2001-2003 VT7SODC SYMBOLS The symbols used throughout this manual show specific Service procedures. lf supplementary information is required per- taining to these symbols, it would be explained specifically in the text without the use of the symbols. @ Replace the partlsl with a new one(s) before assembly. '7E Use recommended engine oil, unless otherwise specified. 75 Use molybdenum oil solution (mixture of the engine oil and molybdenum grease in a ratio 011:1), fl Use multlrpurpose grease (lithium based mum-purpose grease NLGl # 2 or equivalent). Use molybdenum disulfide grease (containing more than 3 % molybdenum disulfide, NLGI ti 2 or ($1 equivalent). Example: Moiykote® BR-Z plus manufactured by Dow Corning, U,S.A, Mum—purpose M'Z manufactured by Mitsubishi Oil, Japan Use molybdenum disulfide paste (containing more than 40 % molybdenum disulfide, NLGl # 2 or equivalentl. (@i Example: Molykote® G—n paste, manufactured by Dow Corning, U.S.A. Honda Moly 60 (U.S.A, only) Rocol ASP manufactured by Rocol Limited, UK. Rocol Paste manufactured by Sumioo Lubricant, Japan fl Use silicone grease. gm Apply a locking agent. Use a middle strength locking agent unless otherwise specified. J‘m Apply sealant. % Use DOT 4 brake fluid. Use the recommended brake fluid unless otherwise specified. a Use fork or suspension fluid. A Fayv Words Abput Safety Service Information The service and repair information contained in this manual is intended for use by qualified, proiossional technicians. Attempting service or repair without the proper training, tools, and equipment could cause injury to you or others. it could also damage the vehicle or create an unsafe condition. This manual describesthe proper methods and procedures ior performing service, maintenance, and repairs. Some proce- dures require the use or specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure or a tool that is not recommended by Honda, must determine the risks to their personal safety and the safe operation of the vehicle. If you need to replace a part, use genuine Honda parts with the correct part number or an equivalent part. We strongly recom- mend rhat you do not use replacement parts of inferior quality. For Your Customer's Safety Proper service and maintenance are essential to the customer's safety and the reliability of the vehicle. Any error or oversight while servicing a vehicle can result in faulty operation, damage to the vehicle, or injury to others. For Your Safety AWARNING . : Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this Because this manual is intended for the professional service techni— mm“ and “her 59m” ma‘ar'als carerl'V- clan, we do not provide warnings about many basic shop safety practices (ergo Hot parts , wear glovesl. if you have not received shop safety training or do not feel confident about your knowledge AWARNING of safe servicing practices, we recommend that you do not attempt g . , to perform the procedures described in this manual. Failure to Dr0per|v folIOW instructions and precau- tions can cause you to be seriously hurt or killed. Some of the most important general service safety precautions are given below. However, we cannot warn you oi every conceivable hazard that can arise in perlorming service and repair procedures. Only you can decide whether or not you should perform a given task. Follow the procedures and precautions in this manual Carefully. important Safety Precautions Make sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment. When performing any service task, be especially careful of the following: - Read all or the instructions before you begin, and make sure you have the tools, the replacement or repair pans, and the skills required to perform the tasks safely and completely. ~ Protect your eyes by using proper saiely glasses, goggles or face shields any time you hammer, drill, grind, pry or work around pressurized air or liquids, and springs or other slated-energy components. if there is any doubt, put on eye protec- tion. ~ Use other protective wear when necessary, for example gloves or safety shoes. Handling hot or sharp pans can cause severe burns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. - Protect yourself and others whenever you have the vehicle up in the air. Any time you lirt the vehicle, either with a hoist or a jack, make sure that it is always securely supported. Use iack stands. Make sure the engine is turned off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: ~ Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. ~ Burns from hot pans or coolant. Let the engine and exhaust system cool before working in those areas. - injury from moving parts. If the instruction tells you to run the engine, be sure your hands, fingers and clothing are out of the way. Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. - Use only a nonflammable solvent, not gasoline, to clean parts. ~ Never drain or store gasoline in an open container. . Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts. HOW TO USE THIS MANUAL This service manuai describes the service procedures for the VT750IJC Foilow the Maintenance Schedule (Secllon 3i recommendations to ensure thar the vehicle is in peak operating condition and «he emission levels are wirhin rhe standards set by the Caitlorhia Air Resources Board (CARE). Performing the rust scheduled maintenance is very important. It compenseres lor the initial wear that occurs during the breakrin period. Sections i and 3 apply to the whole vehicle. Section 2 illuslrates procedures for removal/installerion of componenrs rhar may he required In periorm service described mlhe folio Seclions a rhrough i9 describe pans of the ve according to location. Firid the sectron you want on lhis page, lheo mm m the able of contents on the rim page or rhc secrian. Most seclions sran wiih an assembly or system iilustrarion, serr vlce information and (roubleshooring for the section. The subser quenl pages give delaiied procedures ll you dcn'i know the source or me Ircuhie, 90 re Section 21, Trouhieshoaong. Vour saiery, and she sarety of mhcrs, IS very .mponanl. To help yuu make inlormea dacisians we have provided salety messages arid other Inlarmarion rhroughoot this manuai. or course, it is not practical or p sible to warn you about all the hazards associalcli With servicing (his vehicle. Vou must use your own good iudgemenh You will find imaananl safety iriIarmalion in a variety cl iorrns including: 4 Safely Laoeis- on rho vehicle - Safely Messages . preceded by a safoxy aien symbol A and one or three signal words, DANGER. WARNING. or CAUTION. These signal words mean: W You WILL be KILLED or SERIOUSLY HURT if you don‘t foliow irisvunions. You CAN be KILLED or SERIOUSLY HURT u you am mow mamas. You CAN be HURT ii you darn lcllow l Irislmctions. - Inslrucfions - how Io service this vehicle correctly and safely. As you read this manual, you will line ihlorrnation mat is pre- ceded by a NOTICE symbol. The purpose of this message Is :0 heip prevent damage to your vehicle, omer properly, or the environment. ALL INFORMATION, ILLUSTRATIONS, DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR 00., LTDL RESERVES THE RIGHT TO MAKE CHANGES AT ANV TIME WITHOUT NOTICE AND WITHOUT INCURRING ANV OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT Wer’rEN PERMISSION. THIS MANUAL Is WRITTEN FDR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE 0F MAINTENANCE 0N HONDA MOTORr CYCLES, MDTOR SCOOTERS, OR ATVs. HONDA MOTOR 00., LTD SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION I I FRAME/BODV PANELS/EXHAUST SYSTEM MAINTENANCE El ENGINE LUBRICATION SYSTEM I ' FUEL SVSTEM u COOLING SVSTEM . i ‘ ENGINE REMOVAL/INSTALLATION I. CLUTCH/GEARSHIFI’ LINKAGE ll ALTERNATOR/STARTER CLUTCH E I . CVLINDER HEAD/VALVES I I : I CYLINDER/PISTON I I I CRANKSHAFT/TRANSMISSION E CHASSIS FRONT WHEEL/SUSPENSION/STEERINGE REAR WHEEL/BRAKEISUSPENSION I I I HVDRAULIC DISC BRAKE I a ELECTRICAL BA‘ITERY/ CHARGING SVSTEM I I ! IGNITION SVSTEM ELECTRIC STARTER I [I UGHTS/METERS/SWITCHES I E I WIRING DIAGRAM E : I INDEX , TROUBLESHOOTING E. r Date uIJssue: September, 2000 © HONDA MOTOR ca, LTD. i1. SENERAL INFORMATION SERVICE RULES 1-1 LUBRICATION 81 SEAL POINTS 1-16 MODEL IDENTIFICATION 1-1 CABLE & HARNESS ROUTING 1—18 m SPECIFICATIONS 1-3 EMISSION CONTROL SYSTEMS 1-28 TORQUE VALUES 1-10 EMISSION CONTROL INFORMATION TOOLS 144 LABEL (U.S.A. only) 1-30 SERViCE RULES 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Paris that don’t meet HONDA’s design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable wllh English fasteners. 4. install new gaskets, Osrings, cotter pins, and lock plates when reassembling. 5. When tightening belts or nuts, begin with the larger diameter or inner boll first. Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean pans in cleaning solvent upon disassembly. Lubricate any sliding surfaces belom reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all electrical wires as shown On pages 1-18 through 1-27, Cable 8t Harness Routing. MODEL IDENTIFICATION 1-1 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBEH FRAME SERIAL NUMBER l The Vehicle Identification Number lVlNl is attached on the left side of the steering head. The frame serial number is stamped on the right side of the steering head, ENGINE SERIAL NUMBER CARBURETOH IDENTI FICATlON NU MBER The engine serial number is stamped on the right side of the crankcase below the rear cylinder, COLOR LABEL The color label is attached on the frame back of the left side caver. When ordering color-coded parts, always spear lfy the designated color code, The carburetor identification numbers are stamped on the intake side of the carburetor body as shown. 1-2 GENERAL INFORMATION SPECIFICATIONS — GENERAL ‘ ITEM SPECIFICATIONS DIMENSIONS Overall length 2,335 mm (91.9 in) Overall width 800 mm (31.5 inl Overall height 1,070 mm (42.1 in) Wheeibase 1,645 mm (64.8 in) Seat height 675 mm (26.6 in) Ground clearance 140 mm (5.5 in) Dry weight (49 state/Canada type) 2245 kg (494.9 lbsl (California type) Curb weight (49 state/Canada typel (California type) Maximum weight capacity 225.7 kg (497.6 lbsl 235.4 kg (519.0 lbsl 2363 kg (520.9 lbsl 166 kg (366.0 lbs) FRAME Frame type Double cradle Front suspension Telescopic fork Front axle travel 108 mm (4.3 in) Rear suspension Swingarm Rear axle travel 80 mm (3.1 in) Front tire size 110/80—19 598 Rear tire size 160/80—15 M/C 748 Front tire brand Dunlop F24 Bridgestone G515 Rear tire brand Dunlop K425 Bridgestone G702 Front brake Hydraulic single disc brake Rear brake Internal expanding shoe Caster angle 34“ 00' Trail length 152 mm (6.0 in) Fuel tank capacity , 13.0 liters (3.43 US gal, 2.86 Imp gall Fuel tank reserve capacity 4.0 liters (1.06 US gal, 0.88 Imp gal) ENGINE Cylinder arrangement 2 cylinders 52“ V transverse Bore and stroke Displacement Compression ratio Valve train Intake valve opens closes opens closes Exhaust valve Lubrication system Oil pump type Cooling system Air filtration Crankshaft type Engine dryweight Firing order Cylinder number 79.0 x 76.0 mm (3.11 X 2.99 inl 745 ch (45.4 cu»inl 9.0 : 1 Silent multi»|ink chain driven and OHC with rocker arm 0° BTDC ~ at 1 mm (0.04 in) lift 20° ABDC 30° BBDC 0° ATDC Forced pressure and wet sump Trochoid Liquid Cooled Viscous paper element Unit type, two main journals 68.2 kg (1504 lbs) Front - 308” — Rear - 412“ 7 Front Front: #2, Rear: #1 GENERAL INFORMATION * GENERAL (Cont'dl ITEM SPECIFICATIONS CARBU REFOR Carburetor type Throttle bore Constant Ventu ri 34 mm (1.3 in) Starting system Charging system Regulator/rectifier Lighting system DRlVE TRAIN Clutch system Mum-plate, wet Clutch operation system Cable operating Transmission Constant mesh, 5-5peed Primary reduction 11566 (65/39) Final reduction 2.471 (42T/17T) Gear ratio 1st 3.166 (38/12) 2nd 2.000 (34/17) 3rd 1.500 (30/20) 4th 1.173 (27/23) 5th 1.042 (25/24) Gearshift pattern Left loot operated return system, 1 — N - 2 — 3 — 4- 5 ELECTRICAL Ignition system Full transistorized ignition Electric starter motor Triple phase output alternator SCR shorted/triple phase full wave rectification Battery GENERAL INFORMATION Unit: mm (in) " LUBRICATION SYSTEM ITEM STANDARD SERVICE LIMIT Engine oil capacity at draining 2.2 liters (2.32 US qt, 1.941mp qt) g ’ at filter change 2.4 liters (2.54 US qt, 2.11 Imp qt) — , at disassembly 2.5 liters (3.06 Us qt. 2.55 Imp qt) — Recommended engine oil Honda GN4 or HP4 4~$troke oil or equivalent motor oil APl service Classification SF or $6 Viscosity: SAE 10w-4o Oil pressure at oil pressure switch 530 kPa (5‘4 kgf/cmz, 77 psi) at 5,500 rpm l80°Cli76°Fl Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 — 0.22 (0.006 — 0.009) 0.35 (0.014) Side clearance 0.02 - 0.07 (0.001 7 0.003) 0.10 (0.004) v FUEL SYSTEM ITEM SPECIFICATIONS uretor identification number 49 state/Canada type VDFZD California type VDF2C Main J73t Front #105 Rear #108 Slow jet #40 Pilot screw initial/final opening See page 522 Float level 7.0 mm (0.28 inl Base carburetor (for synchronization) Rear cylinder (#1) Idle speed 1,000 1100 rpm Carburetor vacuum difference 20 mm Hg (0.7 in Hgl Throttle grip free play 2— 6 mm (1/12 » 1/4 in) — COOLING SYSTEM ITEM SPECIFICATIONS Coolant capacity Radiator and engine 1.75 liters (1.85 US qt, 1.541mp qtl Reserve tank 04 liter (0.42 US qt, 0‘35 Imp qt) Radiator cap relief pressure 108 — 137 kPa (1.1 A 1.4 kgf/cm7,16 — 20 psi) Thermostat Begin to open 80 — 84”C (176 —183°F) Fully open 95“C (203°F) Valve lift 8mm (0.3 in) minimum Recommended antifreeze Pro Honda HP coolant or an equivalent high quality ethylene glycol antifreeze containing silicatevfree corrosion inhibitors 1-5 GENERAL INFORMATION Unit: mm (in) 7 CLUTCH/GEARSHIFT LINKAGE ITEM STANDARD SERVICE LIMIT Clutch lever free play 10720 (037570.750) # Clutch spring free length 45.5 (1.79) 43.9 (1.73) Clutch disc thickness A 2.62 — 2.70 (0.103 , 0.107) 2.3 (0.09) 5 2.927108 (0115—0121) 2.6 (0.10) Clutch plate warpage —— 0.30 (0.012) Clutch outer guide |.D. 21.991 — 22.016 (0.8658 —- 0.8668) 22.03 (0.867) O.D. 29.994 — 30.007 (1.1809 — 1.1804) 29.98 (1.180) Oil pump drive sprocket LD. 30.025*30.145(1.1821—1.1S68) 30.15 (1.187) Mainshak OD. at clutch outer guide 21.967 — 21.980 (0.8648 -— 0.8654) 21.95 (0.864) Unit mm (in) 7 ALTERNATOR/STARTER CLUTCH ITEM STANDARD SERVICE LIMiT Staner driven gear 1.0. 40000 — 40.021 (1.5748 —1.5756) 40.10 (1.579) O.D. 57.749 — 57.768 (2.2736 — 2.2743) 57.73 (2.273) Staner clutch ouker LD. 74.414 — 74.440 (2.9297 — 2.9307) 74.46 (2.931) Unit: mm (in) * CYLINDER HEAD/VALVE ITEM STANDARD SERVICE LIMIT Cylinder compression 1,275 i 98 kPa (13.0 1 1.0 kgf/cml, 7 185 :14 05001 400 rpm Cylinder head warpage 0.10 (0.004) Valve, Valve defiance IN 015 1 00210006 x 0.0008) Valve guide EX 0.20 i 0.02 (0.008 1 0.0003) — Valve stem 0.0. IN 5475—5490 (02156—02161) 5.45 (0.215) EX 6.600 - 6.615 (0.2598 — 0.2604) 6.55 (0.258) Valve guide I'D. IN 5500—5512 (02165—02170) 5.56 (0.219) EX 6.600 — 6.615 (0.2598 — 0.2604) 6.65 (0.262) Stem—to-guide clearance IN 0.010 — 0.037 (0.0004 - 0.0015) 0.10 (0.004) EX 0.030 — 0.060 (0.0012 — 0.0024) 0.11 (0.004) Valve guide projection above IN 19-5 (0-77) A“ cylinder head EX 18.0 (0.71) ”— Valve seal width IN/EX 0.90 — 1.10 (0.035 A 0.043) 1.5 (0.06) Valve spring free lengih IN 42.14 (1.659) 40.58 (1.598) EX 42.83 (1.086) 41.25 (1.624) A Camshaft Cam {obs heigm IN 37.188 — 37.348(1.4641—1.4704) 37.16 (1.463) EX 37.605 - 37.765 (1.4805 —1.4863) 37.58 (1.480) Journal O.D. 21.959 — 21.980 (0.8645 - 0.8054) 21.90 (0.862) Runout —— 0.03 (0.012) Oil clearance 0.050 A 0.111 (00020 ~ 0.0044) 0.13 (0.005) identification marks "F”: Front, “R": Rear — Rocker arm |.D. lN/EX 12.000 —12.018(0.4724 — 0.4731) 120501.474) Rocker arm shaft 0.D. lN/EX 11.965— 11.984 (0.4711 —0.4718) 11.83 (0.466) Rocker arm iFiston, oTston Piston mark direction "IN" mark facing toward the intake side —— ”"95 Piston 0.0. 78.97 — 78.99 (3.109 2 3.110) 78.90 (3.106) Piston 0.D. measurement point 7 2 17 (0.3 2 0.7) from bottom J'skin Piston pin hole (.0. 10.002 — 18.008 (0.7007 — 0.7090) 10.05 (0.711) Piston pin 0.0. 17.994 718.000 (0.7084 A 0.7087) 17.98 (0.708) Piston-(o-pistun pin clearance 0.002 — 0.014(0.00017 0.0006) 0.0410002) piston ring_m.ring Top 0025 - 0.055 (0.0010 - 0.0022) 0.08 (0.003) groove clearance Second 0.015 — 0.045 (0.0005 - 0.0019) 0.07 (0.003) Piston ring and gap Top 0.15 — 0.25 (0.005 — 0.010) 0.30 (0.012) Second 0.25— 0.40 (0010—0016) 0.50 (0.02) Oil (side roii) 0.20 — 0.80 (0.000 — 0.031) 1.0 (0.04) Piston ring mark Top "R" mark — Second "RN" mark Cylinder~to~piston clearan;_ 0.010 — 0.045 (0.00044 0.0018) 0.10 (0.004) Connecting rod sman end 1.0. 19.015— 18.034 (0709347100) 18.07 (0.711) Connecting rod—to-piston pin Clearance 0010 — 0.040 (0.0009 — 0.0016) 0.06 (0002) Unit: mm (in) ~ CRANKSHAFTITRANSMISSION ITEM STANDARD SERVICE Lerl' Crankshaft Side ciearance 0.05 - 0.20 (0.002 — 0.009) 0.30 (0.012) Runout —— 0.03 (0.001) Crankpin oil clearance 0.028 - 0.052 (0.0011 — 0.0020) 0.07 (0.003) Main journal oil ciearance 0.030 — 0.046 (0.0012 — 0.0013) 0.07 (0003) Transmission Gear (.0. M3, M5 20000—28021 (1.1024— 1.1032) 29.04 (1.104) c1, 02, c4 31000731025 (1.2204— 1.2215) 31.05 (1.222) Bushing 0.0. M3,M5 27.959—27.980(1.100771.1016) 27.94(1.100) c1, 02, c4 30.950—30.975(1.2185— 1.2195) 30.93 (1.218) Bushing 1.0. M3 25.000 — 25.021 (0.9843 2 0.9851) 25.04 (0.985) cz 27.995 — 20.010 (1.1021 — 1.1030) 29.04 (1.104) Gear_m.bush. M3, M5 0020 — 0092100008 — 0.0024) 0.10 (0.004) ing clearance 01, c2, (:4 0.025 — 0.075 (0.0010 2 0.0030) 0.11 (0.004) Mainshaft 0.0. at M3 bushing 24.972 — Z4.993(0.9831— 0.9840) 24.95 (0.982) Countershaft 0.0. at cz bushing 27.957 - 27.950 (1.1011 — 1.1010) 27.95 (1.100) Bushing-to» M3 0007 — 0.049 (0.0003 — 0.0019) 0.00 (0.003) 5““ “WM” 02 0015—0049 (00005—00019) 0.0810003) snimork 1.0. 13.000s 13.021 (05118—05120) 1304 (0.513) 50111 fork ciaw thickness 5.93 — 6.00 (0.233 — 0.230) 5.6 (0.22) 701111: (orisnah 00 12.966 412.984 (0.5105 — 0.5112) 12.90 (0.508) 511111 drum 0.0. (at left sideioumai) 11.966— 11.994 (0.4711 —0.4718) 11.94 (0.470) 1—7 GENERAL INFORMATION Unit: mm (in) e FRONT WHEEL/SUSPENSIONISTEERING ITEM STANDARD SERVICE LIMIT 7 Minimum tire tread depth 1.5 (006) Cold tire pressure Up “5 90 kg (200 lb) lead 200 kPa (2.00 kgI/cmz, 29 psi) '7 Up to maximum weight capacity 200 kPa (2.00 kgf/cl'nz. 29 psi) __ Axle runout 0.20 (0.008) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.00108) Wheel hub-icerim distance Page 13-12 Wheel balance weight ——-—— 60 g (2.1 oz) Fork Spring free length 492.4 (19.39) 482.5 (19.00) Tube runout 0.20 (0.008) Recommended fork fluid Pro Honda Suspension Fluid SS-S Fork fluid level 124 (4.9) Fork fluid capacity 473 1 2.5 Cm] (16.0 i 0.08 US OZ, 16.6 i 0.09 Imp oz) I Steering head bearing preload 0.43 , 1.04 kgf (0.95 - 2.29 lbf) Unit: mm (in) K REAR WHEEL/BRAKEISUSPENSION ITEM STANDARD SERVICE LIMIT Minimum tire tread depth 2.0 (008) Cold tire pressure Up to 90 kg (200 lb) load 200 kPa (2.00 kgf/crn’, 29 psi) — Up to maximum weight capacity 250 kPa (2.50 kgf/cmz, 35 psi) Axle runout 0.20 (0.005) Wheel rim runout Radial — 2.0 (0.08) Axial — 2.0 (0.08) Wheel hubvto-rim distance Page 14»8 Wheel balance weight —--— 70 g (2.5 01) Drive Chain slack 15 — 25 (0.600 , I) 40 (1.6) Drive chain size/link RK 525 SMOZS/124 L ~— Rear brake Drum |.D. 180.0 -180.3(7.09 — 7.10) 181 (7.13) i Lining thickness 5 (0.2) 2 (0.1) l Pedal free play 20 — 30 (3/4 —1-1/4> —-—- Shock absorber spring preloed adjuster setting 2nd position A — HYDRAULIC Disc BRAKE U""‘ mm "m ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT A ——- Brake disc thickness 5.3 — 6.2 (0.23 — 0,24) 5 (0.21 jrake disc runout 0.30 (0012) Master cylinder ID. 7 11.000 —11.043(0.4331—0.434el 110510.435) Master piston 0.13. 10.957 — 10.984 (0.4314 s 0.4324) 109450143091 7"" Caliper cylinder 10. 27.000— 27.050 (1.0030. 1.0650) 27.05 (1.065) Caliper piston 00. 26.918 — 26.968 (1.0598 — 1.0617) 26.91 (1.055» 1-8 GENERAL INFORMATION 7 BATTERY/CHARGING SYSTEM ITEM SPECIFICATIONS Battery Capacity ,_ ... 159 — 12 KB Current leakage 1 mA max. Voltage Fully charged 13.0 —13;2v _ .. V awe/68°F) Needs charging Below 12.3 v Charging current Normal 1.1 Axsamh Quick W 5.5Ax 1.0 h >kirarnator Capacity 0.333 kW/5,000 rpm WW“ éiiarging coil resistance (zone/awn 0.1 , 1.0 fl — IGNITION SYSTEM ITEM SPECIFICATIONS Spark plug Standard DPR8EA-9 lNGK), X24EPR-U9 (DENSO) For cold climate lbalow 5°C/4’I “Fl DPR7EA-9 (NGKII X22EF‘R-U9 (DENSO) For extend high speed riding DPRSEAVS (NGK), X27EPRAu9 (DENSO) 8 ar plug gap 0.8 — 0.9 mm (0.03 - 0.04 In) IgnI-ion coil primary peak voltage 100Vminimum Ignition pulse generator peak voltage 0.7 V minimum Ignition timing (”F" markl 6.2“ BTDC at idle Unit: mm (in) — ELECTRIC STARTER ITEM STANDARD SERVICE LIMIT Startel motor brush length 12.5 (0.49l 6.5(016l — LIGHTS/METERSISWITCHES ITEM SPECIFICA‘HONS Bulb Headlight lhigh/Iuw beaml 12 V — 60/55 W Brake/taillight r 12V—2’I/5W Front turn signal/running light 12V—21/5 Wx2 Reartum signal light 12V—21Wx2 instrument light LED x 6 Turn signaiindicaror LED High beam indicator LED Neutral indicator LED Coolant temperature indicator LED Oil pressure indicator LED Fuse Main fuse 30 A _ Sub-fuse 10Ax4,15Ax'| En’moror switch Start to close (ON) 98 A10§°01200 — 216°F) Stops to open (OFF) 93—97°C (199—207“Fl Thermosensur resis- at 80°C (176”F) 45 - 60 n tam at 120°C l248°Fl 10 — 20 II ._ 7 Carburetor heater resistance at 20°C l68°Fl 13 — 15 n Fuel puma flow capacity Minimum 900 cm: (30.4 us oz, 31.7 Imp oz) per minut; 1-9 GENERAL INFORMATION TORQUE VALUES A STANDARD TORQUE TORQUE FASTENER TVPE . Mm (Wm M“, FASTENER TVPE Mm "(9pm, mm) 5»mm bolt and nut 5 (0,5, 3.6] 57mm screw 4 (04: 2»9l 6-mm bolt and nut 10 (1.0, 7) 67mm screw 9 (0-9. 6.5) 3_mm ban and nut 22(2‘2119) 6-mm flange bolt (8-mm headland nut 12 (1.2, 9i 10.mm bolt and nut 34 (3‘5, 25) 6-mm flange bolt (10-mm head) and nut 12 (1.2. 9) 12_mm bolt and nut 54 (55, 40) 8—mm flange bolt and nut 26 (2.7, 20) 10~mm flange bolt and nut 3901.0, 29) - Torque specifications listed below are for important fasteners, - Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealant to the threads. 2. Apply locking agent to the threads. 3. Apply grease to the threads and seating surface. 4. Apply oil to the threads and seating surface. 5. Stake. 6. Left hand threads. 7. U»nut. 8. ALOC bolt: replace with a new one. 9. BreakAol‘f bolt. _ ENGINE THREAD TORQUE "EM 07" DIA. lmrn) Mm lkgf~m, lhf-fll REMARKS MAINTENANCE: Spark plug 4 12 14 (1.4, ml Crankshaft hole cap 1 30 15 (1.5, 11l NOTE 3 Timing hole can 1 22 15 (1.5, 111 NOTE 3 Valve adjusting screw lock nut 6 7 23 (2,3, 17l NOTE 4 Oil drain bolt 1 14 29 (3.0, 22l Oil vfilter Cartridge 1 20 10 (1.0, 7i NOTE 4 Vacuum plug 2 5 3 (0.3, 2.2) LUBRICATION SYSTEM: Oil pressure switch 1 PT1/8 12 (1.2, 9) NOTE 1 Oil pressure switch terminal screw 1 4 2 (0.2, 14) Oil pump bolt 5 6 13 (1.3, 9) FUEL SYSTEM: Air cleaner housing stay bolt 1 6 12 (12, Si COOLING SYSTEM: Water pump boil: 5 6 13 (1.3, 9) cLUTCH/GEARSHlFT LINKAGE: Clutch lifter plate bolt 4 6 12 (1.2, 9) Clutch center lock nut 1 18 127 (13.0, 94) NOTE 4, 5 Primary drive gear bolt 1 12 88 (9.0, 65) NOTE 4 Gearshift return spring pin bolt 1 8 23 (2.3, 17] Oil pump driven sprocket bolt 1 6 15l1.5, 11) NOTE 2 ALTERNATOR] STARTER CLUTCH: Flywheel bolt 1 12 127 (13.0, 94) NOTE 4, 5 Stator mounting bolt 4 6 12 (1.2, 9) NOTE 2 Stator wire holder bolt 1 6 12 (1.2, 9) NOTE 2 Starter clutch housing bolt 6 8 29 (3.0, 22l NOTE 2 1-10 GENERAL INFORMATION ‘7 ENGENE (Cont'd) THREAD TORQUE ”EM 0 TV DIA. (mm) N‘m (kgrm. Ibf-ft) REMARKS CYLINDER HEAD/VALVES: O/Iinder head cover bolt 4 6 10 (1.0, 7) Overhead cover bolt 8 6 12 (1‘2, 9) Cam sprocket bolt 4 7 23 (2.3, 17) NOTE 2 Cam Chain tensioner mounting ban 4 6 10 (1.0, 7) Camshaft huider 87mm bolt 6 8 23 (2.3, 17) 87mm nut 4 8 23 (2.3, 17) Cylinder head 87mm bolt 4 8 23 (2.3’ 17) NOTE A 10Amm nut 8 10 47 (4.8, 35) NOTE 4 Cyiinder head fin mounting bOIt 15 6 1D (1.0, 7) I CHANKCASEICHANKSHAFI'ITRANSMISSION: Crankcase 87mm ban 14 8 23 (2.3, 17) Connecting rod bearing cap nut 8 8 33 (3,4, 25) NOTE 4 Drive chain guide plate boll 2 6 12 (1.2, 91 Neutral swimh 1 1O 12 (1.2, 9) 1-11 GENERAL INFORMATION T FRAME THREAD TORQUE ITEM 0 TV DIA. (mm) N-m (kgfrm, Ibr-rt) FRAME/BODY PANELS/EXHAUST SVSTEM: Footpeg bracket bolt 4 1O 34 (3.5, 25) Exhaust pipe joint not A 8 25 (2.5, 18) Muffler mounting nut 2 8 26 (2.7, 20) Exhaust pipe joint pipe bolt 1 3 20 (2.0, 14) Seat mounting bolt 2 8 26 (2.7, 20) Rear fender bolt 2 10 64 (6.5, 47) Shock absorber stud bolt 1 14 108 (11.0, 80) Left grab rail mounting nut 1 24 88 (9.0, 65) Fuel tank bolt 1 8 19(1.9, 14) Fuel valve 1 22 34 (3.5, 25) Fuel valve screw 1 5 0.6 (0.06, 0.43) Left crankcase rear cover bolt 1 6 12 (1.2, 9) MAINTENANCE: Side stand assembly bolt 2 10 49 (50, 39) Spoke nipple 104 4 4 (0.4) COOLING SYSTEM: Radiator mounting bolt 6 1 (0.1, 07) Fan motor switch 16 18 (1.8, 13) ENGINE REMOVAL/INSTALLATION: Front engine upper/lower mounting nut 2 1o 54 (5.5, 40) Rear engine mounting nut 1 10 54 (5.5, 40) Front engine bracket bolt 2 8 26 (2.7, 20) Rear engine bracket bolt 2 8 26 (2.7, 20) Gearshift arm pinch bolt 1 6 12 (12, 9) Drive sprocket fixing plate bolt 2 6 10 (1.0, 7) CLUTCH/GEARSHIFI' LINKAGE: Gearshift pedal pivot bolt 1 10 34 (3.5, 25) FRONT WHEEL/SUSPENSION/STEERING: Steering stem nut 1 24 103 (10.5, 76) Steering bearing adjustment nut 1 26 Steering bearing adjustment lock nut 1 25 v Top bridge pinch bolt 2 8 26 (2.7, 20) Bottom bridge pinch bolt 2 10 49 (5.0, 36) Handlebar upper holder bolt 4 8 23 (2.3, 17) Handlebar lower holder nut 2 8 23 (2.3, 17) Front axle bolt 1 14 59 (6.0, 43) Front axle pinch bolt 4 8 22 (2.2, 16) Front brake disc bolt 6 8 42 (4.3, 31) Fork cap 2 38 22 (2.2, 16) Fork socket bolt 2 8 20 (2.0, 14) REAR WHEEL/BRAKE/SUSPENSION: Rear axle nut 1 18 93 (9.5, 69) Driven Sprocket nut 5 12 33 (9.0, 65) Shock absorber upper/lower mounting bolt 4 8 26 (2.7, 20) Swingarm pivot not 1 14 88 (9.0, 65) Swingarm pivot adjusting bolt 1 26 25 (2.5, 18) Swingarm pivot lock nut 1 26 64 (6.5, 47) Drive chain Slider screw 2 5 3 (0.3, 2.2) Rear brake stopper arm nut 2 B 20 (2.0, 14) Rear brake arm bolt 1 S 28 (2.9, 21) Rear brake middle rod joint bolt 1 1O 34 (3.5, 25) REMARKS page 1323 page 1349 NOTE 8 NOTE 2 NOTE 7 NOTE 7 NOTE 7 1-12 GENERAL INFORMATION 7 FRAME (Cont’dl , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgf~m, mm) REMARKS HVDRAULIC BRAKE: Brake caliper mounting bolt 2 8 30 (3.1, 22] NOTE 8 Brake caliper pin bolt 1 8 13 (1.3, 9) NOTE 2 Brake cariper bracket pin be“ 1 8 27 (2.8, 20] NOTE 2 Pad pin 1 10 18(1.8,131 Pad pin plug 1 1o 3 (0.3, 221 Brake caliper b1eed valve 1 8 6 (0.6, 4.3) Brake lever pivot belt 1 6 1 (0,1, 0,71 plvot nut 1 6 6 (0.6, 4.31 Brake mamer Cylinder holder bolt 2 6 1211.2, 91 Brake master cylinder reservoir cap screw 2 4 2 (0.2, 1.4) 1 Flor“ blake light switch screw 1 4 1 (0.1, 0.7) Brake hose oil bolt 2 10 3413.5, 25) BATTERY/CHARGING SVSTEM: Battery case cover screw 1 6 9 (0.9, 6.51 ELECTRIC STARTER: Starter motor cable terminal nut 1 6 1011.0, 7) ‘ LlGHTS/METER/SWITCHES: ‘ 1 Side s1and switch mounting 1:01: 1 6 10110.71 1 Thermosenscr 1 PT 1/8 8 (0.8, 5.8) 1 NOTE 1 1gnifion switch mounting bolt 2 6 12 (12, 3| NOTE 9 Horn mounting bolt 1 S 21 (2.1,151 Speedometer cover bolt 2 6 1011.0,71 OTHERS: Side stand pivot b0” 1 10 1011.0, 7) look nut 1 10 2913.0, 221 . Tool box cover screw 3 4 210.2, 1.4) L 1-13 GENERAL INFORMATION TOOLS NOTES: 1. Alternative tool, 2. Equivalent commercially available in USA. 3. Not available in USA. — driver attachment — driver handle 07953 r MJ10100 07953 — MJ10200 07953 — MJ1000A (U.S.A. onlyl DESCRIPTION TOOL NUMBER REMARKS REF. SECTION Carburetor float level gauge 074017 0010000 5 Oil pressure gauge 07506 — 3000000 NOTE 2 4 Vacuum gauge attachment 07510 4 3000200 NOTE 1: 07LMJ — 001000A (U.S.A. only) 3 Oil pressure gauge attachment 07510 2 4220100 NOTE 2 4 Gear holder 07724 2 0010100 NOTE 3 0 Flywheel holder 07725 — 0040000 NOTE 2 9 Rotor puller 07733 — 0020001 NOTE 1:07933 — 3290001 (U.S.A. only) 9 Valve guide driver, 5.5 mm (IN) 07742 ~0010100 10 Valve guide driver, 0.5 mm (EX) 0774220010200 NOTE 1: 07942 — 6570100 (U.S,A. only) 10 Valve guide driver, (adjustable typel 07743 7 0020000 NOTE 3 10 Attachment, 32 x 35 mm 07746 2 0010100 14 Attachment, 37 X 40 mm 07746 » 0010200 8 Attachment, 42 X 47 mm 07746 —- 0010300 12, 13, 14 Attachment, 52 x 55 mm 07746 2 0010400 12, 13 Driver 30 mm ID. 07746 -— 0030300 13 Pilot, 15 mm 07746 4 0040300 14 Pilot, 20 mm 077457 0040500 12, 13, 14 Pilot, 25 mm 07746 2 0040600 12 Pilot, 30 mm 07746 — 0040700 8 Pilot, 28 mm 07746 — 0041100 12 Bearing remover shalt 07746 7 0050100 , 13,14 Bearing remover head. 20 mm 07746 2 0050600 13, 14 l Driver 07749 — 0010000 8,12,13,14 Valve spring compressor 07757 4 0010000 10 Valve seat cutter 10 —— seat curler, 27.5 mm (45° IN) 07780 » 0010200 : NOTE 2 i seat cutter, 35 mm (45° EX) 07780 7 0010400 — (lat Cutter, 28 mm (32°1Nl 07780 7 0012100 — — flat cutter, 35 mm (32° EX) 07700 — 0012300 — interior cutter, 30 mm (60° IN) 07780 — 0014000 — interior Cutler, 37.5 mm (60” EX) 07780 — 0014100 ~ —0utter holder, 5.5 mm (IN) 07781—0010101— — cutter holder, 6.0 mm (EX) 07781» 0010202 4 Valve adjusting wrench 07908 , KE90000 NOTE 1: 07908 — KE90100 (USA. only) 3 Snap ring pliers 07914 - SA50001 , 14,15 Steering stem socket 07915,:5710101 NOTE 1: 07916— 3710100 1 13 Bearing remover set 07936 — 3710001 NOTE 3 ‘ 12 7 remover weight 07741 — 0010201 NOTE 1107936 — 371020A (USA, only] or 07936 — 3710200 — remover handle 07936 — 3710100 — remover head 07936 2 3710600 Bearing race remover 07946 2 3710500 NOTE 1: M9360 — 277 — 91774 (USA only) 13 Bearing driver remover 07946 — KA50000 14 Driver shaft 07946 — MJ00100 NOTE 3 14 Attachment 07946 — MJ00201 NOTE 3 14 Fork seal driver 07947 — KA50100 13 Fork seal driver attachment, 07947 — KF00100 13 41 mm ID. Ball race remover set 07953 — MJ10000 NOTE 1: 07953 - MJ10003 or 13 1-14 GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SECTION Valve guide reamer, 5.5 mm (IN) 07984 7 2000001 10 Valve guide reamer, 6.? mm (EX) 07984 7ZE20001 NOTE 1107984 —Z'E2000D (U.S.A. only) 10 Pivot lock nut wrench 07GMA _ KT70200 NOTE 3 7, 14 Oil filter wrench 07HAA 7 PJ701DD 3 Peak voltage adaptor 07HGJ — 0020100 NOTE 1: Peak voltage tester 17 (USA. only) Drive chain moi Set 07HMH—MR10103 NOTE 1:07HMHiMR7DIOE 3 (U.S.A. onlyl Spoke wrench 07JMA _ MRI-30100 NOTE 2 3,13,14 Clutch center holder 07JMB ~ MN50301 NOTE 1: O7HGB — 001DOOA 8 (U.$.A. only) Pilot screw wrench 07KMA — MSSOIO‘I 5 Vacuum gauge set 07LMJ - OO‘IOODA NOTE I: M9373 - 021 — XXXXX 3 (USA, only) Vacuum/pressure pump A937X — D41- XXXXX NOTE 1: ST— AH 72607 M07 (USA. only) 5 ST , AH , 255 7 MC7 (USA only) 1-15 GENERAL INFORMATION LUBRICATION & SEAL POINTS — ENGINE LOCA'HON MATERIAL REMARKS Camshaft lobes/journals Valve stem lvalve guide sliding surface) Rocker arm slipper surface Rocker arm shaft outer surface Connecting rod bearing surface Crankshaft journals Clutch outer guide outer surface Transmission gear shift fork groove Transmission collar inner and outer surface Transmission spline collar outer surface Connecting rod small end inner surface Molybdenum oil solution (a mixture of 1/2 engine oil and 1/2 molybdenum disulfide greasel Piston outer surface Piston ring outer surface Piston pin outer surface Primary drive gear bolt threads and seating surface Flywheel bolt threads and seating surface Starter clutch sprag sliding lock surface Starter idle gear and reduction gear shaft outer surface Clutch center lock nut threads Clutch lifter arm—torright crankcase cover sliding surface Clutch lifter rod~to—right crankcase cover sliding surface Clutch disc outer surface Cylinder stud bolt threads Cylinder head 87mm bolt threads Valve adjusting screw threads and seating surface Cylinder head mounting bolt, nut seating surface Cylinder head cover mounting rubber seal whole surface Connecting rod bolt/nut threads and seating surface Transmission gear teeth Oil filter cartridge threads and Owing Bearings rolling area O»rings Engine oil Air cleaner housing—to—chamber band inside surface Crankshaft hole cap threads Timing hole cap threads Oil seal lips Multipurpose grease Oil pressure switch threads Thermosenser threads Left and right crankcase mating surface Left and right crankcase cover mating surface Sealant See page 4—3. See page 19-8. Cam sprocket bolt threads Starter Clutch housing bolt threads Oil pump driven sprocket bolt threads Stator wire holder bolt threads Gearshift cam plate bolt threads Transmission bearing set plate bolt threads Countershaft oil seal set plate bolt threads Cam chain tensioner set plate bolt threads Stator mounting bolt threads Oil filter boss threads (crankcase side) Ignition pulse generator bolt threads Left crankcase cover bolt threads Locking agent rCGating width: 6.5 t1 mm (026 :l: 0.04 inl See page 9-4. 1-16 — FRAME GENERAL INFORMATION LOCATION MATERIAL REMARKS Side stand pivot sliding surface tearing head bearing sliding surface Steering head dust seal lips Clutch lever pivot bolt sliding surface Throttle grip inner surface Throttle pipe rolled-up portion, throttle cable end Rear wheel axle sli ng surface Rear wheel sleeve sliding surface Rear brake cam sliding surface Rear brake shoe-to-cam sli ’ng surface Fleer brake anchor pin sliding surface Rear brake pedal and rod pivotsliding surface Rear brake pedal middle rod joint bolt sliding surface Swingarrn pivot dust seal lips Swingarm pivot needle bearing rolling area Footpeg and pillion step pivot sliding area Dust seal lips Oil seal lips Multi-purpose grease Spreading 1.09 Spreading 1.0 — 2.0 g Spreading 0.2 — 0.3 g Steering bearing adjustment nut threads Rear brake cam felt seal Engine oil Brake master cylinder piston cups Brake master cylinder piston Brake caliper piston Brake caliper piston seals DOT 4 brake fluid Brake lever pivot Brake lever contacting surface of master piston Brake caliper pin sliding surface Brake caliper bracket pin sliding surface Brake caliper dust seals Silicone grease Spreading 0.1 g min Spreading 0.4 g min Spreading 0.4 g min Front fork socket bolt threads Final driven flange stud bolt threads Brake caliper bracket retainer bolt threads Brake caliper bracket pin boltthreads Brake caliper pin bolt threads Locking agent Swingarm pivot bolt and distance collar whole surface Gear oil Drive chain #80 — 90 gear oil Front fork rebound spring Front fork spring Front fork oil seal, dust seal lips Fork fluid Cable insides Cable lubricant Tianwe grip rubber inside HondaBond A or Honda grip cement (U.s.A. only) 1-17 GENERAL INFORMATION CABLE & HARNESS ROUTING CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE THROTTLE CABLES LEFT HANDLEBAR - SWITCH WIRE LEFT TURN SIGNAL WIRE RIGHT TURN SIGNAL WIRE SPEED SENSOR WIRE RIGHT HANDLEBAR SWITCH 6P CONNECTOR IGreenI TURN SIGNAL WIRE CONNECTORS LEFT HANDLEEAR SWITCH 9P CONNECTOR (Black) SPEED SENSOR 3P HEADLIGHT CONNECTOR CLAMP (White (ape portion) 1-18 GENERAL INFORMATION , , w SPEEDOMETEH WIRE ,,, s! (Q: r« 9; KIA} a” CLUTCH CABLE / / LEFT TURN SIGNAL WIRE MAIN WIRE HARNESS FRONT BRAKE HOSE THROTTLE CABLES SPEED SENSOR WIRE 1-19 GENERAL INFORMATION MAIN IRE HARNESS SPARK PLUG WIRES FRONT IGNITION COIL E B U T L E U F \ E .II. 8 TE 0L RB HA TC 3M” #1.! 5/ § . H 5% my \ ~fi \._\\\\ p. O ' N WATER HOSE SUB-AIR CLEANER TUBE CHOKE CABLES SPARK PLUG WIRE CARBURETOR HEATER WIRE ”I -20 GENERAL INFORMATION ALTERNATOR WIRE STARTER MOTOR CABLE SUB—WIRE HARNESS (OIL PRESSURE SWITCH WIRE, NEUTRAL SWITCH WIRE) SIDE STAND SWITCH OIL PRESSU RE SWITCH 1-21 GENERAL INFORMATION FUEL TANK BREATHER TUBE FUEL TUBE (to fuel tank) FUEL TU BE (10 carburetorI / GROUND POINT FUEL PUMP BREATHER TUBE WIRE BAND: BA‘I'I'ERV NEGATIVE I—I CABLE ’ ALTERNATOR WIRE - SIDE STAND SWITCH WIRE - SUB»WIRE HARNESS (OIL PRESSURE SWITCH WIRE, NEUTRAL SWITCH WIRE) . STARTER MOTOR CABLE & GROUND CABLE ~ IGNITION SWITCH WIRE 1-22 GENERAL INFORMATION CONNECTOR BOOT: . IGNITION PULSE GENERATOR 2P CONNECTOR (White) FAN MOTOR SWITCH 2F CONNECTOR (Black) WIRE BAND: ' IGNITION PULSE GENERATOR WIRE - FAN MOTOR SWITCH WIRE . REAR BRAKE LIGHT SWITCH WIRE CLUTCH CABLE THERMOSENSOH HORN WIRE REAR BRAKE LIGHT SWITCH 2F CONNECTOR (Black) IGNITION PULSE GENERATOR WIRE I As REAR BRAKE LIGHT SWITCH SIPHON TUBE FAN MOTOR SWITCH RESERVE TANK OVEHFLOW TUBE 1-23 GENERAL INFORMATION AIR TEMPERATURE SWITCH SPARK PLUG WIRES CONNECTOR BOOT: ' REGULATOR/RECTIFIER IGNITION CONTROL MODULE 3P’ 2P CONNECTOR (Whne) IICMI CONNECTOR BOOT: - BRAKE/TAILLIGHT & REAR TURN SIGNAL WIRE CONNECTOR / . ‘ «\h ~-‘ I MAIN WIRE HARNESS "Q I I! E ‘2“ '17;:. R I @i ¢ REGULATOR/RECTIFIER STARTER RELAY SWITCH (including main fuse 30A) CONNECTOR BOOT: ‘ IGNITION SWITCH 3P CONNECTOR (Black) ‘ NEUTRAL & OIL PRESSURE SWITCH FUSE BOX 2P CONNECTOR (Red) (including diode) ' SIDE STAND SWITCH 2P CONNECTOR (Green) 0 FUEL PUMP 2P CONNECTOR IWI’IIIEI FUEL TANK BREATHER TUBE 1-24 1-25 GENERAL INFORMATION CALIFORNIA TYPE: EVAPORATIVE EMISSION CARBURETOR AIR VENT (EVAP CAVI CONTROL VALVE No.10TUBE No. 4 TUBE (From EVAP canister) \ No.11 was © / \ \ \ §ng\ No. 5 TUBE ., \‘ng‘m‘ ‘ \ No, 4 TUBE .l IFrom EVAP canister) No. 5 TUBE No.6 TU BE EVAPORATIVE EMISSION (EVAP) PURGE CONTROL VALVE ‘i -26 GENERAL INFORMATION No. 4 TUBE No. 4 TUBE (To EVAP purge control valve) (To EVAP CAV control valve) No. 2 TUBE (To open air) EVAPORATIVE EMISSION IEVAP) CANISTER No. 1 TUBE (To fuel tankI No. 4 TUBE VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY-I: EVAPORATIVE FAMILV-I:I CALIFORNIA VEHICLE 1 z E o :2 av» was; comm VALVE This label is located on the reverse side of the left side cover. 1-27 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency and California Air Resources Board (CARB) require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and main~ tained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emission standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor’s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons Control of hydrocarbons is very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight Carbon monoxide does not react in the same way, but it is toxic, Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydrocarr bons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emis~ sion control system. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the combustion chamber. Condensed crankcase vapors are accumulated in a drain tube it must be emptied periodically (page 3-3). The drain tube needs to be checked for oil accumulation more frequently if the machine has been consistently ridden at high speeds or in rain. AIR CLEANER CHAMBER AIR CLEANER HOUSING CRANKCASE BREATHER CASE EREATHER TUBE PLUG CARBURETORS c—v: FRESH AIR «: BLOVVABV GAS 1 -28 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) This model complies with California Air Resources Board (CARB) evaporative emission requirements. Fuel vapor from the fuel tank and carburetor is directed into the evaporative emission (EVAP) canister where it is adsorbed and stored while the engine is stopped. When the engine is running and the evaporative emission (EVAPI purge control valve is open, fuel vapor in the EVA? canister is drawn into the engine through the carburetor. EVAP PURGE CONTROL VALVE ii I? I II F. _» ‘- Jr-W DRAIN R EVAP CANISTER EVAP CAV CONTROL VALVE EVAF‘ CAV CONTROL VALVE (ENGINE STOP) TO OPEN AIR <5: FRESH AIR -: FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMFERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replace ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or I2l the use of the vehicle after 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: 1, Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conduct exhaust gases, 2. Removal of, or puncturing of any part of the intake system. 3, Lack oi proper maintenance. 