000 EIAPHRAGM Install the removed parts In reverse order of disassemblv. 4-16 OWNER'S MANUAL 0 MAIN JETS Remove the float chamber body. Remove the float and flat valve. SLOW JET PLUG Remove the slow jet plug. Remove the primary main jet. Remove the primary main nozzle. Install the # 0 primary main nozzle # D primary mam nozzle: 16021-NAIDOO Remove the secondary main iets and install new jets as follows: KIT A: #10213” cylinders) KIT B: #130 (ND. 1, 4 cylinders) # 135 (No. 2, 3 cylinders) NOTE The main jets described should above are standard and should be chaHQEd according to the actual C'Ima[)C and racing conditions. Install the float, float valve and float chamber body. 9. AIR FANNEL INSTALLATION Install the air lannels with the bosses aligned with the grooves in the carburetors. 4-17 OWNER'S MANUAL 1!]. BREAK-IN flPERATIflN The crankshaft and connecting rod bearings should be bruken m as (allows: (1) 3,000 rpm --------------- 100 km (2) 4,000mm ‘ [3) 5,000Ipm (4) 6.000 rpm ~ H (5) 7,000 rpm --------- 4-18