4. Replacing any moving pans of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 1-29 GENERAL INFORMATION EMISSION CONTROL INFORMATION LABEL An Emission Control Information Label is located on the reverse side of the left side cover as shown. The left side cover must be removed to read it It gives basic tune-up specifications. VEHICLE EMISSION CONTROL INFOR- MATION UPDATE LABEL After making a high altitude carburetor adjustment, attach an update label on the reverse side of the left side cover as shown (page 5-23). Instructions for obtaining the update label are given in Service Letter No. 132. When readjusting the carburetors back to the low altitude specifications, be sure to remove this update label, VACUUM HOSE ROUTING DIAGRAM LABEL (California type only) The Vacuum Hose Routing Diagram Label is on the reverse side of the left side cover as shown (page 1—27). UPDATE LABEL EMISSION CONTROL INFORMATION LABEL VACUUM HOSE ROUTING DIAGRAM (California type only) 1-30 2. FRAME/BODY ‘PANELS/ EXHAUST SYSTEM SERVICE INFORMATION 2-1 LEFT CRANKCASE REAR COVER 2-3 TROUBLESHOOTING 2-1 REAR FENDER 2-4 SEAT . 2-2 GRAB RAIL 2-5 FUEL TANK 2-2 EXHAUST SYSTEM 2-5 SIDE COVER 2-3 SERVICE INFORMATION GENERAL This section covers removal and installation of the frame body panels, fuel tank and exhaust system. ~ Work in a well ventilated area. Smoking or allowing flames or sparks in the working area where gasoline is stored can cause a fire or explosion. - Always replace the exhaust pipe gasket when removing the exhaust pipe from the engine. - Always inspect the exhaust system for leaks after installation. TORQUE VALUES Footpeg bracket bolt Exhaust pipe joint nut Muffler mounting nut Exhaust pipe joint pipe bolt Seat mounting bolt Rear fender bolt Shock absorber stud bolt Left grab rail mounting nut Fuel tank mounting bolt Fuel Valve Fuel valve screw Left crankcase rear cover bolt Shock absorber upper/lower mounting bolt TROUBLESHOOTING Excessive exhaust noise . Broken exhaust system . Exhaust gas leaks Poor performance ' Deformed exhaust system . Exhaust gas leaks . Clogged muffler 34 N~m (3.5 kgf~m, 25 |bf~fll 25 Nm (2.5 kgfim, 18 |bf~ftl 26 Nm (2.7 kgf~m, 20 Ibf-ft) 20 N'm (2.0 kgf-m, 14 lbffll 26 Nm (2.7 kgf~m, 20 |bI~ftl 64 Nm (6.5 kgf‘m, 47 Ibf‘ftl 108 Nvm (11.0 kgf‘m, 80 Ibfvftl 88 N-m (9.0 kgf‘m, 651bf‘ftl 19 NM (1.9 kgf'rn, 14 lbf‘fll 34 NM (3.5 kgf~m, 25 Ibf'fl) 0.6 N‘m (0.06 kgf'm, 0.43 lbf‘ftl 12 N~m (1.2 kgf-m, 9 lbf‘ft) 26 N-m (2.7 kgf-m, 20 Ibf‘fi) 2-1 FRAME] BODY PANELS/EXHAUST SYSTEM SEAT REMOVAL Remove the seat mounting bolts, collars, and seat belL Slide and remove the seat rearwards to avoid dam- aging the rear fender surface. INSTALLATION Install the seat by inserting the hook of the seat under the raised lip of the frame and push the seat to the forward. Align the bolt holes and install the seat belt, collars and mounting bolts, then tighten the bolts to the specified torque. TORQUE: 26 N‘m (2.7 kgfvm, 20 IN“) Remove the seat isee abovel. Remove the speedometer (page 194). Turn the fuel valve to the of! position. Disconnect the fuel tube and breather tube. Remove the fuel tank mounting bolt, washer and col- lar. Slide and remove the fuel tank rearwards, Installation is in the reverse order of removal. TORQUE: Fuel tank mounting bolt: 19 N-m (1.9 kgfvm, 14 Ibf-fl) SEAT BELT COLLARS BOLTS BOSS FUEL TANK BOLT WASHER BREATHER TU BE 2-2 FRAME/BODY PANELS/EXHAUST SVSTEM SEDE COVER GROMMETS Release the side cover bosses and tab from the grammars and side cover. Instaliarion is in the reverse order of removal. LEFT CRANKCASE REAR COVER Remove the Cllp and washer from me boss of “we cover. Remove me cover bolt, washer and collar, Reiease the bosses from (he grommets and remove the weft crankcase rear cover. lnstaHatlon is in the reverse order of removal. TORQUE: Left crankcase rear cover bolt: 12 N1“ (12 kgf~m, 9 Ibfifl) LEFT CRANKCASE REAR COVER 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM EEAR FENDER REAR FENDER ASSEMBLY ASSEMBLY REMOVAL/INSTALLATION Remove (he seat (page In Discunnect the brake/\aillight, rear turn signal wire connectors located in the connector boot, Remove the four bulls, washers and rear fender assembly from the frame to avoid scratching the rear fender. TORQUE: Rear fender bait: 64 N-m (6.5 kgf~m, 41 let) DISASSEMBLY/ASSEMBLV SEAT BRACKET BOLTS Remove the two bolts and seal brackel. Remove the setting bolt, Remove the screw and collar, then remove the rear SETT'NG BOLT fender from the sub-fame Assembly is in the reverse order of disassemblyr REAR FENDER SCREW COLLAR FRAME/BODY PANELS/EXHAUST SYSTEM GRAB RAiL MOUNTlNG NUT Remove the rear fender assembly (see prevlous pager LEFT GRAB RAIL LEFT GRAB RAIL Loosen the left grab rail mounting nut, then remove the grab rail. RIGHT GRAB HAIL Remove the right shock absorber (page 14714). RIGHT GRAB RAIL Remove the shock absorber stud bolt. then remove the grab rail. Installation is in the reverse order of removal. TORQUE: Shock absorber upper/lower mounting bolt: 26 NJ“ (2.7 kgf‘m. 20 IN“) Left grab rail mouming nut: 88 N-m (9.0 kgf-m, 65 lbf-lt] Shock absorber stud bolt: 108 Mm (11.0 kgf~m, 80 IN“) EXHAUST SYSTEM WASHERS REMOVAL Remove the bolts, washers and right footpeg assemr bly from the frame. /. / RIGHT FOOTPEG 2-5 FRAME] BODY PANELS I EXHAU ST SYSTEM Remove the exhaust pipe joint nuts. Remove the muffler mounting nuts and exhaust pipe/muffler assembly. RemDVe the exhaust pipe joint collars. Remove the front and rear gaskets. EXHAUST PIPE JOINTS JOINT COLLARS MOUNTING NUTS INSTALLATION Install the exhaust pipe joint co|lars. Make sure new gaskets are installed in the proper position. Align the rear exhaust pipe flange with the cylinder head stud bolts, Loosely install the exhaust pipe joint nuts and mounting nuts, Tighten the mounting nuts to the specified torque. TORQUE: 26 Nrm [2.7 kg~m, 20 lbffl) JOINT COLLAR Tighten the joint nuts to the specified torque. TORQUE: 25 N-m (2,5 kgf~m, 18 lbI-fll install the washers and right footpeg assembly. Install the washers and bracket bolts, then tighten the bolts to the specified torque. TORQUE: 34 Nvm [3.5 k91~m, 25 [hf-fl) RIGHT FOOTPEG 2-6 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY REAR EXHAUST PIPE OVER PROTECTOR MUFFLER PROTECTORS REAR MUFFLER REAR EXHAUST PIPE PROTECTOR FRONT MUFFLER EXHAUST PIPE BANDS FRONT EXHAUST PIPE V JOINT PIPE MUFFLER Pnorecron MUFFLER Drive the rear and of the protector using the plastic PROTECTOR hammer and break the lock tab lreverse side of the protector) and remove it, Do not reuse the removed protector. PLASTIC HAMMER install the new protector by aligning the holders with the tabs on the muffler. TABS 3. MAINTENANCE SERVICE INFORMATION 3-1 EVAPORATIVE EMISSION CONTROL MAINTENANCE SCHEDULE 3_3 SYSTEM (California type only) 3-14 FUEL LINE j 34 DRIVE CHAIN 345 THROTTLE OPERATION 3.4 BRAKE FLUID 3-18 CARBURETOR CHOKE 35 BRAKE SHOES/PADS WEAR 3.13 AIR CLEANER 3_6 BRAKE SYSTEM 3.19 cRANKCASE BREATHER 3.5 BRAKE L'GHT SWITCH 3-20 SEARK FLUG 3,, HEADLIGHT AIM 3.20 VALVE CLEARANCE 3.3 CLUTCH SYSTEM 3-20 ENGINE OIL 340 SIDE STAND 3.21 ENGINE OIL FILTER ' 3-10 SUSPENS'o“ 3-22 CARBURETOR SVNCHRONIZATION 3-11 NUTS’ BOLTS' FASTENERS 3-22 ENSINE IDLE SPEED 3-12 WHEELS/"RES 3-23 RADWOR COOLANT 343 STEERING HEAD BEARINGS 3.24 COOLING SYSTEM 3.13 SERVICE INFORMATION SPECIFICATIONS a Place the motorcycle on a level ground before starting any work. ITEM SPECIFICATIONS Throttle grip free play 2—6 mm (1/12 —1/4inl Spark plug Standard DPRSEA-S INGKJ X24EPR-U9 (DENSO) For cold climate/below DPR7EA-91NGKI (5”C/41°F) XZZEPR-US (DENSO) For extended high speed DPRSEA~9 INGK) riding X27EPR-U9 (DENSO) Spark plug gap 0.8 — 0.9 mm (0.03 — 0.04 in) Valve clearance IN 0.15 t 0.02 mm (0.006 t 0.0008 in) EX 0.20 i 0.02 mm (0.008 t 0.0008 in) Engine oil capacity at draining 2.2 liters (2.32 US qt, 1.94 Imp qt) at oil filterchange 2.4 liters (2.54 US qt, 2.11 Imp qt) at disassembly 2.9 liters (3.06 US qt, 2.55 Imp qti Recommended engine oil Honda 6N4 or HP4 4-stroke oil or equivalent motor Oil API service classification SF 0r 5G Viscosity: SAE TOW-40 Carburetor Vacuum difference Within 20 mm Hg (08 in Hg) base carburetor: NO. ‘l (rearl l Engine idle Speed 1,000 :100 rpm MAINTENANCE ITEM SPECIFICATIONS Drive chain slack 15-25 mm (0.600 — 'l in) Drive Chain size/link (RKi ’ 525 SMOZS/124 L Recommended brake fluid DOT 4 Brake pedal (ree play 20 7 30 mm (0.750 — 1.250 in) Clutch lever free play 10 — 20 mm (0.375 , 0.750 ini Cold tire pressure Up to 90 kg (200 lbs) from 200 kPa (2.00 kgl/cm1,29 psi) '03“ Rear 200 kPa (2.00 kgi/cm’, 29 psi) Up to maximum Front 200 kPa (2.00 kgf/cm’, 29 psi) weight capacitv Rear 250 kPe (2.50 kgf/cmz, 36 psi) Minimum tire tread depth Front 1.5 mm (0.05 in) Rear 2.0 mm (0.08 in) ‘iire size Front 110/8049 595 Rear 160/80-15 me 743 Tire brand Dunlap Front F24 Rear K425 Bridgestone Front G515 Rear 0702 TORQUE VALUES Spark plug 14 N-m (1.4 kgf-m,10lbf-fti Crankshaft hole cap Timing hole can Valve adjusting screw lock nut Oil drain bolt Oil iilter cartridge Vacuum plug Rear axle nut Side stand assembly bolt Side stand pivot bolt Side stand lock nut Overhead cover bolt TOOLS Valve adjusting wrench Oli filter wrench Spoke wrench Vacuum gauge attachment Vacuum gauge set Drive chain tool set 15 Nrm (1.5 kgf-m, 11 lbf'fti 15 NW) (1.5 MW“, 11 lbfrfti 23 N‘m (2.3 kgf‘m, 17 |bf~fti 29 Nrm (3.0 kgf~m, 22 lbf~fti 10 N-m (1.0 kgf~m, 7 lbf~f0 3 N-m (0.3 kgf'm, 2.2 leI) 93 Nrrn (9.5 kgf-m, 69 Ibf‘fti 49 N~m (5.0 kgfvm, 39 Ibf'iti 10 N-m (1.0 kgfvm, 7 |bf~ft) 29 Nrm (3.0 kgfvm, 22 lbf~fti 12 N~m (1.2 kgf-m, 91bf~ffl 07908 — KEBOOOD 07HAA— PJ70100 O7JMA — MR60100 07510 — 3000200 07LMJ — OO1000A 07HMH » MH10103 Apply grease to the threads and seating surface. Apply grease to the threads and seating surface Apply oil to the threads and seating surface. Apply oil to the threads and seating surface Urnut. or 07908 — KE90100 (U.S.A. onlyl or equivalent cammercially available in USA. or 07LMJ , 001000A (U.5.A. only) or M9373 , 021—XXXXX (U.S.A. only) or 07HMH — MR701OB (U.S.A. onlyi 3-2 MAINTENANCE MAINTENANCE SCHEDULE Perform the PREeRlDE INSPECTION in the Owner's Manual at each scheduled maintenance period. !: inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean R: Replace A: Adjust L: Lubricate The following items require some mechanical knowledge. Certain items (particularly those marked" and MI may require more technical information and tools. Consult your HONDA dealer. \\ FREQUENCY WH'CHEVER ODOMETER READING [NOTE II COMES d) REFER TO \\ FIRST x 1,000 mi 0.6 A 8 12 1s 20 24 PAGE ITEM \ @ NOTE x 100 km 10 64 123 192 255 320 384 * l FUEL LINE , I I I 3-4 “ THROTTLE OPERATION I I I 3—1: 1 CARBURETOR CHOKE I I I as 0, AIR CLEANER NOTE 2 R R are E CRAN KCASE BREATHER NOTE 3 c c c c c c are E SPARK PLUG ' I R I R I R 3-7 E + vALVE CLEARANCE I I I I 343 g ENGINE OIL R R R R 3—10 E ENGINE OIL FILTER R R Fl R 3710 a *1 CARBURETOR stCHRONIZATION I I I 3-11 E * ENGINE IDLE SPEED I I I I I I I 3—12 ”‘ RADIATOR COOLANT NOTE 5 I I R 3713 + COOLING SYSTEM I I I 313 L EyggaATIVE EMISSION CONTROL NOTE 4 l l 344 DRIVE CHAIN 3-15 g BRAKE FLUID 3-18 2 BRAKE SHOES/PADS WEAR 3-13 é BRAKE SVSTEM 3-19 2 * BRAKE LIGHT SWITCH 3-20 E * HEADLIGHT AIM 3-20 3 CLUTCH SVSTEM 3-20 3 SIDE STAND 3721 5 * SUSPENSION 3-22 5‘ *1 NUTS, BOLTS, FASTENERS 3-22 2 H WHEELS/TIRES 3-23 1* STEERING HEAD BEARINGS 344 * Should be serviced by your dealer, unless the owner has proper tools and service data and is mechanically qualified. "i in the interest of safety, we recommend these items be serviced only by your HONDA dealer. NOTES: 1, At higher Odometer reading, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or at full throttle 4. California type only. 5. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill. 3—3 MAINTENANCE FUEL LINE Remove the Iefl side cover (page 2-3). Check the iuel lines for deterioration, damage or leak- age. Replace the fuel lines if necessary. For the tube routing, see section 1. THROTTLE OPERATION Check for any deterioration or damage to the throttle cables, Check the throttle grip (or smooth operation. Check that the throttle opens and automatically closes in all steering positions, It the throttle grip does not return properly, lubricate the throttle cable and overhaul and lubricate the throttle grip housing. For lubrication: Disconnect the throttle cables at their upper ends (page 13-3). Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a lightweight oilt lithe throttle grip still does not return properly, replace the throttle ca blast Reusing a darn- With the engine idling, turn the handlebar all the way aliedarabr-ior- to the left and right to ensure that the idle speed does mallybentar not change, kmked "WINE If idle speed increases, check the throttle grip free cable can urevent play and the throttle cable connection, proper throttle slide operation Measure the throttle grip free play at the throttle grip and may/sadtoa flange. loss ofthmflle 00’7””, while FREE PLAY: 2 - 6 mm (1/16 - 1/4 in) riding, Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster. Loosen the lock nut and turn the adjuster to obtain the free play. Tighten the lock nut and reposition the adjuster boot properly after the adjustment has been made 3-4 MAINTENANCE Major adjustments are made with the lower adjuster. Loosen the lock nuts and turn the adjuster to obtain the free’ play. Tighten the lock nuts after the adjustment has been made. Recheck the throttle grip free play. CARBURETOR CHOKE This motorcycle's choke system uses a fuel enriching circuit controlled by a starting enrichment (SE) valve. The SE valve opens the enriching circuit via a cable when the choke knob on the left side of the carbure- tor is pulled up. Check for smooth choke knob operation and lubricate the Choke if required. Check the choke cable for frayed, kinked or other damage. STARTING ENRICHMENT (SE) VALVE Starting enrichment system operation can be checked by the way the engine starts and runs, r Difficulty in starting before the engine is warmed up (easy once it is warmed up): SE valve is not completely opened - idle speed is erratic even after warm—up (imperfect combustion): SE valve is not completely closed. When the above symptoms occur, inspect the SE valve using the following procedure. SE VALVE NUTS ' 3... Remove the carburetor (page 55). Remove the choke cable boots from the SE valve nuts. Loosen the SE valve nuts and remove them from the carburetors MAINTENANCE Pull the SE valve knob all the way out to fully open ’ , ‘ ‘ , SE VALVE ‘ position and recheck for smooth operation of the SE L i ' ' - ‘ valve knob. There should be no free play. Check valve seat on the SE valve for damage. Reinstall the SE valve in the reverse order of removal. AIR CLEANER ) ELEMENT NOTE: - The viscous paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. BOLTS lime motarcycie Remove the four bolts from the air cleaner housing is used in wet or cover and remove the cover. dusty areas, Remove the air cleaner element. more frequent ' inspections are Replace the air cleaner element in accordance with required. the maintenance schedule or any time it is exces- AIR CLEANER HOUSING sively dirty or damaged, COVER Install the air cleaner element in the reverse order of removal. CRANKCASE BREATHER NOTE: - Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the transparent section of the breather tube. Remove the air cleaner housing breather tube plug from the tube end and drain deposits into a suitable container. then install the tube plug securely. BREATHER TUBE PLUG 3-6 SPARK PLUG Front cylinder left side and rear cylinder right side plugs: To prevent dam- age :0 the cylin- der head, hand» tighten the spark plug before using a Wrench to tighten to the specified torque. Remove the two bolts and cylinder head overhead cover. Disconnect the spark plug caps and clean around the spark plug bases. NOTE: - Clean around the spark plug bases with com- pressed air before removing, and be sure that no debris is allowed to enter the combustion chamber. Remove the spark plugs and inspect or replace as described in the maintenance schedule Check the insulator for cracks or damage, and the electrodes for wear, fouling or discoloration Replace the plug if necessary. It the electrode is contaminated with carbon deposits, clean the electrode using the spark plug cleaner. Clean the spark plug electrodes with a wire brush or special plug cleaner. Check the gap between the center and side electrodes with a wire-type teeler gauge If necessary, adiust the gap by bending the side electrode carefully. SPARK PLUG GAP: 0,80- 0.80 mm (0.031 — 0,035 In) Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification TORQUE: 14 N1" (1.4 kgfm, 10 “7“!) Install the spark plug caps TORQUE: Overhead cover bolt: 12 Nm (12 kgf-m, 5 IM) MAINTENANCE SPARK PLUG CAP 3—7 MAINTENANCE VALVE CLEARANCE INSPECTION NOTE: ' - Inspect and adjust the valve clearance while the engine is cold (below 35°C, 95“F). ' Adjust the front cylinder head valves first. Remove the front and rear cylinder head covers (page10-4l. Remove the timing hole cap and crankshaft hole cap. FRONT CYLINDER HEAD Rotate the crankshaft counterclockwise and align the "FT" mark on the flywheel with the index mark on left crankcase cover. Make sure the piston is at TDC [Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is slack in the rocker arm. If there is no slack, it is because the piston is moving through the exhaust stroke to TDC. Rotate the crankshaft one full turn and match up the ”FT” mark again. Measure the front cylinder head valve clearance by inserting a feeler gauge between the valve adjusting screw and valve, VALVE CLEARANCES: IN: 015 i 0.02 mm (0.003 t 00008 in) EX: 0.20 i 0.02 mm (0.003 t 0.0008 in) REAR CYLINDER HEAD Rotate the crankshaft counterclockwise and align the ”RT" mark on the flywheel with the index mark on the left crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is slack in the rocker arm. If there is no slack, it is because the piston is moving through the exhaust stroke to TDC. Rotate the crankshaft one full turn and match upthe ”RT" mark again. ICRANKSHAFT HOLE CAP . _ FRONT: INDEX MARK ”Ff" MARK Hie-N ) \ INDEX MARK ”RT” MARK // l 3-8 MAINTENANCE Measure the rear cylinder head valve clearance by inserting a feeler gauge between the valve adjusting screw and valve. VALVE CLEARANCES: IN: 0.15 t 0.02 mm (0.006 1 0.0008 in) EX: 0.20 i 0.02 mm (0008 i 0.0008 in! ADJ USTMENT Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. Apply oil to the valve adjusting lock nut threads. Hold the adjusting screw and tighten the lock nut. TORQUE: 23 MM [23 kghn, ‘l‘l lM-ftl TOOL: Valve adjusting wronch 07908 - KE90000 or 07908 - KE90100 (USA. only) After tightening the lock nut, recheck the valve clear- EDGE, Install the front and rear cylinder head cover (page 10-16). Apply grease to the timing hole cap and crankshaft hole cap threads. Coat the new O-rings with oil and install them onto the timing hale cap and crankshaft hole cap, Tighten the timing hole cap and crankshaft hole cap. TORQUE: 15 N-m (1.5 kgf-m. 11 letl MAINTENANCE ENGINE OIL Start the engine and let it idle for a few minutes. Stop the engine, remove the oil filler cap/dipstick and wipe the oil from the dipstick with a clean cloth. Wait 2 or 3 minutes after stopping the engine, With the motorcycle in an upright position, insert the dip— stick into the dipstick hole without screwing it in. If the oil level is below or near the lower level mark on the dipstick, add the recommended oil up to the upper level mark. RECOMMENDED ENGINE OIL: Honda GN‘ or HP4 make all or equiv-lent motor oil certified to meet API service classification: SF or $6 Viscosity: SAE 10W—40 NOTE: - Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. Reinstall the oil filler cap/dipstick For engine oil change, see below. ENGINE OIL FILTER NOTE: . Change the engine oil with the engine warm and the motorcycle on Its side stand to assure com plate and rapid draining Engine and exhaust system pens become very hot and remain hot for some time after the engine is run‘ Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. Remove the engine oil drain bolt and liller cap/dip- stick, and drain the oil. Remove and discard the oil filter cartridge. TOOL: Oil filter wrench 07HAA - PJ70100 Alter draining the all completely, install and tighten the engine oil drain bolt with a new sealing washer‘ TORQUE: 29 NM (34) kgf-m, 22 lbfltl OIL FTELER CAP/DIPSTICK OIL FILTER WRENCH ~ 3-10 MAINTENANCE Apply oil to a new oil filter o-ring and the oil filter threads and install the oil filter cartridge. a TORQUE: 10 N-m (1.0 kglvm, 7 Ibfrft) Fill the crankcase with the recommended oil lsee pre» vinus page]. Install the oil filler cap/dipstick. Start the engine and let it idle for 2 or 3 minutes Stop the engine and check that the oil level is at the upper level mark on the dipstick (see previous page). Make sure there are no oil leaks. jao-RING SARBURETOR SYNCHRONIZATION Perform this maintenance with the engine at normal operating temperature and the transmission in neu- tral. Place the motorcycle on a level surface. Remove the air cleaner housing (page 573). Remove the spark plug cap from the left side of the rear cylinder head, then remove the four bolts, choke cable holder and rear left cylinder head fin, Reinstall the spark plug cap. Remove the plugs and washers from the cylinder head intake ports. PLUGS AND WASHERS Install the vacuum gauge attachment, VACUUM GAUGE ATTACHMENT Connect the vacuum gauge to the gauge attachment. TOOLS: Vacuum gauge attachment 07510 - 3000200 or Vacuum gauge set 07qu — oowooA lU.S.A. only] or M9375 — 021 - XXXXX [U.S.AV only) MAINTENANCE The base carbuV retar is the No. 1 (rear) carbulefor. Remove the fuel tank (page 24) and connect a suit- able tube between the fuel tank and fuel line. 1. Start the engine and adjust the idle speed with the throttle mop screw to the specification below. IDLE SPEED: 1,000 i 100 rpm 2. Check the difference in vacuum between each car, buretor. CARBURETOR VACUUM DIFFERENCE: 20 mm Hg [0.8 in H9) 3. Turn the synchronization adjusting screw so that the difference between each carburetor is below the specification. 4, Be sure the synchronization is stable by snapping the throttle grip several times. 5. Snap the throttle grip several times and recheck the idle speed and difference in vacuum between each carburetor. Disconnect the vacuum gauge and install the removed parts. TORQUE: Vlcuum plug: 3 Matt (0.3 MM, 2.2 lbf'ft) Cylinder head (in bolt: 10 N-m (1.0 kgf~m, 7 lbffll ENGINE IDLE SPEED NOTE: - Inspect and adjust idle speed after all other angina adjustments are within specifications. - The engine must be warm for accurate adjustment. Ten minutes of stop»and-go riding is sufficient, Warm up the engine, Support the motorcycle on a level surface and shift the transmission into neutral. Check the idle speed and adjust by turning the throt- tle stop screw if necessary. IDLE SPEED: 1,000 i 100 rpm SYNCHRONIZATION ADJ USTI NG SCREW THROTTLE STOl= SCREW 3-12 MAINTENANCE RADEATOR COOLANT LEVEL CHECK Check the coolant level in the reserve tank with the engine running at normal operating temperature. The level should be between the "UPPER” and ”LOWER" level lines with the motorcycle in a vertical position on a flat level surface. If necessary, remove the reserve tank cap and fill to the "UPPER" level line with a 5050 solution of dis- tilled water and recommended antifreeze (coolant mixture preparation: page 6-4). fl‘\ “LOWER" LEVEL LlNE RECOMMENDED ANTIFREEZE: Pro Honda HP coolant or an equivalent high quality ethylene gl col antifreeze containing silicate-free corrosion inhlbitors. Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or block— age of radiator passages. Using tap water may cause engine damage. Check to see if there are any coolant leaks when the coolant level decreases very rapidly. if the reserve tank becomes completely empfyi there is a possibility of air getting into the cooling system. He sure to remove all air from the cooling system as described on page 6-4‘ fiGOLING SYSTEM Check the radiator air passage for clogging or dam- age. Straighten bent fine with a small, flat blade screw dri- ver and remove insects, rnud of other obstructions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over 20% of the radiating surface. moi/{Ton For radiator replacement, refer to page 6-8t Remove the fuel tank (page 2-2) and check for any coolant leakage from the water pump, water hose and hose joints, Make sure the hoses are in good condition; they should not show any signs of deterioration. Replace any hose that shows any sign of deteriora~ tion. Check that all nose clamps are tight. MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) Check the tubes between the fuel tank, EVAP Denis, ter, EVAP purge control valve, EVAP CAV control valve and carburetors for deterioration, damage or loose connections. , Check the EVAP canister for cracks or other damage. Refer to the Vacuum Hose Routing Diagram label and Cable & Harness Routing {page may for tube can nectlons. EVAP CANISTER EVAP CAV CONEOL VALVE \\_ CONTROL VALVE 3-14 DRIVE CHAIN CHAIN SLACK INSPECTION Turn the ignition switch to the off position, place the motorcycle on its side stand and shift the transmis- sion into neutral. Check the slack in the drive chain lower run midway between the sprockets. CHAIN SLACK: 15 - 25 mm (0.600 — 1 in) ADJUSTMENT Loosen the rear axle nut. Turn both adjusting bolts an equal number of turns until the correct drive chain slack is obtained. Make sure the index marks on both adjusters are aligned with the rear end of the swingarm. Tighten the rear axle nut to the specified torque. TORQUE: 93 Nm (9.5 kgf-m, 69 Ibl~ftl Recheck the drive chain slack and free wheel rotation. Check the drive chain wear indicator label attached on the left drive chain adjuster. lithe red zone of the indicator label reaches the end of the swingarrn, replace the drive chain with a new one lsee next pagel. CLEANING AND INSPECTION Clean the chain with a soft brush using a nonAIlam- mable or high flash point solvent and wipe it dry. Be sure the chain has dried completely before lubri- eating, inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fit- ting links, or otherwise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. inspect and replace the sprockets as necessary. MAINTENANCE 15-25mm _ (0.600—1 in) . 3-15 MAINTENANCE When using the special 200/, fol- low the manu- facturer’s instruction. LUBRICATION Lubricate the drive chain with #8040 gear oil or equivalent chain lubricant designed specifically for use with 0=ring chains. Wipe off the excess chain lube. SPROCKET INSPECTION Inspect the drive and driven sprocket teeth for dam- age or wear. Replace if necessary. Never use a worn chain on new sprockets, Both chain and sprockets must be in good condition, or the new replacement parts will wear rapidly. Check the attachment bolt and nuts on the drive and driven sprockets. If any are loose, torque them. REPLACEMENT This motorcycle uses a drive chain with a staked masterlink. Loosen the drive chain. Assemble the special tool. TOOL: Drive chain tool set 07HMH — MR10103 or 07HMH — MR70103 (U.S.A. only) NONVFLAMMABLE OR HIGH FLASH POINT SOLVENT NORMAL DRIVE CHAIN TOOL SET 3-16 r i Locate the crimped pin ends of the master link from the outside of the chain and remove the link with the drive chain tool set. Remox’Ie the drive chain. Remove the excess drive chain links from the new drive chain with the drive chain tool set. SPECIFIED LINKS: 124 links REPLACEMENT CHAIN: RK: 525 SMOZE Remove the left crankcase rear cover (page 2-3), Install the new drive chain over the drive and driven sprackets. Assemble the new master link, O-rings and master link plate with the drive chain tool set. Measure the master link pin length projected from the plate. SPECIFIED LENGTH: 120 -1.40 mm (0.047 -0.055 in) Stake the master link pins with the drive chain tool set. Make sure the master link pins are staked properly by measuring the diameter of the staked area, DIAMETER OF THE STAKED AREA: 5.50 - 5.80 mm (0.217 — 0.228 in) MAINTENANCE MASTER LINK llllllllll ' i DRIVE CHAIN TOOL SET i MASTER LINK 1 LINK ‘l<—'———‘|24 LINKS-—I>, 5 PLATE OvRINGS £9 DFiIVE CHAIN TOOL SET SLIDE CALIPER MAINTENANCE A drive chain with a clip-type master link must not be used. After staking, check the staked area of the master link for cracks. If there is any cracking, replace the master link, 0- rings and plate. Install the left crankcase rear cover (page 2-3), BRAKE FLUID Do not mix dif- ferent types of fluid, as they are not campatl'ble with each other. Do not allow for- sign material to enter the system when iiiling the reservoir. NOTE: - When the fluid level is low. check the brake pads for wear (see below). A low fluid level may be due to worn brake pads If the brake pads are worn, the caliper piston is pushed out, and this causes a low reservoir level. Avoid spilling fluid on painted, plastic or rubber pans. Place a rag over these pans whenever the system is serviced. Position the handlebar to the straight ahead position so that the reservoir is level and check the front brake reservoir level through the sight glasst If the level (float edge) is near the lower level mark, remove the cover, set plate and diaphragm and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge. Refer to page 15—3 for brake fluid replacement/bleed- ing procedures. BRAKE SHOES/ PADS WEAR FRONT BRAKE PAD Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of the wear limit groovet Refer to page 154 for brake pad replacement. CASTING LEDGE SIGHT GLASS WEAR LlMlT GRUOVES 3-18 MAINTENANCE REAR BRAKE SHOE "A" M/ARK Replace the brake shoes if the arrow mark an the brake arm aligns with the reference mark ”A" when the rear brake is applied. FRONT BRAKE Firmly apply the brake lever, and check that no air has entered the system, If the lever feels soft or spongy when operated, bleed air from the system. Inspect the brake hose and fittings for deterioration, cracks and leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer to page 15-3 for brake bleeding procedures REAR BRAKE PEDAL FREE PLAV Measure the rear brake pedal free play, FREE PLAY: 20 — 30 mm (0.750 -1,250 in) Make surezhat Adjust the brake pedal free play by turning the the cuwut in the adiusting nut at the brake arml adjuezmg m is seated on the brake arm joint. ADJUSTING N UT 3-19 MAINTENANCE BRAKE LIGHT SWITCH The from brake Ilghl switch does not require adjustment HEADLIGHT AIM Adjust the head- light beam as specified by local laws and regulations, CLUTCH SYSTEM Adjust the rear brake light switch so the brake light comes on just prior to the brake actually being engaged.’ If the light fails to come on, adjust the switch so the light comes on at the proper time. Hold the switch body and turn the adjusting nut, Do not turn the switch body. Adjust vertically by turning the vertical adjusting screw. Adjust horizontally by turning the horizontal adjustr ing screw. Measure the clutch lever free play at the end of the clutch lever, FREE PLAV: 10 — 20 mm (0.375 - 07/50 in] Adjust as follows: ADJUSTER ‘ Minor adjustments are made at the adjuster near the lever. Loosen the lock nut and turn the adjuster. Tighten the lock nut. ”we: If the adjuster is threaded out near its limit and the correct lree play cannot be obtained, turn the adjuster all the way in and back out one turn, Tighten the lock nut and make a major adjustment as described on the next page. \ LOCK NUT 3-20 MAINTENANCE Meier adjustments are performed at the clutch lifter LOCK NUT ADJUSTING NUT arm. Loosen the lock nut and turn the adjusting nut to adjust/play. Hold the adjusting nut securely while tightening the lock nut. If proper free play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch (see section 7). giii‘iE STAND Support the motorcycle on a level surface, Check the side stand spring for damage or loss of tension. Check side stand assembly for freedom of movement and lubricate the side stand pivot if necessary. Make sure the side stand is not bent. Check the side stand ignition cuteofl system: — Sit astride the motorcycle and raise the side stand. ,, —- Start the engine with the transmission in neutral, 2 ' a 5 ~‘ then shift the transmission into gear, with the Clutch lever squeezed. ¥ Move the side stand down. —The engine should stop as the side stand is low» ered, If there is a problem with the system, check the side stand switch (page 19-14). 3—21 MAINTENANCE SUSPENSION FRONT SUSPENSION INSPECTION Check the‘ action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire assembly for signs of leaks, damage or loose lasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to section 13 for fork service. REAR SUSPENSION INSPECTION Check the action of the shock absorber by compress ing it several times, Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired, Tighten all nuts and bolts, Reter to section 14 for shock absorber service. Raise the rear wheel off the ground and support the motorcycle securely. Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side. Replace the bearings if any Iooseness is noted (see section 14). NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to their correct torque values (page 1-12). Check that all cotter pins, safety clips, hose clamps and cable stays are in place and properly secured. 3—22 MAINTENANCE WHEELS/TIRES While making sure the fork is not allowed to move. raise the front wheel and check (or play. Turn the wheelsand check that it rotates smoothly with no unusual noises. As the swingarm If faults are found, inspect the wheel bearings. pivot is included Support the motorcycle securely and raise the rear in thls check, be wheel off the ground. sulem confirm Check for play in either the wheel or the swingarm zhelocation of pivot. Turn the wheel and check that it rotates the play (so; smoothly with no unusual noises. from the wheel Marinas or the It abnormal conditions are suspected, check the rear swingarm pivot). wheel bearings (see section 14). Tap an the inspect the spokes for looseness by tapping them spokes and be with a screwdriver. sure that the if 3 spoke does not sound clearly, or if it sounds dif- some clear terent from the other spokes, tighten it to the speci metallic sound fled torque. can be heard an all spokes. TORQUE: 4 Nm (0.4 kgf-m. 2.9 Ith) TOOL‘ Spoke wrench WJMA - MR60100 or equivalent commercially available In U.S.A. Check the tire pressure with the tire pressure gauge, when the tires are cold. RECOMMENDED TIRE PRESSURE: Up to 90 kg (200 lbs): Front: 200 “’8 (2.00 kgflcm‘, 29 psi) Near: 200 kPa (2.00 kgi/cm‘, 29 psi) Up to maximum weight up: . Front: 200 k?! (2.00 kqf/crnz. 29 psi) Hear: 250 kPa (2.50 kgllcm'. 36 psi) Check the tires for cuts, embedded nails. or other damage. Check the front and rear wheels for trueness (refer to section13 and 14). Measure the tread depth at the center 01 the tires. Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: Front: 1.5 mm (0.06 in) Rear: 2.0 mm (0.08 in) 3-23 MAINTENANCE STEERING HEAD BEARINGS Raise the from wheel off the ground and support the motorcycle securely, Check that the handlebar moves freely from side to side and the control cables do not interfere with han- dlebar rotation. {f the handlebar moves unevenly, binds, or has verti» cal movemem, inspect the steering head bearings (see secfion 13). 3-24 LU BRICATION SYSTEM ROCKER ARM CAMSHAFT PISTON OIL JET CRANKSHAFT MAINSHAFT COUNTEHSHAFT OIL PRESSURE SWITCH T — OIL PUMP ENGINE OIL FILTER PRESSURE RELIEF VALVE OIL STRAINER 4-0 4. LUBRICATION SYSTEM SERVICE INFORMATION 0 4-1 OIL PRESSURE CHECK 4-3 TROUBLESHOOTING 4-2 OIL PUMP 4-4 SERVICE INFORMATION GENERAL ACAUTION Used engine oil may cause skin cancer ll repeatedly left in Contact with the skin rot prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, I! is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. - The service procedures in this section can be performed with the engine in the frame. - When removing and installing the oil pump use care not to allow dust or dirt to enter the engine. ' If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. ~ After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct. - For oil pressure indicator inspection, refer to section 19 of this manual. SPECIFICATIONS _ > Unit: mm (Inl ITEM STANDARD SERVICE LIMIT Engine oil capacity at draining 2.2 liters (2.32 US qt.1.54lmp qt) — at iiltcr change 2.4 liters (2.54 US qt, 2.11 Imp qt) — at disassembly 2.9 liters (3.06 US qt, 2.55 imp qt) — Recommended engine oil Honda GNA or HP4 4-stroke oil or equivalent motor oil AP] service classification SP or 56 Viscosity: SAE low-40 Oil pressure at oil pressure switch 530 kPa (5.4 kgl/cmz, 77 psi) at _ . 7 . 5,500 rpm (safe/176$) Oil pump rotor Tip clearance 0.15 (0005) 0.2001008) Body clearance l 0.15 — 0.22 (0.006 - 0.009) 0.35 (0 01 Al W Slda clearance j 0.02 — 0.07 (0.001 — 0.003) 0.10 (0.004) TORQUE VALUES Oil pressure switch 12 N-m [1.2 kgI-m, 9 lbI-ft) Apply sealant to the threads. Oil pressure switch terminal screw 2 N-m (0.2 kgf-m, 1.4 Ibf‘ft) Oil pump bolt 13 Nam [13 kgfvm. 9 lbf‘ftl TOOLS Oil pressure gauge 07506 7 3000000 ——:r»!— or equivalent commercially available in USA. Oil pressure gauge attachment 07510 ‘ 4220100 ~ 4-1 LUBRICATION SYSTEM TROUBLESHOOTING Oil level too low — high oil consumption . External Oll leak - Worn piston rings or incorrect piston ring in: ' Worn cylinder - Worn valve guide or stem seals Oil contamination (white appearance) ‘ Coolant mixing with oil _ Faulty head gasket 7 Water leak in crankcase Low oil pressure ~ Oil level low ~ Oil pressure relief valve stuck open - Clogged oil strainer or filter - on pump worn or damaged . Incorrect oil being used No oil pressure - Oil level [00 low ' Oil pump drive chain or drive/driven sprocke ~ Oil pump damaged High oil pressure ' Oil pressure relief Valve stuck closed - Plugged gallery, or melering orifice - Incorrect oil being use 4-2 LU BRICATION SYSTEM Oil. PRESSURE CHECK if the engine is cold, the pressure reading will be abnormally high. Warm up the engine to normal aperating tempera- ture before startan this test Stop the engine. Remove the switch cover and disconnect the oil pres— sure switch wire by removing the terminal screw. Remove the oil pressure switch and connect an oil pressure gauge attachment and gauge to the pres- sure switch hole. TOOLS: Oil pressure gauge attachment 07510 - 4220100 or equivalent commercially available in USA. Oil pressure gauge 07506 — 3000000 or equivalent commercially available in USA. Check the oil level and add the recommended oil if necessary (page 340). Start the engine and check the oil pressure at 5,500 rpm lBO”C/176°F). ATTACHMENT OIL PRESSURE: 530 kPa (5,4 kgl/v:m’r 77 psi) 5‘09 the engine. Do not apply to the thread head Apply sealant to the oil pressure switch threads as shown and install it. 3- 4 mm TORQUE: 12 N~m (1.2 him, 9 lbfvft) Connect the oil pressure switch wire and tighten the terminal screw to the specified torque. TORQUE: 2 Min (0.2 kgf‘m, 1.4 lbffl) / install the switch cover. J (Em Start the engine. Check that the oil pressure indicator goes out after 1 or 2 seconds. If the oil pressure indicator stays on, stop the engine immediately and determine the cause (page 19-9). LUBRICATION SYSTEM OIL PUMP REMOVAL Separa‘e the crankcase "3399124). Remove the bolt and oil relief pipe. Remove the pressure relief valve and O-ring. thn the oil pump is ready to be disassembled. loosen the three oil pump cover bolls. Remove the two oil pump mouming bolts and oil pump Remove the collars and O-rings. Remove :he dowel pin‘ DOWEL PIN 4-4 LUBRICATION SYSTEM DISASSEMBLY on. PIPE Remove the oil pipe, oil pipe seal and O-rings. PIPE SEAL Remove the oil strainer and packing Vrom «he oil , ‘ . ' ‘ STRAINER pump. ‘ PACKING Remove the bolts and pump cover. ‘ ' BOLTS COVER Remove the dowel pins. Remove the spacer, rotor shaft, drive pin, inner and outer rotor, SPACER 4.5 LUBRICATION SVSTEM PRESSURE RELIEF VALVE Remove the snap ring and disassemble the pressure relief valve. Check the spring and piston for wear or damage. Check the valve for clogging or damage. Assemble the parts in the reverse order of disassem- bly. INSPECTION Temporary install the following: 7 outer rotor — inner rotor — rotor shaft, drive pin Measure the rotor tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump body clearance, SERVICE LIMIT: 0.35 mm (0014 in) PISTONV SNAP RING 15mm LUBRICATION SYSTEM Place the spacer into the inner rotor groove. Install the dowel pins into the oil pump body. ‘ DOWEL PlNS Install the oil pump cover onto the pump body with the cover bolls. SPACER Coat a new packing with engine oil and install it into the < STRAINER groove of the oil pump, and install the oil strainer into the oil pump. PACKING ‘93 3 E Coat a new oil pipe seal with engine oil, then install it to the oil pipe 3‘ _ @ E Coat the new O-rings with engine oil, and install them to 0_R|NGS the oil pipe with their tapered side facing out. Install the oil pipe to the oil pump securelyt 997E INSTALLATION Install the collars and dowel pin. Coat the new Orrings with engine oil and install them onto the Collars. DOWEL PIN 4—8 LU BRICATION SYSTEM Remove the drive pin and rotor shaft. Measure the OH pump side clearance. SERVICE LIMIT: 0‘10 mm (01104 in) ASSEMBLY INNER ROTOR SNAP RING OUTER ROTOR RELIEF PIPE DRIVE PIN WASHER @ ROTOR SHAFT SPRING PISTON DOWEL PINS OIL PIPE PRESSURE RELIEF VALVE OIL PUMP COVER PACKING PIPE SEAL O-RINGS OIL STRAINER InstaII the outer rotor and inner rotor, Insert the rotor shaft and instalI the drive pin by aligning the slots in the inner rotur‘ DRIVE PIN 4—7 Install the oil pump with the mounting bolts. Coat a new O-ring with engine oil and install it into the groove of the pressure relief valve, Install the pressure relief valve to the oil pump securely. Install the oil relief pipe with boIL Tighten the oil pump mounting bolts Tighten the oil relief pipe boil and oil pump cover bolls, TORQUE: 13 Min (13 kgf-m. 9 lbf-hl Assemble me crankcase (page 12-19). LU BRICATION SYSTEM 4-9 FUEL SYSTEM 5-0 5. FUEL SYSTEM SERVICE INFORMATION 5-1 CARBURETOR ASSEMBLY 5-15 TROUBLESHOOTING 5-2 CARBURETOR CLEANING 5-15 AIR CLEANER HOUSING 5-3 CARBURETOR COMBINATION 5-16 SUB-AIR CLEANER 5-4 CARBURETOR INSTALLATION 5-17 CARBURETOR REMOVEL 5-5 PILOT SCREW ADJUSTMENT 5-22 VACUUM CHAMBER 5-9 HIGH ALTITUDE ADJUSTMENT 5-23 FLOAT CHAMBER/PILOT SCREW 5-11 FUEL PUMP REMOVAL/INSTALLATION 5-24 AIR CUT-OFF VALVE 5-14 EVAPORATIVE EMISSION CONTROL CARBURETOR SEPARATION 545 SYSTEM (California type only) 5-24 SERVICE INFORMATION GENERAL - Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. - Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, result- ing in loss of vehicle control. - Before removing the carburetor, place an approved fuel container under the drain tube, loosen the drain screw and drain the carburetort - After removing the carburetor, cover the intake port of the cylinder head with shop towel to prevent any foreign material from dropping into the engine. ~ When disassembling the fuel system parts, note the locations of the O»rings. Replace them with new ones on reassembly. - If the vehicle is to be stored for more than one month, drain the float chamber. Fuel left in the float chamber may cause clogged iets, resulting in hard starting or poordriveability. - Forfuel tank removal and installation see section 2. ~ Refer to section 19 for carburetor heater inspection. . All hoses used in the evaporative emission control system (California type only) are numbered {or identificatlon. . When connecting one of these hoses, compare the hose number with Vacuum Hose Routlng Diagram Label on page 1‘27, for its proper routing, He sure the to remove diaphragms before cleaning air fuel passages with compressed alr. The diaphragms might be damaged. SPECIFICATIONS ITEM SPECIFICATIONS Carburetor identifica» 49 state/Canada type VDFZD ‘i°“ "umbe' California type vonc iMain jet Front #105 Rear #108 Slow jet #40 PilotEew initial/final opening See page 5—22 Twat level 7.0 mm (0.23 in) Base Carburetor (for synchronization) Rear cylinder (#1) Idle speed 1,000 i100 rpm Carburetor vacuum difference 20 mm Hg (0.7 in Hg) Throttle grip free play 2 , 6 mm (1/12 — 1/4 in) 5—1 FUEL SYSTEM TORQUE VALVES Vacuum plug Air cleaner housing stay bolt v Choke cable holder bolt TOOLS Carburetor float level gauge Pilot screw wrench Vacuum/pressure pump A Vacuum pump — Pressure pump 3 N-m (0.3 kgf-m, 2.2 lbf-ftl 12 N~m (1‘2 kgf‘m,9 Ibfrftl 10 N-m (1.0 kgf-m,7 lbfeft) 07401 — 0010000 07KMA — MSGOiO’I A937X — 041 — XXXXX or ST — AH — 260 — MC7 (USA. only) ST — AH — 255 — MC7 (U.S.A. only) TROUBLESHOOTING Engine cranks but won’t start - No fuel in tank - No fuel to carburetor — Fuel filter clogged — Fuel line clogged — Fuel level misadjusted — Fuel tank breather tube restricted l49 state/Canada type) — Evaporative Emlssion (EVAPl tube No.1 restricted lCaIlfornia type) - Too much fuel getting to the engine — Air cleaner clogged — Flooded carburetor < Intake air leak - Fuel contaminated/deteriorated — Jets clogged ‘ Improper Starting Enrichment (SEl valve operation - SE valve circuit clogged ‘ Improper throttle operation - Faulty fuel pump lsystem inspection, see page 19-14) - No spark at plug lignition system faulty) Lean mixture . Fuel jets clogged ~ Float valve faulty - Float level too low - Fuel line restricted ' Carburetor air vent tube clogged . Intake air leak ' Vacuum piston faulty ' Needle valve faulty - Emission control system faulty (California type) — Evaporative Emission Carburetor Air Vent (EVAP CAVl control valve faulty — Hose of the emission control system faulty Rich mixture ~ SE valve open - Float valve faulty - Float level too high - Air jets clogged n Air cleaner clogged - Vacuum piston faulty a Emission control system faulty (California type onlyl — EVAP purge control valve faulty — Hose of the emission control system faulty Engine stalls, hard to start, rough idling - Fuel line restricted - Fuel mixture too lean/rich - Fuel contammated/deteriorated —— Jets clogged - Intake air leak ' Idle speed misadjusted - Float level misadjusted - Fuel tank breather tube restricted (49 state/Canada typel - EVAP tube Noti restricted {California type) - Pilot screw misadjusted - Starting enrichment valve circuit clogged - Ignition system malfunction ' Emission control system faulty (California type) — EVAP CAV control valve faulty — EVAP purge control valve faulty — Hose of the emission control system faulty Afterburn when engine braking is used - Lean mixture in slow circuit - Air cut-off valve malfunction - Ignition Control Module llCMl stops ignition intermit< tently to prevent over revolution (working over rev limiter function) Poor performance ldriveabilityl and fuel economy - Fuel system clogged - Ignition system malfunction ' Emission control system faulty (California type onlyl — EVAP CAV control valve faulty — Hose of the emission control system faulty 5-2 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL MOUNTING BOLTS Remove the fuel tank lpage 2—2). Remove xhe two mounting bolts. Loosen lhe band screw and remove the air cleaner housing. INSTALLATION Apply grease to the air cleaner housing band inside surface. Install the air cleaner housing and tighten (he band SCI’SW. Install and tighten (he mounting bolts. lnstall the fuel tank (page 272lr AIR CLEANER HOUSING AIR CLEANER CHAMBER REMOVAL] INSTALLATION Remove the air cleaner housing (see above). AIR CLEANER CHAMBER Loosen the band screwsi Disconnect the crankcase breather case tube from the air cleaner chamber and remove the air cleaner BREATHEH CASE TUBE chamber. lnstallation is in the reverse order of removal. BAND SCREWS 5-3 FUEL svsnzm SUB-AIR CLEANER Remove the fuel tank (page 2-2). Remove the front cylinder left overhead cover (page 3-7). / Disconnect the sub-air cleaner tubes, Remove the sub-air cleaner case cover from the case stay. Remove the sub»air cleaner case and remove the ele- ment from the case. SUB-AIR CLEANER ELEMENT Wash the element in non-flammable or high flash point solvent, squeeze out the solvent thoroughly. and allow the element to dry‘ Never use gasoline or low flash point salvents for cleaning the element. A fire at explosion could result. Soak the element in gear oil (SAE #804)!“ and squeeze out the excess Installation is in the reverse order of removal. SUBVAIR CLEANER CASE COVER / SUB-AIR CLEANER TUBES ELEMENT #80—90 GEAR DIL Squeeze out 5-4 FUEL SYSTEM CARBURETOR REMOVAL Remove the a?! cleaner chamber (page 5-3). FUEL TUBE Release the fuel tube from the tube clampt Loosen the carburetor drain screws and draln the car— buretor. Remove the following: — screw — throttle drum cover Loosen the throttle cable lock nut. Remove the following: 7 screw and wire clamp 7 screw and throttle drum cover stay —— three screws and throttle cable stay Disconnect the throttle cables from the throttle drum. Remove the bolt and choke cable holder, Disconnect the carburetor heater connectors from the rear carburetort CHOKE CABLE HOLDER ‘ FUEL SYSTEM Disconnect the sub-air cleaner tube from the rear carr buretor. Loosen the band screw at the insulator sider Disconnect the carburetor heater connectors from the from carburetor. Disconnect the sub-air cleaner tube from the from carburetor. Loosen the band screw at the insulator side. 5-6 FUEL SVSTEM California iype The tube number of the evaporative emission cumrol TUBING DIAGRAM: only: system are printed on all tubes. Refer to the tubing diagram for the tube connections. Disconnect the No. 5 tube and No. 10 tube from the rear carbureturt Disconnect the No.5 tube and Ne. 11 tube from (he FUEL TANK front carburetor. Disconnect the No. 6 tube (49 slate/Canada type: air vent tube) from the Evaporative Emission Carburetor Air Vent (EVAF CAV) Controi valve. CARBURETORS No.10TUBE No. 11 TUBE Release the carburetor with (he insulators from the cylinder head intake ports while carefully raising the carburetor assembly. Remove the carburetor assembly by rotating it and then disconnecting the fuel tube from the carburetor. Loosen the band screw and remove the insulators from each carburetort 5-7 FUEL SYSTEM Remove the choke cable boots from the Starting Enrichment (SE) valve nuts. Loosen the SE valve nuts and remove them from the carburetors. , SE VALVE NUTS Disconnect the carburetor air vent tubes {California ' AIR VENTTUBE No. 6 tube) from the carburetors and release the ,, ‘ tubes from the clamps. Disconnect the fuel tube from the carburetors and release the tube from the clamps. FUEL TUBE 5-8 FUEL SYSTEM ASSEMBLY/DISASSEMBLY NOTE: - Refgr to the following pages for service of each part. - Vacuum chambers, float chambers, pilot screws and air cut-off Valves can be serviced wi‘hout sepv arating the carburetors. - Keep each carburetor’s pans separate from The other’s so you can install xhe pans in their original location RETAINER AIR CUT-OFF VALVE COVER DIAPHRAGM HOSE JOINT IN NEEDLE HOLDER PLUG ’ SPRING PILOT SCREW JET NEEDLE THROTTLE STOP SCREW /\ 1f CARBURETOR HEATER FLOAT PIN \ O-RING R k SLOW JET a\NEEOLE JET HOLDER MAIN JET SEALING WASHER D'APHRAGM/ COMPRESSION SPRING FLOAT CHAMBER FLOAT VACUUM PISTON FLOAT VALVE VALVE SEAT/FILTER VACUUM CHAMBER VACUUM CHAMBER COVER REMOVAL * ’ " ' Remove the four screws and vacuum chamber cover. ' SCREWS ' ' FUEL SVSTEM Remove the compression spring and diaphragm/Vac- uum piston. Check the piston for smooth operation up and down in the carburetor body. Turn the needle holder counterclockwise while press- ing it in and remove the holder flanges from the pis— ton grooves. Remove the needle holder, spring and jet needle from the vacuum pistonl INSPECTION Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. Check the diaphragm for damage, pin holes, wrinkles or bend. Replace these parts if necessary. Air will leak out of the vacuum chamber if the dia- phragm is damaged in any way even a pin hole. INSTALLATION Install the jet needle into the vacuum piston. Install the spring onto the needle holder and set the jet needle holder into the piston. Turn the needle holder clockwise while pressing it until it looks. Holder flanges and piston grooves should be fitted after turning. VACUUM PISTON' _ JET NEEDLE SPRING / DIAPHRAGM/ VACUUM PISTON DIAPHRAGM/VACUUM PISTON NEEDLE HOLDER 5-10 FUEL SYSTEM install the vacuum piston/diaphragm into the carbu- retor body by aligning the tab of the diaphragm with the cavity. Lift the bottom of the piston with your finger to set the diaphragm rib in the groove in the carburetor body. Align NOTE: - Be careful not to pinch the diaphragm, and to keep the spring straight when installing the chamber cover by compressing the spring. Install the spring and chamber cover while the piston remains held in place. Align the concave of the cover with the cavity in the carburetor and secure the cover with at least two screws before releasing the vacuum piston. Tighten the four chamber cover screws. @AT CHAMBER/PILOT SCREW REMOVAL Remove the four screws, clamp and float chamber. Remove the O»ring from the float chamber groove. No.7 (base: rear) Remove the throttle stop screw. carburetor only: SCREWS 5-11 FUEL SVSTEM Remove the float pin. float and float valve, Remove the following: — main jet —— needle let holder — slow jet — flout velve seat/filter and sealing washer Forpmperpilot Cover all openings with tape to keep particles out screw adjustment when the plugs are drilled. both pilot screws muslbe replaced Use extreme care when drilling into the pilot screw aver: ilonly ans plug to avoid damaging the pilot screw. requires it. Center punch the pilot screw plug to center the drill point. - Drill through the plug with a 4 mm (5/23 in) drill bit. v Attach a drill stop to the bit 3 mm (1/8 In) from the ' ‘ AWE SEAT/FILTER end to prevent drilling into the pilot screw. DRIVER Force the self-tapping 1 mm screw (H/C 069399, P/N SCREW FLIERS 93903-35410) into the drilled plug and continue turn- ing the screw driver until the plug rotates with the SCI'EW. Pull out the screw head with pliers to remove the plug Use compressed air to clean the pilot screw area and remove metal shavings, Turn each pilot screw in and carefully count the num- ber of turns until seats lightlyr Make a note of this to use as a reference when reinstalling the pilot screw. TOOL: Pllnt screw wrench 07KMA - M560101 Vhe pilot screws Remove the following: are {salary pre-set — pilot screw and shauld not be — spring removed unless — washer me carburetors — O—rlng are uVerhEuIed. Damage ta the pilot screw seat will occur if the pilot screw is tighten against the seat. 5-12 FUEL SYSTEM FLOAT VALVE INSPECTION Check the float for damage, deterioration or fuel in the float. Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination. A worn or contaminated valve does not seat properly and will eventually flood the carburetor. JETS/FILTEH/PILOT SCREW Check each jet for wear or damage. Clean the jets with non-flammable or high flash point solvent and blow open with compressed air. Check the filter for damage or clogging, and be sure the filter is securely installed onto the valve seat. > , ' Clean the filter with low pressure compressed air. 1 . , PILOT SCREW Check the pilot screw for wear or damage. Replace it if it is worn or damaged. 3’3, 1‘) FLOAT LEVEL V ' l.‘ . 5 Check the float level after checking the float valve, SLOW JET ' valve seat and float, VALVE SEAT» FILTER , Set the carburetor so that the float valve end just contacts the float arm lipt Be sure the float valve tip is securely in contact with the valve seat. Measure the float level with the float level gauge. TOOL: Float level gauge 07401 - 0010000 FLOAY LEVEL: 1.0 mm (0.28 in) If the level is out of specification and the float arm lip can be bent, adjust the float level by carefully bend- ing the lip. INSTALLATION Install the following: — new O-ring — washer — spring Install the pilot screw and return it to its original posi- tion as noted during removal. Perform the pilot screw adjustment if a new pilot screw is installed (page 5-22). Install the following: — new sealing washer and float valve seat/filter R... — slow jet — needle jet holder M __ — main jet SPR'NG 5-13 FUEL SYSTEM Nor irrearr carburetor only: Hang the float valve onto the float arm lip. FLOAT ’ f , V “' FLOAT VALVE Install the float valve with the float in the carburetor ‘ , __ , g ’ / body, then install the float pin through the body and float. Install a new O-ring into the chamber cover groove. Install the chamber cover with the clamp and tighten the four screwsr Install the throttle stop screw. AIR CUT-OFF VALVE RETAINER 1" , . COVER The air-cut off valve cover is under spring pres- sure. Do not lose the spnng and screws, REMOVAL Remove the two screws and retainer while holding the air cut-off valve cover, then remove the cover and spring. Remove the diaphragm and O-ring. Remove the sutrair cleaner hose joint if necessary SCREWS INSPECTION Visually check the following: —the diaphragm for deterioration or pin holes —the spring for deterioration —the needle of the diaphragm for excessive wear at the tip —the orifice of the air vent for clogging or restriction —the 0»ring for damage Blow open air passage in the cover with compressed air. ‘ DIAPHRAGM 5-14 FUEL SYSTEM INSTALLATION WNG Install a new O-ring with the flat side facing the car- if buretor bodvv Install the diaphragm and spring and air cut-off valve cover. Be sure the diaphragm and O—ring do not interfere with the cover. install the retainer and screws by holding the air out- off valve cover and tighten the screws, \ COVER CARBURE‘E‘OR SEPARATION Loosen the synchronization screw until there is no tension and remove the adjusting springe Remove the two connecting screws, Carefully separate the carburetors, then remove the thrust spring. ADJUSTING SPRiNG GARBURETOR CLEANING Separate the carburetors (see previous page), Remove all parts (diaphragm/vacuum chamber, float valve, all jets, pilot screw, air cut-off valve and sub While applying vacuum to the EVAP CAV control zzlx‘e vacuum port, pump air through the open air BLOCKED TUBE PRESSURE PUMP Air should flow through the EVA? CAV control valve and out the air vent port that goes to the carburetor air vent joint Plug the air vent port (No. 6 tube fitting) that goes to the carburetor air vent joint. While applying vacuum to the vacuum port, apply air pressure to the open air port. It should hold steady. Replace the EVAP CAV control valve if pressure is not retained. Remove the pumps and install the EVAP CAV control valve in the reverse order of removal. VACUUM PUMP §> 5-26 COOLING SYSTEM THE R M OSTAT RADIATOR RESERVE TANK WATER PUMP 6—0 6. COOLING SYSTEM SERVICE INFORMATION 6-1 THERMOSTAT 6-6 TROUBLESHOOTING 6—2 RADIATOR/COOLING FAN 6—8 SYSTEM TESTING 6-3 WATER PUMP 6-12 COOLANT REPLACEMENT 6-4 RADIATOR RESERVE TANK 644 SERVICE INFORMATION GENERAL AWARNING Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding. Always let the engine and radiator cool down before removing the radiator cap. NOTICE] Using coo/ant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages, Using tap water may cause origins damage, Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. Avoid spilling coolant on painted surfaces. After servicing the system, check for leaks with a cooling system tester. If any coolant gets in your eyes, rinse them with water and consult a doctor immediately, if any coolant is swallowed, induce vomiting, gargle and consult a physician immediately, - If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. - Referto section 19 for fan motor switch and thermosensor information. SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity "I" Radiator and engine 1.75 liters (1.35 us at. 154 Imp qt) Reserve tank 0A liter (0.42 US qt, 0.35 Imp qt) 'Radiator cap relief pressure 1 108 ~137 kPa(1.1— 1.4 kgf/om1,16 - 20 psi) Thermostat Begin to open ‘ 80 v 84°C (176 -183"F) Fully open 95°C (203°F) Valve lift 8 mm (0.3 in) minimum Recommended antifreeze Pro Honda HF coolant or an equivalent high quality ethylene glycol antifreele containing Sllicate-Iree corrosion inhibitors TORQUE VALUES Water pump bolt 13 NM (1.3 kgf~m, 9 lbf-ft) Radiator mounting bolt 1 N‘m (0.1 kgrm, 0,7 Ibf-ft) Fan motor switch 13 N-m (1.3 kgf-m,13|bfift) [139519-53 Thermosensor 8 N-m (0.8 kgrm, 5.8 lbf-ftl page 19-3 Drive chain guide plate bolt 12 N-m (1,2 mm, 9 lbf‘ft) 6—1 COOLING SYSTEM TROUBLESHOOTING Engine lemperamre too high ‘ Thermostat stuck closed ~ Faulty radiator cap » - lnsufficiem coolant - Passages blocked In radiator, hoses or Water jacket - Air in system - Faulty cooling fan motor - Faulty fan motor switch - Faulty waler pump Engine temperature mu law - Thermostat stuck open - Faulty fan motor switch Coolant leaks - Faulty water pump mechanical seal - Deteriorated O-rings - Faultv vadialor cap - Damaged or deteriorated cyllnder head gasket - Loose hose connection or clamp ' Damaged or deteriorated hoses 6-2 COOLING SYSTEM SYSTEM TESTING RADXATOH CAP COOLANT (HYDROMETER TEST) I Remove the fuel tank (page Z»2). The engine must Remove The radiator cap. be cool before removing the radiator cap, or severe scalding may result Test the coolant gravity using a hydrumeter, v STANDARD COOLANT CONCENTRATION: 50% Lonk for contamination and replace the coolant if necessal’Y- HyDRoMETER / XK // ~\ § fl Coolanuemper- a!uvs°C(°F) 0 5 r 10 15 20 25 30 35 40 45 50 Coolant ralio % 6-3 COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap. Wet the sealing surfaces of the cap, then install the cap to the tester. Excessive pres Pressure test the radiator cap using the tester. sure can damage Replace the radiator cap if it does not hold pressure, the cooling sysr or if relief pressure is too high or too low. It must tern components. hold the specified pressure for at least 6 seconds. Du not exceed . , . _ 137 kPa (1.4 RADIATOR CAP RELIEF PRESSURE: , , COOLING SYSTEM TESTER kgf/cm’, 20 psi}. 108— 131 k?! (1.1 — 1.5 kgflcmz, 16 —20 psi) (commercially available) ' Pressurize the radiator, engine and hoses using the tester, and check for leaks COOLING svsrm ? Repair or replace components if the system will not hold the specified pressure for at least 6 seconds. COOLANT REPLACEMENT The effectiveness of coolant decreases with the accu- mulation of rust or if there is a change in the mixing ANTIFREEZE proportion during usage. Therefore, for best perfor- SOLUTION mance change the coolant regularly as specified in the maintenance schedule. Mix only distilled, low mineral water with the (ETHVLENE GLYCOL antifreeze, BASE SOLUTION) Low MINERAL on DISTILLED WATER RECOMMENDED MIXTURE: 50 — 50 (dlstllled water and antifreeze) COOLANT RECOMMENDED ANTIFREEZE: Pro Honda HP coolant or an equivalent ethylene glycol antifreeze containlng sllleata-free corrosion inhlbitorsl NOTICE Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or block age of radiator passages. Using tap water may cause engine damage. REPLACEMENT/AIR BLEEDING NOTE: - When filling the system or reserve tank with coolant (be sure to check the coolant level), place the motorcycle in a vertical position on a flat level surface, Remove the fuel tank (page 2-2). Remove the radiatcr capt Drain the coolant from the system by removing the drain bolt and sealing washer on the water pump Coven Reinstal| the drain bolt with a new sealing washer. TORQUE: 13 N-m (1.3 kgf-m, 9 [MRI Remave the radiator reserve tank (page 6-14). Remove the reserve tank can from the reserve tank and drain the coolant. Drain the coolant and rinse the inside of the reserve tank with water. Install the radiator reserve tankt (page 6—14). Fill the system with the recommended coolant through the tiller opening up to the filler neck. Remove the reserve cap and fill the radiator reserve tank to the upper level linet Bleed air from the system as follows: 1. Shift the transmission into neutral. Start the engine and let it idle for 2 7 3 minutes. 2. Snap the throttle 3 — 4 times to bleed air from the system. 3. Stop the engine and add coolant to the proper level if necessary. Reinstall the radiator cap. 4. Check the level of coolant in the radiator reserve tank and fill to the upper level if it is low. COOLING SVSTEM DRAIN BOLT COOLING SVSTEM THERMOSTAT REMOVAL Drain the Ecolant (page (rd). Remove the air cleaner housing (page 5—31 Remove the sub-air cleaner (page 54). Remove the front cylinder right overhead cover l page 1011). Remove the thermostat housing mounting bolt with the ground terminal. Remove the thermostat housing cover bolts and cover. Remove the O-ring and thermostat. INSPECTION Visually inspect the thermostat for damage. Replace the thermostat if the valve stays open at room temperature Wearinsulated Heat the water with an electric heating element to gloves and ade- operating temperature for 5 minutes. quate eye prorez.» Suspend the thermostat in heated water to check its tian. operation Keep flammable materials away THERMOSTAT BEGINS TO OPEN: from the electric 80 - 34'0 (176 — 183'FI heating element. VALVE LIFI‘: Do not ler the 8 mm (0.3 in) minimum at 95°C (203°F) thermostat or thermometer Replace the thermostat if the valve responds at tem- touch the pan, or peratures other than those specified, you will get false readings. THERMOMETER 6-6 INSTALLATION Install the thermostat into the housing by aligning the housing groove as shown. Make sure the thermo- stat issecurely installed. Install a new Oiring into the housing. Install the thermostat housing cover with bolts and tighten the cover bolts securelvt Install the thermostat housing and tighten the mount- ing bolt with the ground terminal. Install the front cylinder right overhead cover (page 10~19L install the sub-air cleaner (page 5—4). Install the air cleaner housing (page 5-3it Fill and bleed the cooling system (page 374x COOLING SYSTEM COOLING SYSTEM RADIATOR/COOLING FAN REMOVAL Drain the coolant (page s4). Disconnect the fan momr switch 2P connector (Black). Release the fan motor switch wire from the wire band. Loosen the hose band and disconnem the lower radi- ator hose. Remove the rahietorrnounting bolt/washer, then pull out the radiatorr ' Loosen the hose band and disconnect the upper radi- akor hose Remove (he radiamr grille/radiator by releasing ihe mounting rubbers from the radiator stayi 2P CONNECTOR (Black) 6-8 COOLING SYSTEM DISASSEMBLY MOUNTING RUBBERS Remove the radiator mounting rubbers and radiator grille from the radiator. Disconnect the fan motor switch connector. Remove the fan motor assembly by removing the three bolts, wire clamp and ground termlnalv CONNECTOR Remove the fan nut and cooling fan SHRQUD COOLING FAN Remove the fan motor wires from the clamps of the shroud. Remove the three mounting bolts and fan motor. For fan motor switch information, refer to page 19»B. BOLTS 6-9 COOLING SVSTEM RADIATOR GRILLE ASSE M BLY RADIATOR COOLING FAN MOUNTING RUBEHS Install the fan motor onto the shroud and tighten the mounting bolts. Apply locking agent to the fan motor nut threads. Install the cooling fan onto the motor shaft by align- ing the flat surfaces. Tighten the fan nut. Clamp the fan motor wires secureiyt Install the fan motor assembly, ground terminal and wire clamp onto the radiator, then tighten the mount- ing boltst Clamp the fan motor wire and bend the wire clamp as shown Connect the fan motor switch connector. FAN MOTOR SWITCH WIRE C‘LAMP WIRE CLAMP GROUND TERMINA:/ SHROUD BOLTS CLAMPS \ CONNECTOR 6—10 COOLING SYSTEM holes with the bosses on the radiator. Install the radiator mounting rubbers to the radiator bosses. Install the radiator grille m the radiator by aligning its MOUNTING RUVBBEH INSTALLATION Hook the radiator mounting rubbers to the radiator stay. Connect the upper radiator hose and tighten the radi~ ator hose band. Connect the lower radiator hose and tighten the radi» ator hose band. LQyVER flOSE : , 6-1 1 COOLING SYSTEM Install the radiator mounting bolt/washer. men tighten ' ‘ v _ V '- ' BQLT/VVA.HER' to the specified torque. " ' TORQUE: 1 Nm (0.1 kg'm, 0.7 Ml!) Connect the fan motor switch 2P connector (Black). Set the tan motor wire lo the wire band. Fill and bleed the cooling system (page 6-6). Install the fuel tank (page 24). WATER PUMP MECHANICAL SEAL INSPECTION Inspect the telltale hole for signs 0! coolant leakage. If there is leakage, the mechanical seal is defective, and it should be replaced (see below). REMOVAL Remove the engine from the frame (see section 9). Remove the four bolts, clamp and water pump cover. 6-12 Remove the O-ring from the water pump body. Remove the drive chain guide plate hens and guide plate. Disconnect the water hose, then remove the water pumpbody from the crankcase. Remove the O-ying from the watet pump body. ASSEMBLY WATER PUMP O-RING SEALING WASHER INSTALLATION Coa‘ a new Oaring with engine oil and insxall it omo the stepped ponion of the water pump body Install the water pump body into the crankcase while aligning (be water pump shaft groove with the oil pump shaft end. “WATE’ HOSE ' * ,1 WATER PUMP COVER COOLING SYSTEM SEALING WASHER DRAIN BOLT COOLING SYSTEM Align the mounting bolts holes in the water pump and crankcase and make sure the water pump is securely installed. Route the oil pressure switch wire and neutral switch wire securely (page'l-‘lSL Install the drive chain guide plate and guide plate bolts. Connect the water hose and tighten the hose band securely. Install a new Orring into the groove in the water pump. Install the water pump cover, clamp and four mount- ing bolts, Tighten the drive chain guide plate bolts to the speci- fied torque. TORQUE: 12 Mm (1.2 kgfiml 9 let] Tighten the water pump bolts to the specified torque TORQUE: 13 Mn (13 km, 9 “7”!) Install the engine in the frame (see section Sit RADIATOR RESERVE TANK REMOVAL] INSTALLATION Remove the radiator/cooling fan (page 6-8). Disconnect the reserve tank over flow tube. Disconnect the siphon tube and drain the coolant. Remove the reserve tank can from the reserve tank and drain the coolant. Remove the mounting bolt, clip nut and reserve tank. Install the removed pans in the reverse order of removal. Fill the mdiator reserve tank with coolant (page e4). , BOLT. CLIP NUT 6-14 ENGINE REMOVAL/INSTALLATION BE N-m [9.0 kgf‘m, 65 lbf-m 5:1 N-m (5.5 kgf~m, AD Ibf'fl) 10 N-m (1.0 kgf-m, 7 IN“) 7-0 7. ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL SERVICE INFORMATION 7—1 ENGINE INSTALLATION 7—2 7-7 SERVICE INFORMATION GENERAL - A iloorjack or other adjustable support is required to support and maneuver the engine. (florfl Do not support the engine using the engine of! filter. - When removing/installing the engine, tape the frame around the engine beforehand for frame protection. 1 The following components require engine removal for service. 7 Oil pump (section 4) — Water pump (section 6) — Cylinder head (section 10) - Cylinder, piston (section 11) 7 Crankshaft/connecting rod (section 12) —- Transmission, gearshift drum, shift fork (section 12l — Crankcase (section 12l - The following components can be serviced with the engine in the frame. — Carburetor (section 5) - Clutch, gearshift linkage (section a) — Ignition pulse generator, primary drive gear (section B) — Alternator (section 9) —- Flywheel/starter clutch and starter reduction gear, idle gear (section 9) — Camshaft (section 10) — Starter motor (section 17) - swingarm pivot bolt removing/tightening procedure, see section 14, SPECIFICATIONS ITEM SPECIFICATIONS Engine dry weight 68.8 kg (151 lbs) Engine oil capacity after at disassemblv 2.9 liters (3.06 US qt, 2.55 Imp qt) Coolant capacity (radiator and engine] 175 liters (1.85 US qt, 1,54 Imp qt) TORQUE VALUES Front engine upper/lower mounting nut Rear engine mounting nut Front engine bracket bolt Rear engine bracket bolt Gearshift arm pinch bolt Drive sprocket fixing plate bolt Swingarm pivot nut Swingarm pivot adjusting bolt Swingarm pivot lock nut Radiator mounting bolt Starter motor cable nut Rear brake middle rod joint bolt Overhead cover bolt Pivot look not wrench 54 N-m (5.5 kgr-m, w ram) 54 Nrm (5.5 kgf-m, w |bf~ftl zs N-m (2.7 kgrm, 20 lot-ft) 25 Not (2.7 kgr-m, 20 (bi-m 12 N~m (1.2 Win» 9 (bin) 10 N-m (1.0 kgf-m, 7 Ibf‘ft) as N-rn (9.0 kgf—m, 65 Ibf-ft) 25 N-m (2.5 kgf-m, 18 [bf-ft) 64 N-m (6.5 kgf-m, 47 lot-ft) 1 N-m (0.1 kgf-m, 0.7 (th) 1o N-m (1.0 kgf-m, 7 lbi-ft) 34 N-m (3.5 kgf—m, 25 Ibf-ftl 12 N-m (1.2 kgf-m, 9 (arm 07GMA 7 K170200 U-nut. Not available in USA. 7-1 ENGINE REMOVAL/INSTAUATION ENGINE REMOVAL Remove the fuel tank (page 2~2). Drain the Eoolent (page 64). Drain the engine oil it the crankcase is to be serviced (page 3710). Support the motorcycle securely. Remove the following: — right side cover (page 2-3) — exhaust system (page 2-5) ~ subair cleaner (page 5-4) fl carburetor (page 5-5) ~ gearshift pedal/rod (page 340) — cylinder head fin (page 10—4) ~ crankcase breather cover (page 10-5) Remove the overhead covers. Disconnect the spark plug capsr Disconnect the ignition pulse generator 2P connector (White). Release the ignition pulse generator wire from the wire bandr Disconnect the side stand switch 2P connector (Green), Disconnect the neutral switch and oil pressure switch 2? connector (Rad), Disconnect the alternator 3P connector (White). Release the alternator wire, engine sub»herness (neu- tral switch and oil pressure switch wire) and side stand switch wire from the wire band. 2P CONNECTOR (Red) 7-2 Remove the bolt and clutch cable holder. then disr connect the clutch cable from the clutch lifter arm. Unhook the rear brake ligh‘ switch spring from the rear brake middle rod. Remove the rear brake pedal middle rod ioint bolt and unhook me brake pedal spring. Remove the brake pedal/rod and plain washer. Remove the nut and starter motor cable. Remove the bolx and starter motor ground terminal. Loosen the rear axle nut. Turn the drive chain adjus‘ers on both sides of the swingarm as necessary. Move the rear wheel forward fully, making me drive chain fully slack. ENGINE REMOVAL/INSTALLATION SPRING DRIVE CHAIN ADJUSTERS 7-3 ENGINE REMOVAL/INSTALLATION Remove the bolts and drive sprocket fixing plate. 'fixme FLAil'E Remove the drive sprocket. Remove the thermostat housing mounting bolt with the ground terminal. Disconnect the thermosensor connector. Remove the radiator mounting bolt/washer, then pull out the radiator‘ Loosen the hose band and disconnect the upper redi- ator hose. Remove the bolts and water hose pipes from the both cylinder heads. Remove the O-rings from the water hose pipesl WATER HOSE PIPE v; ENGINE REMOVAL/INSTALLATION Remove the thermostat housing assembly as shown. THERMOSTAT HOUSING Loosen the hose band and disconnect the water hose from the water pump. Release the side stand switch wire from xhe two clamps. 7-5 ENGINE REMOVALI|NSTALLATION During engine remavzl, hold me engine securely and be careful nut to damage the frame and engine. Place a floor jack ur other adjustable support under the engine. NOTE: , - The jack height must be continually adjusted to relieve stress for ease of bolt removal. Remove the front engine upper mounting nut. Remove the front engine tower mounting nut Remove the front engine upper mounting belt and cailar. Remove the front engine bracket bolts and bracket. Remove the front engine lower mounting bolt and two collars. Remove the rear engine mounting nut and bo|t. Remove the bolts and rear engine bracket UPPER MOUNTING NUT \‘ A, BRACKET 0LTs ,» /’ i / ENGINE REMOVAL/INSTALLATION NOTE: - Swingarm pivot bolt removing procedure, see page 14715. Remove the pivot bolt caps and swingarm pivot nut. Remove the swingarm pivot lock nut while holding the pivot bolt. TOOL: Pivot lock nu! wrench 07GMA — KTIBZOO Not available in USA. Loosen the swingarm adjusting bolt by turning the pivot bolt. Pull out the swingarm pivot bolt to remnve it, then remove the swingarm pivot collars and distance col- lar. . Remove the engine from the right side of the frame. . SWINGARM PIVOT LOCK NUT’ ENGINE lNSTALLATION NOTE: - Route the wires and tubes properly (page 148). - Finger tighten the mounting bolts and nuts, then tighten the bolts and num to the specified torque. Be sure to use the engine mounting bolts in their cor rect positions. Use a floor jack or other adjustable support to care- fully maneuver the engine into place. Carefully align the bolt holes in the frame and engine. ENGINE REMOVAL/INSTALLATION Use a floor jack or other adjustable support to care» fully maneuver the engine into placet Carefully align the bolt holes in the frame and engine‘ NOTE: - Swingarm pivot bolt tightening procedure, see page 14-20. Install the following: — swingarm pivot distance collar — swingarm pivot collars — swingarm pivot bolt — adjusting bolt — lock nut — pivot nut —— pivot bolt caps TOOL: Pivot lock nut wrench 07GMA — K170200 Not available in U.S.A. TORQUE: Swingarm pivot nut: 88 NM (9.0 kgf‘m, 65 lbl-ft] Swingarm pivot adjusting bolt: 25 NM (2.5 kgf‘m, 18 Ibflt) Swingarm pivot lock nut: 64 MI" (6.5 kgf'm, 47 let) Install the rear engine bracket and bracket bolts, Install the rear engine mounting bolt and nut. 7-8 ENGINE REMOVAL/INSTALLATION Install the two collars and from engine lower mountr , ing bolt. Install the front engine bracket and bracket bolts. Install the collar and from engine upper mounting bolt. install the front engine lower mounting nut. Install the front engine upper mounting nut. Tighten all the engine bracket bulls and mounting balls/nuts to the specified torquel TORQUE: Front engine upper/lower mounting nut 54 N~m (5‘5 kgf~m, M) Ibf-fi) Rear engine mourning nut: 54 MM (5.5 kgim, 40 lbf'ft) Front engine bracket bolt: 26 N-m (2.7 kgl-m, 20 Ibl-H) Rear engine bracket bolt: 26 N~m [2.7 kghn, 20 left) Clamp the side stand switch wire to the wire clamps and route the side stand switch wire properly (page 1-18), Connect the water hose to the water pump and tighten the hose band. ENGINE REMOVAL/INSTALLATION Install the thermostat housing assembly as shown. Coat the new Oerings with coolant and install them onto the water hose pipes. Connect the water hose pipes to the both cylinder headst Install and tighten the water hose pipe bolts. Connect the upper radiator hose and tighten the hose band. Install the radiator mounting bolt/washer, than tight- en to the specified torque. TORQUE: 1 Min (0.1 kgfm, 0.7 lbflt) Connect the thermosensor connector. Install the thermostat hausing and tighten the mountr ing bolt with the ground termmaL THERMOSTAT HOUSING CONNECTOR 7-10 ENGINE REMOVAL/INSTALLATION Install the drive chain to the drive sprocket. lnstall the drive sprocket to the countershaft with the markiacing out. Align the drive sprocket fixing plate tooth and coun- tershaft groove, then install the fixing plate Install and tighten the drive sprocket fixing plate bolts to the specified torque TORQUE: 10 N-m (1.0 kgf-m, 7 let) Connect the starter motor ground terminal with the bolt and tighten the bolt. Connect the starter motor cable. Tighten the nut to the specified torque. TORQUE: 10 N~m (LO kgl-m. 7 IM-h) Install the plain washer and brake pedal/rod with the middle rod joint bolt. Tighten the middle rod joint bolt to the specified torque‘ TORQUE: 34 Nm (3,5 kgf-m, 25 IbMt) Hook the brake pedal springr Hook the clutch cable end to the clutch lifter arrn, then install the clutch cable holder with the bolt. Hook the rear brake light switch spring to the rear brake middle rod. SPRING 7-11 ENGINE REMOVAL/INSTALLATION Home the wires properly (page 1- 18). Route the wires Set the alternator wire, engine subrharness (neutral switch and oil preesure switch wiresl and side stand switch wire to the wire band. and set the starter motor cable and ground Cable. Clamp all wires to the wire band. Connect the alternator 3P connector (White). Connect the neutral switch and oil pressure switch 2? connector (Red). Connect the side stand switch 2F connector (Green). Connect the ignition pulse generator 2? connector properly (White). lpaga 1- 13), Set the ingintion pulse generator wire to the wire band. Install the following: — gearshift pedal/rod (page 8~20l — crankcase breather cover (page 10-17) — sub—air cleaner (page 5-4) — carburetor (page 5-15) — cylinder head fin (page 10—18) — exhaust system (page 2-6) — right side cover (page 2-3) Connect the spark plug caps. Install the overhead covers. TORQUE: Over head cover bolt: 12 N1“ ".2 kgfm, 9 Ibfft) Fill the crankcase with recommended engine oil it drained (page 3—10). Fill and bleed the cooling system (page 6-4). Install the fuel tank (page 2-2). Adiust the following: 7 clutch lever free play (page 3‘20) 7 drive chain slack (page 3—15) 3F CON N ECTOR (White) 2P CONNECTOR (Green)v 2P CONNECTOR (Red) _.._.—__I 2P CONNECTOR (White) ' 7-12 CLUTCH/GEARSHIFI’ LINKAGE 88 NW (9.0 kgf-rn, 65 lbf-h) 8—0 8. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 8-1 GEARSHIFT LINKAGE 8-12 TROU BLESHOOTING 8-2 CLUTCH INSTALLATION 8—14 RIGHT CRLANKCASE COVER RIGHT CRANKCASE COVER REMOVAL 8-3 INSTALLATION 8-18 CLUTCH REMOVAL 8-4 GEARSHIFT PEDAL/ROD 8-20 PRIMARV DRIVE GEAR 8-9 SERVICE INFORMATION GENERAL - The clutch and gearshift linkage parts can be serviced with the engine installed in the frame. ' Engine oil viscosity and level and. the use of oil additives have an effect on clutch disengagement. Oil additives of any kind are specifically not recommended. when the clutch does not disengage or the motorcycle creeps with the clutch disengaged, inspect the engine oil viscosity and level before servicing the clutch system. - The crankcase must be separated when the transmission, shift drum and shift forks require service (see section 12). SPECIFICATIONS Unit: mm (Inl .. ITEM STANDARD SERVICE LIMIT Clutch lever free play 10 — 20 (0.375 — 0.750) — _C|u£ch_spring free length 45.5 (1.79) 43.9 H.733) Clutch disc thickness A 2.62 — 2.78 (0.103 — 0.107) 2.3 (0.09) B 2.92—3.03 ((1115—0121) 2.3 (0.10) Clutch plate warpage . . _ — 0.3010012) Clutch outer guide I |.D. ., ., V721,99‘I—22.016(0.8658 — 0.8668) 22.03 (0.867) 29394—30007 (1.1803— 1.1304) 29.9BI1JBO) . g 30.025—30.145(1.1821—1.1868) 30.15I1.187) Mainshaft CD. at clutch outer guide 21.967 — 21.980 [0.8648 — 0.8654) 21.95 (0.564) TORQUE VALUES Clutch lifter plate bolt 12 N-m (1.2 kgf‘m, 9 Ibf~ftl Clutch center lock nut 127 N-m (13.0 kgfrm, 94 lbf-ftl Apply oil to the threads and seating surface, Stake. Primary drive gear bolt 88 N‘m (9,0 kgf-m, 65 |bf~ft) Apply oil to the threads and seating surface. Oil pump driven sprocket bolt 15 Nrm (1.5 kgfrm, 11 Ibf-ftl Apply locking agent to the threads. Gearshift arm pinch bolt 12 Nrm (1.2 kgf~m, 9 Ibf-ft) Gearshift pedal pivot bolt 34 N-m (3.5 kgfvm, 25 |bf~ftl Gearshift return spring pin bolt 23 N»m (2.3 kgf~rn, 17 Inf-ft) TOOLS Gear holder 07724 — 0010100 Not available in USA. Attachment, 37 x 40 mm 07746 A 0010200 Pilot, 30 mm 077116 7 0040700 Driver 07749— 00100000 Clutch center holder 07JMB— MN50301 -—0r 07HGB A 001000A (U.S.A. only) or 07HGB°r001010A and Holder collars "A" 07HGB— 0010205 or (Set of 4) 07HGB 001020A Holder plate 07HGB 0010103 (U. S. A. ocmly) l j 8-1 CLUTCH/GEARSHIFI' LINKAGE TROUBLESHOOTING Clutch lever too hard - Damaged, kinked or dirty clutch cabIe ' Improperly routed clutch cable ' Damaged clutch lifter mechanism - Faulty clutch lifter plate bearing Clutch will nnt disengage or motorcycle creeps with clutch disengaged ‘ Too much clutch lever free play - Warpage clutch plate - Loose clutch center lock nut - Engine oil level too high, improper oll viscosity or all additive used clutch slips - Clutch lifter sticking - Worn clutch discs - Weak clutch springs - No clutch leverfree play - Engine oil level too low or oil additive used Hard to shift Improper clutch operation Incorrect engine oil viscosity Incorrect clutch adjustment Bent or damaged gearshift spindle - Damaged shift drum cam grooves (section 12) - Bent shift forks or fork shaft (section 12). Transmission jumps out of gear ~ Broken shift drum stopper arm ' Broken gear shift linkage return springs - Damaged shift drum cam grooves - Bent shift fork shalt (section 12) - Worn or bent shift forks (section 12) - Worn gear dogs or slots (section 12) CLUTCH/GEARSHIFI' LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3—10). Remove the exhaust system (page 2-5). Remove the bolt and clutch cable holder, then disV connect the Clutch cable from the clutch lifter arm‘ Unhouk the rear brake light switch spring from the rear brake middle rod. Remove the cover Dads and right crankcase cover. Remove the dowel pins‘ DISASSEMBLV Remove the clutch lifter red by turning the like! arm clockwise‘ 8-3 CLUTCH I GEARSHIFI' LINKAGE Remove the snap ring and return spring. Remove the clutch lifter arm. INSPECTION Check the dust seal for fatigue or damage. Check the needle bearing for wear, damage or loose fit, Check the clutch lifter arm for damage or bending. Check the return spring for fatigue or damage. Replace these parts if necessary. CLUTCH REMOVAL Remove the right crankcase cover (see previous Page). Loosen the clutch lifter plate bolts in a crisscross pat- tern in two or three steps, and remove the bolts, clutch springs and litter plate. It the clutch outer guide wlll be removed, loosen the driven sprocket bolt while the clutch is still installed. Unstake the clutch center lock nut to avoid damaging the mainshaft threads. I SFROCKET BOLT .P". Llfirémm” NEEDLE‘éEARWG—s" 8-4 CLUTCH/GEARSHIFI' LINKAGE Hold the pressure plate with the clutch center holder and loosen the clutch center lock nun TOOLS: clutchoenter holder 07JMB — MN50301 or 07HGB - 001000}! (U.S.A. only) or Holder pla‘e 07HGB — 0010103 or 07HGB — 001010A lu.s.Al only) and Holder collars 'A' 07HGB —- M10205 (set of 4) or 07HGB — 001020A (U. . only) Remove the lock nut. Remove the lock washer and plain washer. Remove the following: — clutch center ~— iudder spring, spring seat — clutch discs — clutch plates — pressure plate Remove the thrust washer and clutch ouxer. CLUTCH/GEARSHIFI LINKAGE Remove the oil pump driven sprocket bolt and washert Remove the oil pump driven sprocket, drive chain and drivesprocket as a set. Remove the clutch outer guide fmm the mainshaft. INSPECTION CLUTCH LIFTER PLATE BEARING Check the lifter plate bearing for damage Turn the bearing inner race with your finger, The bearing should turn smoothly and quietly without play, Also check that the bearing outer race fits tightly in the plate. Replace the hearing it necessary. Replace the CLUTCH SPRING clutch springs as Measure the clutch spring free length a set. SERVICE UMIT: “.9 mm (1.73 in) SPRING 8-6 CLUTCH/GEARSHIFI' LINKAGE Replace the discs CLUTCH DISC andplates as .9 Check the clutch discs for signs of soaring or discolv set. oration. Measure the thickness 0! clutch discs A and B. SERVICE LIMITS: Disc A: 2.3 mm (0.09 in) Disc B: 2.6 mm (0.10 in) Replace the discs CLUTCH PLATE and plates asa Check the clutch plate for excessive warpage or dis- set. coloration. Check the plate warpage on a surface plate using a Ieeler gauge, SERVICE LIMIT: 0.30 mm (0.012 in) CLUTCH OUTER GUIDE Measure the clutch outer guide ID. and OD. SERVICE LIMITS: I. 72.03 mm [0.867 in) 0. .. 29.98 mm (1.180 in) OIL PUMP DRIVE SPROCKET Check the oil pump drive sprocket for damage. Measure the drive sprocket LD. SERVICE LIMIT: 30115 mm [1.187 in] JUDDER SPRING, SPRING SEAT Check (he judder spring and spring sea! for distor- tion, wear or damage. JUDDER spm . é? mg SEAT 8-7 CLUTCH/GEARSHIFI' LINKAGE MAINSHAFI' Measure the mainshaft O.D‘ at the clutch outer guide. SERVICE LIMIT: 21.95 mm (0.864 in) CLUTCH CENTER Check the clutch center for nicks, indentations or abnormal wear made by the clutch plates. CLUTCH OUTER Check the primary driven gear teeth for wear or dam» age. Check the slots in the clutch outer for nicks. indenta- tions or abnormal wear made by the clutch discs. Check the needle bearing far damage. The bearing should turn smoothly and quietly with» out play, Also check that the bearing cuter race fits tightly in the clutch outer. Replace the hearing if necessary (see next pageL CLUTCH/GEARSHIFI' LINKAGE CLUTCH OUTER NEEDLE BEARING ATTACHMENT REPLACEMENT , ' Press the needle bearing out of the clutch uuter. Press the new needle bearing into the clutch outer with the mark facing out. The needle bearing outer surface is 1.0 mm (0.03 in) be|ow the outer edge of the clutch outer needle bear- ing cavity. TOOL: Drive: 07749 — 0010mm Anachmem, 37 x 40 mm 07746— amazon Pilot. 30 mm 07746 — (mom: 1.0 mm NEEDLE BEARING PRIMARY DRIVE GEAR REMOVAL Remove the clutch (page 8—4), Remove the ignition pulse generator mounting bolts. Remove the ignition pulse generator and wire grom- mete, Temporarily install the clutch outer onto the main- shaft. (page 844). Hold the primary drive gear with the gear holder. Loosen the primary drive gear bolt to avoid damag~ ing the ignition pulse generator rotor. TOOL: Gear holder 07724 — 0010100 Not available in USA. 8-9 CLUTCH I GEARSHIFT LINKAGE Remove the clutch outer. Remove the primary drive gear bolt and washer. Remove the ignition pulse generator rotor. Remove the following: — primary drive sub-gear — friction spring — primary drive gear and springs INSPECTION Check the serrated teeth of the primary drive gear and sub»gear for wear or damage. Check the primary drive gear spring and friction spring for fatigue or damage. INSTALLATION Be sure to install the springs into the primary drive gear grooves. Install the friction spring, Set the sub-gear onto the drive gear by aligning the three holes on the sub—gear and primary drive gear, and contacting the sub-gear tabs against the drive gear springs. SPRINGS 8—10 CLUTCH/GEARSHIFI' LINKAGE Install the primary drive gear assembly by aligning the wide groove with the wide tooth, Apply engine oil to the primary drive gear bolt threads Install the ignition pulse generator rotor by aligning the wide groove with the wide tooth. Install the primary drive gear bolt and washer and loosely tighten the bolt‘ Temporarily install the clutch outer (page 8-14), Hold the primary drive gear with the gear holder. Tighten the primary drive gear bolt to the specified torque TOOL: Gear holder 07724 — 0010100 Not available in U.$.A. TORQUE: 88 N-m (9.0 kgf-m. 65 le'tl Apply locking agent to the ignition pulse generator bolt thread, Install the ignition pulse generator and tighten the mounting bolts securely. Apply sealant to the wire grommets and install them to the crankcase groove securelyt install the clutch (Page SJAL 8-11 CLUTCH/GEARSHIFI' LINKAGE GEARSHIFI' LINKAGE REMOVAL Remove the clutch (page 8—4). Remove the left crankcase rear cover (page 2-3). Remove the gearshift arm pinch bolt and gearshift arm from the gearshift spindle. Remove the oil pipe stay mounting bolt and oil pipe/stay. Remove the O-ring from the oil pipe/stay, Pull out the gearshift spindle from the crankcase while unhooking the shifter arm from the gearshift cam plate. Remove the gearshift cam plate bolt and cam plate. Remove the dowel pin from the gearshift drum. M“ " I CAM PLATE 8-12 Remove the following: 7 stopper arm bolt — washer 7 stopper arm 7 return spring 7 collar INSPECTION Check the gearshift spindle for wear or damage. Check the return spring for fatigue or damage. INSTALLATION Install the following: — collar — return spring — stopper arm — washer — stopper arm bolt Install the dowel pin into the gearshift drum, Install the cam plate by aligning the hole in the cam plate with the dowel pin while lift up the stopper arm with a screwdriver. Apply a locking agent to the cam plate bolt threads and install it. Tighten the stopper arm bolt and cam plate bolt securelvt CLUTCH/GEARSHIFT LINKAGE 8-13 CLUTCH/GEARSHIFI' LINKAGE Install the gearshift spindle into the crankcase by aligning the return spring ends with the return spring pin bolt to avoid damaging the spindle oil seal (left crankcase side). Cost 8 new O-ring with engine oil and install it onto the oil pipe/stay groove. Install the oil pipe/stay with the mounting bolt and tighten the bolt securely. Install the gearshift arm to the gearshift spindle by aligning the punch mark on the spindle with the cutout in the gearshift arrnt install and tighten the gearshift arm pinch bolt to the specified torque, TORQUE: 12 Nm (1.2 kgf~m, 9 IM-ftl Install the left crankcase rear cover (page 2-3lt Install the clutch (see below)‘ CLUTCH INSTALLATION Im OUTER GUID , .t 19 Apply molybdenum oil solution to the outer surface of the clutch cuter guide and install it to the main- shaft. 8-14 Install the oil pump driven sprocket with the ”IN " mark facing inside. Install the oil pump drive sprocket, drive chain and driven sprocket as a set. Apply locking agent to the driven sprocket bolt threads and install it with the washerl NOTE: . Tighten the driven sprocket bolt, after installing the clutch assembly. Install the clutch outer by aligning the holes in the clutch outer with the pins on the oil pump drive sprocket while turning the oil pump driven sprocket. Be sure to install the clutch outer securely by aligning the primary drive gear and sub-gear teeth with a slot- ted head screwdriver. NOTE: - Align the holes in the clutch outer with the pins on the oil pump drive sprocket while turning the driven sprocket with the drive chain and pushing the clutch outer onto the mainshaft. Install the thrust washer unto the mainshaft. CLUTCH/GEARSHIFF LINKAGE CLUTCH/GEARSHIFI' LINKAGE Coat the clutch discs with engine oil. Install the Spring seat and judder spring to the clutch center as shown. CLUTCH OUTER Install the seven clutch discs A and seven clutch THRUST WASHER plates and one clutch disc B alternately, starting with a disc B to the clutch center‘ Install the pressure plate, clutch discs, clutch plates PRESSURE PLATE judder spring, spring seat and clutch center as a set to the clutch outer. SPRING SEAT JUDDER SPRING CLUTCH PLATES BCLUTCH DISCS A ECLUTCH DISC B CLUTCH CENTER When installing the clutch disc B, align the end grooves in the clutch outer with the tabs of disc, CLUTCH ”'3‘: B Install the plain washert Install the new lock washer with the "OUT SIDE” mark facing out. lg? L999: WASHByai 8-16 Apply engine oil to the threads of the new clutch cenr ter luck nut, and install and loosely tighten it. Hold the clutch pressure plate with the clutch center holder and tighten the clutch center lock nut to the specified torque. TOOLS: Clutch center holdel 07JMB — MN'50301 or 07HGB — 001000A lU.S.A. only) or Holder plate 07HGB — 0010103 or 07HGB — 001 01 0A (U.S.A. only) and Holdzr collars "A" 07HGB ~ 0010208 (set M 4) or 07HGB — 001020A (USA only] TORQUE: 127 Mm (13.0 kgf~m, 94 lbf‘fll Stake the lock nu! into the mainshafl groove. Install the clutch springs and clutch lifter plate with the bolts. Tighten the clutch lifter plate bolts in a crisscross pat- tern in several steps. TORQUE: 12 Nm (1,2 kgf‘m, 9 lbl-ft) if the oil pump driven sprocket is removed, tighten the drlven sprocket bolt to the specified torque. TORQUE: 15 Nm ”.5 kgf-m, 11 lbm) Install the right crankcase cover (see next page). CLUTCH/GEARSHIFT LINKAGE CLUTCH/GEARSHIFI' LINKAGE RIGHT CRANKCASE COVER [’7ENEEDLE BEARIGS INSTALLATION ‘ , _; ASSEMBLY Apply engine oil to the clutch lifter arm needle bear- ings and dusl seal lips. Apply engine oil to the clutch lifter arm sliding sur» face and insmll it into the right crankcase cover. lnslall the return springl _ Install ma snap ring to the lifter arm shah groove securely. NOTE: - Make sure the return spring and is hooked in the case cover tab by turning the clutch lifter arm shaft. Apply engine oil lo the :lulch lifter rod sliding sur- face. Turn the clutch lifter arm clockwise and install the lifter rod by aligning the rod end with the groove in the clutch lifter arm shah, 8-18 INSTALLATION Clean the right crankcase and right crankcase cover mating surfaces thoroughly, being careful not to damage tharn. Apply a thick coating of liquid sealant to the right crankcase cover side. Install the dowel pins install the right crankcase cover with ths cover bolts. Hook the clutch cable end to the clutch lifter arm, then install the clutch cable holder with the bolt. Tighten the right crankcase cover bolts in a crisscross pattern in several steps Hook the rear brake light switch spring to the rear brake middla (0d. Install the exhaust system (page 2-3). Fill the engine oil (page 3-10). Fen‘orrn the clutch system adjustment (page 3-20), CLUTCH/GEARSHIFI' LINKAGE J‘m CLUTCH/GEARSHIFI' UNKAGE GEARSHIFI' PEDAL] ROD REMOVAL Remove the left cmnkcase rear cover (page 273), Remove the gearshift arm pinch bolt and gearshift arm from the gearshift spindlet Remove the pivot bolt, cap nut and gearshift pedal/rod from the frame. INSTALLATION Apply grease to the gearshift pedal pivot bolt sliding area, Install the gearshift pedal/rod with the plvnt bolt Install the cap nut and tighten the pivot bolt by holdr ing the nut TORQUE: 34 MM (3.5 kgfim, 25 IBM!) Install the gearshift arm to the gearshift spindle by aligning the punch mark on the spindle with the cutout of the gearshift arm. Install and tighten the gearshift arm pinch bolt to the specified torque. TORQUE: 12 N-m l1 2 Raf-m. 9 IM-fll Install the left crankcase rear cover (page 2-3), PIVOTB LT. I CAP N UT 8-20 ALTERNATO RI STARTER CLUTCH 127 N-rn (13.0 kgV-m,941bf-ft) 9-0 9. ALTERNATOR/STARTER CLUTCH SERVICE IN FORMATION TROUBLESHOOTING LEFT CRANKCASE COVER REMOVAL 9-1 STATOR REPLACEMENT 9~2 9-1 LEFI' CRANKCASE COVER INSTALLATION 9-3 9-2 FLYWHEEL, STARTER CLUTCH 9-4 SERVICE INFORMATION GENERAL This section covers service of the alternator stator, flywheel and starter clutch. These parts can be serviced with the engine installed in the frame. - Refer to section 16 [or alternator stator inspection. ' Refer to section 18 for starter motor servicing. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter driven gear LD. "Thoma—40.021 (15748— 1.5756) 40.10 (1.579) n 0.0. 574759 — 57768 (2.2736 — 22743) 57.73 (2.273) istaflzr clutch outer I.Dr ‘ 74.414 — 740440 (2.9297 — 2.9307) 74.46 (2.931) TORQUE VALUES Flywheel bolt Stator mounting bolt Stator wire holder bolt Starter clutch housing bolt Drive chain guide plate bolt Left crankcase rear cover bolt TOOLS Flywheel holder Rotor puller TROUBLESHOOTING Engine does not turn - Faulty starter clutch - Damaged starter reduction gear - Damaged starter idler gear 127 NP" (13.0 kgftm, 94 lbf-ft) l2 N'm (1‘2 kgftm, 9 lbirft) 12 N-m (1.2 kgf‘m, 9 leO 29 N-m (3.0 kgf‘m, 22 Ibi-ft) 12 N-m (1.2 kgf~m, 9 [bf-ft) 12 N~rn (1.2 kgf-m, 9 |bi~ftl 07725 — 0040000 07733 - 0020001 Apply oil to the threads and seating surface Left-hand threads Apply locking agent to the threads, Apply locking agent to the threads Apply locking agent to the threads. or equivalent commercially available in U.S.A. or 07933 — 32800!“ 9-1 ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the seat (page 2—2). Remove the left crankcase rear cover (page 2-3). Release the alternator wire from the wire band. Disconnect the alternator 3P connector (White) in the connector boot. Be careful during Release the side stand switch wire from the two wire removal, clam ps. because the Iell Remove the eleven cover bolts and two wire clamps. crankcase cover Remove the drive chain guide plate bolt (upper bolt (stator) ls magi only), then remove the left crankcase cover. nstically attached to the flywheel. Remove the dowel pins. STATOR REPLACEMENT REMOVAL Remove the stator wire holder bolt and holder. Remove the stator wire grommets from the crankcase cover groove. Remove the four stator mounting bolts and stator. STATOR 9-2 ALTERNATOR/STARTER CLUTCH INSTALLATION GROMMETS STATO R LEFT CRANKCASE COVER Apply locking agent to the stator mounting bolts and wire holder bolt threads, Route the stator wire properly, then install the stator to the left crankcase cover with the mounting bolts. Tighten the stator mounting bolts to the specified torque. TORQUE: 12 Nm (12 kgf'm, 9 lbf-It) Apply sealant to the wire grommets and install them to the left crankcase cover groove securelyt Install the wire holder with the bolt and tighten it specified torquet TORQUE: 12 N-rn (1.2 kgf‘m, 9 lbf-ftl LEFI' CRANKCASE COVER INSTALLATION Clean the left crankcase and left crankcase never met- ing surfaces thoroughly, being careful not to damage them. Apply a thick coating of liquid sealant to the left crankcase cover side. 9-3 ALTERNATOR/ST ART ER CLUTCH Be careful during installation, benause the left crankcase cover (stator) is magr netiL-ally attached to the flywheel. Install the dowel pins. Install the left crankcase cover. Apply locking agent to only the specified crankcase cover bolt as shown. Install the 2 wire clamps and 11 crankcase cover bolts. Tighten the left crankcase cover bolts in a crisscross pattern in several steps Install and tighten the drive chain guide plate bolt to the specified torque. TORQUE: 12 Min (1.2 kgt-m, 9 "7"!) Clamp the side stand switch wire to the wire clamps and route the alternator wire properly (page 1-18), Connect the alternator 3P connector (White). Set the alternator wire to the wlre band. Install the left crankcase rear cover (page 2»3)‘ Install the seat (page 2-2). FLYWHEEL, STARTER CLUTCH FLYWHEEL REMOVAL Remove the left crankcase cover (page 92x Remove the starter idler gear and shaft. Remove the starter reduction gear and shaft. 9-4 ALTERNATOR/STARTER CLUTCH Hold the flywheel with the flywheel holder. FLYWHEEL HOLDER .7 file flywheel Remove the flywheel bolt and washer. ‘ ‘ ban has left hand threads. TOOL: Flywhgel hnlder 07725 — 0040000 or equivalent wmmetcially available in U.S.A. Remove the flywheel and starter driven gear using the rotor pullert TOOL: Rotor puller 07733 — 0020001 or 07933 — 3290001 lu.s.A. only) Remove the needle bearing‘ Remove the woodrufi key from the crankshaft to avoid damaging the crankshaft. Check the needle bearing for abnormal wear or dam- age, replace if necessary STARTER DRIVEN GEAR, STARTER CLUTCH HOUSING REMOVAL ONE-WAV CLUTCH OPERATION Vou should be able to turn the staner driven gear counterclockwise smoothly, but the driven gear should not turn clockwise. Remove the starter driven gear from the flywheel while turning the driven gear counterclockwise. ALTERNATOR/STARTER CLUTCH Do nut remove the clutch hous- ing, unless it is "906582” to inspect it. If the starter clutch our" replacement is necessary, replace Ina clulch auter and ans-way clutch as a sat. Hold the flywheel with the flywheel holder. Remove the starter clutch housing bolls. TOOL' . Flywheel holder 07725 — 0040000 or owivalom wmnma'alw avlllable in USA Separate the starter clutch housing from the Ilv» wheel. Remove tha one-way clutch from rho stuner clutch outer, being careful that the spring does not come of! the one-way clutch. lithe spring was out of the clutch groove, replace the one-way clutch (clutch and spring) as an assembly when innulling. STARTER CLUTCH OUTER INSPECTION ONE-WAY CLUTCH Chuck the one—way clutch snrag Ior abnormal wear, damage or irregular movement STARTER CLUTCH OUTER Check the sxaner clutch outer inner contact surface for abnormal wear or damage. Measure (he stanev clutch outer I.D. SERVICE LIMIT: 74.46 mm (2.881 in) 9-6 STARTER DRIVEN GEAR INSPECHDN Check the roller contact su rlaoe for abnormal wear or damage. Measure the starter driven gear I.DV SERVICE LIMITS: 57.639 mm (2.2692 in) STARTER REDUCTION GEAR Check the starter reduLtion gear, shaft and journal for abnormal wear or damage: STARTER IDLER GEAR Check the starter idler gear, shaft and journal for abnormal wear or damage. STARTER DRIVEN GEAR, STARTER CLUTCH HOUSING INSTALIATION Make sure the spring is held into the groove in the one~way clutch. Apply engine oil to the one-way clutch sprag and install the one-way clutch into the starter clutch outer with the flaged side facing the flywheel, Make sure the spring does not come off the one-way clutch. Apply locking agent to the starter clutch housing bolt threadsr Install the starter clutch housing onto the flywheel with the bolts. STARTER DRIVEN GEAR ALTERNATOR/STARTER CLUTCH STARTER CLUTCH HOUSING FLYWHEEL ID‘LER GEAR ALTERNATOR] STARTER CLUTCH Hold the flywheel with the flywheel holder. Tighten the starter clutch housing bolts to the speci- fied torque. TOOL: . Flywheel huIder D7725 - 0040000 or equivalent commercially available in U.S.A. TORQUE: H N-m (3.0 kgl-m, 22 Ibfvft) Install the starter driven gear to the flywheel while turning the driven gear counterclockwise. FLYWHEEL INSTALLATION Clean the tapered area of the crankshaft with a degreasing agent and wipe it off completely. Install the woodruff key in the key groove of the crankshaft. Apply engine oil to the needle bearing and install it to the crankshaft. Clean the tapered area of the flywheel with a degreasing agent and wipe it off completely Set the flywheel over the crankshaft by aligning the its groove with the woodruft key and install it. 9-8 ALTERNATOR/STARTER CLUTCH The flywheEI Apply engine oil to the flywheel bolt threads and bolt has Iefi- install it with the washer. hand threads, Hold the flywheel and tighten the flywheel bolt to the specified torque. TOOL: Flywheel holdef 07725 — 0040000 nr equivalent commercially available In U.S.A, TORQUE: 127 Mm (13.0 kgf-m, 94 lefi Apply engine oil to the starter reduction gear shaft and idler gear shaft outer surfaces. Install the starter idler gear with the ”OUT" mark fat} ing out and install the shaft Install the starter reduction gear and shaft. Install the left crankcase cover (page 9-3), 9-9 CYLINDER HEAD/VALVE 10 N-m (1.0 kgf‘m, 7 Ibf‘ft) 23 N-m (23 kgf~m, 17 mm) 12 N-rn (1.2 kgf~m, 9 [bf-ft) 23 Nrm (2.3 kgf-m, 17 lbf-ft) 10 N~m (1.0 kgf-m, 7 Ibfrft) 10 N-m (1,0 kgf~m, 7 lb'Ht) 10—0 10. CYLINDER HEAD/ VALVE SERVICE INFORMATION TROUBLESHOOTING CYLINDER COMPRESSION 1 0-1 1 0-2 1 0-3 CYLINDER HEAD COVER REMOVAL CAMSHAFT CAMSHAFI' HOLDER CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD REMOVAL 10-19 CYUNDER HEAD DISASSEMBLY 10-20 VALVE GUIDE REPLACEMENT 10-23 10-4 VALVE SEAT INSPECTION/REFACING 10-24 10-6 CYIJNDER HEAD ASSEMBLY 10-27 CYUNDER HEAD INSTALLATION 1 0-28 10-16 SERVICE INFORMATION GENERAL . This section covers service of the cylinder head, valves and Camshafts. - The camshaft can be sen/iced with the engine installed in the Irarne. ~ Tu service the cylinder head and valves, the engine must be removed from the frame. - When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tions. - Clean all disassembled parts with cleaning solvent and dry them by bowing them off with compressed air before inspection. - Pour clean engine oil into the oil pockes in the cylinder head during assembly to lubricate the camshaft. - Be careful not to damage the mating surfaces when removing the head cover and cylinder head. SPECIFICATIONS Unit: mm (In) ITEM STANDARD SERVICE LIMIT Cylinder compression 1.275 t 90 kPa (13.0 21.0 kaI cmZ, _ l 185 i 14 psi) at 400 rpm Cylinder head werpage 0.1010004) 'Valve, W“, 6.33;,“ "" IN 015 a 0.02 (0.006 1 0.0003) — "”9 guide Ex 0.20 z 0.02 (0,003 1 0.0003) — valve stem 03, IN i 5.475 - 5.490 (0.2156 — 0.2161) 5.45 (0.215) EX ; 6.600 — 6.615 (0.2598 - 0.2604) 6.55 (0.250) Valve guide (D, IN ‘ 5.500 - 5.512 (0.2165 — 0.2170) 5.56 (0,219) EX ‘ 6.600 — 6.615 (0.2598 — 0.2604) 6.65 (0.262) slammguide gramme IN 0.010 - 0.037 (0.0004 — 0.0015) 0.10 (0.004) EX 0.030 — 0.060 (0.0012 — 0.0024) 0.11 (0.004) Valve guide projection above m 19.5 (0.77) cylinder head EX 18.0 (0.71) Valve seatiwidth IN/EX 0.90 A 1.10 (0.035 — 0.043) 1.5 (0.06) Valve spring free length IN 4214 (1.659) 40.58 (1.598) Ex 420311686) 41.25 (1.624) Camshaft Cam lobe height [N 371136 _ 37.348 (1.4641 — 1.4704) 37.16 (1463) Ex 37.605 e 37.765 (1.4805 —1.4868) 37.50 (1.480) qurnal 0.0. '''' 21.959 , 21.980 (0.8645 — 0.8654) 21.90 (0.862) Runout — 0.0310012) Oil clearance 0050—0111(000204.0044) 0.13 (0005) Identification marks "F": Front, "R": Rear 7 Rocker arm LD. lN/EX 12.000~12.018 (0.47z4~ 0.4731) 12.05 (0.474) Rocker arm shaft 0.1.7. lN/EX 11.966 — 11.984 (0.4711 — 0.4710) 11.83 (0.466) Rocker arm~to-rocker arm shaft clearance 0.016 — 0.052 (0.0006 — 0.0020) 0.07 (0.003) 10-1 CYLINDER HEAD/VALVE TORQUE VALUES Cylinder head cover bolt Overhead cover bolt Air cleaner housing stay bolt » Cam sprocket bolt Cam chain tensioner mounting bolt Camshaft holder 8-mm bolt 8amm nut Cylinder head a-rnrn bolt 10—min nut Cylinder head fin mounting bolt Spark plug Crankshaft hole eap Timing hole cap Valve adjusting screw lock nut TOOLS Valve guide driver, 5.5 mm (IN) Valve guide driver, 6-6 mm (EX) Valve guide driver (adjustable type) Valve spring compressor Valve seat cutter —— seat cutter, 27.5 mm (45" IN) ~ 5th cutter. 35 mm (45° EX) — flat cutter, 28 mm (32° lN) — flat cutter, 35 mm (32" EX) — interior cutter, 30 mm (60” IN) —— interior cutter, 37.5 mm (60" EX) — cutter holder, 5.5 mm (IN) — cutter holder, 6.6 mm (EX) Valve guide learner, 5.5 mm (IN) Valve guide reamer, 6.6 mm (EX) TROUBLESHOOTING 10 Nrm (1,0 kgf-m, 7 lbf-it) 12 N-m (1.2 kgf-m, 91bf~ft) 12 N-m (1.2 kgftm, 9 lbfit) 23 N-m (2.3 kgfm, 17 lhf-fl) 10 N-m (1.0 kgl-m, 7 mm) 23 N-m (2.3 kgf-m. 17 Item) 23 N-m (2.3 kgr-m. 17 lbf—ft) 23 N-m (2,3 kghm, 17 lbr-ft) 47 Ntm (4.8 kgf-m, 35 lbf-(l) 10 NM (L0 kgf-m, 7 lbf-fl) u N-m (1.4 kgf-m,1oibf-ftl 15 N-m (1.5 kgfrm. 11 lbf-ft) 15 N~m (1.5 kgf~m, 11 lbf-ftl 23 Nrm (2.3 kgf~m, 17 let) 07742 a 00101 00 07742 — 0010200 07743 a 0020000 07757 - 0010000 07780 — 0010200 07780 a 0010400 07780 —- 0012100 07780 - 0012300 07780 - 0014000 07780 - 0014100 07781 — 0010101 07781 — 0010202 07984 — 2000001 07984 — ZEZOOO1 Apply locking agent to the treads. Apply oil to the threads and seating surface. Apply oil to the threads and seating surface. Apply grease to the threads. Apply grease to the threads. Apply oil to the threads and seating surface. or 07933 — 3290001 (USA. only) Not available in U.S.A. Equivalent commercially available in U.S.A. or 07984 — ZEZDODD (USA. only) Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top and noise with a sounding rod or stethoscope (see page 10-3 for engine compression testing). Compression too low, hard starting or poor performance at low speed . Valves — Incorrect valve adjustment — Burned or bent valves — Incorrect valve timing ~ Broken valve spring ——« Uneven valve seating . Cylinder head 7 Leaking or damaged cylinder head gasket 7 Warped or cracked cylinder head — Loose spark plug - Cylinder/piston (see section 11) Compression too hlgh ' Excessive carbon build-up on piston head or combustion chamber Excessive smoke v Worn valve stem or valve guide - Damaged stern seal . Cylinder/piston problem (see section 11) Excessive noise - Incorrect valve clearance - Sticking valve or broken valve spring - Worn or damaged camshaft - worn cam chaln - Worn or damaged cam chain tensioner - Worn cam sprocket teeth - Cylinder/piston problem (see section 11) Rough idle - Low cylinder compression 1 0-2 CYLINDER HEAD/VALVE CYLINDER COMPRESSION mmmsm GAUGE Warm up the engine to normal operating tempera- ture. Stop the engine, disconnect the spark plug caps and remove one spark plug at a time. NOTE: - To measure the cylinder compression of each cylinder, remove only one plug at a timer Install the compression gauge into the spark plug hole. Shift the transmission into neutral. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. The maximum reading is usuallv reached within 4 — 7 seconds, COMPRESSION PRESSURE: 1275 t 98 kPa (13.0 1 1,0 kgflcm', 135 2 u psi) at 400 rpm If compression is high, it indicates that carbon deposits have accumulated on the combustion cham- ber and/or the piston crown. lithe compression is low, pour 3 — 5 w (0.1 —- 0,2 oz) of clean engine oil into the cylinder through the spark plug hole and recheck the compression If the compression increases irom the previous value, check the cylinder, piston and piston rings. If compression is the same as the previous value, check the valve for leakage. 10-3 CYLINDER HEAD/VALVE CYLINDER HEAD COVER REMOVAL FRONT Remove the air cleaner housing (page 53). Drain the coolant (page 6-4). Remove the mounting bolts and front overhead cover. Disconnect the spark plug can, then remove the mounting bolts and right front cylinder head fin. Remuve the sub-air cleaner (page 5-4). Disconnect the spark plug Capt Remove the mounting bolts and left tront cylinder head fin. Remove the bolt and sub-air cleaner case stay from the cylinder head covert Remove the thermostat housing mounting bolt with the ground terminal. Disconnect the water hoses from the thermostat housing Remove the following: — cylinder head cover bolts 7 rubber washers —— mounting rubber seals Remove the cylinder head cover to avoid damaging the head cover mating surface. CYLINDER HEAD FIN \ , \ . OVERHEA COVER v 1 0-4 Remove the head cover gasket. REAR Remove the fuel tank (page 272). Remove the air cleaner housing (page 543). Remove the mounting bolts, leit and right overhead covers Disconnect the spark plug cap, then remove the mounting bolts, choke cable holder and left rear cylinder head fine Disconnect the spark plug cap. Remove the mounting bolts, air cleaner case stay and right rear cylinder head fin, Remove the rear left spark plug wire mounting clip from the frame. Remove the mounting bolts and crankcase breather cover. Disconnect the air supply hose from the breather cover. 1 0-5 CYLINDER HEAD/VALVE Remove the following: —‘ cylinder head cover bolts 7 rubber washers — mounting rubber seals Remove the cylinder head cover to avoid damaging the head cover mating surface Remove the head cover gasket. CAMSHAFT, CAMSHAFI' HOLDER REMOVAL NOTE: - The camshaft can be serviced with the engine installed in the frame. - The rear cylinder camshaft service uses the same procedure as for the front cylindert Remove the front cylinder head cover (page 10-0. Remove the crankshaft hole cap and timing hole cap. Remove the camshaft end holder bolts and camshaft end holder. 10-6 CYLINDERAHEADIVALVE Remove the dowel pins. Before releasing the cam chain tensioner, measure the cam chain tensioner wedge 8 length as shown. SERVICE LIMIT: 6 mm (0.2 in) When the service limit is exceeded, replace the cam chain. To replace the cam chain. remove the following parts: — cam sprocket (see below) — front cylinder: flywheel (see section 9) — rear cylinder: primary drive gear (see section 3) Release the cam chain tensioner by pulling wedge A straight up while holding wedge B dowri then secure the wedge A with a 2mm pin as shown. Be Carefulnmto Remove the cam sprocket bolt, turn the crankshaft Ierthe cam counterclockwise one full turn (360°) and remove the sprvcket bolts other cam sprocket bolt. fal/ into the Erankcasa. CYLINDER HEAD/VALVE Remove the cam sprocket from the camshaft flange with the cam chain. Remcve lhe following: — three 8-mm bolts — oil guide plate — two 8-mm nuts —— washer — camshaft holder assembly Remove the dowel pins. Remove (he cam chain from the cam sprocket. Anach a piece of wire (0 the cam chain to prevem it from falling into the crankcase. Lifi me camshaft and remove it. Remove the cam sprocket. CAM CHAIN 1 0-8 CYLINDER HEAD] VALVE CAMSHAFI' HOLDER DISASSEMBLY When disassemr Remove the exhaust rocker arm shaft, exhaust rocker bling, mark and arm and wave washer from the camshaft holder. Store the disas- * sembled parts to ensure that they are reinstalled in their original ”cations. Remove the intake rocker arm shaft, intake rocker arms and wave washers from the camshaft holder. INSPECTION CAMSHAFI' RUNOUT Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial indicator. SERVICE LIMIT: 0‘05 mm (0.002 In) CAM LOBE HEIGHT Measure the height of each cam lube using a micrometer. SERVICE LIMITS: IN: 37.16 mm (1.463 in) ems-1,53 mm (1,480 in) 1 0—9 CYLINDER HEAD/VALVE DU not rotate the camshaft during inspection. CAMSHAFI' JOURNAL 0.D. Measure the CD. of each camshaft journal. SERVICE LIMIT: 21.90 mm (0.862 in) Inspect the oil passages ofthe camshaft. Inspect the camshaft journal surfaces of the camshaft holder, end holder and cylinder head for scoring or evidence of insufficient lubrication. CAMSHAFI' OIL CLEARANCE Clean 0“ any oil from the journals of the cylinder head, camshaft holder, end holder and camshaft. Put the camshaft onto the cylinder head and lay a strip or plastigauge lengthwise on top or each camshaft journal. install the following: — dowel pins — camshaft holder assembly — oil guide plate — three 8mm bolts — washer — two 8-mm num —— dowel pins — camshaft end holder — end holder bolts Tighten the end holder bolts. Tighten the camshaft holder 8-mm bolts and 8-mm nuts in a crisscross pattern in several steps. TORQUE: 23 Nm (2.3 kgf-m, 17 “7”!) Remove the camshaft holder and end holder. Measure the width of each plastigauge. The widest thickness determines the oil clearance. SERVICE UMIT: 0.13 mm (0005 in) When the service limit is exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head, camshaft holder and end holder if the clearance still exceeds the service limit. 10-10 CYLINDER HEAD/VALVE ROCKER ARM, ROCKER ARM SHAFT Inspect the rocker arm shafts and rocker arms for abnormal wear or damage. Check the rocker arm shafts and rocker arms for clogged oil holes. Measure the CD. of each maker arm shaft. SERVICE LIMIT: 1133 mm (0.466 In) Measure the ID. of each rocker arm. SERVICE UMIT: 12.05 mm (0.474 in) Subtract each rocker arm shaft OD. from the corre— sponding rocker arm LD. to obtain the rocker armm- rocker arm shaft clearance. SERVICE LIMIT: 0.07 mm (0,003 in) CAMSHAFT HOLDER ASSEMBLY INTAKE ROCKER ARM INTAKE ROCKER ARM SHAFT WAVE WASHERS EXHAUST ROCKER ARM SHAFT EXHAUST ROCKER ARM INTAKE ROCKER ARM CAMSHAFT HOLDER WAVE WASHER Apply molybdenum oil solution m the rocker arm 'N- ROCKER ABM}, . . _‘ EX- ROCKER ARM slipper surfaces. . ‘ NOTE: - The exhaust rocker arm has a larger slipper face than the intake rocker arm. 10-11 CYLINDER HEAD/VALVE Apply molybdenum oil solution to the rocker arm shaft sliding surfaces Install the wave washers, intake rocker arms and intake rocker arm shaft to the camshaft holder. install the wave washer to the "A" mark side on the camshaft holden install the exhaust rocker arm and exhaust rocker arm shaft to the camshaft holder, Position the grooves and holes in the rocker arm shafts vertically, aligning the bolt holes of the camshaft holder. 10312 CYLINDER HEAD/VALVE INSTALLATION NOTE: ' v ‘ - The Camshafts are identified by marks on their ' flanges. Front cylinder camshaft: index notch (TDC; Top , Dead Center) mark and “F” mark ‘ ’ Rear cylinder camshaft: "R" mark - If both (front and rear) camshafts were removed, install the front cylinder camshaft first, then install the rear camshaft. - If the rear camshaft was not serviced, remove the rear cylinder head cover (page 10-5) to check the " ' camshaft position. ”R” MARK" - If the front camshaft was not serviced, remove the front cylinder head cover (page 104) to check the camshaft position. ”F" MARK PISTON AND CRANKPIN LOCATION DIAGRAM: F: FRONT FIST N TDC or THE FRONT CYLINDER R: REAR HSTOR COMPRESSION STROKE TDC OF THE EXHAUST STROKE TDC OF THE REAR CYLINDER COMPRESSION STROKE TDC OF THE EXHAUST STROKE BOTH CAMSHAFTS INSTALLATION "FT" MARK ”RT" MARK Turn the crankshaft counterclockwise and align the "FT" mark on the flywheel with the index mark on the left crankcase cover. then make sure the front cylinder piston is at "TDC (Top Dead Center)”. Install the front cylinder camshaft (see next page). After installing the front camshaft, face up the "F" mark on the front camshaft, then turn the crankshaft counterclockwise 308° and align the "HT" mark on the flywheel with the index mark on the left crankcase cover, then install the rear camshaft (page 10-16). INDEX MARK INDEX MARK 10-13 CYLINDER HEADNALVE HIONT CAMSHAFT INSTALLA'HON Remove the rear cylinder head cover and camshaft end holder. Check the rear cylinder camshaft position as follows: ' ‘ Turn the crankshaft counterclockwise and align the ‘RT' mark on the flywheel with the index mark on the left crankcase cover, then check the ”R' mark on the rear camshaft flange. — If the ‘R" mark faces up. turn the crankshaft coun~ terclockwise 412" (align the “Fr" mark on the fly~ wheel with the index mark on the left crankcase cover) and begin installation of the front camshaft. — If the "R" mark faces down (cannot be seen), turn the crankshaft clockwise 52" (align the “FT" mark on the flywheel with the index mark on the left crankcase cover) and begin installation of the front camshaft install the cam sprocket with the ‘IN' mark facing inside. Lubricete the camshaft lobes and journals with molybdenum oil solution. Install the camshaft onto the cylinder head through the cam sprocket, Temporally align the index lines of the cam sprocket with the upper surface of the cylin- der heedr Place the camshaft into its correct position with the ”F” mark on the flange facing up and install the cam chain onto the cam sprocket by the aligning the index lines with the upper surface of the cylinder headr Install the dowel pins. “R” MARK INDEX LINES INDEX MARK 'lN' MARK ‘ 10-14 CYLINDER HEAD/VALVE Lubricate each rocker arm slipper surfaces with molybdenum all solution. NOTE: . Before camshaft holder installation, loosen the valve adjusting screws and lock nuts. Install the following: — camshaft holder assembly —— washer — two S-mm nuKS — oil guide plate r three 8-mm bolts Tighten the camshaft holder 87mm bolts and B-mm nuts in a crisscross pattern in several steps. TORQUE: Z3 N~m (2.3 kgfm, 17 "3”!) Install the cam sprocket onto the camshaft flange. NOTE: - Be sure the index lines on the cam sprocket align with the upper surface of the cylinder head when the "FT" mark on the flywheel is aligned with the index mark on the left crankcase covert Apply a locking agent to the cam sprocket bolt threads. Align the bolt hole in the sprocket and camshaft flange and install the cam sprocket bolt. Turn the crankshaft one revolution. Apply a locking agent to the remaining sprocket bolt threads and install the cam sprocket bolt. Tighten it to the speci- fied torquel TORQUE: 23 Nm (2.3kgfm, 17 le‘t) Turn the crankshaft one revolution again and tighten the other bolt to the same torque. Remove the ZAmm pin holding cam chain tensioner wedge A. CYLINDER HEAD/VALVE Install the dowel pins. Install the camshaft end holder with the flat surface facing inside. Install and tighten the camshaft end holder bolts. Adjust the valve clearance (page 3—8). REAR CAMSHAFI' INSTALLATION Remove the front cylinder head cover and camshaft end holder. Check the front cylinder camshaft posi» tion as follows: Turn the crankshaft counterclockwise and align the ”FT" mark on the flywheel with the index mark on the left crankcase cover. — If the ”F” mark on the front camshaft flange faces up, turn the crankshaft counterclockwise 308‘ and align the ”RT" mark with the index mark. — If the "F" mark on the front camshaft flange faces down (cannot be seen). turn the crankshaft counr terclockwise 668° and align the ”RT” mark with the index mark The remainder of the rear cylinder camshaft installa» tion is the same as the procedures described on page 10-14, except the mark on the camshaft flange that 'shuuld face up should be an "R". CYLINDER HEAD COVER INSTALLATION Pour engine oil into the oil pocket in the cylinder head until the cam lobes are covered. Clean the gasket groove of the cylinder head cover thoroughly. NOTE: ' It is easier to install the cylinder head cover gasket, apply HondaBond A or equivalent to the gasket groove ofthe cylinder head cover. END HOLDER “F” MARK INDEX LINES INDEX MARK HDNDABOND A 0R EQUIVALENT 10-16 REAR Clean the cylinder head cover mating surface of the cylinder head. Install the new gasket onto the cylinder head cover, Install the rear cylinder head cover to avoid damag- ing the head cover mating surface. Apply engine oil to all the mounting rubber seal sur- faces. lnstall the lollowing: — mounting rubber seals — rubber washers — head cover bolts Tighten the cylinder head cover bolts to the specified torque. TORQUE: 10 Nm (1.0 kgfml 7 mm) Install the new O-ring into the crankcase breather cover groove. Install the crankcase breather cover with the belts Tighten the crankcase breather cover halts. Connect the air supply hose. Install the rear left spark plug wire mounting clip. CYLINDER HEAD/VALVE 10-17 CYLINDER HEADNALVE Install the right rear cylinder head fin with the air cleaner case stay and mounting bolts to the specified torque. TORQUE: 12 Nm (1.2 kgf-m,9 IM—ftl Tighten the cylinder head fin mounting bolts to the specified torque. TORQUE: 10 NM [1.0 kgfim. 7 let) Connect the spark plug cap. Install the left rear cylinder head tin with the choke cable holder and mounting bolts. Tighten the mounting bolts to the specified torque, TORQUE: 10 M!!! (1.0 Ital-m, ‘I Ibf-ft) Connect the spark plug cap. Install the left and right overhead cover with the muunting boltsi Tighten the bolts to the specified torque. TORQUE: 12 Min (12 kgf-m, 9 let) Install the air cleaner housing (page 5-3) Install the fuel tank (page 2-2) FRONT Clean the cylinder head cover mating surface 0! the cylinder head. Install the new gasket onto the cylinder head cover. Install the front cylinder head cover to avoid damag- ing the head cover mating surtacel Apply engine oil to the mounting rubber seal whole surfaces. Install the following: — mounting rubber seals — rubber washers — head cover bolts Tighten the cylinder head cover bolts tn the specified torque. TORQUE: 10 NM [1.0 kgf-m, 7 let) CYLINDER HEAD FIN RUBBER SEALS 10—18 CYLINDER HEAD] VALVE lnstall the thermostat housing with the ground termi vial and mounting bolt. Tighten the bolt. Connect the water hoses to thermostat housing. GROUND TERMINAL BOLT N WATER HOSES install the left front cylinder head fin with the mount— SUB-Alina lng bolts. CLEANER STIWX'Y Tighten the bolts to the specified torque. TORQUE: 10 Mm (1.0 kgf~m, 7 letl Install the sub—air cleaner stay with the bolt and tight- en the bolt. install the sub-air cleaner (page 54). Connect the spark plug cap. install the right front cylinder head tin with the mounting bolts. Tighten the bolts to the specified torquet TORQUE: 10 Nm (1.0 kgfin, 7 “SM“ Connect the spark plug cap, Install the front overhead cover with the mounting bolts. Tlghten the bolts to the specified torque. TORQUE: 12 N-m (1‘2 kgf-m, 9 Ibf-fll Install the air cleaner housing (page 53). Fill and bleed the cooling system (page 64). CYLINDER HEAD REMOVAL Remove the engine from the frame (see section 7). Remove the camshaft holder and camshaft (page 106). Remove the mounting bolts, washers, cushion rub— ber and cam chain tensioner. CYLINDER HEAD/VALVE Remove the following: —twa 8—mm bolts and washers — S-mm bolt wfour10»mm nuts and washers Prv me cylinder head a! the prying using a screwdriver and remove the cylinder head. Remove the gasket and dowel pinsi Remove the cam chain guide. CYLINDER HEAD DISASSEMBLY Compressing the valve springs mare "Ian n60- Essary will 25 use loss of Valve spring tension, NOTE: - Mark all parts during disassembly so they can be placed back in (hair original locations for installa- tion laterr Remove the valve spring cutters using the valve spring compressor. TOOL- Valve spring oomprnsor 07757 - 0010000 Remove the following: — spring retainer — valve spring —- valve — stem seal — spring seat SPRING SEAT SPRING VALV STEM SEAL RETAINER CUTIERS 10-20 Gasket material will come off easier if soaked in high flash point cleaning solvent. INSPECTION CYLINDER HEAD Remove the carbon deposits from the combustion chamber, being careful nm to damage the gasket sur- facev Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with a snaight edge and feeler gauge. SERVICE LIMIT: 0.10 mm (DAMN in) VALVE SPRING Measure the valve spring free length. SERVICE LIMITS: IN: 40.58 mm (1.598 in) EX: 41.25 mm (1.52! in] VALVE/VALVE GUIDE Check that the valve moves smooxhly in (he guide. Check the valve for bending, burning or abnormal wean Measure each valve stem an and record it. SERVICE LIMIYS: IN: 5.45 mm (0.215 in) EX: 6.55 mm (0258 in) CYLINDER HEAD/VALVE CYLINDER HEAD/VALVE Ream the Valve guide to remove any carbon buildrup before measuring the guide. Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. TOOLS: Valve guide reamer, 07984 — 2000001 55 mm (IN) Valve guide reamer, 07984 — ZE20001 6.6 mm (EX) 0: 07934 —- ZE2000D (U.S.A. only] Measure each valve guide LD. and record it. SERVICE LIMITS: IN: 5.56 mm (0.219 in) EX: 6.65 mm (0.262 in) Subtract each valve stem CD. from the correspond- ing guide ID. to obtain the stem-tD-guide clearance. SERVICE IJMIT S: IN: 0.10 mm (0.004 in) EX: 0.11 mm (0.004 in) If the stern-tu-guide clearance exceeds the service limit, determine if a new guide with standard dimen- sions would bring the clearance within tolerance. If so, replace any guides as necessary and ream to (it, If the stem-to-guide clearance exceeds the service limit with a new guide, also replace the valve. Inspect and reface the valve seats whenever the valve guides are replaced (see next page). CAM CHAIN TENSIONER, CAM CHAIN GUIDE CAM CHA'N TENSIQNER ' Check the cam chain tensioner and earn chain guide for excessive wear ur damage and replace them if necessary. CAM CHAIN GUIDE 10-22 CYLINDER HEAD/VALVE VALVE GUIDE REPLACEMENT Chill the valve guide in a freezer for about an hour. Wear insulated Heat the cylinder head to 130‘C ~ 140°C (275“F — 290“F) glavss to avnid with a hot plate or oven. Do not heat the cylinder head burns when han- beyond 150°C (300"F). Use temperature indicator dling the heated sticks, available from welding supply stores, to be sure cylinder head. the cylinder head is heated to the proper temperature. NOTICE Using a torch to heat the cylinder head may cause warping. Support the cylinder head and drive out the old guides from the combustiun chamber side of the cylinder head. my; euibe DRIVEtj TOOLS: Valve guide driver, 07742 — 0010100 55 mm (IN) Valve guide driver, 07702 - 0010200 6.6 mm (EX) or 07933 — 3290001 [U.S.A. only) Ea careful hat in Adjust the valve guide driver to the valve guide height. damage the IN: 195 mm cylinder head. TOOL: EX: 180 mm Valve guide driver 07743 - 0020000 “— Not available in U.S,A. VALVE GUIDE PROJECTION ABOVE CYLINDER HEAD: IN: 195 mm [0.77 In) EX:18.0 mm [0.71 In) VALVE GUIDE DRIVER Drive the new guides in from the camshaft side of the Cylinder head while the cylinder head is still heated, U.S.A. only procedure: 7 Using a marker, mark the valve guide with a line at the correct height as specified above. 7 Chill the guides. — Drive in the valve guide to the line. ACheck the proieuion height with calipers to verity they are within specification. E G IDE’DRIVEH 1 0-23 CYLINDER HEAD/VALVE Let the cylinder head cool to room temperature, then ream the new valve guide. TOOLS: Valve guide roam”, 07984 — 2000001 5.5 mm llNl Valve guide reamer. 07984— E20001 6.6 mm lEXl or 079m — ZEZOOOD IU.S.A. only) NOTE: - Take care not to tilt or lean the reamer in the guide while reaming. if the valve is installed slanted oil leaks from the stern seal and improper valve seat contact will result and you will not be able to reface the valve seats. - Insert the reamer from the combustion chamber side of the head and always rotate the roamer Clockwise. Clean the cylinder head thoroughly to remove any metal particles after reaming and raface the valve seat. VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to each valve face. Tap the valve against the valve seat several times using a hand-lapping tool, without rotating the valve, to make a clear pattern. Remove the valve and inspect the valve seat face (see following page). The valve cannot be ground, If the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve. The valve seat contact should be within the specified width and even all around the circumference. STANDARDS: 0.90 - 1.10 mm (0.035 — 0.043 in) SERVICE LIMITS: 1.5 mm (0.06 in] If the valve seat width is not within specification, reface the valve seat (see next page). HAND-LAEPING TQOL 1 0—24 Inspect the valve seat face for. - Damaged face: # Replace the valve and reface the valve seat. - Uneven seat width: 7 Replace the valve and reface the valve seat. - Contact area (too high or too low) ~ Reface the valve seat REFACING NOTE: - Folluw the refacing manufacturer's operating instructions. - Be careful not to grind the seat more than neces sary. If the Contact area is tao high on the valve, the seat must be lowered using a 32° flat cutter. TOOLS: Flat cutter, 28 mm (32" IN) Flat cutter, 35 mm (32" EX) 07780- 0012100 07780- 0012300 ‘ or equivalent commercially available in UrS‘A‘ If the Contact area is too low on the valve, the seat must be raised using a 60° interior cutter. TOOLS: Interior cutter, 30 mm (60’ lb" 07780 - 001.000 Interior cutter, 37.5 mm (60° EXI 07780— 001mm or equivalent commercially available in USA. CYLINDER HEAD/VALVE 4%: DAMAGED FACE UNEVEN SEAT WIDTH TOO LOW T00 HIGH 45° 60‘ 32° CONTACT T00 HIGH OLD SEAT WIDTH 9 32° CONTACT T00 LOW OLD SEAT WIDTH ’ / 1 0-25 CYLINDER HEAD/VALVE Using a 45“ seal cutter, remove any roughness or irregularities from the seal. TOOLS: Seat cutter, 27.5 mm (45° IN) 07780 — 0010200 Seat cutter, 35 mm (45° EX) 07780 — 0010400 or equivalant commercially available in U.S.A. ROUGHNESS Using a 32° flat cutter, remove 1/4 ol the existing valve seat material. TOOLS: Flat cutter, 28 mm (32“ IN) 07780 — 0012100 Flat cutter. 35 mm (32° EX] 07780 - 0012300 or equivalent commarcially available in USA. Using a 60: interior cutter, remove 1/4 of the existing valve seat material, TOOLS: lmarior cm", 30 mm (60° IN) 07780- 001w00 interior cutter, 37.5 mm (60" EX) 07780 - 0014100 or equivalent commercially available in U.S,A. Using a 45“ seat cuner, cut the seat to (he proper width. TOOLS: Seal cutter, 27.5 mm (45" IN) 07780 — 0010200 Seal cutter, 35 mm (45" EX) 07780— 0010400 or equivalent commercially available in U.S.A. Make sure all pining and irregularmes are removed, OLD SEAT WIDTH OLD SEAT WIDTH 0,90 , 1.10 mm (0.035 , 0,043 inl 1 0-26 CYLINDER HEAD/VALVE NOTE HAND-LAPPING Tool. ~ Change the angle of the lapping tool frequently to ’ ' prevent uneven seat wear. Lapping cnm- After cutting the seat, apply lapping compound to the pound can cause valve face, and lap the valve using light pressure. damage if it enters between After lapping, wash any residual compound off the the valve stem cylinder head and valve. and guide. Recheck the seat contact after lapping. CYLINDER HEAD ASSEMBLY COTTEFlS ——-—>®@‘/ RETAINER STEM SEAL SPRlNG / SPRING SEAT ,/ VALVE GUIDE CVLINDER HEAD INTAKE VALVES Blow through all oil passage in the cylinder head @ with compressed air. V STEM SEAL Install the spring seats and new stem seals. Lubricate each valve stern with molybdenum oil solu- tion and insert the valves into the valve guides. Insert the valve into the guide while turning it slowly to avoid damaging the stem seal. NOTE: - Do not interchange the intake and exhaust valves. The exhaust valve is larger than the intake valves. VALVE CYLINDER HEAD/VALVE Compressing the valve spring more than n» essarv when installing the valve callers may cause loss or valve spring tension Support the cylinder head above the work bench suflscs to prevent possible valve damage. CYLINDER HEAD INSTALLATION Install the valve springs with the tightly wound coils facing the combustion chamber. NOTE: - Do nm‘imerchange the intake and exhaust valve springs. The exhaust valve springs are thicker than the intake valve springs. I TIGHTLY WOUND COILS Install the valve spring retainer, COMBUSTION CHAMBER SIDE NOTE: - To ease installation of the Cotters, grease them first. VALVE SPRING COMPRESSOR Compress the valve spring with the valve spring compressor and install the valve cutters. TOOL: Valve spring compressor 07757 — 0010000 Tap the valve stems gently with a salt hammer to firmly seat the cotters. Clean any gasket material from the cylinder mating surfaces. Make sure the cam chain guide bosses are in the grooved of the cylinder. ‘BOSSES AND GROOVES 1 0-28 Install the dowel pins and new gasket Route the cam chain through the wlinder head and install the cylinder head onto the cylinder. Apply engine oil to the cylinder head 107mm nuts and 8~mm bolts threads. Install the following: a washers and four1l}mm nuts —— 6-mm bolt — washers and two 8-mm bolts Tighten the 6-mm bolt. Tighten the 8~rnm bolts and 10-mm nuts to the criss- cross pattern in several steps. TORQUE: 8vmm bolt: 23 MM (23 kgim, 17 let) 10-min nut: ‘7 Ni" (4.8 kgfm, 351M!” Install the cushion rubber and cam chain tensioner with the tensioner mounting bolts and new sealing washerst Tighten the mounting bolts to the specified torque. TORQUE: 10 Ill-m HA) kgfm, 7 “IMO Install the camshaft and camshafl holder (page 10-13lt Install the engine onto the frame (page 7-7). CYLINDER HEAD/VALVE 11-0 11. CYLINDER] PISTON SERVICE INFORMATION TROUBLESHOOTING CYLINDER REMOVAL PISTON REMOVAL 11-1 11-2 11-3 11-4 PISTON RING INSTALLATION PISTON INSTALLATION CYLINDER INSTALLATION 11-7 11-8 11-9 SERVICE INFORMATION GENERAL To service the Cylinder/piston, the engine must be removed from the frame. Take Care not to damage the Cylinder wall and piston. Be Careful not to damage the mating surfaces when removing the cylinder. When removing the piston, clean carbon and sludge from the top of the cylinder. When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locav tions. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Cylinder ID. 79000—7901?) (34102—31103) 79.10 (3.114) >00t—of-round — 0.00 (0.002) Taper —— 0.06 (0.002) m Warpage ' 0.10 (0.004) Piston, piston Piston mark direction ”IN” mark facing toward the intake side — “93 'Pisterrd. ' 73.97 — 739913.105 — 3.110) 78.90 (3.105)’ Piston O.D. measurement point 7 — 17 (0.3 — 0.7) from bottom 01‘ skirt I — Piston pln ncIe 1.13. 18.002 — 18003107037 — 0.7090) ' 130510.711) —Pi-ston pin 0.0. 7 17.094 —1s.00010.7004- 0.7087) 17.98 (0.708) Piston-to-piston pin clearance 0.002 4 0.014 (0.0001 — 0.0006) 0.0410002) Piston ring-(wring Top 0025 — 0.055 (0.0010 — 0.0022) 0.00 (0.003) """" groove clearance Second 0.015 - 0.045 (0.0000 — 0.0018) 0.07 (0.003) piston ring and gap Top 0.15—0.25 (0006—0010) 0.3010012) Second 0.25 — 0.00 (0.010 - 0.016) 0.50 (0.02) on (side rail) 0.20 — 0.30 (0.003 — 0.031) 1.0 (0.00) Piston ring mark Ton ”R" mark — Second ”RN” mark — Cvlinder—to-piston clearance 0.010 — 0.045 (0.0004 — 0.0018) 0.10 (0004) En; t' 9 rod small end l.D. 18.016—18.034(0.709370.7100) 180710.711) _ Connecting’Fodto-psston pin engage" 7‘ ’ 7 0.016 , 0.040 (0.0000— 0.0010) 0.06 (0.002) 11-1 CVUNDERIHSTON TROUBLESHOOTING Compression too low, hard starting or poor peflarmance at low speed - Leaking cylinder head gasket - Worn, stuck or broken pisfinn ring - Worn or damaged cylinder and piston Compression too high. averheating or knocking - Excessive carbon builtrup on piston or combustion chamber Excessive smoke r Worn cylinder, piston nr piston rings ~ Improper Installation of piston rings ‘ Scored or scratched piston or cylinder wall Abnormal noise (piston) . Worn piston pin or pistan pin hole ' Worn cylinder, piston or piston ring ~ Worn connecting rod small and 11—2 CYLINDER] PISTON CYLINDER REMOVAL , JOINT (35% Remove the cy|inder head (page 1019). Remdve the joint clips and disconnect the water joint pipe by sliding it. Remove the Orring. Front cylinder only: Remove the two bolts and water hose joint. Remove the Orring from the water hose jointt Remove the cylinder. Remove the water joint pipe and O-ring. Remove the gasket and dowel pins, The gasket wil/ Clean the top of each cylinder thoroughly to avoid came offeasier if damaging the gasket surfaces. it is soaked in solvent, CYLI NDEH/ PISTON CYLINDER INSPEC'HON 7 " .' lnspect the cylinder bore for scratches or wear. Measure the cylinder ID. at three levels on the X and Y axis. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 7110 mm (3.110 mm) Measure the cylinder for taper and out-of—round at three levels in an X and Y axis. Take the maximum reading to determine the taper and out-ohound. SERVICE LIMIT: Taper: 0.06 mm (0.002 ill) Out a! round: 006 mm (0,002 in) ./’T‘\-\. TOP \ X MIDDLE \\ /V/ //V——“\\ BOTTOM Check the cylinder for warpage by placing a straight edge and a feeler gauge across the stud holes as shown. SERVICE IJMIT: 0.10 mm (0.004 in) PISTON REMOVAL . . PISTON Place a clean shop towel over the crankcase to pre- vent the piston pin clip from falling into the crankcase. Remove the piston pin clip using a pair of pliers. Remove the piston pine Remove the piston. 11-4 CYLINDER/PISTON Remove the oil jets and check for clogging. Remove the Oerings from the oil jets. Inspect the piston rings for movement by rotating the rings. The rings should be able to move in their grooves without catching. Da nordamage Spread each piston ring and remove it by lifling it up the piston ring by at a point ius‘ opposite the gap. spreading me and [on far. Clean urban Clean carbon deposits from the piston ring grooves. depasirs {mm the rl'ng grauves with a ring zha: will be discarded. Never use a wire brush; it will scrarch the groove, PISTON/PISTON RING INSPECTION Inspen the piston for abnormal wear or damage. Measure the diameier ofthe piston at 7 ~ 17 mm (0.3 — 0.7 in) from the honom and 90° to (he piston pin hu|e. SERVICE UMIT: 7830 mm (1106 in) Calculate the cylinder-to-pismn clearance (cylinder I.D.: see previous page). SERVICE LIMIT: 0.10 mm (0.004 in) CYLINDER/PISTON Measure and record the piston pin hole 1D. in an X and Y axis. Take the maximum reading to determine the LB. SERVICE LIMIT: 13.05 mm (0.111 in) Measure and record the piston pin CD. at three points. SERVICE UMIT: 17.98 mm (0.708 in) Calculate the pistonitaspistan pin clearance by sub— tracting the piston pin CD. from the piston pin hole I.D4 SERVICE LIMIT: 0.04 mm (0.002 in) Measure and record the connecting rod small end LD. SERVICE LIMIT: 10.07 mm (0.711 in) Calculate the connecting rod~to«piston pin clearance by subtracting the piston pin CD. from the small end |.D. SERVICE LIMIT: 0.06 mm (0.002 in) Temporarily install the piston rings to their proper position with the mark iecing up. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the clear- ance using a feeler gauge. SERVICE LIMITS: Tap: 0.08 mm (0.003 ml Second: 007 mm (0003 mi Insert the piston ring into the bottom of the cylinder squarely using the piston. Measure the and gap using a ieeler gauge. SERVICE UMITS: YOP: 0.30 mm (0.012 in] Second: 0.50 mm (0.02 in) Oil (side rail): 1.0 mm (0.00 in) 11-6 CYLINDER STUD BOLT REPLACEMENT If it is necessary to replace the cylinder stud bolts. remove the stud bolts from the crankcase. Apply engine oil to the stud bolt threads. Install the stud bolts with the tab Side facing the cylinder head side. After installing, be sure to measure the distance from the top of each stud bolt to the crankcase surface as shown. STANDARD LENGTH: 8 x189 mm: 186 mm (7.3 in) 10 x 177 mm: 169 mm (6.6 in) 12 x177 mm: 169 mm (6.6 In) PISTON RING INSTALLATION NOTE: - Do not confuse the top and second rings: The top ring indicates the "R" mark and second ring indicates the “RN” mark. - Be carelul not to damage the piston and rings dur- ing assembly‘ To install the oil ring, install the spacer first, then install the side rails‘ stagger the ring end gaps 120° as shown. PISTO N CYLINDER] PISTON STUD BOLT 98 | L L( TAB 8x189 mm 10x177 mm, L2 5 177 mm "R" MARK s6 TOP RING SECOND RING SIDE RAIL SPACER OIL RING SIDE RAIL 11—7 CYLINDER] PISTON Clean the piston heads, ring lands and skirts. Apply engine oil to the piston rings outer surfaces. Carefully install the piston rings onto the piston with the markings racing up. After installing the rings, check that they rotate freely without stickingt PISTON INSTALLATION Coat the new O—rings with engine oii and install them onto the oil jets. Install the oil lets into the crankcase properly with the jet hole facing toward the connecting rod side. Place a clean shop towel over the crankcase to pre- vent the clip from falling into the crankcase. Apply engine oil to the piston pin outer surface. Set the piston over the connecting rod with the ”W" mark facing towards the intake side and install the piston pin through the piston and connecting rod. Install the new piston pin clips. Make sure the piston pin clips are seated properly and their and gaps are not aligned with the cut-outs in the position. PISTON RINGS / 4____.__ \ CLIP CUTVOUT 11-8 CYLINDER/PISTON CYLINDER INSTALLATION .7 , . DOWEL PINS Clean the gasket surface of the crankcase thoroughly. being careful not to damage it, and careful not to allow gasket material into the crankcase. Install the new gasket and dowel pins. Apply engine oil to the cylinder wall, piston and pisV ton ring outer surfaces. Before installing the cylinder, coat new Orrings with coolant and install them into the end grooves in the water joint pipe and install the joint pipe into the cylinder. Be careful not to Route the cam chain through the cylinder and install damagei’le pis- the cylinder over the piston while compressing the Ian rings and piston rings with your fingers. cylinder wall. Slide the water joint pipe in position and connect the cylinders. Install the joint clips in the joint grooves. Coat a new O-ring with coolant and install it in the water hose joint groove, Install the water hose joint with bolts onto the front cylinder and tighten the water hose jolnt bolts. Install the cylinder head (page 1028). CRANKSHAFI'ITRANSMISSION 33 N-m (3.4 kgf>m, 25 lbf‘ffi 23 NW) (2.3 kgf-m, 17 lbfAfl) 1 2-0 12. CRANKSHAFT/TRANSMISSION SERVICE INFORMATION 12-2 TRANSMISSION 12-12 TROUBLESHOOTING 12-3 CRANKCASE BEARING REPLACEMENT 12-18 CRANKCASE SEPARATION 1Z4 CRANKCASE ASSEMBLV 12 20 CRANKSHAFI'ICONNECTING ROD 12»6 29 NAm (3.0 kgftm, 22 lbf-IK) 12 N-m (1.2 kgf‘m, 9 lbf'fl) 2 N-m (0.2 kgf-rrl, 174 Ibf-ft) 12-1 CRANKSHAFI'ITBANSMISSION SERVICE INFORMATION GENERAL ' The crankcase halves must be separated to service the connecting rod, crankshaft. transmission (including the shift fork and shift drum) and oil pump (section 4). To service these parts. the engine must be removed from the frame (section 9). ~ The following parts must be removed before disassembling the crankcase. — Engine oil filter (page 340) a Water pump (section 6) — Ignition pulse generator and primary drive gear (section 8) — Clutch and gearshift linkage (Section 8) — Alternator (section 9) 7 Flywheel/starter clutch and starter reduction gear, idle gear (section 9) — Cylinder head (section 10) — Cylinder/piston (section 11) ~ Starter motor (section 18) - - Be careful not to damage the crankcase mating surfaces when servicing. Mark and store the connecting rod and bearings to be sure of their correct locations. If the bearings are improperly installed they will block the oil holes, causing insufficient lubrication and eventual engine seizure. - Be careful not to damage the main journal bearing inserts during crankshaft removal and installation. Connecting rod bearing inserm are select fitted and are identified by color code. Select replacement bearings from the code table. Check the oil clearance using a plastigauge after replacing bearing inserts. - Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshm Side clearance 0.05 — 0.20 (0.002 - 0.003) 0.30 (0.012) I ____,, Runout — 0.03 (0.001) Crankpin oil clearance _ 0.029 - 0.052 (0.0011 — 0.0020) 0.07 (0.003) Main iournal oil clearance 0.030 — 0.046 (0.0012 — 0.0019) 0.07 (0.003) Transmission GearlD. M3, M5 23000—29021 (1.102.1— 1.1032) 20.04 (1.104) (:1. c2, 04 31000—31025 (1.2204- 1.2215) 31.05 (1.222) aging 0)). M3, M5 27.959—27.930(1.1007- 1.1015) 27.94 (1.100) c1, 02, c4 30.950 - 30.975 (1.2185 — 1.2195) 30.93 (1.219) Bushing (,0. M3 25.000 - 25.021 (0.9843 — 0.9051) 25.04 (0.995) c2 27995—20016 (1.1021 — 1.1030) 29.04 (1.104) Gunmbushrng M3. M5 0020 - 0.052 (0.0008 — 0.0024) 0.10 (0.004) clearance c1, c2, C4 0025 - 0.075 (0.0010 - 0.0030) 0.11 (0.004) Mainshaft 0.0. at M3 bushing 24.972 — 24.993 (0.9931 — 0.9840) 24.95 (0.932) M Countershaft 04D. at C2 bushing 27.967 - Z7.980(1.1011—1.1015) 27.95 (1.100) Bushing.m.shafl M3 0007 — 0.049 (0.0003 - 0.0019) 0.09 (0.003) clearance C2 0015 — 0049100005 — 0.0019) 0.03 (0.003) Shift fork (.0. 13.000 — 13.021 (0.5119 — 0.5125) 1104(0513) Shift fork claw thickness 5.99 — 5.00 (0.233 » 0.236) 5.6 (0.22) sum fork shaft 0.0. 12.966— 12304105105 — 0.5112) 12.90 (0.509) snm drum 0.0. (at left side journal) 11.966— 11.994 (0.4711 — 0.4718) 11.54 (0.470) 1 2-2 TORQUE VALUES Crankcase 87mm bolt Connecting rod bearing cap nut Drive chain guide plate bolt Neutral switch on pressure switch Oil pressure switch wire terminal screw Oil filter cartridge TOOLS: 23 N-m (2.3 kgf-m, 17 lbftft) 33 N-m (3,4 kgf—m, 25 lot-ft) 10 NY" (1.0 kgf-m, 7 Ith) 12 NT" (1.2 kgf—m, 9 lbf-ft) 12 N-m (1.2 kgf—m, 8 lbf-ftl 2 N-l'n (0.2 kgf—m, 1.4 [bf-ft) 10 N-m (1.0 kgf-m, 7 lbf-ftl 07746 , 0020300 07746 — 0010400 Attachment, 42 x 47 mm Attachment, 52 x 55 mm Pilot, 20 mm 07746 — 0040500 Pilot, 25 mm 07746 , 0040600 Film, 28 mm 07746 7 0041100 Driver 07749 — 0010000 Bearing remover set ~ remover weight — remover handle 7 remover head 07936 , 3710001 07741 — 0010201 07936 -— 3710100 07936 — 3710600 TROUBLESHOOTING Excessive noise . Worn crankshaft main journal bearings . Worn connecting rod bearings - Worn connecting rod small and . Worn, seized or chipped transmission gear . Worn or damaged transmission bearing Hard to shift - Bent shift fork . Bent shift fork shaft - Damaged shift drum guide groove - Damaged shift fork guide pin Transmission jumps out of gear - Worn gear dogs or slots - Worn shift drum guide groove - Worn shift fork guide pin - Worn shift fork groove in gear CRANKSHAFTITRANSMISSION Apply oil to the threads and seating surface. Apply sealant m the threads. Apply oil to the threads and seating surface. Not available in USA. or 079367 371020A (U.S.A. only) or 07936 — 3710200 1 2-3 (IRAN KSHAFTITRANSMISSION CRANKCASE SEPARATION Refer to Service Information (page 12-2) for removal of necessary parts before disassembling the crankcase. Disconnect the neutral switch connector and remove the neutral switch and washer. Remove the switch cover and disconnect the oil pres- sure switch wire by removing the terminal screw. Remove the oil pre$ure switch. Remove the bolts and countershaft bearing oil seal set plate. OIL PRESSURE svyiTgH 5 Remove the bolt and front cam chain tensioner set plate. Remove the front cam chain from the crankshaft. Remove the bolts and transmission bearing set plate. Remove the bolt and rear cam chain tensionar set plate. Remove the rear cam chain from the crankshaft. Loosen the two Ermm bolts and five B—rnm bolts and remove them from the left crankcase. CHAlN 1 2-4 Loosen the three 6mm bults and eight 8-mm bulls and remove them with a washer from the right crankcase. Place the crankcase assembly will! the left side down. Carefully separate the right crankcase from the left crankcase. NOTE: ~ Use the pry slots at the front and rear of the crankcase if necessary. Remove the dowel pin and collar. Remove the O-ring from the oil pipe. CRANKSHAFT/ TRANSMISSION &mm BOLTS . a? 5mm BQLTSW PRY SLOTS DOWEL PIN 12-5 CRANKSHAFTITRANSMISSION CRANKSHAFI'ICONNECTING ROD CRANKSHAFT CRANKSHAFI' REMOVAL ‘ Separate the crankcase (page 1274). During crankshaft Remove the crankshafl from the left crankcaser and connening rod service, be careful nut to damage the main journal Or can- necrmg rod hear my inserts. CONNECTING ROD REMOVAL Befora removing the connecting rods, check Ihe big end side clearance. Measure the clearance by inserting a Ieeler gauge between the crankshaft and conneaing rod big and. SERVICE LIMIT: 0.30 mm (0.012 in) Remove the connecting rod bearing cap nuts and bearing caps. NOTE: ‘ Tap Ihe side of the cap ligmly if the bearing cap is hard to remove. Mark the rods, bearings and caps as you remove them to indicale the correct cylinder and position on the crankpins for reassembly. For the cunnecfing rod small end inspection, see page 11-5. 12-6 Do not rotate the crankshaft am. iny inspection. CONNECTING ROD BEARING INSPECTION Inspect the bearing inserts for unusual wear, damage or pee1ing and replace it necessary. CRANKSHAFT RUNOUT Place the crankshaft on a stand or V-blocks. Set a dial indicator as shown. Rotate the crankshaft two revolutions and read the runOUI. SERVICE LIMIT: 0.03 mm (01101 in) CRANKPIN OIL CLEARANCE Clean off any oil from the bearing inserts and crankpins. Put a strip of plastigauge lengthwise on each crankpin avoiding the oil hole, Carefully install the connecting rods and bearing caps on the correct crankpins, Apply engine oil to the threads and seating surfaces of the bearing cap nuts. Install the nuts and tighten them evenly. TORQUE: 33 N1" I14 kgf-m, 25 IbMtl CRANKSHAFI'ITRANSMISSION CRANKSHAFI' Q) 40 — 50 mm (1.6— 2,0 in) PLASTIGAUGE 1 2—7 CRANKSHAFI'I TRANSMISSION Remove (he bearing caps and measure the com» pressed plastigauge aI iis widest paint on each Crankpin to determine the oil clearance. SERVICE LIMIT: 0.01 mm (0.603 in) If the clearance exceeds the service limit, select Ihe correct replacement bearings as follows, CONNECTING ROD BEARING SELECTION Record the connecting rod ID. Code number. NOTE: - Number 1 or 2 on the connecting rod is the code for the connecting rod LD. Record the crankpin 0.0. code lener. NOTE: - Leners A or B on each crank weighr is the code for the crankpin 0.D. Cross reference the connecling rod and crankpin codes to determine the replacemem bearing color code. Connecting rad LD. code ' 2 Crankpin 0D. l$3.000 — 43.007 43,008 — 43.016 code (Lam—LN) (16932—16935) A 39.982 — 39.990 Brown Black (1.5741 — 1.5744) B 39.976 , 39.982 Black Blue (1538*15741) CRANKPIN BEARING INSERT THICKNESS: Blue: 1485 - 1.489 mm (0.0589- 0.0590 in) Black .451 - 1.495 mm (0.0587 - 0.0598 in) Brown. 1487 - 1.451 mm (0.0585 — 0.0587 in) CONNECTING ROD I.D. CODE NUMBER COLOR CODE 1 2-8 CRANKSHAFTITRANSMISSION MAIN BEARING INSPECTION Clean off any all from the bearings and the crank- shaft journals. Measure and record the crankshaft main journal 0D. Becarefulnaua Measure and record the main bearing ID. in the damage we crankcase inside ofthe bearing whi/e Calculate the clearance between the main journal and measuring in main bearing. SERVICE LIMIT: 0.07 mm (0,003 in) If the oil clearance exceeds the service limit, replace the crankcase 1 2-9 CRANKSHAFr/TRANSMISSION CONNECTING ROD/CRANK SHAFI SELECTION An alphabetical weight code is stamped on the con- necting rod. lt a connecting rod requires replacement, you should select a rod with the same weight code as the origir nal. But if that is unavailable, you may use one of the om- ers specified in the following chart. The “0" mark in the table indicates that matching is possible in the crossed codes, WEIGHT CODE From connecting rod weight code —— A B C Rear connecting rod weight code A ‘ O 0 E O 0 0 C 0 0 “‘ For selecting crankshaft weight — select “L" crankshaft weight, it the front rod and rear rod have code A ('). — select ”H" crankshaft weight, if the front rod and rear rod have code C l“). — select crankshaft weight with no code, other than the above two cases. CRANKSHAFT/CRANKCASE SELECTION Crankshaft and crankcase are select fined. Record the main journal O.D. code number 1 or 2. Record the main journal bearing er. code A or B, If the crankshaft and/or crankcase are replaced, select them with the following fitting table The "0" mark in the table indicates that mating is possible in the crossed code. Main journal 0D. code 1 2 Main journal bearing I.D. code A 0 B 0 12—10 CONNECTING ROD INSTALLATION Wipe any oil off of the connecting rod. cap and hear- ing inserts. lnstallthe bearing inserts on the connecting rods and caps by aligning the tab with the groove, Apply molybdenum oil snlution to the thrust surface of the bearings. Install the rods and caps on the crankshaft by align- ing the ID. Code on the rod and cap. Be sure each part is installed in its original position, as noted dur» ing removal. Apply engine oil to the threads and seating surfaces of the bearing cap nuts. Install the nuts and tighten them in several steps. TORQUE: 33 MM (3! kgI-m, 25 “3"!) After tightening the nuts, check that the connecting rods move freely without binding. CRANKSHAFT INSTALLATION Apply molybdenum all solution to the main bearing inserts and install the crankshaft into the leit crankcase. Assemble the crankcase (page 12-20). CRANKSHAFI'ITFIANSMISSION 12—11 CRANKSHAFI'ITRANSMISSION TRANSMISSION :SyIFEFORk SHA' REMOVAL ’ Separate ‘he crankcase (page 1274). Pull the shift fork shaft and remove it from the shift forks. Remove xhe shift drum and shift forks. Remove the mainshaft and countershalt from the left . ' J crankcase as assembly, .- DISASSEMBLV MAINSHAFT Disassemble xhe mainshah and countershafl. COUNTERSHAFF 12-12 INSPECTION GEARS Check the gear dogs, dog holes and teeth for damage or excessive wear, Measure the ID. of each gear. SERVICE LIMITS: M3, M5 gears: 28.04 mm (1.104 in) C1, C2, Cl gears: 31.05 mm (1.22 in) BUSHING Check the bushing for wear or damage. Measure the CD. of each bushing. SERVICE LIMITS: M3, M5 gear bushing: 27.94 mm (1,100 in) 01, C2. Cd soar bushing: 30.93 mm (1.218 in) Measure the ID. of each bushing. SERVICE LIMITS‘ M3 gear hushmg: 25.00 mm (0.985 in) C2 gear bushing: 28.0! mm (1,104 in) MAINSHAFI’ICOUNTERSHAFI' Check the spline grooves and sliding surfaces for abnormal wear or damage. Measure Ihe an of the mainshaft and countershaft at the gear bushing sliding areasl SERVICE LIMITS: Malnshafl at M3 gear bushing: 24,95 mm (0.982 in) Coumershaf: at C2 gear bushing: 27.95 mm (1.100 in) Calculate the gear-to-bushing and bushingm-shafl clearance. SERVICE LIMITS: Gear-Io‘bushing (M3. M5): 0.10 mm (0.004 In) (C1, C2, 04): 0‘10 mm (0.004 In) Bushing~tn-shafl (M3): 008 mm (0003 ' ) (02): 008 mm (0003 In) CRANKSHAFTI TRANSMISSION 12—13 CRANKSHAFI'ITRANSMISSION SHIFT FORK Check for deformation or abnormal wear. Measure the shift fork claw thickness. SERVICE LIMIT: 5.6 mm (0.22 in) Measure the shift fork LD. SERVICE LIMIT: 13.04 mm (0.513 inI SHIFT FORK SHAH Check for bends, abnormaI wear or damage. Measure the shift fork shaft OD. SERVICE LIMIT: 12.90 mm (0.508 in) SHIFT DRUM Check the shift drum bearing for excessive play or damage. Turn the outer race of the bearing with your finger. The bearing should tUrn smoothly and quietly. Inspect the shift drum end for scoring, scratches, or evidence of insufficient lubrication. Check the shift drum grooves for abnormal wear or damage. Measure the shift drum on at the left end. SERVICE LIMIT: 11.94 mm (0.470 in) 12-14 CRANKSHAFTITRANSMISSION SHIFI' DRUM, SHIFI' FORK SHAFT JOURNAL SHIFT FORK SHAF" JOURNAL Check the right and left crankcase shift fork shaft _ A ‘V journal for wear or damage. ' Check the left crankcase shift drum journal for Wear or damage. TRANSMISSION ASSEMBLY Clean all parts in solvent. Apply molybdenum oil solution lo the gear and bush- ing sliding surface and shift fork grooves to ensure initial lubrlcatian. Assemble all parts into their Original positions, NOTE: ~ Check the gears for freedom of movement or rota- tion of the shaft. - Install the washers and snap rings with the cham~ fered edges facing the thrust road side. Do not reuse a worn snap ring which could easily spin in the groove. - Check that the snap rings are seated in the grooves and align their end gaps with the grooves of the spline. MAINSHAFT SPLINE WASH ASHE SNAP RING ER THRUST w R 5mm; suSHrNG M4 GEAR (23 T) M3 GEAR (20 T) SPLINE WASHER SNAP RING M3 BUSHING M5 GEAR (24 T) M2 GEAR (17 T) WASHER AND SNAP RING DIRECTION 12-15 CRANKSHAFI'ITRANSMISSION COUNTERSHAFI' c5 GEAR (25 T) SPLINE BUSHING C4 GEAR (27 T) CZ GEAR (34 T) » C2 BUSHING SNAP RING LOCK WASHER COUNTERSHAFI' SPLINE WASHER SFLINE WASHER C1 GEAR (38 T) AR T CS GE (30 ) SPLINE BUSHING THRUST WASHER WASHER AND SNAP RING DIRECTION INSTALLATION BEARINGS Apply engine oil K0 Khe foIIowing pans: — mainshafl bearing — countershafl bearing — shifl drum bearing ‘- Q 12—16 GRANKSHAFTITRANSMISSION Install the mainshaft and countershaft to the left THRUST WASHER crankcase as an assembly to avoid damaging the countershaft oil seal. MAlNSHAFT Be sure to install the countershaft thrust washer. NOTE: ' Each shift fork has an identification mark; 'L“ is for the left shift fork, ”C” is for the center shift fork, “R" is for the right shifi fork. ”L" MARK * ‘ "R" MARK Install the shift forks into the shifter gear grooves with the markings facing up, Install the shit! drum by aligning the shift fork guide pins with the shift drum guide grooves. Apply engine oil to the shift fork shaft and insert it through the shift forks into the left crankcase with the stepped end facing up After installing. check for smooth transmission oper- ation. Assemble the crankcase (page 12720). CRANKSHAFI'ITRANSMISSION CRANKCASE BEARING REPLACEMENT LEFT CRANKCASE: , LEFI' CRANKCASE BEARING Remove the following: 7 crankshaft (page 1276) — transmission (page 1242) 7 oil pump (page 4—4) Drive the left countershah bearing out of the left crankcase and remove the oil seaL Remove the left mainshaft bearing using the specia| tools. TOOLS: Bearing remover set 07536 — 3710001 Not available in U.S.A‘ — remover head 07936 — 3710600 — remover handle 07936 — 3710100 - remover weight 077.1 - 0010201 or 07935 - 371020A (USA. only) or 07936 — 3710200 Drive the left mainshaft bearing into the left crankcase with the seal side facing down, TOOLS: Mainshaft hearing: Driver 07749 - 0010000 Attachment, 42 x ‘7 mm 07746 - 0010300 Pilot, 20 mm 07746 - 0040500 Drive the left countershaft bearing into the left crankcase with the marking side facing up. TOOLS: Countershah bearing: Driver 07749 - 0010000 Attachment, 52 x 55 mm 07746 - 0010100 Pilot, 28 mm 07746 - 0001100 Apply grease to the new countershaft oil seal lip and install it. Check the gearshift spindle ail seal for damage. Replace the gearshift spindle oil seal if necessary. Install the folluwing: 7 oil pump (page 4-8) — transmission (page 1216) 7 crankshaft (page 1211) Q $9.6. COUNTERSW on. SEAL 12-18 CRANKSHAFT/TRANSMISSION RIGHT CRANKCASE BEARING Separate (he crankcase (page 1274). Drive the right mainshaft bearing and countershaft bearing out of the righx crankcase. Drive the rigm mainshah bearing mm the right DRIVER crankcase with the marking side 'acing up, TOOLS: Mainshaft bearing: Driver 07749 — 0010000 Attachment, 52 x 55 mm 07746 — 0010400 Pilot, 25 mm 07746 - 0040500 Drive the right countershah bearing into me rigm crankcase with the seal side facing up. TOOLS: Countershafl bearing: Driver 077‘9 — 0010000 Attachment 42 x ‘7 mm 07746 - 0010300 Pilot; 20 mm 07746 - oowsoo Assemble the crankcase (see next page). flXINng’ir-‘r’ BEAfiJNG 12-19 CRANKSHAFT/TRANSMISSION CRANKCASE ASSEMBLY Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Install the following: — crankshaft (page 12—11) 7 transmission (page 12-16) 7 oil pump (page 4—8) install the dowel pin and Dollar. Coat a new O—ring with engine oil and install it to the oil pipe. Apply liquid sealant to the crankcase mating sur» faces. Carefully install the right crankcase over the left crankcase. Install the three 6-mm bolts. install the eight 8-mm bolts with the washer (washer position is indicated by the 'A' mark). Tighten the emm bolts. Tighten the 8—mm bolts in a crisscross pattern in sev7 eral steps. TORQUE: 23 MI“ (2.3 kgffin. 17 IbMt) DOWEL PIN r a . LEFI’ CRANKCASE 8»mm BOLTS - ‘ . ' MAFK 12-20 Install the two 6—mm bolts and five 8»mm bolts. Tighten the 6-mm bolts. Tighten the 87mm bolLs in a crisacross pattern in SeVr eral steps. TORQUE: 23 Nm (2.3 kgf-m, 17 “1”“ Apply a locking agent to the cam chain tensioner set plate bolt and transmission bearing set plate bolt threads. Install the transmlssian bearing set plate with the bolts, then tighten the bolts. Install the rear cam chain tensioner set plate with the bolt, than tlghtsn the bolt, Install the rear cam chain through the crankcase. Apply a locking agent to the cam chain tensioner set plate bolt threads Install the Iront cam chain tensioner set plate with the bolt, then tighten the bolt. Install the front cam chain through the crankcase. Install the oil pressure switch (page 4.3). Install the neutral switch (page 19-13). Apply a locking agent to the countershaft oil seal set plate bolt threads. Route the engine sub-harness properly and install the countershafi bearing oil seal set plate with the bolts, then tighten the bolts. Install the other remaining parts. OIL FREE SWITCH CRANKSHAFI'ITRANSMISSION 12-21 FRONT WHEELISUSPENSIONISTEERING 23 Min (2.3 kgf—m, 17 lbf'fl? O r K . W ‘ ‘ ‘ m r 103 N~m (10.5 kgfvrn, 76 mm) .~ ’ i) N- 2. kfr ,16Ibf—ft .“9 \- 22 m(29m > Ii, *1" 26 N-m (2‘7 kgf-m.201bV-ft) <( 49 N~m (5.0 kgf‘m, 36 lbf-ft) \ 30 N-m13.1kgf-m,ZZIbF-ft) 22 Mr" (2.2 kgf—m, 16 lbfvfl) 13-0 13. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 13.1 I TROUBLESHOOTING 13-2 l HANDLEBAR . 13-3 FRONT WHEEL 13-8 FORK 1 3- 1 5 STEERING STEM 13-23 SERVICE INFORMATION GENERAL - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. - Raise the front wheel off the ground by supporting the - Refer to section 15 for hydraulic brake system service. - Refer to section 19 for light. meter and switch service. SPECIFICATIONS frame securely. Unit: mm (in) ITEM I STANDARD SERVICE LIMIT Minimum tire tread depth 1' V . 1.5 (0.06) Told tire pressure Up to 90 kg (200 lb) load 5 200 kPa (2.00 kgt/crm, 29 psi) — gaig‘zi’tgmmu'“ ”'9'“ | 200 kPa (2.00 kgflcm7. 29 psi) —— AAile runout — 0.20 (0.003) wheel m m no... Radial — 2.0 (0.00) Axial — 2.0 (0.03) Wheel hub—to-rim distancerAi .4 ‘ Page 13-12 m Wheel—balance weight ‘ — 60 g (2.1 01) Fork Spring free length 492.4(1939) 482.5 (19.00) Tube runout ' W _’ 0.20 (0.008) ‘hecommended fork fluid Pro Honda Suspension Fluid sea — Fork fluid level 12401.9) —— Fork fluid capacity 473 g 2.5 cm3 (16.0 = 0.08 US oz, _ 16.6 a: 0.09 Imp 0:) Steering head bearing preload 0.43 —1.00 kgf (0.95 — 2.29 Ibf) — TORQUE VALUES Steering stem nut Steering bearing adjustment nut Top bridge pinch bolt Bottom bridge pinch bolt Handlebar upper holder bolt Handlebar lower holder nut Front axle bolt Front axle pinch bolt Front brake disc bolt Fork cap Fork socket bolt Brake master cylinder holder bolt Brake caliper mounting bolt 103 Mm (105 kgf-m. 76 Ith) 21 N~rn (2.1 kgf~m, 15 Ibf-ft) 2); him (2.7 kgf~m, zo “Wm 49 N~rn (5.0 kgrm, 36 lbf-ft) za N-m (2.3 kgI-m, 17 lbf‘ft) 23 N-m (2.3 kgl~m, 17 Ibm 59 N-m (6.0 kgr-m, 43 let) 22 N-m (2.2 kgrm, Is lbf-ft) 42 NM (4.3 kgf—m, 31 [bf-ft) 22 Nvm (2.2 kgf—m. 16 mm) 20 N‘m (2.0 kgf-m, u Ibf~ft) 12 N-m (1.2 kgrm, 9 Ibf~m 30 N-m (3.1 kgrm, 22 Ibf-It) Apply oil to the threads and seating surface. ALOC bolt: replace with a new one. Apply locking agent to the threads. ALOC bolt: replace with a new one. 13-1 FRONT WHEEL/SUSPENSIONISTEERING TOOLS Attachment, 42 x 47 mm Attachment, 52 x 55 mm Driver 30 mm I.D‘ ‘ Pilot, 20 mm Bearing remover shaft Bearing remover head, 20 mm Driver Steering stem socket Bearing race remover Fork seal driver Fork seal driver attachment, 41 mm ID. Ball race remover set 7 driver attachment —— driver handle Spoke wrench TROUBLESHOOTING Hard steering 07745* 0010300 07746 — 0010400 077467 0030300 077467 0040500 07746~ 0050100 07746— 0050600 07749 — 0010000 07916— 3710101 07946 — 3710500 07947 , KA50100 07947 — KF00100 07953 —~ MJ10000 07953 — MJ10100 07953 — MJ10200 O7JMA — MR60100 . Steering bearing adjustment nut too tight . Worn or damaged steering head bearings - Worn or damaged steering head bearing races Bent steering stem insufficient tire pressure - Faulty front tire Steers tn one side or does not track straight Bent fork - Faulty steering head bearings - Damaged steering head bearings ' Bent frame - Worn wheel bearings - Bent front axle - Worn swingarm pivot component (section 14) Front wheel wobbling - Bent rim - Worn wheel bearings - Faulty tire - Unbalanced tire and wheel or 079166710100 or M9350-277-91774 (U4 ‘ only) or 07953rMJ10005 or 07953-MJ1000A (U.S.A. only) or equivalent commercially available in U.S.A, Soft suspension - Weak fork spring - Low fluid level in fork ' Insufficient fluid in fork - Low tire pressure Hard suspension - High tire pressure - Bent fork 0 High fluid level in fork - Incorrect fluid weight - Clogged fluid passage Front suspension noisy - Loose fork fasteners - insufficient fluid in fork Wheel hard to turn - Faulty wheel bearings - Bent front axle ' Brake drag - Faulty speedometer gear 13-2 HAN DLE BAR Keep the master cylinder upright to prevent air from entering the hydraulic system. REMOVAL Remove the rear View mirrors. Disconnect the clutch switch connectors. Remove the two bolts, clutch lever bracket holder and clutch lever bracket from the handlebar. Remove the two attachlng screws and the left han- dlabar switch housing from the handlebart Disconnect the from brake light switch connectors Remove the from brake switch wire from the wire clip on the handlebar. Remove the bolts, master cylinder holder and master cylinder from the handlebar. FRONT WHEEL/SUSPENSION/STEERING REAR VIEW MIRRORS FRONT WHEEL/SUSPENSIONISTEERING Remove the two attaching screws Remove the bolt caps, socket bolts and handlebar upper hulders. Remove the handlebar from the lower holders. Move the handlebar to obtain sufficient slack in the throttle cables so they can be disconnected from the throttle grip flange. Remove the right handlebar switch housing from the handlebar. Remove the throttle gripr Remove the handlebar. Remove the left handlebar grip and/or grip ring it necessary. Handlebar grip replacement, see page 13-7. INSTALLATION Apply grease to the throttle grip flange groove and install the throttle grip onto the handlebar. THROTI‘LE CABLES F6. 7 1‘ ' THROTI'LE GRIP 13-4 FRONT WHEEL/SUSPENSIONISTEERING Home the cable Apply grease to the throttle cable ends. and W/I’es pm' Connect the throttle cables to the throttle grip flange. perly {page 1718). Place the handlebar unto the lower holders and align the punch mark on the handlebar with the top of the lower holder. install the upper holders with the punch marks facing tom/am. Install the socket bolts and tighten the for- ward bolts first. then tighten the rear bulls. TORQUE: 23 Nm (2.3 kgf-m, 17 [bl-fl) lnstall the bolt caps. Install the right handlebar switch housing onto the handlebar, aligning the locating pin with the hole in the handlebar. Install the attaching screws and tighten the tamard screw first, then tighten the rear screw. FRONT WHEEL/SUSPENSIONISTEERING Install the master wlinder and master cylinder holder PUNCH MARK with the ”UP" mark facing up Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-fl) Set the front brake light switch wine to the wire clip. Connect the front brake light switch connectors. HOLE , GRIP RING Set the grip ring onto the left handlebar switch housA ing. Install the left handlebar switch housing onto the handlebar, aligning the locating pin with the hole in the handlebar‘ Install the attaching screws and tighten the forward screw first, then tighten the rear screw. SCREWS Install the clutch lever bracket and bracket holder ' ., l . - ' PUNCH MARK with the “UP” mark facing up. . l . Align the end of the clutch lever bracket with the punch mark on the handlebar and tighten the upper bolt first, then tighten the lower boltt Connect the clutch switch connectors. ; . - , {$3 ”UP” MARK 7 ' ' ; ‘ CDNNECTO It" RS 13-6 Allow the adhe» sive to dry for an hour before using. Allow the adher sive to dry for an haur before using. lnstali the rear view mirrors. HANDLEBAR GRIP REPLACEMENT NOTE: ‘ Instail the grip end cap to the handlebar grip first, then install the grip to the handlebar. GRIP END CAP Remove the handlebar grip end cap by prying it with a screwdriver. Install the grip end cap while aligning the tabs with the grooves in the handlebar. LEFI' HANDLEBAR GRIP Clean the inside surface 01 the left handlebar grip and the outside surface of the handlebar. install the grip and cap to the handlebar grip. Apply HondaBond A or Honda Grip Cement (U.S.A. onlyl or equivalent to the inside surface of the left handlebar grip and to the outside surface of the left handlebar. Wait 3 - 5 minutes and install the grip. Rotate the grip for even application of the adhesive. THROTTLE GRIP Clean the inside surface of the throttle grip and the outside surface of the throttle piper Install the grip end cap to the throttle grip. Apply HondaBond A or Honda Grip Cement (USA. only) or equivalent to the inside surface of the throt- tle grip and to the outside surface of the throttle pipe. Wait 3 , 5 minutes and install the grip. Rotate the grip for even application of the adhesive FRONT WHEELISUSPENSION/STEERING HEAR VIEW MIRRORS TABS @@ GROOVES GRIP END CAP LEFT HANDLEBAR G RIP RIGHT HANDLEBAR GRIP 13-7 FRONT WHEEL/SUSPENSION] STEERING FRONT WHEEL 7ng q’sgriéc’i’k' REMOVAL ‘ Raise the front wheel off the ground by supporting the frame securely. Remove the screw and speed sensor. Loosen the right axle pinch bolts. Remove the from axle bolt. Do not operate Loosen the left axle pinch bolts. the fmm brake Pull the front axle out and remove the front wheel. [ever after removing the front wheel a! it will be Very diffi» cult to separate the brake pads. Remove the side collar from the right side of the wheel. 1 3-8 Remove the speedometer gear box from the left side of the wheel. INSPECTION AXLE Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 In) WHEEL Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator readingt SERVICE LIMITS: Radlalt 2.0 mm (0.08 In) Axial: 2,0 mm (0.08 in) WHEEL BEARING Turn the inner race of each bearing with your fingert The bearings should turn smoothly and quietly Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. FRONT WHEEL/SUSPENSION/STEERING SPEEDOETER GEAR BOX! 1 3-9 FRONT WHEEL/SUSPENSIONISTEERJNG DISASSEMBLY Remove the dust seals from b0!!! sides of the wheel. Remove the speedometer gear retainer. Remove lhe six socket bolts and brake disc. Install ‘he bearing remover head into the bearing‘ From me apposite side install the bearing remover shah and drive the bearing out 01 the wheel hub. ”the bearings fiemova lhe distance collar and drive out the olher an removed, bearing, they must be replaced with TOOLS: new ones Be-ring umnvu shift 07746 - 0050100 Bearing rumour head. 20 mm ants-0050600 13+10 FRONT WHEEL/SUSPENSION] STEERING ASSEMBLY DISTANCE COLLAR DUST SEAL (@ BEARING BEARING BRAKE DISC FRONT WHEEL SPEEDOMEYER GEAR RETAINER SOCKET BOLT Drive in a new right bearing squarely with the mark- ing facing up until it is fully seated, Install the distance collar. Drive in a new lefi wheel bearing squarely with the marking facing up until it is seated using the special tools‘ TOOLS: Driver 07749 - 0010000 Attachment, 42 x 47 mm 07746-001030!) Pilot, 20 mm 07746 - 0040500 FRONT WHEELI SUSPENSlONI STEERING WHEEL CENTER ADJUSTMENT Wheel center adjustment is necessary when new spokes are installed Measure distance B (rim width) and calculate dis tance A as follows: A = 79 mm (11 in) ~ 3/2 Adjust the rim position and distance A by tightening the spokes to the specified torque in two or three progressive steps. TOOL: Spoke wrench WIJMA - MRSO‘IDI) or equivalent commercially available in USA. TORQUE: 4 N-m (0.4 km, 2.9 M“) Install the brake disc onto the wheel hub with the stamp facing out. Install new socket bolts and tighten them in a cries» cross pattern in several steps. TORQUE: ‘2 Min [43 kghn, 31 IM-ft) WHEEL BALANCE NOTE: - The wheel balance must be checked when the tire is temountedt - For optimum balance, the tire balance mark (a paint dot on the side wall) must be located next to the valve stem Remaunt the tire if necessary 13-12 Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel. Do nut get grease on the brake disc or slapping power will be reduced. FRONT WHEEL/SUSPENSION/STEEHING Mnunt the wheel, tire and brake disc assembly on an inspection stand. Spin the wheel, allow it to stop. and mark the lowest (heaviest) part of the wheel with chalk. Do this two orthree 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 a balance weight on the lightest side of the snake, opposite the chalk marks, add just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 60 g (2.1 oz) to the lront wheel. Install the speedometer gear retainer into the left wheel hub, aligning the tangs with the slots in the hub. Apply grease to the new dust seal lips and install the dust seals into both sides of the wheel until they are fully seated. INSTALLATION Apply grease to the inside of the speedometer gear box, and install the gear box into the left wheel hub. FRONT WHEEL] SUSPENSION] STEERING Install the side collar into the right wheel huh. be 7’ no TVAXL‘E Place the front wheel between the tork legs so the brake disc is positioned between the pads, being careful not to damage the pads Align the groove in the speedometer gear box with the lug on the left lurk leg. insert the front axle from the left side until it is fully seated. Make sure the index line on the axle is aligned with the fork leg and tighten the left axle pinch bolts, TORQUE: 22 Min (2.2 kgfm. 16 Ile) Install and tighten the front axle bolt. TORQUE: 59 N-m “5.0 kghn, 48 mm Tighten the right axle pinch belts. TORQUE: 22 M!“ (2.2 hat-m, 1G Ith) Install a new O-ring onto the speed sensor shaft groovet Install the speed sensor by aligning the slot with the tang of the gear box Install and tighten the screw securely. 13-14 FRONT WHEEL/SUSPENSIONISTEERING FORK REMOVAL Remove the front wheel (page 13-8). Remove the headlight (page 19-3). Release the wire clamps and disconnect the front turn signal mm wire connectors. Remove the bolL collar and turn signal light assemv blv. Remove the four bolts and from brake hose clamp and irum fender. Do nut hang the Remove the brake caliper mounting bolts and the brake caliper brake caliper from the fork leg, fmm the brake hose. Remove the bolt cap. Loosen the fork top bridge pinch bolt When The fork is ready to be disassembled, loosen the fork cap, but do not remove it. CAP PINC 0LT 13-15 FRONT WHEEL] SUSPENSION] STEERING Laosen rhe bottom bridge pinch hon and remove the ”NC“ BOLT from fork from the fork top bridge and steering stem. '7 DISASSEMBLV FORK CAP Remove xhe fork cap. The fark cap is Remove the O-ring from the fork capr under spring pressure. Use care when removing it. SPACER Remove (ha following: —— spacer — spring seat — fork spring FORESPRING Four out the fork fluid by pumping the fork tube up and down several times 13-16 FRONT WHEEL/SUSPENSION] STEERING Hold the front fork in a vise with soft jaws or a shop towel. If the fur/r piston Remove the fork socket bolt and sealing washer. turns with the - socket bolt, tem- porarily install (he York spring, spring seat, spacer and fork cap. Remove the fork piston and rebound spring from the fork lube. Remove the dust seal, Remove the stopper ringr Pull the fork tube out until resismnce from the slider bushing is felt. Then move it in and our, tapping me bushing lightly until me fork tube separates from the fork slider. The slider bushing will be forced our by the fork tube bushingr 13-17 FRONT WHEEL/SUSPENSIONISTEERING Do not remove the ram tubs bushing unless it is necessary to replace it with a new one‘ Remove the oil Iock piece. OIL L9CI( PIECE , Remove the oil seal, back-up ring and slider bushing from the fork tube. BACK-UP RING I ‘ ’ FORK TUBE BUSHING INSPECTION FORK SPRING Measure the fork spring free length. SERVICE LIMIT: 482.5 mm (19.00 In) FORK TUBE/SLIDER/PISTON ‘ _ 3 FORK PISTON Check the fork mbe, fork inder, DII lock piece and fork FORK TUBE i ‘ ‘ I ‘ ' piston for score marks, and excessive or abnormal ’ ’ " ' " wear, Check the fork piston ring ior wear or damagsi Check ‘he rebound spring for fatigue or damage. Replace the component if necessaryo FORK SLIDER 13-18 FRONT WHEEL/SUSPENSION[STEERING Set the fork tube in V—blocks and measure the fork tube runout with a dis! indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflnn is worn so that the copper BUSHING surface appears on more than 3/4 of the entire sur- faCE- BACKVUF RING Check the back-up ring: replace it it there is any dis- tortion at the points shown. ASSEMBLY CHECK POINTS Before assembly, wash all parts with a high flash COPPER point or non-flammable solvent and wipe them off SURFACES completely. UST SEAL :lSTON RING D FORK PISTO SPACER FORK CAP STOPFER RlNG\Q 6/ /© / , OIL SEAL BACK-UP RING ’ 0.3mm SLIDER BUSHING L? SPRING SEAT / REBOUND SPRIN/G / FORK SPRING FORK SLIDER «WW\‘ 39;qu WASHER FORK TUBE BUSHING OIL LOCK PIECE FORK SOCKET BOLT 13-19 FRONT WHEEL/SUSPENSIONISTEERING FORK PISTON Install the rebound Spring onto the fork piston. Install the fork piston into the fork tube. FORK TUBE REBOUND SPRING Install the oil lock piece onto the fork piston end. ¢ Install the fork tube imo the fork slidel. v FORK TUBE BUSHING Install the new lork tube bushing if the bushing has b d. Be" rem‘we @ OIL LOCK PIECE FORK SLIDER Hold the fork slider in a vise with soft jaws or a shop a?! ' _ .. n AILING WASHER towel. " SE Apply locking agent to the fork sncket bolt threads ‘ ' _ . .. and install the socket bolt with a new sealing washer ‘ into the fork piston. lithe fork piston Tighten the socket bolt to the specified torque‘ turns with the socket bolt, tem- TORQUE: 2|) N-m (2‘0 kgfvm, 14 let) pmmy install me fork spring, spring seat, spacer and fork cap. 13-20 Place the slider bushing over the fork tube and rest it on the slider. Put the backup ring and an old bushing or equivalent tool on top of the slider bushing. Drive the bushing into place and remove the old bushing or equivalent tool. Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal lipr C03! 3 new oil seal with fork fluid and install it over the fork tube with the marked side facing up. Drive the oil seal into place. TOOLS: Fork seal driver Fork seal driver attachment. 41 mm LD. 07947 — M50100 07947 — KFOO‘IOO Install the stopper ring into the groove in the fork slider. Apply fork fluid fo the lip of a new dust seal and instaIi the dust seaL Remove the vinyl rape from the fork tube top end. Pour the specified amount of the recommended fork fluid in the fork tuber RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid 55-8 FORK FLUID CAPACITY: A13 5: 2.5 cm3 (16.0 i 0.08 US oz. 15.6 3: mm Imp oz] Pump the fork rube several times to remove the trapped air from the lower portion offhe fork tuber Compress the fork tube fully‘ Measure {he oil level from the top of the fork tube. FORK FLUID LEVEL: 124 mm (4.9 in) FRONT WHEELISUSPENSIONISTEERING FOFLK SEAL DRIVER STOPPER RING an»? OIL SEAL BACK-UP RING SLIDER BUSHING sTopfiE'fijNE . . r l OIL LEVEL FRONT WHEEL/SUSPENSIONISTEERING V Tights/i the fork cap after installing the fork tube ink? the fork bridges. Pull the fork tube up and install the fork spring with the tightly wound coil side facing down. Install the spring seat and spacer. Coat a new O-ring with fork fluid and install it into the fork cap groove. Install the fork cap into the fork tube. INSTALLATION Install the fork tube into the steering stern and fork top bridge. Align the top end of the fork tube with the upper sur- face of the top bridge as shown‘ Tighten the bottom bridge pinch bolt TORQUE: 49 Mm (5.0 kgf~m. 36 “If-hi Tighten the fork top bridge pinch boltt TORQUE: 26 Nm (2.7 kgf-m, 20 Ibfit) Tighten the fork cap. TORQUE: 22 N-m (2.2 kgfm, 16 [but] Install the bolt cap to the fork top bridge pinch bolt. SPACER FORK TUBE SPRING SEAT FORK SPRING 13—22 FRONT WHEEL/SUSPENSION/STEERING Install the brake caliper onto the front fork with the new mounting bolts. Tighten the mounting butts to the specified torque. TORQUE: 30 N1“ (3.1 kgfim, 22 lbf-ftl install the front fender and brake hose clamp. install and tighten the from fender bolts. Install the turn signal light assembly, collar and bolt onto the front fork‘ Tighten the bolt securely. Route the front turn signal light wire properly. Connect the wire connectors and clamp theme install the front wheel (page 13-13). install the headlight (page 19-3). STEERING STEM REMOVAL Remove the handlebar (page 13-3). Remove the front wheel (page 13-8). Remove the headlight (page 19-3) and the front turn signal assembly (page 13—15). Release the wire clamps and disconnect all the con- nectors in the headlight case. FRONT WHEEL/SUSPENSIONISTEERING 7 Remove the two nu‘s and headlight case with the bracket, Remove me bolt and brake hose clamp from the steering stem. Loosen the steering stern nut. Remove khe following: — front forks (page 13—15) — stem nut and washer — fork top bridge Straighten the lock washer tabs, and remove the luck nut and lock washer. LOCK NUT 13-24 Always replace the bearing and races as a 52!. Loosen the steering bearing adjustment nut, hold the steering stem and remove the adjustment nut using the special tooL TOOL: ' Steering stem socket 07915 - 37I010‘l or 07916 - 3710100 Hold the steering stem and remove the following: 7 upper dust seal — upper inner race — upper steering bearing — steering stem —- lower steering bearing Check the steering bearings, inner and outer races for wear or damage Remove the upper bearing outer race using the spe- cial tools. TOOLS: Ball race remover set 07953 — MJ‘WOOO — driver attachment 01953 — MJ1OWB — driver handle 07953 - W102i") or 0753 — MJ‘IOOOB nr 07953 — MJIOOOA (USA. nnlvl or Driver “7949 — 371001 Aflach ment. 37 x 40 mm 07746 - 00‘0200 FRONT WHEEL/SUSPENSIONISTEERING STEERING STEM SOCKET ATTACHMENT ' DRiVEfiV HANDLE , _ FRONT WHEELISUSPENSIONISTEERING Remuve the lower bearing outer race using the spe- cial teal, TOOLS: Bearing race remover 07946 — 3710500 or M9360 - 277 - 9177‘ (USA only) or Drive! 07949 — 3710001 Attachment, 37 x 40 mm 07746 - 0010200 Install the stern nut unto the stem to prevent the threads from being damaged when removing the lower bearing inner race from the stem, Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the slem. Remove the dust seaL INSTALLATION STEM NUT WASHER Q LOCK NUT LocK WASHER é/ \, \Q STEERING BEARING ADJUSTMENT NUT ® DUST SEAL TOP BRIDGE UPPER INNER RACE A, UPPER BEARING UPPER OUTER RACE LOWER INNER RACE HEADLIGHT CASE/BRACKET DUST SEAL ._..© LOWER OUTER RACE LOWER BEARING 13-26 FRONT WHEEL/SUSPENSIONISTEERING Apply grease to the new dust seal lip and install it over the steering stem. Install the new lower bearing inner race using a hydraulic press. TOOL: Driver 30 mm ID. 07746 — 0030300 Drive the new lower bearing outer race into the steer ing head pipe. TOOLS: Drive: 07749 — 0010000 Attachment, 52 x 55 mm 07746 - 0010400 DRIVER ,_ L Drive the new upper bearing outer race into the a DRIVER, steering head pipe, v TOOLS: Driver 07749 -0010000 Attachment, 42 x 47 mm 07746— 0010300 Apply grease to each new steering slam bearing rolling contam surface and fill it up. lnstall the lower bearing onto the sleering stern. lnstall the upper bearing onto the sleering head pipe. lnsen the stem into the steering head pipe. FRONT WHEEL/SUSPENSIONISTEERING Install the upper inner race. Apply grease to the new upper dust seal lip and install it. > Apply oil to the steering bearing adjustment nut threads and install it. Tighten the steering bearing adjustment nut to the STEERING STEM SOCKET specified torque using the special taol. TOOL' Ste-(Inn stem socket 07918 - 3710101 or 07916 -3710100 TORQUE: 21 MI! (2.1 kqu, 15 “1"!) Turn the steering stem Iock—toJock five times. Retighten the adjustment nut to the same torque. 13—28 FRONT WHEEL/SUSPENSIONISTEERING Install the new look washer to align its bent tabs with the grooves in the adjustment nut LOCK NUT Install and finger tighten the lock nut all the way. Further tighten the lock nut, within 90°, to align its LOCK WASHER grooves with the tabs of the lock washer. V Bend up the lock washer tabs into the grooves of the lock nut. ADJUSTMENT NUT Install the following: — steering top bridge 7 washer ~ steering stern nut WASHER, STEM NUT , \ Route the cables Temporarily install the front forks. and wire properly Tighten the stern nut to the specified torque. (page 1. 18) YOROUE: 103 NM (10.5 ”gin, 7S IbMt) Make sure the steering stern moves smoothly with- out play or binding, Install the front fork (page 1322). install the brake hose clamp by tightening the bolt. Install the headlight case with the bracket onto the steering stem and tighten the mounting nut. Route all the connectors into the headlight caset Connect all the connectors in the headlight case and clamp them. Install the front turn signal assembly (page 13-23) and the headlight (page 19-31 Install the from wheel (page 13-13). Install the handlebar (page 134), FRONT WHEEL/SUSPENSIONISTEERING STEERING BEARING PRELOAD Raise the from wheel off (he ground. Position the steering stem to the straight ahead posi— tion. ’ Hook a spring scale to the fork tube between the fork top and botmm bridges. Make sure there is no cable or wire harness interfer— ence. Pull the spring scale keeping the scale at a right angle to the steering stem. Read the scale a! the poim where the steering mem lust starts to move right and left. STEERING BEARING PRELOAD: 0.43 - 1.04 kgf (035 —2.29 Ibl) If the readings do not fall within the limits, readjust the sIeering bearing adjus1ment nut. Install the removed parts in the reverse order of removal. liFl 13-30 REAR WHEEL/BRAKE/SUSPENSION 25 N-m (2.5 kgf-m, 18 lbf-ft) 88 N-m (8.0 kgfim, 65 )bf-m 64 Nm (6.5 kgf~m, 47 Ibf-fl) 26 Nrm (2.7 kgf-m, 20 lbfm 93 N-m (9.5 kgbm, 69 |bf~ft) 26 N-m (2.7 kgf'm, 20 Ibfrft) 1 4—0 14. REAR WHEEL/BRAKEISUSPENSION SERVICE INFORMATION 14—1 SHOCK ABSORBER 14-14 TROUBLESHOOTING 14-2 SWINGARM 14.15 REAR WHEEL . 14-3 REAR BRAKE PEDAL/ROD 14-22 REAR BRAKE 14-11 SERVICE INFORMATION GENERAL - When servicing the rear wheel, shock absorber, or swingarm, raise the rear wheel off the ground by supporting the frame securely. - Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. ‘ When using the lock nut wrench, use a deflecting beam type torque wrench 20 inches long. The lock nut wrench increases the torque wrench’s leverage, so the torque wrench reading will be less than the torque actually applied to the lock nut. The specification given on the next page Is the actual torque applied to the lock nut, not the reading on the torque wrench when used with the lock nut wrench. The procedure later in the text gives both actual and indicated. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT _ _ nimum tire tread depth 2.0 (008) Cold tire pressure Up to 90 kg (200 lb) load 200 kPa (2.00 kgf/cmz, 29 psi) — Salingzigax'mum we‘gh‘ 250 kPa (2.50 kgf/cm’, 36 psi) —- > Axle runout —— 0.20 (0.008) Wheel rim runout Radial V ' — 2.0 (0.08) ’ Xx}? — 2,0 (0,08) Wheel hub-to-rim distance Page 14—3 Wheel balance weight ' — 70 g (25 oz) _ Drive chain slack 15 - 25 (0,600 — 1) 40 (16) Drive chain size/link RK 525 SMOZS/124 L — Rear brake Drum l.D. 130.0 -180.3(7.09 -7.10) 181 (7.13) Lining thickness i 5 (0.2) 2 (0.1) Pedal free play 20—30(3/«4-1/45‘- — Shack absorber spring preload adjuster setting 2nd position — 14-1 REAR WHEELIBRAKEISUSPENSlON TORQUE VALUES Rear axle nut Driven sprocket nut Shock absorber upper/lowermounting bolt Swingarm pivot nut Swingarm pivot adjusting bolt Swingarm pivot lock nut Drive chain slider screw Rear brake stopper arm nut Rear brake arm bolt Rear brake middle rod joint bolt Spoke nipple TOOLS: 07746 —— 0010100 07746 - 0010300 07746 — 0040300 07746 , 0040500 07746 — 0050100 07746 7 0050600 07749 ~ 0010000 07914 — SA50001 07946 — KA50000 07946 — MJ00100 07946 — MJODZO‘I O7GMA — KWOZOO 07JMA — MR60100 Attachment, 32 x 35 mm Attachment, 42 x 47 mm Pilot, 15 mm Pilot, 20 mm Bearing remover shaft Bearing remover head, 20 mm Driver Snap ring pliers Bearing driver remover Driver shaft Attachment Pivot lock nut wrench Spoke wrench TROUBLESHOOTING Soft suspension - Waak shock absorber spring ~ - Oil leakage from damper unit ' - Incorrect suspension adjustment - Low tire pressure 93 N-m (9.5 kgf-m, 69 [bf-ft) 83 N»m (9.0 kgf-m, 65 lbf-ft) 26 Nrm (2.7 kgf-m, 20 Ibffl) 88 N‘m (9.0 kgf-m, 65 mil!) 25 N-m (2.5 kgfvm, 1B lbf-ft) 64 N-m (6V5 kgfvm, 47 Ibf-ft) 3 N~m (0‘3 kgf-m, 2‘2 lbf-ft) 20 NM (2.0 kgf-m, 14 lbf'fl) 28 N~m (2.9 kgf~m, 21 lbf'fil 34 Min (3.5 kgf-m, 25 lbf-m 4 Nrm (0.4 kgf-m, 2.9 lbf-fl) Uinur. U»nut. U-nut. Not available in U,S.A. Not available in USA, Not available in U.S.A. Equivalent commercially available in USA, Wheel turns hard Faulty wheel bearings Brake drag (section 15) Ben! rear axle Suspenslon noise Hard suspension - - Damaged shock absorber mounting bushing - Incorrect suspension adjustment - Damaged swingarm pivot bearing - Bent damper rod - High tire pressure Rear wheel wobbling - Bent rim - Worn wheel bearings Faulty tire Unbalanced tire and wheel Low tire pressure Faulty swingarm pivot bearings Binding shock case Faulty rear damper Loose fasteners Worn suspension pivot bushings 14-2 REAR WHEEL/BRAKE] SUSPENSION REAR WHEEL REMOVAL Raise the rear wheel off the ground and support it firmly. Remove fihe rear brake adjusting nut, disconnect the brake rod from the brake arm, and remove the brake arm join! and spring Remove the following: — cotter pin 7 nul — plain washer 7 brake stepper arm mbber — brake stopper bolt Loosen and remove the rear axle nut and washer. Turn the drive chain adjusters on both sides of the swingarm as necessary. Move the rear wheel forward fully, making the drive chain fully slack. Remove the drive chain from the final driven sprocket Pull out the rear axle, then remove the rear wheel. REAR AXLE . Remove both side collars. REAR WHEEL] BRAKE] SUSPENSION Replace the wheel hearings in pairs. Remove The brake panel from the brake drum. INSPECTION AXLE Place the axle in valocks and measure the runoul. Actual moon! is 1/2 the tolal indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) WHEEL Check the rim runout by placing the wheel in a truing stend‘ Spin the wheel slowly and read the runout using a dial indicator‘ Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Had" I: 2‘0 mm (0.08 in) AXII 2.0 mm [0.08 in) WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in (he ‘ hubl 1 4—4 FINAL DRIVEN SPROGKEI' Check the Condition of the final driven sprocket teeth. Replace the sprocket if it is worn or damaged. Neverinstall a new drive chain on a worn sprocket or a warn chain on new sprockets. Both chain and sprockets must be in good condition or the replace- ment chain or sprocket will wear rapidly, Final driven sprocket replacement, See below. FINAL DRIVEN SPROCKEI' REPLACEMENT NOTE: - If the final driven sprocket requires replacement, insnect the drive chain and drive sprocket. Remove the five nuts by holding the rear wheel, then remove the sprocket from the bolts. Install the new driven sprocket with the nuts, then tighten the nuts to the specified torque. TORQUE: 88 Nm (9.0 kgfim, 65 “114!) DISASSEMBLV Remove the final driven flange with the sprocket from the wheel hub. NOTE: - If it is hard to remove the final driven flange, tap the sprocket in several locations with a piece of wood or a soft hammer. Remove the damper rubbers and O~ring. REAR WHEEL/BRAKEISUSPENSION REAR WHEEL/BRAKEISUSPENSION If the bearings are removed, they must be replaced with new anes. Install the bearing remover head into me hearing. From the opposite side insta|| the bearing remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. - TOOLS: Bearing remover shaft 07746 — 0050100 Bearing remover head, 20 mm D7746 - m - 0x A » mam BEARING REILOVER HEAD FINAL DRIVEN FLANGE Remove the dusx seal from the final driven flange. Drive the bearing and collar oui of the driven flange using the suitable tool. ' BEARING 14-6 REAR WHEEL/BRAKEISUSPENSION ASSEM BLY DISTANCE COLLAR FINAL DRIVEN FLANGE BEARING DUST SEAL N UTS O-RING BEARING REAR WHEEL DAMPER RUBBERS COLLAR BEARING DRIVEN SPROCKET Place the new driven flange bearing with the marking {A ,mfi ‘ DRIVER facing down. ’ "' From the opposite side drive in the driven flange col- lar squarely to the driven flange bearing using the special tool. TOOLS: Driver 07759 — 0010000 Attachment. 32 x 35 mm 07746 - 0010100 Pilot, 20 mm 07746- 0010300 _‘ ‘ ~ PILOT Drive in the new bearing and collar into the final dri- {XI—TAG DHIVER ven flange with the marking facing up until it is seated TOOLS: Driver 07749 — 0010000 Attachment, ‘2 x 47 mm 07745 — 0010300 Pilot, 20 mm 07746 — 0010300 REAR WHEEL] BRAKE] SUSPENSION Drive in a right bearing squarely with the marking facing up until it is fully seated. Install the distance collar. Drive in a new left bearing squarely with the marking facing up until it is seated. TOOLS: Driver 077“ - 0010000 Attachment, 42 x 47 mm 07745 — 0010300 Pilot, 20 mm 077“ — 0040500 WHEEL CENTER ADJUSTMENT Wheel center adjustment is necessary when new spokes are installed. Measure distance B (rim width) and calculate dis- tance A as follows: A=72.7 mm (2.86 in) — 3/2 Adjust the rim position and distance A by tightening the spokes to the specified torque in two or three progressive steps. TOOL: Spoke Wench 07JMA — MR60100 or equivalent commercially available in U.S.A. TORQUE: 1 MM (0.4 kgfln. 2.9 thtl Check the damper rubber for deterioration or dam- age and replace the rear wheel assembly with a new one if necessary. Coat a new O-ring with grease. Install the damper rubbers and Orring into the wheel hub. 14-8 REAR WHEEL/BRAKE/SUSPENSION Install the final driven flange assembly onto the left wheel hub. Apply grease to the new dust seal lips, then install it into the driven flange. WHEEL BALANCE NOTE: ‘ The wheel balance must be checked when the tire is remounteclt - For optimum balance, the tire balance mark (a paint dot on the side wall) must be located next to the valve stem. Remount the tire if necessary. Wheel balance Mount the wheel, tire and brake disc assembly on an directly affects inspection stand. the stability, Spin the wheel, allow it to stop, and mark the lowest handling and (heaviest) part of the wheel with chalk. overall safety of Do this two or three times to verity the heaviest area, the motorcycle. If the wheel is balanced, it will not stop consistently Carefully check in the same position balance before reinstalling the wheel. To balance the wheel, install balance weights on the 'EAl-ANCE WElGHT lightest side of the wheel, the side opposite the chalk ' Q marks, add just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 70 g (2.5 oz) to the rear wheel‘ 14-9 REAR WHEELI BRAKE I SUSPENSION INSTALLATION Install the brake panel assembly into the right wheel hub. ' Ins(all both side collars. NOTE: - Do not interchange the left and right side collar. The left side collar is longer than the right side collar. Positian the rear wheel between Khe swingarm‘ Insan the rear axle lhmugh the swingarm, wheel hub and side collars. Install tha drlve chain over the driven sprocket. Install (he washer and rear axle null 14—10 REAR WHEEL/BRAKE] SUSPENSION Install the brake stopper arm bolt. Install the following: — brake stopper arm rubber — plain washer — stopper arm nut Tighten the nut to the specified torque. TORQUE: 20 N-m (2.0 Raf-m, 14 “7140 Install a new cotter pin. Connect the brake rod to the brake arm with the ' ' spring and brake arm joint. STOPPER ARM NUT Install the rear brake adiusting nut. Adjust the drive chain slack (page 3-15). Tighten the rear axle nut to the specified torque. TORQUE: 98 MM (9.5 kgfm, 89 IBM!) Adjust the rear brake pedal free play (page 3-19). REAR BRAKE Remove the rear brake panel from the rear wheel (page 1L3). INSPECTION Measure the rear brake drum LD, SERVICE UMIT:181 mm (7.13 in) Measure the brake lining thicknesst SERVICE LIMIT: 2 mm (0.1 in) REAR WHEEL/BRAKEISUSPENSION DISASSEMBLY Remove the cotter pins and set plate. Expand the brake shoes and remove them from the brake cam and anchor pin. Remave the Shae springs from the shoes. Remove the brake arm bolt and arm from the brake cam. Remove the indicator plate, felt seal and brake cam from the brake panel. INDICATORVE'LA‘I'E chTER PINS BRAKE SHOES FELT SEAL 14-12 REAR WHEEL] BRAKE] SUSPENSION ASSEMBLY INDICATOR PLATE BRAKE ARM BOLT FELT SEAL BRAKE SHOES BRAKE CAM BRAKE ARM COTTER PINS BRAKE PANEL SHOE SPRINGS SET PLATE Apply grease lo the anchor pin, Apply grease to the sliding and shoe contacting sur- faces of lhe brake cam and install the cam into the brake panel, Apply oil to the felt seal and install the seal on the brake paneL Install the indicator plate, aligning ils wide tooth with the wide groove in me brake cam. INDICATORFLATE ‘ " FELTSEAL 14—13 REAR WHEEL/BRAKE/SUSPENSION SWINGARM _ . RIVE CHAIN C—QVER REMOVAL Remove the following: ~ exhaust system (page 275) 7 rear wheel (page 1t3) Remove the bolts and drive chain cover. Remove the shock absorbers (see previous page). Remove the pivot bolt caps and swingarm pivot nut. Remove the swingarm pivot lock nu! while holding the pivot bolt. TOOL: Pivot lock nut wrench 07GMA — KT'IOZOO Not available in U.S.A. Loosen the swingarm adjusting bolt by turning the pivot bolt. Remove the pivot bolt and swingarm. 14-15 REAR WHEEL/BRAKEISUSPENSION Remove the swingarm pivot collars from the right side pivot. Remove the swingarm pivur distance collar from (he Ie‘fl side pivot and remove the collar bushing from the distance collar. DISASSEMBLY Remove the following: a two screws a two chain slider washers — drive chain slider — cotter pin — nut — plain washer — spring washer — brake stopper arm bolt — brake stopper arm Remove the dusr seals from the left side pivot, Remove the oil seals from the right side pivor. PIVOT COLLARS DRIVE CHAIN SLIDER BRAKE STOPPER ARM DUST SEALS OIL SEALS 14-16 REAR WHEEL/BRAKE/SUSPENSION INSPECTION Check the swingarm for cracks or other damage. Check (he distance collar, collar bushing and pivot collars’. Check the dust seals and oil seals. Check the pivot bearings. PIVOT BEARING REPLACEMENT SNAP RING Remove the snap ring irom me right pivot. TOOL: Snap ring pliers 07914 -— SA50001 Drive rhe ball bearings our 0f the swingarm using a DRlVER SHAH hydraulic press and special tools. TOOLS: Driver shaft 07946 - MJ00100 Not available in U.S.A. Attachment 07946 - MJ00201 Not available in USA, or Pilot, 15 mm 07748 - 0040300 Attachment, 28 x 30 mm 07946 — 1870100 Driver shah 07916 — 3710001 ATTACHMENT Drive the needle bearing our of the swingarm using a BEARING DRlVER hydraulic press and special rools. REMOVER TOOLS: Bearing driver remover 07945 — msoooo Attachment 07946 — MJDOZM Not available in U.S.A. or Film, 20 mm 07746 — 0040500 Attachment, 28 X 30 mm 07946 - 1870100 Driver shah 07946 — 3710001 REAR WHEEL/BRAKE/SUSPENSION Apply grease to the new needle bearing, Press the needle bearing into the swingarm with the marking side facing out so the needle bearing outer surface is 4.0 mm (0.16 in) below the outer edge of the swingatm pivot bearing cavity. TOOLS: Drivot 07749 — 0010000 Attachment 07946 - "400201 Not available in U.S.A. or Attachment,28 x30mm 07946- 1070100 Apply grease to the new ball bearings. Press the ball bearings into the swingarm with the marking side facing out until they are fully seated. TOOLS: Driver 07749 - 0010000 Attachment. 32 x 35 mm 07746 - 0010100 Pilot, 15 mm 077.6 - 0040300 Install the new snap ring into the right pivot. TOOL: Snap ring pliars 0791‘ - SA50001 ArrAcHMENT / Pl LOT SNAP RING 4 mm (0.16 in) __L 14-18 REAR WHEEL] BRAKE] SUSPENSION ASSEMBLY SCREWS CHAIN SLIDER DRIVE CHAIN COVER SL|DER WASHERS OIL SEAL / . BOLTS SNAP RING ‘5, 9% BALL BEARINGS g7" @ DRIVE CHAIN ADJUSTERS SWINGARM / OIL SEAL \ , ' DUST SEAL ' NEEDLE BEARING BRAKE STOFFER ARM DUST SEAL Apply grease to the new dust seal lip and oil seal lips. Insrall the dust seals into the left side pivotl Install the oil seals into the right side pivot. OIL SEALS ’ Install the following: — brake stopper arm bolt 4 brake stopper arm 7 spring washer 7 plain washer — nut . ,STOPPER- ARM NUT Tighten the nut to the specified torque. TORQUE: 20 Nm (2.0 kgfm, 14 IM-h) install a new cutter pin. 14-19 REAR WHEEL/BRAKE/SUSPENSION Install the drive chain slider with the arrow mark fac- ing down. Install the chain slider washers and screws. Tighten the screws to the specified torque. TORQUE: 3 Mn “1.3 kghn, 2.2 IbI-fl) INSTALLATION Apply gear oil to the pivot distance collar inner sur- faces. Apply grease to the pivot distance collar outer sur- faces. Apply grease to the distance collar bushing outer and inner surfaces. Apply grease to the pivot collar outer surfaces, Install the collar bushing to the distance collar and install the distance collar in the left side pivot. Install the pivot collars in the right side pivot. Place the swingarm into the frame. Apply gear oil to the swingarm pivot bolt outer sur- face. Insert the swingarm pivot bolt. Be sure the tip of the adjusting bolt does not pro- trude inward. Turn tho swingarm adjusting bolt completely in by hand. Push the pivot bolt’s hex shank into the adjusting bolt's socket head. Tighten the swingarm pivot adjusting bolt with the pivot bolt. TORQUE: 25 Nm (2.5 ngm, 18 lhflt) PIVOT COLLARS 14-20 REAR WHEEL/BRAKEISUSPENSION Refer m turque Install and tighten the swingarm pivot lock nut fully wrench reading by hand, then tighten the lock nut to the specified information on torque while holding the pivot bolt using the special page 1471 mul. “Service lnfarma- flan”, TOOL: Pivot lock nut wrench 07GMA — [(170200 Not available in U.S.A. TORQUE: ActuaI: 64 N-m (6.5 kgf-m, 47 "3”!) Indicated: 58 N'm (5.9 kngl. 43 lhf‘fl) Install and tighten the swingarm pivot nut to the specified tnrquet TORQUE: 88 NM (9.0 kgfvm. GS Ibfitl Install the pivot bolt caps. Install the drive chain cover by aligning the set plate with the tab on the swingarm‘ Install the shock absorbers (page 144 Al. Install and tighten the drive chain cover bolts. Install the rearwheel (page 14710). Install the exhaust system (page 276). REAR WHEEL/BRAKEISUSPENSION REAR BRAKE PEDAL/ ROD REMOVAL Remove the exhaust system (page 2-5). Remove the rear brake adjusting nut, disconnect the brake rod from the brake arm, and remove the brake arm joint and spring. Unhook the rear brake light switch spring from the rear brake middle rod and remove the right footpeg bracket. Remove the rear brake middle rod joint bolt and unhoak the brake pedal spring, Remove the brake pedal/rod assembly and plain washer. Remave the cotter pin, joint pin and middle rod. , SNAP RING Remove the following: — snap ring — bushing washer — dust seals ~ footpeg bracket — rear brake pedal CUTTER PIN 14-22 REAR WHEEL/BRAKE/SUSPENSION Remove the cutter pins, joint pins and rear brake v , COTTER PINS middIe arm. ‘ . > I INSTALLATION Install The removed parts in the reverse order of removal. BUSHING WASHER @ BRAKE ROD ”fin“ DUST SEALS SPR'NG FOOTPEG BRACKET SNAP RING '6‘ BRAKE ARM JOINT CO‘I'IER FIN I MIDDLE ROD JOINT BOLT 3‘ N m (3. 5 kgI— m, 25 lbth MIDDLE ROD JOINT SPRING\/ SPRING ADJUSTING NUT PLAIN WASHER REAR BRAKE PEDAL JOINT PIN JOINT PIN MIDDLE ROD , CO‘I'I'ER PIN JOINT PIN 14-23 HYDRAULIC DISC BRAKE 2 N-m (0,2 mm, 1.4 mm) 12 N-m (‘1.2 kgf-m, 9 |bf~ft) 34 N-m (3.5 kgf‘m, 25 lbf-fl) 30Nvm(3.1kgf»m, .3 i 221nm) , 34 Nm 13.5 kgf-m. 25 ibfrfl) 18 N~m11.8 kgf~m4 13 Inf-m 15-0 15. HYDRAULIC DISC BRAKE SERVICE INFORMATION 151 BRAKE PAD/DISC 15-4 TROUBLESHOOTING 15-2 BRAKE MASTER CYLINDER 15-5 BRAKE FLUID REPLACEMENT] BRAKE CALIPER 15-10 AIR BLEEDING 15-3 SERVICE INFORMATION GENERAL ACAUTION . Avoid breathing dust particles. Frequent inhalation of brake pad dust, regardless of material composition could be halardous to your health. ~ Never use an air hose or brush to clean hrake assemblies. Use an OSHA-approved vacuum cleaner. . A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent . Avoid spllling brake fluid on painted, plastic or rubber parts. Place a rag or shop towel over these parts whenever the system is serviced. Be careful whenever you remove the reservoir cap; make sure the reservoir is horizontal first. . Bleed the hydraulic system if it has been disassembled or if the brake feels spongy. - Never allow contaminants (dirt, water, etc] to get into an open reservoir. - Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible. ‘ Always check the brake operation before riding the motorcycle. SPECIFICATIONS Unit: mm (in) ITEM 3 STANDARD SERVICE umrr e fled brakefluid l DOT4 _.._ —— 'Erake «IE5 thickness ; 5.3 — 6.2 (0.23 - 0.24) 5 (0.2) "eatersc‘marb‘ . _ “ 656(0912) '5 Master cvlinderlD. i 11.000— 11043104331 -0.4348) 11.05 (0.435) Master piston O.D. l 10.957 — 10.984l01314 — 0.4324) 10345 (0.4309) Caliper cylinder LD. 27.000 — 27.050 (1.0630- 1.0650) 27.06l1,065) Caliper piston 0D. 26.318 - 26.968 (1.0598 -1r0617) 26.51(1.059) Brake caliper mounting bolt Brake caliper pin bolt Brake caliper bracket pin bolt Pad pin Pad pin plug Brake caliper bleed valve Brake lever pivot bolt Brake lever vaot nut Brake master cylinder holder bolt Brake master cylinder reservoir cap screw Front brake light switch screw Brake hose oil bolt T00 L: Snap ring priers 30 Nm (3.1 kgf—m, 22 Ibf-ft) 13 N-m (1.3 kgf-m, 9 Ibl‘fi) 27 N-m (2.8 kgf-m, 28 “Wm 18 N-m [1.8 kgf-m, 13 lbf-ft) 3 N-m (0.3 kgf-m, 2.2 Ibf-ftl 6 NW) (06 kgf‘m. 4.3 IN“) 1 N-m (0.1 kgf-rn, 0t7 Ibf'fll 6 N-m (0.6 kgf-m, 4.3 IN“) 12 N-m (1.2 kgfvm, 9 lbf'fl) 2 NM (0.2 kgf-m, 1.4 Ibf-fl) 1 NM (0.1 kgf-m, 0.7 Ibfrfl) 34 N4m (3.5 kgf~m, 25 lbfrfi) 07914 , SA50001 ALOC bolt: replace with a new one. Apply locking agent to the threads. Apply locking agent to the threads. 15—1 HYDRAULIC DISC BRAKE TROUBLESHOOTING Brake lever soft or spongy - Air in hydraulic system - Leaking hydraulic system» - Contaminated brake pad/disc ~ Worn caliper piston seal - Worn master cylinder piston cup ~ Worn brake pad/disc - Contaminated caliper - Caliper not sliding properly - Low brake fluid level - Clogged fluid passage - Warped/deformed brake disc - Sticking/warn caliper piston - Sticking/warn master cylinder piston . Contaminated master cylinder ' Bent brake lever Brake lever hard - Clogged/restricted brake system - Sticking/worn caliper piston - Caliper not sliding properly - Clogged/restricted fluid passage - Warn caliper piston seal - Sticking/worn master cylinder piston - Bent brake lever Brake drag - Contaminated brake pad/disc - Misaligned wheel - Badly worn brake pad/dist: - Warped/deformed brake disc - Caliper not sliding properly - Clogged/restricted fluid passage . Sticking/worn caliper piston 15-2 HYDRAULIC DISC BRAKE BRAKE FLUID REPLACEMENT] AIR BLEEDING BRAKE FLUID DRAINING A Contaminated Position the handlebar to the straight ahead position brake disc arpad so the reservoir is level before removing the reser- reduces stopping voir cap. ”OWE“ ”mam Remove the screws. reservoir cap, set plate and contaminated pads diaphragm. andclean a conta- minared disc with a high qualiry brake deg/easing agent. Do natal/ow far Connect the bleed hose to the bleed valve. sign material to Loosen the bleed valve and pump the brake lever enlerthe System until no more fluid. flows out of the bleed valve. when filling the reservoir. BRAKE FLUID FILLING] BLEEDING Use only DOT! Fill the reservoir with DOT 4 brake fluid from a sealed brake fluid tram a containerr sea/edcontsiner. Connect a commercially available brake bleeder to the bleed valve. Do not mix differ» Pump the brake blesder and loosen the bleed valve, ent types of fluid. adding fluid when the fluid level in the reservoir is low They are not com- patible. NOTE: . Check the fluid level often while bleeding the brake to prevent air from being pumped into the system‘ When using a brake bleeding tool, follow the manufacturer’s operating instructions. Repeat the previous procedures until air bubbles do not appear in the plastic hose. NOTE: - If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon taper Close the bleed valve and operate the brake levert If it is still spongy, bleed the system again. HYDRAULIC DISC BRAKE If a brake bleeder is not available, use the following procedure: Connect a plastic hose to the bleed Valve. Pump up the system pressure with the brake lever until leverAresistance is felt. 1. Squeeze the brake lever. open the bleed valve 1/4 turn and then close it. Do not release the brake lever until the bleed valve has been closed 2. Release brake lever slowly and wait several 5er ends after it reaches the end of its traval. Repeat the steps 1 , 2 until air bubbles do not appear in the bleed hose. Tighten the bleed valve. TORQUE: 6 NM (0.6 kgf‘m, 4.3 Ibffll Fill the reservoir to the upper lever line with the DOT 4 brake fluid. Install the diaphragm, set plate and reservoir cap. Tighten the reservoir cap sum TORQUE: 2 "-1" (0.2 kgf-m, 1.4 lbflll BRAKE PAD/ DISC Always replace the brake pads in pairs :0 assure even disc pressure BRAKE PAD REPLACEMENT Push the caliper pistons all the way in by pushing the caliper body inward to provide clearance tor the new pads. Remove the pad pin plug and laosan the pad pin. SCREWS 3 \W RESERVOIR CAP SET PLATE DlAPH RAGM 1 5-4 Remove the pad pin and brake pads. Make sure the pad spring is installed in position. Install new pads so their ends rest on the pad retain— er an the bracket properly. Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper. Tighten the pad pin. TORQUE: 18 “km (1.8 kglm, 13 “1”!) Install and tighten the pad pin plug. TORQUE: 3 NM [0.3 kgfm, 2.2 IthI Operate the brake lever to seat the caliper pistons against the pads. BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Measure the brake disc thickness at the several points. SERVICE LIMIT: 5.0 mm (0.20 in) Replace the brake disc it the smallest measurement is less than service limit. First make sure the wheel bearings are normal, or you will not get accurate results. Check the brake disc for runout. SERVICE LIMIT: 0.30 mm (0.012 MI Replace the brake disc if the runout exceeds the ser» vice limit. HYDRAULIC DISC BRAKE 1 5-5 HYDRAULIC DISC BRAKE BRAKE MASTER CYLINDER REMOVAL Drain the brake fluid from the hydraulic system (page15-3). Remove the rear view mirror. Disconnect the front brake ighx switch connectors Disconnect the brake hose by removing the oil bolt and sealing washers. Remove the bolts, master cylinder holder and master cylinder from the handleban DISASSEMBLY Remove the following: — screw — from brake light switch — brake lever pivot nut — brake lever pivot bolt — brake lever >O|L BOLT BOLTS BRAKE LIGHT SWITCH SCREW PIVOT BOLT PIVOT NUT‘ 1 5-6 HYDRAULIC DISC BRAKE a piston boot PISTON BOOT — snap ring SNAP RING FLIERS TOOL: Snap ring pliars 07914 - SASOOO‘I — washer — master piston — spring Clean the master cylinder, reservoir and master pis- ton in clean brake fluid. INSPECTION Check the piston cups Ior wean deterioration or dam- age‘ Check me master cylinder and piston for scoring or damage. PISTON ‘ WASHER Measure the mas‘er cy|inder LD. SERVICE LIMIT: 11.05 mm (0.435 In) Measure (he masxer piston O.D. SERVICE LIMIT: 10.945 mm [0.4309 in) 1 5-7 HVDRAULIC DISC BRAKE ASSEMBLY PISTON BOOT PIVOT BOLT SNAP RING MASTER PISTON MASTER CYLINDER BRAKE LEVER PIVOT NUT FRONT BRAKE LIGHT SWITCH SCREW Coat the master piston and piston cups with clean brake fluid. Install the spring onto the piston end. Do not a/law (he Install the piston/spring into the master cylinder, prsmn cup lips to Install the washer. rum Inside Out. PISTON CUPS (1: Be cenainrhe Install the snap ring Into the groove in the master SNAP RING PUERS snap ring is cylindert firm/y seared in the groove. TOOL: Snap ring pliers Msu- SAsmm 1 5-8 Install the piston boot into the master cylinder and the groove in the master piston, Apply silicone grease to the brake lever contacting surface of the master piston. PISTON BOOT Apply silicone grease to the brake lever pivot. Install the brake lever and pivot bolt. and tighten the pivot bolt. TORQUE: 1 N~rn (0.1 kgf-m, 0.7 lbflt) lnstall and tighten the brake lever pivot nutt TORQUE: 6 N~rn (0.6 kgf-m, 4.3 lbm) Install the front brake light switch and tighten the screw, TORQUE: 1 MM (01 kgfm, 0.7 lhlft) SCREW INSTALLATION install the master cylinder and holder with the "UP" mark facing up. Align the end of master cylinder with the punch mark on the handlebar, and tighten the upper bolt first, then tighten the lower bolt. TORQUE: 12 NM (1.2 kgfm, 5 Ibffl) HYDRAULIC DISC BRAKE V flue" MARK 1 5-9 HYDRAULIC DISC BRAKE Connect the brake hose to the master cylinder with the oil bolt and new sealing washers, and tighten the brake hose oil bollv TORQUE: 34 Nm (3.5 kgfin, 25 1M4!) Connect the front brake light switch connectors. Install the right rear View mirror. Fill and bleed the hydraulic system (page 15-3). BRAKE CALIPER REMOVAL Drain the brake fluid from the hydraulic system (page 15-3). Disconnect the brake hose from the caliper by remov- ing the oil bolt and sealing washers. Remove the brake caliper mounting bolts and speed sensor wire guide bolt, Remove the brake caliper. Remove the brake pads (page 15-4). DISASSEMBLV ' . ' BRACKET Remove the following: — caliper bracket from lhe caliper body — caliper pin boot from the bracket CALIPER PlN BOOT 15-10 Do not use high pressure air ar bring ma nozzle ma close to the inlet. —— bracket pin boot from the caliper body 7 pad spring Place a shop towel over the pistons Position the caliper body with the pistons down and apply small squirts of air pressure to the fluid inlet to remove the pistons, Push the dust seals and piston seals in and lift them out to avoid damaging the piston sliding surface. Clean the seal grooves with clean brake fluid INSPECTION Check the caliper cylinder and pistons for scoring or other damage. Measure the caliper cylinder |.D. SERVICE LIMIT: 27.06 mm (1.065 in) Measure the caliper piston 0D, SERVICE LIMIT: 26.91 mm (1.059 in) HYDRAULIC DISC BRAKE PM ET PIN BODT V} PAD SPRING 15-11 HYDRAULIC DISC BRAKE ASSEMBLY BRAKE CALIPER BRACKET CALIPER PIN BOOT BLEED VALVE L0 {@2 " PISTON SEALS BRAKE CALIPER DUST SEALS '@ PAD SPRING CALIPER PIN BOLT w BRACKET F'IN BOLT CALIFER PISTONS PAD PIN BRAKE PADS PAD PIN PLUG BRACKET PIN BOOT Coat new dust and piston seals with silicone grease @ and install them into the seal groaves in the caliper. V 'fiWlSTON SEALS Coat the caliper pistons with clean brake fluid and install them into the caliper with the opening toward the pads. / fl a / I w 9" WA @DUST SEALS/ % If the bracket pin boot is hard or deteriorated, replace / BRACKET PIN BOOT it with new one Install the bracket pin boot into the caliper. Install the pad spring. PAD SPRING 15-12 HYDRAULIC DISC BRAKE if the caliper pin boot are hard or deteriorated, , BRACKET replace them with new ones. Install the caliper pin boot into the bracket, Pack silicone grease to the inside of the caliper pin boot and bracket pin boot Install the caliper bracket over the caliper body. Install the brake pads (page 15-4). Install the brake caliper assembly over the brake disc and onto the front fork. Install and tighten new caliper bracket mounting bolts. TORQUE: 30 Min (3.1 kgflm, 22 Ihf'fll Install and tighten the speed sensor wire guide bolt. Clamp the speed sensor wire. Connect the brake hose to the brake caliper with the oil bolt and new sealing washers, and tighten the brake hose oil bolt. TORQUE: 34 Nm (3.5 kgfim, 25 IbMt) Fill and bleed the hydraulic system (page 15-3), w , a, V SEALING WAS ERSL~ 15-13 BATTERY/CHARGING SVSTEM MAIN FUSE 30A REGULATOR/RECTIFIER §> ' \l ‘ IV V ’ ' /- ‘ ’ j ‘ ‘ ‘&" Egg 1 ~ \ 1 7 ~ ‘ q - ALTERNATOR BAT—TR YVVGFUW |I||I HEGULATOFI/ __ RECTIFIER ALTERNATOR Y : Yellow (3 : Green R : Red W : White 16-0 16. BATTERY/CHARGING SYSTEM SERVICE INFORMATION 16—1 CHARGING SYSTEM INSPECTION 16—7 TROUBLESHOOTING 16—3 ALTERNATOR CHARGING COIL 16-8 BATTERY , 16-4 REGULATOR/RECTIFIER 16-8 SERVICE INFORMATION GENERAL AWARNING The battery gives an explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charg- mg. The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns Wear protective cloths ing and a face shield. 7 if electrolyte gets on your skin, flush with water, i If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. Electrolyte is poisonous. — If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a physician immedir ately. - Always turn off the Ignition switch before disconnecting any electrical component. ~ Some electrical components may be damaged it terminals or connectors are connected or disconnected while the ignition switch is in the on position and current is present. ' For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place. - For a battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery. ' The maintenance free battery must be replaced when it reaches the end of its service life. - The battery can be damaged it overcharged or undercharged, or if left to discharge for long period. These same con- ditions contribute to shortening the ”life span“ of the battery. Even under normal use, the performance of the battery deteriorates after 2 — 3 years, . Battery voltage may recover after battery charging, but under heavy load, the battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an overcharging symptom, If one of the battery cells is shorted and battery voltage dose not increase. the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. - Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the bet- E tery is frequently under heavy load, such as having the headlight and taillight on for long periods of time without rid- ing the motorcycle. . The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every 2 weeks to prevent sulfation from new rring. - When checking the charging system, always follow the steps in the troubleshooting flow chan (page 16—3). - For alternator service, refer to section 9t BATTERV CHARGING - This model comes with a maintenance free lMFl battery. Remember the following about MF batteries. 7 Use only the electrolyte that comes with the battery. # Use all of the electrolyte. —— Seal the battery properly. — Never open the seals again. . For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. 16-1 BATTERY] CHARGING SYSTEM BATTERY TESTING Refer to the Operation Manual for the recommended battery tester for detailed battery testing. The recommended battery tester puts a “load" on the battery so the actual battery condition of the load can be measured. Recommended battery tester BM — 210 - AH. BM - 210 ur BATTERV MATE, or equivalent SPECIFICATIONS ITEM SPECIFICATIONS Battery A Capacity 12 v7 12 Ah D " Current leakage 1 mA max. Voltage Fully charged 13.!) , 13.2 V (zone/68"“ Needs charging V V 7 Below 12.3 v Charging current Normal 1.1 Ax 5— 10 h Quick 55 A x 1.0 h Alternator Capacity 7 V 7 0,333 kW/5,000 rram Charging coil resistance (ZOJC/GIFFI 0.1 r 1.0 :1 TORQUE Battery case cover screw 9 N-m (0.9 kgfrm, 6.51bf-ft) 1 6-2 TROUBLESHOOTING Battery is damaged or weak Remove the battery (page (6-4). Check the battery condition using the recom- mended battery tester. RECOMMENDED BATTERV TESTER: BM — 210 — AH, BM — 210 or BATTERY MATE, or equivalent I Correct Install the battery (page 164). Check the battery current leakage (Leak test: page new. SPECIFIED CURRENT LEAKAGE: 1 mA max. Correct Check the alternator charging coil (page 1&8) STANDARD: 0.1 - 1.0 n (20'6/68“FI | Co rrect — . _ .—I— Measure and record the battery voltage using a digital multimetarlpage16-4I. Start the engine. Measure the charging voltage (page 16-7). Compare the measurements to the result of the ‘ following calculation. l MEASURED BATTERY VOLTAGE < MEASURED CHARGING VQLTAGE < 15.5 V Incorrect I Perform the regulator/rectifier wire harness inspectionlApage 1&8), l Correct Faulty regulator/rectifier fl Incorrect—> - — Incorrect -—-— BATTERY] CHARGING SYSTEM Faulty battery Disconnect the regulator/rectifier 2F connector and recheck the battery current leakage, | l Incorrect Correct L Faulty charging coil Faulty regulator/rectifier - shorted wire harness Faulty ignition switch Incorrect —> - Correct —. - Faulty battery Incorrect -—— - Open circuit in related wire Loose or poor contacts of related terminal 1 6-3 BATTERY] CHARGING SYSTEM BATTERY Set the connec— tor ban! and [CM properly Ipaga 1-18). REMOVAL/INSTALLATION Remove the seat (page 272). Remove the ignition control mudule (ICM) off the bat tery case cover. Remove the cover screw and case cover by releasing the case tabs from the cover slits. with the ignition switch OFF, disconnect the negative (—) Cable first, the" disconnect the positive (+) cable. Remove the battery. Install the battery in the reverse order of remuval. TORQUE: Cover wow: 9 Nm [0.9 kgf-m, 6.51M”) NOTE: v Connect the positive (+) cable first. then connect the negative (—) cable, - After connecting the battery cables. coat the termi- nals with grease. VOLTAGE INSPECTION Remove the battery case cover. Measure the battery voltage using a commercially available digital multimeter. VOLTAGE (20"CI68"F): Fully charged: 13.0- 13.2 V Under charged: Below 123 V BATE RV 16-4 For accurate test rasuirs, be sure [he taste/'5 cables and clamps are In good working condition and that a secure COHNECHDH can be made at the battery. For the first check, DO NOT charge the bar- tery before test- ing,‘ test it in an ”as is ” condi- lion. BATTERY TESTING NOTE: - Always clear the work area of flammable materials such as gasoline, brake fluid, electrulyte, or cluth towels when operating the tester, the heat gener- ated by the tester may cause a fire. Remove the battery. Securely connect the tester's positive (+l cable first, then connect the negative (—) cable. TOOL: Battery tester BM-Z‘lo—AH or BM-210 lU.S.A. only) Set the temperature switch to “HIGH" or "LOW” depending on the ambient temperature. Push in the appropriate test button for three seconds and read the condition of the battery an the metert NOTICE - To avoid damaging the tester, only test batteries with an amperage rating afiess than 30 Ah. - Tester damage can result from overheating when: —- The test button Is pushed in for more than three seconds. — The tester is used without being allowed to 500/ for at least one minute when testing more than one battery. — More that ten consecutive tests are perfurmed without allowing at least a 30-minute cool- down period. The result of a test on the meter scale is relative to the amp. hour rating of the battery. ANY BATTERY READING IN THE GREEN ZONE lS 0K. Batteries should only he charged if they register in the VEL- LOW or RED lone. BATTERVI CHARGING SYSTEM TESTE R BA'I'I'ERY HIGH: 15°C (60°F) or higher LOW‘ 15°C 160°F) or lower TEST BUTI'ONS YELLOW (-1) GREEN (+1, +2, +3) § RED (*3, —2l 16-5 BATI'ERYICHARGING SYSTEM BATTERY CHARGING Remove the battery (page 19‘). NOTE: , - Be sure that the area around the charger is well Ventilated, clear of flammable materials, and free from heat, humidity, water and dust. - Clean the battery terminals and position the bat tery as far away from the charger as the leads will permit. - Do not place batteries below the charger 7 gases from the battery may corrode and damage the charger. - Do not place batteries on top of the charger. Be sure the air vents are not blocked, BATTERY AMP. HR. Tum the 1. Turn the Power Switch to the aft position, SELECTOR SWITCH power nn/offat 2. Set the battery Amp. Hr. Selector Switch for the the charger, size of the battery being charged. 55 m 50 not at the bat» , 35 to 540 9.5 to 16.0 tery terminals. TOOL: Christie battery charger M01012/2 ° '° 3'° "5'5 ‘° 3° tu.s.A only) Set the appropriate amp. hour rating. 3. Set the Timer to the position indicated by the Honda Battery Tester; RED~3. RED-2 or YELLOW 1. If you are charging a new battery, set the switch to the NEW BATT position. 4. Attach the clamps to the battery terminals: RED to Positive, BLACK to Negative. Connect the battery cables only when turn the Power Switch to the off position. 5. Turn the Power Switch to the on position. The charger 6. When the timer reaches the ”trickle” position, the will automati— charging cycle is complete. Turn the Power Switch TIMER cal/y switch to to the off position and disconnect the clamps Trrckle the "trickle” 7. Let the battery cool for at least ten minutes or until made after the gassing subsides after charging. set charging 8. Retest the battery using the Honda Battery Tester time has and recharge if necessary using the above steps. elapsed. 1 6-6 CHARGING SYSTEM INSPECTION Do not discon- llact the battery or any cable in the charging sys tem wllhaur first switching 0H0”? lgnlllorl switch. Failure to follow (his precaution can damage the tester or electri- cal campunnnts. Remove the battery case cover (page 15-4). CURRENT LEAKAGE TEST Turn the ignition switch OFF, and disconnect the neg ative (7) cable from the battery. Connect the ammeter (+1 probe to the negative (,1 cable and the ammeter (-l probe to the battery H ter minal With the ignition switch OFF, check for current leak- age. NOTE: - When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester. - While measurlng current, do not turn the ignition switch ON. A sudden surge of current may blow out the fuse in the tester. SPECIFIED CURRENT LEAKAGE: 1 mA max. If current leakage exceeds the specified value, a shorted circuits is likely. Locate the short by disconnecting connections one by one and measuring the current. CHARGING VOLTAGE INSPECTION NOTE: ‘ Be sure that the battery is in good condition before performing this test. Start the engine and warm it up to the operating tem— perature; stop the engine. Connect the multimeter between the positive and negative terminals of the battery. NOTE: - To prevent a short, make absolutely certain which are the positive and negative terminals or cables, With the headlight on Hi beam, restart the engine. Measure the voltage on the multimeter when the engine runs at 5,000 rpm. STANDARD: Measured battery voltage (page 16-4) < Measured charging voltage (see above) < 15.5 v BATTERY] CHARGING SYSTEM NEGATIVE (4 TERMINAL H PROBE 16-7 BATTERY/CHARGING SYSTEM ALTERNATOR CHARGING COIL INSPECTION Remove the seat (page 2-2). Disconnect the alternator 3F connector (white). Measure the resistance between the Vellow wire ter~ minels of the alternator side connector. STANDARD: 0.1 — 1.0 fl [Zo'C/Ga'F) Check for continuity between each Vellow wire termi- ALTERNElBR nal of the alternator side connector and ground. 3? CONNECTOR There should be no continuity. Replace the alternator stator if resistance is out of ZREGghA'JEofi/RECT'HER specification, or if any wire hes continuity to ground. C C OR Refer to section 9 for alternator stator replacement. REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the seat (page 2-2). Disconnect the regulator/rectifier 2P connector (white). Check the connector for loose contacts or corroded terminalst BATTERY LINE Measure the voltage between the fiethite wire ter- minal and ground. There should be battery voltage at all times. BOLTS EATTERV CASE GROUND UNE Check the continuity between the Green wire termi~ nal and ground. There should be continuity at all times REMOVAL INSTALLATION Remove the following: — seat (page 2-2) — right side cover (page 2-3) Disconnect the alternator 3P connector and regula- tor/rectifier 2P connector. Remove the battery case mounting bolts and move the battery box rearwardt Remove the mountin nuts and the lat t'f . 9 "’9“ Wm ' '°' REGULATOR/RECTIFIER Installation is in the reverse order of removal. NUTS 16-8 IGNITION SVSTEM SIDE STAND SWITCH NEUTRAL SW'TC" IGNITION SWITCH IGNITION PULSE GENERATOR REAR IGNITION MAIN FUSE 30A SNgéusame COIL R Bl/W BIIW IGNITION g SWITCH ? ave “WV FUSE 10A Egfim IGNITION = L—R/EI—N—Bl G I L9 W IGNITION GM—l 5" 5"" Y PULSE wzv GENERATOR up IGNITION CONTROL MODULEUCM) D DOWN _5 T , Bl :BIack NEUTRAL sung STAND V .Yellaw SWITCH SWITCH Bu . mm; a 'Gvezn R :Hed w IWhIle Lg : Lighl green 17-0 17. IGNITION SYSTEM SERVICE INFORMATION 17-1 IGNITION COIL TROUBLESHOOTING 17-2 IGNITION TIMING IGNITION SYSTEM INSPECTION 17-3 17-5 17-6 SERVICE INFORMATION GENERAL - Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is in the on position and current is present. - When servicing the ignition system, always follow the steps in the troubleshooting on page 17-2. - The ignition timing cannot be adjusted since the ignition control module (ICM) is rectory preset. - The ICM may be damaged if dropped. Also, if the connector is disconnected when current is (lowing, the excessive voltage may damage the ICM. Always turn off the ignition switch before servicing. - A faulty ignition system is often related to poor connections. Check those connections before proceeding. - Make sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plugs. - Use a spark plug of the correct heat range. Using a spark plug with an incorrect heat range can damage the engine, . See section a for ignition pulse generator removal/installation. - See section 19 for following components: — ignition switch — engine stop switch — neutral switch — side stand switch SPECIFICATIONS ITEM SPECIFICATIONS 7 Spark plug ‘Standard OPRSEA-Q (NGK), X24EPR-U9 (DENSO) For cold climate (below 5°C/41°F) DPR7EA-9 (NGK), X22EPR~U9 (DENSO) For extend high speed riding DPRSEA-S (NGK), X27EPR-U9 (DENSO) Spark plug-gap 0.8 - 0.9 mm (0.03 — 0.04 in) Ignition coil primary peak voltage 100 V minimum Ignition pulse generator peak voltage 0.7Vminimum Ignition timing l"F" mark) 62“ BTDC at idle TORQUE Timing hole cap TOOL Peak vottage tester (USA. only) or Peak voltage adaptor multitester (impedance 10 Mn/DCV minimum) 15 N-m (1.5 kgfrm, 11 lbf-It) Apply grease to the threads and seating surface 07HGJ 4 0020100 (not available in U.S.A.) with commercially available digital 17—1 IGNITION SVSTEM TROUBLESHOOTING - Inspect the following before diagnosing the system. — Faulty spark plug. 7 Loose spark plug cap or spark plug wire connections. ~ Water got into the spark plug cap (ignition coil secondary voltage leak). ~ If there is no spark at either cylinder, temporarily exchange the ignition coil with a good one and perform the spark test. if there is spark, the exchanged ignition coil is faulty. - “initial voltage" of the ignition primary coil is the battery voltage with the ignition switch in the on position and engine stop switch in the run position (when the engine is not cranked by the starter motor). No spark at spark plugs UNUSUAL connmoN PROBABLE CAUSE [Check in numerical order) Ignition coil No initial voltage with the ‘l. Faulty engine stop switch. primary volt- ignition switch in the on 2. An open circuit in the black/white wire between the ignition coil and age position and engine stop engine stop switch. switch in the run position. (Other electrical compo— nents are normal.) o. . Loose or poor connection of the ignition coil primary wire terminal, or an open circuit in primary coil. . Faulty lCM when the inin’al voltage is normal while disconnecting lCM connector. Initial voltage is normal, but it drops down to 2 — 4 V‘ while cranking the engine. wig- N9 . Incorrect peak voltage adaptor connections. . Battery is undercharged. (Large voltage drops when the engine is started.) . No voltage between the black (+) and ground (—l of the lCM connector. or loose or poorly connected lCM Poor connection or open circu‘ n green (ground) wire oi the lCM. Loose or poor connections. or open circuit in blue/yellow and yellow/blue between the ignition coils and lCM. Faulty side stand switch or neutral switch. An open circuit or loose connection in No.6 related circuit wirest - Side stand switch line: green/white wire - Neutral switch line: light green wire Faulty ignition pulse generator. (Measure peak voltage.) Faulty lCM (when above No. 1 through 8 are normal). Initial voltage is normal, but no peak voltage exists while cranking the engine. Incorrect peak voltage adaptor connections. Faulty peak voltage adaptor. Faulty lCM (when above No. 1 and 2 are normal). Initial voltage is normal, but peak voltage is lower than the standard value. ."NT‘ Fl"? 5"?“ s. The multimeter impedance is too low; below 10 MEI/DCVt Cranking speed is too slow. (Battery is undercharged.) The sampling u‘ming of the tester and measured pulse were not synchro~ nized. (System is normal it measured voltage is over the standard voltage at least once.) Faulty lCM (when above No.1 through 3 are normal). Initial voltage and peak voltage are normal. but no spark jumps at plug. N_. . Faulty spark plug or leaking ignition coil secondary current amperag; V . Faulty ignition coills). Ignition pulse generator Peak voltage is lower than the standard value. .“Nr' P The multimeter impedance is too low; below 10 MQ/DCV. Cranking speed is too slow. (Battery is undercharged.) The sampling timing of the tester and measured pulse were not synchmr nixed. (System is normal if measured voltage is over the standard voltage at least once.) Faulty ignition pulse generator (when above No. 1 through 3 are normal). No peak voltage. NF Faulty peak voltage adaptor. Faulty ignition pulse generator. 1 7-2 IGNITION SVSTEM IGNITION SYSTEM INSPECTION NOTE: - If no spark jumps at the plugs, check all connec- tions for loose or poor contact before measuring each peak voltage. - Use the recommended digital multimeter or a commercially available digital multimeter (imped- ance 10 Mfl/DCV minimum). - The display value differs depending upon the internal impedance of the multimeter. DIGITAL MU LTIMETEH Connect the peak voltage adaptor to the digital multia meter, or use the peak voltage tester. PEAK VOLTAGE ADAPTOR TOOLS: Peak voltage tester IU.S.A. only) or Peak voltage adaptor 07HGJ — 0020100 (not available in USA.) with commercially available digital multimeter (Impedance 10 MQIDCV minimum) IGNITION PRIMARY PEAK VOLTAGE NOTE: - Check all system connections before this inspec» tion. Poorly connected connectors can cause incorrect readings, - Check the cylinder compression at each cylinder and check that the spark plugs are installed cor- rectly in each cylinder. Remover the following: — right side cover (page 2-3) — fuel tank (page 2-2) Disconnect the spark plug caps from the spark plugs on each cylinder head (page 3—7). Connect known-good spark plugs to each spark plug cap and ground the spark plugs to the cylinder heads as done in a sparktestl 1 7-3 IGNITION SYSTEM To avoid electric shock, :10 not much the spark plug or tester probes during this procedure. With the connector connected, connect the peak volt age tester or adaptor probes to the ignition coil pri- mary terminal and body ground. TOOLS: ~ Peak voltage tester (U.S.A. only) or Peak voltage adaptor 0mm — 0020100 (not available in U.S.A.l with commercially available digital muflimeter (impedance ‘0 MfllDCV minimum) CONNECTIONS: Front ignition coil: Blue/yellow (1») — Body ground l~l Rear ignition coil: Yellow/blue (e) -— Body ground (-I Turn the ignition switch to the on position and engine stop switch to the run position. Check for the initial battery Voltage. If battery voltage is not present. follow the checks described in the troubleshooting on page 17v2. Shift the transmission into neutral. Crank the engine with the starter motor and read the Ignition coil primary voltage. PEAK VOLATAGE: 100 V minimum NOTE: . Although measured values are different for each ignition coil, they are normal as long as voltage is higher than the specified value, If the peak voltage is lower than the standard value. follow the checks described in the troubleshooting on page 17-2. IGNITION PULSE GENERATOR PEAK VOLTAGE NOTE: . Check that the cylinder compression is normal and the spark plugs are installed correctly in the cylin- der heads. Remove the seat (page 2-2). Disconnect the ignition control module (ICM) 22F connector. Connect the peak voltage tester or adaptor probes to the White/yellow and Vellow wire terminals of the wire harness side connector. TOOLS: Peak voltage tester (USA, only) or Park voltage adaptor 07HGJ — 0020100 (not available in USA.) with commercially available digihal multimeter (impedance 10 Mil/DEV minimum) CONNECTION: White] yellow — Yellow IGNITION COIL White/yellow 1 7-4 Shift the transmission into neutral. Turn the ign n switch to the on position and the engine stop switch to the run position. Crank the engine with the starter motor and read the ignition pulse generator peak voltage. PEAK VOLTAGE: 0.7 V minimum If the voltage measured at the [CM connecto ‘s abnormal, measure the peak voltage at the ignition pulse generator connector. Remove the fuel tank (page 2-2li Disconnect the ignition pulse generator 2P connector (white) and connect the peak voltage tester or adap— tor probes to the terminals of the pulse generator side connector. In the same manner as at the ICM connector, mea sure the peak voltage and compare it to the voltage measured at the iCM connector. - If the peak voltage measured at the ICM connector is abnormal and the one measured at the alterna- tor connector is normal, the White/Yellow or Yellow wire has an open or short circuit, or loose connections, - If both peak voltages are abnormal, follow the checks described in the troubleshooting on page 17~2. IGNITION COIL Route the spark plug wires prapr eriv (page 1-18). REPLACEMENT Front: Remove the fuel tank (page 2-2). Rear: Remove the right side cover (page 2-3). Disconnect the spark plug caps from the plugs (page 3-7). Remove the following: — spark plug wires from wire band and clip (rear ignition coil only) — ignition coil primary wire connectors — mounting bolts — collars (rear ignition coil only) — ignition coil — spacers Install the new ignition coil and removed parts in the reverse order of removal. IGNITION SYSTEM ‘ /\ lGNITIO PULSE GENERATOR 2P CONNECTOR 1 7-5 IGNITION SVSTEM IGNITION TIMING Start the engine and warm it up to operating temper atura. Stop the engine and remove the timing hole cap from the left crankcase cover. Connect the timing light and tachometer. Start the engine, let it idle (1,000 rpm) and check the ignition timing. The ignition timing is correct if the F mark on the fly- wheel aligns with the index mark on the crankcase cover at idle. Increase the engine speed and make sure the F mark begins to mnva. Connect the timing light to the other cy 'ndefs spark plug wire and check the ignition timing in the same manner as above procedure. Coat a new O-ring with grease and install it onto the timing hale cap. Apply grease to the timing hole cap threads and seat- ing surface. Install the timing hole cap and tighten it, TORQUE: 15 Nm (1.5 kgfm, 11 "3"!) 17-6 ELECTRIC STARTER ENGINE STOP SWITCH CLUTCH SWITCH STARTER SWITCH FUSE BOX [10 AM?) A AND DIODE) MAIN FUSE 30 A SIDE STAND SWITCH NEUTRAL SWITCH STARTER —"’— a “(I3 MOTOR STARTER IGNITION a RELAY SWITCH "IE“ swncn — I “’3' Bl :Black G/R wa FUSE Y :VaIIow STARTER 10A :u I glue swncn ENGME : reen STOP SWITCH Rial FI Red BVW'IEI—C’ O—BI/G—[EI—BI—I—aI/Br 3: fan: FU SE L :LIhx reen 15A 9 g g NEUTRAL :3 L NEUTRAL Lg INDICATOR SIR @swncn DIODE T UP DOWN _——G/H Bl—E—Bl—l El—G/w SIDE STAND SWITCH CLUTCH SWITCH 18-0 18. ELECTRIC STARTER SERVICE INFORMATION 13-1 STARTER RELAV SWITCH 18-10 TROUBLESHOOTING 18-2 DIODE 18-11 STARTE R M OTOR 18-4 SERVICE INFORMATION GENERAL - Always turn the ignition switch to the off position before servicing the starter motor. The motor could suddenly start, causing serious injury. - The starter motor can be serviced with the engine in the frame. - When checking the starter system, always follow the steps in the troubleshooting flow chart (page 18—2). - A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. - If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged, ~ See section 9 for starter clutch servicing. - See section 19 for following components: 7 ignition switch — engine stop switch — starter switch — side stand switch — neutral switch — clutch switch SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.5 (0.49) 65 (0.26) TORQUE Starter motorcable terminal nut 10 Nm (1.0 kgf‘m, 7 Math) 18—1 ELECTRIC STARTER TROUBLESHOOTING NOTE: - The starter motor should operate in either of the following conditions with the ignition switch in the on position and the engine stop switch in the run position. 7 The transmission is in neutral. 7 The transmission is in any gear except neutral, clutch lever squeezed, and the side stand is retracted. Starter motor will not turn v Check for a blown fuse (10 A). - Check that the battery is fully charged and in good condition. Check for a loose or poorly connected battery cable, and open circuit in battery cable, Normal Check for loose or poorly connected starter relay switch terminals. l Normal Check for loose or poorly connected starter motor cable. and open circuit in starter motor cable. Normal With the ignition switch in the on position, push the starter switch and check for a ”click” sound from the starter relay switchl No clicks Y Check the starter relay coil ground line (page 18-10)t To gage 1873 Normal Abnormal —> Abnormal —> Abnormal —> clicks -—> - Poorly connected battery cable - Open circuit in battery cable - Poorly connected terminals - Poorly connected starter motor cable - Open circuit in starter motor cable Connect the starter motor terminal directly to the battery positive terminal. (Because a large amount of current flows, do not use a thin wire.) Abnormal ~—> Starter motor does not turn Starter motor turns + - Faulty starter motor - Loose or disconnected starter motor cable ~ Faulty starter relay switch - Faulty neutral switch ~ Faulty diode - Faulty clutch switch . Faulty side stand switch - Loose or poor connector contact - Open circuit in wire harness 18-2 From page 13—2 LCheckthe starter relay voltage (page 18—10). [7 Abnormal 4». Normal . “J‘ 1 Check the starter relay switch operation (page l 1840). Abnormal —>- Normal Starter motor turns slowly - Weak battery - Poorly connected battery cable - Poorly connected starter motor cable - Faulty starter motor Starter motor turns, but engine does not turn ~ Faulty starter clutch (section 9) Starter relay switch ”clicks", but engine does not turn over ' Crankshaft does not turn due to engine problem - Faulty starter reduction gear or idler gear (section 9) ELECTRIC STARTER Faulty ignition switch Engine stop switch Faulty starter switch Loose or poor connector contact Open circuit in wire harness Faulty starter relay switch Loose or poor starter relay switch 4P connecV tor contact 1 8-3 ELECTRIC STARTER REMOVAL Remove the Iefl side Cover (page 2733). Always turn the Slide the rubber cap Off the Stafler motor terminal ignition switch to and remove the terminal nut and starter motor cable. the affpasitian berm servicing the starter moron Remove the two mounting bolts and negakive cable H, and the starrer motor from the crankcaser Remove the Owing from the starter motor. NEGATIVE CABLE DISASSEMBLY/INSPECTION Remove the starter motor case bolts. Record the loca- Remove the following: SEAL RING REAR COVER Han and number — rear cover alshims. — shims — seal ring Check the bushing in the rear cover for wear or dam- agar SHIMS BUSHING 1 8-4 Remove the ntIowing: 7 from cover 7 lock washer Checkihe dust seal and needle bearing In lhe front cover for deterioration, wear or damage Remove the following: — insulated washer — shims — seal ring — armature Measure the brush length. SERVICE LIMIT: 6‘5 mm (0.26 in) Check for continuity between each insulated brush and cable terminal. There should be continuity. Check for continuity between each positive (+) brush (insulated) and negative (—) brushes. There should be no continuity. ELECTRIC STARTER Locig WASHER BEARING DUST SEAL . SEALRING ‘ ARMATURE SHIMS INSULATED WASHER 1 8-5 ELECTRIC STARTER Check the commutator bars of [he armature for dis- coloration NOTE: - Do not use emery or sand paper an the commute, (or. Check for continuity between pairs of commutator barsl There should ba continuity. Check for conlinuity between each commutator bar and the armature shaft. There should be no cominuity, Remove lhe following: — nut — washer — insulator washers —— O-ring — brush holder assembly erlNG BRUSH HOLDER WASHER NUT W INSULATOR WASHERS 18-6 ELECTRIC STARTER BRUSH 7 Cable terminal 7 insulator — insulated brush ASSEMBLY INSULATED WASHER ARMATURE INSULATED BRUSH BRUSH HOLDEH/ BRUSH SPRINGS SEAL RING NUT O—RING O-RING lNSULATOR SEAL RING FRONT COVER TERMINAL BOLT REAR COVER NEEDLE BEARING DUST SEAL LOCK WASHER STARTER MOTOR CASE Install the following onto the brush holder: — cable terminal ~ insulator — insulated brush RUSH TERMINAL Install the brush holder assembly by aligning the tab with the groove in the motor case. ELECTRIC STARTER The coil may be damaged if rm: magnet pulls the armature against [/15 case. Install the following onto the cable terminal: — new Orring — insulator washers — washer — nut — Push and hold the brushes inside the brush holder. and install the armature through the motor case and brush holder. When installing the armature into the motor case. hold the armature tightly to keep the magnet of the case from pulling the armature against it. Set the brush springs onto the brushes properly. Install a new seal ring onto the motor caser Install the shims and insulated washer onto the armature shaft, Apply grease to the dust seal lip and needle bearing in the front covert Install the lock washer onto the front cover and the front cover onto the motor case Install a new seal ring onto the motor case Install the same number of shims in the same Inca» tions as noted during disassemblyt Install the rear cover onto the motor case by aligning the groove with the brush holder tab (aligning the index IinesIt WASHER INSULATOR WASHERS NUT OVRINGV ARMATURE spa‘msé — LOCK WASHER SEAL RINGV INSULATED WASHER FRONT COVER AIign a? SEAL RING REAR COVER 18-8 ELECTRIC STARTER Align the index lines on the front cover and motor case. Install the motor case bolts and tighten themt INSTALLATION Coat a new O-ring with engine oil and install it into the starter motor groove. Install the starter motor into the crankcase. lnstall the two mounting bolts with the negative cable 1—) as shown and tighten them securely. Connect the starter motor cable onto the motor ter- minal with the terminal nut and tighten it, TORQUE: 10 N-m (1.0 kgfm, 7 Ibffl) Install the rubber cap over the starter motor terminal properly. Install the left svde cover (page 2-3). ELECTRIC STARTER STARTER RELAY SWITCH INSPECTION Remove the right side cover (page 2-3). Shift the transmission into neutral. Turn the ignition switch to the on position and engine stop switch to the run position. Push the starter switch. The coil is normal if the starter relay switch clicks. If you don't hear the switch ”click", inspect the relay switch using the procedure below. GROUND LINE Discnnnect the starter relay switch 4? connectur, Check for continuity between the Green/red wire (ground line) terminal and ground. If there is continuity when the transmission is in nsu» tral or when the clutch is disengaged and the side stand is retracted, the ground circuit is normal. (In neutral, there is a slight resistance due to the diode.) STARTER RELAV VOLTAGE Connect the starter relay switch 4P connector. Shift the transmission into neutral. Measure the voltage between the Vellow/red wire ter- minal h) and ground (-l. It the battery voltage appears only when the starter switch is pushed with the Ignition switch in the on position and engine stop switch in the run position. the circuit is normal. OPERATION CHECK Disconnect the 4P connector and cables from the starter relay switch. Connect the fully charged 127V battery pus e wire to the Yellow/red wire terminal and negative wire to the Green/red wire terminalt There should be continuity between the cable termiA nals while the battery is connected, and no continuity when the battery is disconnected. 18-10 ELECTRIC STARTER INSPECTION Remove the righi side cover (page 273). Open the fuse box and remove the diode. Check for continuity between the diode terminals. When there is continuity, a small vesisiance value will re ister. Q A B if there is continuity in one direaion, the diode is nor- mal. A C B C 18-11 LIGHTS] METERS I SWITCHES SPEEDOMETER FRONT BRAKE LIGHT SWITCH TURN SIGNAL SWITCH DIMMER SWITCH ' (C. ENGINE STOP SWITCH STARTER SWITCH REAR BRAKE LIGHT SWITCH TURN SIGNAL RELAV SPEED SENSOR CAHEUHETORHEATER 5’ ‘ ‘ “ “ FAN MOTOR SWITCH FUEL PUMP SIDE STAND SWITCH IGNITION SWITCH OIL PRESSURE SWITCH NEUTRAL SWITCH 1 9-0 1 9. LlGHTS/METERSISWITCHES SERVICE INFORMATION 19-1 IGNITION SWITCH 19-11 HEADLIGHT 19-3 HANDLEBAR serCHES 19-11 TURN SIGNAL LIGHT 19-4 BRAKE LIGHT SWITCH 19-12 BRAKE/TAILLIGHT 19-4 CLUTCH SWITCH 19-13 METER ASSEMBLY 19-4 NEUTRAL SWITCH 19-13 SPEEDOMETER/SPEEO SENSOR 19-6 SIDE STAND SWITCH 19-14 COOLANT TEMPERATURE INDICATOR] FUEL PUMP 19-14 THERMOSENSOR19-7 HORN 194 e COOLING FAN MOTOR SWITCH 19-8 TURN SIGNAL SWITCH 1946 OIL PRESSURE INDICATOR 19-9 CARBURETOR HEATER 19-10 SERVICE INFORMATION GENERAL WEE] A halogen headlight bulb becomes very hot while the headlight is on. and remains hot for a while after it is turned ofl. Be sure to let it cool down before servicing. - Use an electric heating element to heat the water/coolant mixture for the thermosensor inspection. Keep all flamma- ble materials away from the electric heating element. Wear protective clothing, insulated gloves and eye protection. - Note the following when replacing the halogen headlight bulb. — Wear clean gloves while replacing the bulb. Do not put fingerprints on the headlight bulb, as they may create hot spots on the bulb and cause it to fail. — if you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure, — Be sure to install the dust cover after replacing the bulb, - Check the battery Condition before performing any inspection that requires proper battery voltage. - A continuity test can be performed with the switches installed on the motorcycle The trip meter data" Is erased when the battery Is removed. - The following color codes used are indicated throughout this section Bu: Blue G: Green Lg: Light Green R: Red Bl: Black Gr: Gray 0: Orange W: White Br: Brown Lb: Light Blue P; Pink V: Yellow 19-1 LIGHTS] METERS] SWITCHES SPECIFICATIONS ITEM SPECIFICATIONS Bulbs Headlight(high/luw beam) 12 v—emssw Brake/taillight 12 V— 21/5 W Front turn signal/running light | 12 v — 21/5 w x 2 Rear turn signal light 12V—21Wx2 Instrument light LED x 6 Turn signal indicator LED High beam indicator LED H ' _ Neutral indicator LED Coolam temperamre indicator LED on pressure indicator LED Fuse Main fuse 30 A Sub-fuse 10Ax4,15Ax1 Fan motor switch Starts to close (ON) 98 , 102“C (208 r 216°F) Stops to open (OFF) 93—97°C (159—207?) Thermosensor vesis- at 80°C (176°F) 45 — 60 D ”"68 at120“C(Z43"F) 10—20 9 Carburetor heater resis‘ance at 20°C (63°F) 13 r 15 9 Fuel pump flow capacity Minimum 900 cm3 (30.4 US 01, 31.7 finpioizl per minute TORQUE VALUES Speadomemr cover bolt Thermossnsor Fan motor switch Ignition switch mounting bolt Neutral switch Side stand switch bolt Horn mounting bolt 10 N~m (1.0 kgf-m, 7 Ital-fl) 8 N~m (0.8 kgf‘m, 5,8 let) 18 N~m (1.8 win 13 Ile) 12 Nm (1.2 kgf-m, 9 lbf-ft) 12 N-m (1.2 kgf-m, 9 lbf'fl) 10 N~m (1.0 kgf-mJ lbf-fll 21 N-m (2.1 kgf‘m,15|bf~fl) Apply sealank to the threads Break-off bolt 1 9-2 UGHTS/MEI'ERSISWITCHES HEADLIGHT BULB REPLACEMENT A halogen headlight bulb becomes very hot while the headlight is on, and will remain hot for a while after it is turned off. He sure to let it cool down before servin ing. Remove the two bolts and collarst Carefully raise the lower portion of the headlight and remove the headlight by releasing the tab from the stopper of the case. Disconnect the headlight connector. Remove the dust covert MARK Unhook the bulb retainer and replace the headlight BULB bulb with a new one. NOTICE Avoid touching halogen headlight bulb. Fingerprints can create hot spots that cause a bulb ta break. It you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failuret Install the bulb by aligning the tabs with the head- light grooves end hook the bulb retainer properlvt RETAINER DUST COVER Install the dust cover tightly against the headlight with the ”TOP" mark facing up, Install the headlight in the reverse order of removal. CASE REMOVAL] INSTALLATION Remove the following: — headlight — wire harnesses from clamps itwo nuts and bolts 7 headlight case (remove wires out of the case) Route the wires Install the case and headlight in the reverse order of properly removalt (page 1718). 1 9-3 LlGHTSIMETERS/SWITCHES TURN SIGNAL LIGHT BULB REPLACEMENT Remove the screw and turn signal light lens, While pushing the bulb in, turn it counterclockwise to remove it, and replace it with a new one. Make sure the rubber seal is installed in position and is in good condition, and replace it with new one if necessary Install the lens by aligning the groove with the tab of the turn signal case and tighten the screw. BRAKE/TAILLIGHT BULB REPLACEMENT Remove the two screws and brake/taillight lens, While pushing the bulb in, turn it counterclockwise to remove it, and replace it with a new one Make sure the rubber seal is installed in position and is in good condition, and replace it with new one if necessary. Install the lens and tighten the screws. METER ASSEMBLY REMOVAL Remove the following: —- two cover bolts — meter assembly by sliding it forward — meter1ZP connector INSTALLATION Connect the meter 12P connector and install the dust cover into the meter groove. Be sure to install the setting rubber onto the stay of fuel tank properly. Install the meter assembly onto the fuel tank by aligning the holder of the meter cover with the set- ting rubber . Install the cover bolts and tighten them. TORQUE: 10 N-m (1.0 kgf-m, 7 Ibfit) TAB SEAL RUBBER GROOVE CONNECTOR METER ASSEMBLY 1 9-4 DISASSEM BLVI ASSEMBLY Remove the meter assembly (page 19-4). Remove the fallowing: — two terminal screws — two mounting screws and clamp 7 speedometer and rubber seal 7 switch cap and trip meter reset switch Assembly is in the reverse order of disassem bly. POWER/GROUND LINE INSPEC'HON Remove the meter assembly (page 19-4). Check the following at the meter 12? connector. POWER INPUT LINE Measure the voltage between the Black/brown wire terminal (+) and ground (—l. There should be battery voltage with the ignition switch in the on position BACK-UP VOLTAGE UNE Measure the voltage between the Pink wire terminal (+) and ground H. There should be battery voltage at all times. GROUND LINE Check for continuity between the Green wire terminal and ground. There should be continuity at all limes. SENSOR GROUND LINE Check for continuity between the Green/black wire terminal and ground. There should be continuity at all times. If there is nu continuity, check for an open circuit in the related wire and/or blown fuse. LlGHTSIMETERS/SWITCHES SPEEDOMETER SCREWS METER 12F CONNECTOR 1 9—5 LlGHTS/METERSISWITCHES SPEEDOMETER/SPEED SENSOR SYSTEM INSPECTION R V‘lZ‘P’COVNVNECVTVOh Check that‘the odometer/trip meter functions properly. - If they do not function properly, perform the power/ground line inspection (page 19-5). - If they function properly, check the following. Remove the meter assembly (page 19-4). Remove the speed sensor from the speedometer gear box (page 13—8). Measure the voltage between the Black/yellow (+) and Green/black (v) wire terminals at the meter 12F connector, With the ignition switch in the on position, slowly turn the sensor shaft by using a screwdriver. There should be 0 to 5V pulse voltage. «— If the pulse voltage is present, check the speedome ter gear box function. If it is OK, replace the speedometer. —— If the pulse voltage is absent, check an for open or short circuit in the Black/yellow wire. If the wire is OK, check the speed sensor. SPEED SENSOR INSPECTION Remove the headlight (page 19-3), Turn the ignition switch to the on position and mea- sure the voltage between the Black/brown M and Green/black (—) wire terminals of the speed sensor 3F connector with the connector connected. There should be battery voltage. If there is no voltage, check for open circuit in the Black] brown and Green/black wires. Measure the voltage between the Black/yellow (+) and Green/black (-) wire terminal of the sensor 3? connector with the connector connected. Slowly turn the sensor shaft by using a screwdriver. There should be 0 to 5—V pulse voltage. If pulse voltage is absent, replace the speed sensor. SPEED SENSOR 3F CONNECTOR 1 9-6 COOLANT TEMPERATURE INDICATOR/THERMOSENSOR Wear protective clothing, insulated gloves end eye protec- non. Keep all flammar ole materlals away from the electric heating element. INSPECTION Check that the speedometer and other indicators func- tion properly. - If they do not function, perform the power/ground line inspection (page 19-5). - If they function, check the following. Disconnect the thermosensor connector and ground the connector (Green/blue) terminal with a jumper Wire. Turn the ignition switch to the on position and check the temperature indicator. 7 If the indicator comes an (indicator circuit is nor- mal), check the thermosensor. a If the indicator does not come on, check for open circuit in the Green/blue wire. lithe wire is OK. replace the speedometer. Tho indicator comes on when the engine is cooled Disconnect the thermosensor connector. Turn the ignition switch to the on position and check the temperature indicator. — ii the indicator does not come on. check the ther» mosensor, — If the indicator comes on, check {or a short circuit in the Green/blue wire. If the wire is OK, replace the speedometer. THERMOSENSOR INSPECTION Drain the coolant (page 65). Disconnect the thermosensor connector and remove the thermosensor. Suspend the thermosensor in a pan of coolant (50 A 50 mixture) on an electric heating element and mea» sure the resistance through the sensor as the coolant heats up. NOTE: - Soak the thermosensor in coolant up to its threads with at |east 40 mm (1.57 in) from the bottom of the pan to the bottom of the sensort . Keep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect readings. Do not let the thermometer or thermosensor touch the pan. LIGHTS/METERSISWITCHES THERMOSENSOR CONNECTOR COOLANT TEMPERATURE INDICATOR THERMOMETER THERMOSENSOR LIGHTS] METERS] SWITCHES COOLING Temperature BD”C (176T) 120“C (248°F) Resistance 45 ~ 60 (I 10 — 20 fl Replace the thermosensor it it is out of specification by more than 10% at any temperature listed. Apply sealant to the thermosensor threads. Do not apply sealant to the sensor head. install and tighten the thermosensort TORQUE: 8 N-m (0.8 kgf-m, 5.8 let) Connect the thermosensor connector. Fill and bleed the cooling system (page 64). FAN MOTOR SWITCH INSPECTION Fen motor does not stop Turn the ignition switch to the off position, discon— nect the connector from the fan motor switch and turn the ignition switch to the on position again. - If the fan motor does not stop, check for a short cir-cuit in the Black wire between the fan motor and switch - It the fan motor stops, replace the fan motor switch. Fan motor does not start Before testing, check for a blown fan motor fuse, Warm up the engine to operating temperature. Disconnect the connector from the tan motor switch and ground the connector with a jumper wire, Turn the ignition switch to the on posiu'on and check the fan motor. - If the motor starts, check the connection at the fan motor switch terminal. If it is OK, replace the fan motor switch. - lithe fan motor does not start, remove the fuel tank (page 2-2) and disconnect the fan motor 2P connector. Measure the voltage between the Blue/blackl+) and Green (—l wire terminals at the main harness side 2P connector. There should be battery voltage — if there is battery voltage, replace the fan motor. ; if there is no voltage, check for open circuit In the Blue/black and Green wires, 1 9-8 UGHTSI METERS] SWITCHES REMOVAL] INSTALLATION FAN MOTORSWITCH . Remove the radiator (page 88). Disconnect the fan motor switch connectur and remove the switch Install a new O-ring onto the fan motor switcht lnsmll and tighten the fan motor switch, TORQUE: 18 Ill-m (1.8 kgfim, 13 M4!) Connect the fan motor switch connector. Install the radiator (page 6—11). OIL PRESSURE INDICATOR INSPECTION Remove the left crankcase rear cover (page 2-3). Remove the rubber cap, and disconnect the oil pres- sure switch wire by removing the terminal screw. Indicator does not come on with the ignition switch turned to the on position Ground the wire terminal to the engine with a iumper wire‘ Turn the ignition switch to the on position and check the oil pressure indicator‘ - If the indicator comes on, replace the oil pressure switch (page 4—3)‘ - If the indicator does not come on, check for an open circuit in the Blue /red wire between the oil pressure switch and speedometert Indicator stays on while the engine is running Check for continuity between the wire terminal and ground - If there is continuity, check for a short circuit in the Blue/red wire between the oil pressure switch and speedometer. - If there is no continuity. check the oil pressure (page 4.3). lithe oil pressure is normal, replace the oil pres- sure switch. 1 9-9 LIGHTS/METERSISWITCHES CARBURETOR HEATER AIR TEMPERATlilRE svvncn INSPECTION Remove the seat (page 22). Remove the air cleaner housing (page 5—3). Disconnect the air temperature switch 2P connector. Disconnect the carburetor heater Brown/black wire connectors from each carburetor. Check for continuity between the Brown/black termi» rial of the 2P connector and each heater connector terminal (Brown/black). There should be continuity, lfthere is no continuity, check for an open circuit in the Brown/black wire. CON NECTOR (Brown/black) Measure the voltage between the Black/brown (+i ter minal of the 2P connector and each heater Green iv) wire terminal. There should be battery voltage With the ignition switch in the on position. it there is no voltage, check for an open circuit in related wires, If there is voltage, check the carburetor heater and air temperature switch as follows. Measure the resistance between the carburetor CONNECTOR (Green) heater terminals. STANDARD: 13 - 16 (I (ZO'CISB'Fl It the resistance is out of the above ranges, replace the carburetor heater. 20% : r . OFF Check for continuity between the temperature switch terminals. : o" 0' OFF Above 20%: (68°F): No continuity “n5 '- Bolow 7'0 (45'F): Continuity If the reading is out of specification, replace the air tem- - g 0“ perature switch, REMOVAL/INSTALLATION TERMINAL Disconnect the carburetor heater wire connectors. Remove the carburetor heater and ground terminal. Install the ground terminal and carburetor heater with the end of the ground terminal facing out, and tighten the carburetor heater, Connect the heater connectors Install the removed parts in the reverse order, CAHBURETOH TERMINAL HEATERS 19-10 LIGHTS] METERS] SWITCHES IGNITION SWITCH INSPECTION Remove the right side cover (page 23). Disconnect the ignition switch 3F connector (White). Check for continuity between the switch side connec~ tor terminals in each switch position. Continuity should exist between the color coded wires as follows: Color Position 0N OFF REMOVAL] INSTALLATION Release the ignition switch wire from the wire band and disconnect the 3P connector. Remove the following: — screw and switch cover —— mounting bolts — ignition switch Install the ignition switch with new mounting bolts and tighten thamt TORQUE: 12 MM (12 kgf-m, 9 "2"!) Install the switch cover with the screw and tighten it. Route the wire properly and connect the 3P connec- tor (page 1-18). Install the right side cover. HANDLEBAR SWITCHES conwscron §P CONNECTOR (Green) (Bluthite) Remove the headlight (page 19-3). Disconnect the left handlebar switch 9? (Black) and blue/white wire connectors, and right handiebar switch 6P connector (Green), Check for continuity between the switch side connecA tor terminals in each switch positiont Continuity should exist between the color coded wires as shown in the charts: 9P CONNECTOR (Black) 19—11 LIGHTS] METERS] SWITCHES RIGHT HANDLEBAR SWITCH ENGINE STOP SWITCH ENGINE STOP SMTCH Color , _ _ - Bl/W ems Posltlon OFF RUN 0740 STARTER SWITCH Color ”R 3W" STARTER swrrcn Position FREE . PUSH O——O DIMMER SWITCH LEFT HANDLEBAR SWITCH TURN SIGNAL SWITCH Color Position L N R TURN SIGNAL SWITCH _ HORN SWITCH DIMMER SWITCH Color Bu/W Position Low (N) High HORN SWITCH Color L Bl Br Position 9 / FREE PUSH o—l—o BRAKE LIGHT SWITCH FRONT Disconnect the front brake light switch connectors and check for continuity between the switch termil nals. There should be continuity with the front brake lever squeezed and no continuity with the lever released 19-12 LIGHTS] METERS] SWITCHES REAR Remove the radiator mounting bolt and carefully move the radiator grille forward. Disconnect the rear brake light switch 2P connector (Black) and check for continuity between the connec- tor terminals. There should be continuity with the rear brake pedal depressed and no continuity with the pedal released. CLUTCH SWITCH Disconnect the clutch switch wire connectors and check for continuity between the switch terminals. There should be continuity with the clutch lever squeezed and no continuity with the lever released. NEUTRAL SWITCH INSPECTION Remove the left crankcase rear cover (page 2-3). Disconnect the neutral switch wire connector, Check for continuity between the switch terminal and engine ground. There should be continuity with the transmission in neutral, and no continuity with the transmission in gear except neutral. REMOVAL/INSTALLATION CONNECTOR Disconnect the neutral switch wire connectort Remove the neutral switch irom the crankcase a” SEALING WASHER Install the neutral switch with a new sealing washer and tighten it. TORQUE: 12 Mm (1.2 kgf‘m. 9 RIM) Connect the neutral switch wire connector. Install the left crankcase rear cover (page 2-3). NEUTRAL SWITCH 19-13 LIG HTSI METERS] SWITCHES SIDE STAND SWITCH INSPECTION Remove the right side cover (page 2-3). Disconnect the side stand switch 2P connector (Green). , Check for continuity between the connector termi- nals. There should be continuity with the side stand retracted and no continuity with the side stand Iow- ered. REMOVAL] INSTALLATION Remove the left crankcase rear cover (page 23). Disconnect the side Qand switch 2P connector (Green) and release the switch wire from the wire clips and guide, Remove the side stand switch bolt and the switch. Install the side stand switch by aligning the switch pin with the side stand hole and the switch groove with the bracket pin. Install the side stand switch bolt and tighten it. TORQUE: 10 MM (10 kghn, 7 IM-fl) Romaine side Install the removed parts in the reverse order of standswircn wire removal properly - j ‘ (page 1-18]. 7 ‘ ' U. ‘ SWITCH PIN 1f; HOLE FUEL PUMP FUEL CUT»OFF RELAY SYSTEM INSPECTION Remove the right side cover (page 2-3ll Disconnect the fuel cut-off relay 3P connector (White). Measure the voltage between the Black (+) wire terv minal of the 3P connector and ground H. There should be battery voltage with the ignition switch in the on position. If there is no voltage, check for an open circuit in the Black wire. 19-14 Check for continuity between the Black/blue wire [err minal of the 3P connector and ground. There should be continuity. — If there is continuity, check for open circuit in the Yellow/blue wire between the fuel cutoff relay and ignition control module (lCM). if the wire is OK, replace the fuel cutoff relay. — N there is no continuity, check as follows, Disconnect the fuel pump 2? connector. Short the Black and Black/blue terminals of the relay 3F connector with a jumper wire. Measure the Voltage between the Black/blue (4-) and Green l~l wire terminals on the wire harness side pump 2P connector. — If there is voltage, replace the fuel pump. —— If there is no Voltage, check for an open circuit in the Black/blue and Green wires. For fuel pump replacement, see page 5-24. DISCHARGE VOLUME INSPECTION Remove the left and right side covers (page 2-3). Disconnect the fuel cut-off relay 3P connector (white) and short the Black and Black/blue terminals of the 3P connector with a jumper wire (refer to above inspection). Turn the fuel valve to the off position and disconnect the fuel tube from the tube joint. Hold a graduated beaker under the tuel tube. Turn the ignition switch to the on position (engine stopped) and let fuel flow into a beaker for 5 seconds, then tum the ignition switch to the off position. Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute. FUEL PUMP FLOW CAPACITY: 900 cm3 (30.4 US 02, 31.7 Imp oz) minimum/minute LlGHTS/METERS/SWITCHES 19-15 LlGHTS/METERSISWlTCHES HORN Disconnect the wire connectors from the norm Connect a 12V battery to the horn terminals. The horn is normal if it sounds when the lZ-V battery is connected across the horn terminals. TURN SIGNAL RELAY Tum signal light does not blink Remove the right side cover (page 23). Disconnect the turn signal relay connector. Connect the Black/brown and Gray wire terminals of the wire harness side connector with a jumper wire. Turn the ignition switch to the on position and check the turn signal light by operating the turn signal switch, ' If 613 light does not come on, check for an open cir- cuit in Black/brown and Gray wirest - lithe light comes on. check for continuity between the Green wire terminal and body ground. -- if there is no continuity, check for an open circuit in Green wire. — If there is continuity, check the connector tenni- nals for loose or poor contact If the connector terminals are OK. replace the turn signal relay. ;_RNV 19-16 20. WIRING DIAGRAM ‘ msim _w : mm I l_w~ W WWW z *‘m 4\’ E MNSIGMMSuv “Elm i) I I .5 _—G o a i , [ :I rung —g;f mmmm , s 5 ’MN ,. '°' z, ‘ m m g ; J me 2: WI _ zruw mm mmnmwnuns “m“"u swunliwiwmn m, mm fitMLfi m w {—23%} I —5 _ mm q «NW- m mm W —|y—m_l— y I « ° *1:‘ l_— 5 _m,_n__, g \Ennwmwswsm m EL 3' 7’ mm 3! 1% gm gm 3 IT ; m g a §s , 5 : WWW J: «mm mar-Am », E mnmm |I||l mum-w “WWI” a m summinotwnusrnnmmi ulwwoanl w m: “WWWWW m m 31. um mm. M, m m, Wm 5 m .w mm Hm m 003OZ-MCR-A000 20—1 m umrmm m / I ! «mu-(mm ‘14, mam-m 7 7 mun-4mm “mm-mm mum-noun lulu-«1mm: xa Hal-mam Mun mm IMKE unmwm mu: m u r a w :mvuw mm mm» u: u a mu an mm- mmx 5mm“. russmx erVEstwm EMUNESW'WW mmsmmiwnm SI 15 us 5sz w L x vzwmmnz wmnx Nimmmuwl um um wmuwu mmmwmm munisswi mum uwmwmn x : ma LNIGF m» mm mmlzmv mm mm an x» mm a» m ms. Issaswnm - mm 27 m mwmm mm swim I nwnw E mum wwmsw \mmm mm mm Imwnw mam v m m ME (Mm Nzwuswmcw : x m ”(magma cmmswwm MNSWL mam w~m mama» WW rwmswrrm ms: mmwm . m4 mmm mmmwswmrx a ‘54 mumw‘mwwk MEIER mmmm. M I: w m c m mmwwsmuin n m w W m M m E In unmask m a; as» ”’21. TROUBLESHOOTING ENGINE DOES NOT START OR IS POOR PERFORMANCE AT HIGH HARD TO START 21-1 SPEED 21-3 ENGINE LACKS POWER 21-2 POOR HANDLING 21-4 POOR PERFORMANCE AT LOW AND IDLE SPEED 21-3 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1. Check fuel flow to carburetor Not reaching carburetor 4>- Fuel tank empty - Clogged fuel tube or fuel filter Reaching carburetor - Sticking float valve - Faulty fuel pump - Clogged fuel tank breather V 2. Remove and inspect spark plug 7 Wet plug ——> Flooded carburetor Needle valve open Dirty air cleaner Improperly adjusted pilot screw Starting enrichment (SE) valve stuck open or damaged Good condition 3. Perform spark test — Weak or no spark —>- Faulty spark plug - Fouled spark plug Good spark ' Loose or disconnected ignition system wires Broken or shorted spark plug wire Faulty ignition coil Faulty ignition pulse generator Faulty engine stop switch Faulty ignition switch Faulty ignition control module (ICM) 4, Start by following normal — Engine starts but stops —>- Improper Starting Enrichment (SE) procedure valve operation - Incorrectly adjusted carburetor Engine does not start - Leaking carburetor insulator - Improper ignition timing (faulty ICM or ignition pulse generator) - Contaminated fuel 5. Test cylinder compression 7 Low compression —>- Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket m Seized valve Improper valve timing 21-1 TROUBLESHOOTING ENGINE LACKS POWER 1. Raise wheel off the ground anld spin by hand Wheel spins freely 2. Chleck tire pressure Pressure normal 3. Accelerate rapidly from low to second Engine speed increases l Chleck ignition timing P Correct S" Test cylinder compression Normal compression 6. Check carburetor for clogging Not clogged 7. Remove spark plugs Not fouled or discolored 8. Check all level and condition Co rrect 9. Remove cylinder head cover~~~~- and inspect lubrication Valve train lubricated properly 10.Accelerate or run at high speed —— Engine does not knock Possible cause Wheel does not spin freely a. Pressure low —>- Engine speed does not change ——>- when clutch is released - incorrect ——>- Low compression a——>. Clogged ——>. Fouled or discolored —> - Incorrect ——~> - Valve train not lubricated —‘—~‘>- properly ' Engine knocks Brake dragging Worn or damaged axle or wheel bear- ings Wheel bearings need lubrication Faulty tire Valve Punctured tire Clutch slipping Worn clutch discs/plates Warped clutch discs/plates Weak clutch spring Additive in engine oil Faulty Ignition control module (ICM) Faulty ignition pulse generator Valve clearance too small Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve improper valve timing Carburetor not serviced frequently enough Plug not serviced frequently enough Spark plug of incorrect heat range Oil level too high Oil level too low Contaminated oil Clogged oil passage Clogged oil orifice Worn piston and cylinder Use of poor quality fuel Excessive carbon build-up In combustion chamber Ignition timing too advance (Faulty lClVll Lean fuel mixture 21-2 TROUBLESHOOTING POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause '|. Check carburetor pilot Screw adjustment Correct l incorrect i. *fi———>- See section 5 2. Check for leaking carburetor Leaking —>- Loose carburetor insulator bands insulator ~ Damaged carburetor insulator Na leak l 3. Perform spark test — Weak or intermittent spark —>- Faulty spark plug l - Fouled spark plug Good spark - Loose or disconnected ignition system wires - Broken or shorted spark plug wire - Faulty ignition coil . Faulty ignition pulse generator - Faulty engine stop SWltch - Faulty ignition switch - Faulty ignition control module llCM) 4. Checklgnitiontiming — Incorrect —... ---—>- Faulty ignition control modulellCMl ' Faulty ignition pulse generator POOR PERFORMANCE AT HIGH SPEED Possible cause 1. Disconnect fuel tube at —. . Fuel flow restricted ——-——-—>- Restricted fuel tube carburetor - Restricted fuel tank breather tube l - Faulty fuel valve Fuel llOWS “59W - Clogged fuel filter or strainer 2. Check carburetor for clogging Clogged —- 7—>~ Carburetor not serviced frequently l enough Not clogged 3. Check valve timing _._. . . 77* Incorrect . , 7,4,. Cam sprocket not installed properly l Correct 4. Check ignitiontiming #«~ ~77 incorrect #7 - .74». Faulty ignition control modulellCM) l - Faulty ignition pulse generator Correct 5. Check valve spring i Weak egfia~ Faulty valve spring Not weak 21-3 TROUBLESHOOTING POOR HANDLING Possible cause 1» If steering is heavy >4‘ , —-__..7 “—>. 2. if either wheel is wobbllng _—>. 3. if the motorcycle pullsto one Slde —>. Steering bearing adjustment nut me tight Damaged steering head bearings Excessive wheel bearing play Ben! rim |mproper|v installed wheel hub Excessively worn swingarm pivot bearings Bent frame Tire air pressure incorrect Faulty shock absorber Bent fork Bent swingarm Bent frame Bent front axle Improper wheel alignment 21-4 AIR CLEANER AIR CLEANER HOUSING AIR CUTVOFF VALVE... ALTERNATOR CHARGING COI BATTERY BRAKE CALIPER BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH BRAKE MASTER CYLINDER BRAKE PAD/DISC ..... BRAKE SHOES/PADS WEAR. BRAKE SYSTEM BRAKE/TAILLIGHT CABLE & HARNESS R0 . CAMSHAFT, CAMSHAFT HOLDE CAREIURETOR CHOKE... CARBURETOR CLEANING. CAREURETOR COMBINATION. CAREURETOR DISASSEEMELV CARBURETOR HEATER.. CARBURETOR INSTALLATION. CARBURETOR REMOVAL CARBURETOR SEPARATI N CARBU RETOR SYNCHRONIZATIDN CHARGING SYSTEM INSPECTION. CLUTCH INSTALLATION. CLUTCH REMOVAL CLUTCH SWITCH CLUTCH SYSTEM. COOLANT REPLACEMENT COOLANT TEMPERTU RE INDICATOR! THERMOSENSOR COOLING FAN MOTOR SWITC COOLING SYSTEM COOLING SYSTEM TESTING CRANKCASE ASSEMBLY... CRANKCASE BEARING REPLACEMENT CRANKCASE BREATHER CRANKCASE SEPARATION CRANKSHAFT/CONNECTING R CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY CYLINDER HEAD COVER INSTALLATION . CYLINDER HEAD COVER REMOVAL CYLINDER HEAD DISASSEMBLY. CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVA CYLINDER INSTALLATION CYLINDER REMOVAL DIODE DRIVE CHAIN EMISSION CONTROL INFORMATION LABEL (USA. only) EMISSION CONTROL SYSTEM ENGINE IDLE SPEED ENGINE INSTALLATION . ENGINE OIL. ENGINE OIL FILTE ENGINE REMOVAL EXHAUST SYSTEM 22. INDEX FLOAT CHAMBER/PILOT SCREW. 11 FLYWHEEL STARTER CLUTCH 4 FORK...‘ 1315 FRONT WHEEL 13-8 FUEL LINE FUEL PUMP FUEL PUMP OVAL/INSTAUATION 5»24 FUEL TANK ..... 272 GEARSHIFI' LINKAG GEARSHIFI' PEDAL/ROD. GRAB RAIL . HANDLEBAR 1373 HANDLEBAR SWITCHES. 19-11 HEADLIGHT.“ HEADLIGHT AIM HIGH ALTITUDE ADJUSTMEN HORN IGNITION PULSE GENERATOR IGNITION SWITCH IGNITION SYSTEM IGNITION TIMING ..... LEFI’ CRANKCASE COVER INSTALLATION LEFT CRANKCASE COVER REMOVAL LEFT CRANKCASE REAR COVER. LUBRICATION & SEAL POINTS MAINTENANCE SCHEDULE METER ASSEMBLY ..... 19-4 MODEL IDENTIFICATION 1-1 NEUTRAL SWITCH 19-13 NUTS, BOLTS, FASTENERS OIL PRESSURE CHECKW OIL PRESSURE INDICATOR OIL PUMP PILOT SCREW ADJUSTMENT PISTON INSTALLATION PISTON REMOVAL PISTON RING INSTALLATION PRIMARY DRIVE GEAR RADIATOR COOLANT . RADIATOR RESERVE TANK RADIATOR/COOLING FA REAR BRAKE REAR BRAKE PEDAL/R0 REAR FE N DER REAR WHEEL . REGULATOR/R RIGHT CRANKCASE COVER INSTALLATION RIGHT CRANKCASE COVER REMOVAL. SEAT ..... SERVICE INFORMATION ALTERNATOR/STARTER CLUTCH BATTERY/CHARGING SYSTEM CLUTCH/GEARSHIFI' LINKAGE COOLING SYSTEM CRANKSHAFITI' RA CYLINDER HEADNALVE CYUNDER/PISTON ELECTRIC STARTER ENGINE REMOVAUI FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEUSUSPENSION STEERING INDEX SERVICE INFORMATION FUEL SYSTEM HYDRAULIC DISC BRAKE. IGNITION SVSTEM LIGHTS/METERS/SWITCHES LUBRICATION SVSTEM SERVICE RULES...‘ SHOCK ABSORBER . SIDE COVER SIDE STAND“. SIDE STAND SWITC SPARK PLUG .. SPECIFICATIONS SPEEDOMETER/SPEED SENSOR STARTER MOTOR... STARTER RELAY SWITCH . STATOR REPLACEMENT STEERING HEAD BEARINGS STEERING STEM .. SUB~AIR CLEANER SUSPENSION. SWINGARM EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) EVAPORATIVE EMISSION CONTROL SYSTEM (CaIiInrnia type only). TORQUE VALUES . TRANSMISSION TROUBLESHOOTING ALTERNATOR/STARTER CLUTCH‘ BATTERY/CHARGING SYSTEM CLUTCH/GEARSHFT LINKAGE COOLING SYSTEM. CRANKSHAFT/TRAN CYLINDER HEAD/VALVE CYLINDER/PISTON“ ELECTRIC STARTER ENGINE DOES NOT START OR IS HARD TO START .. ENGINE LACKS POWER FRAME/BODY PANELS/EXHAUST SYSTEM FRONT WHEEL/SUSPENSION STEERING FUEL SYSTEM ..... HYDRAULIC DISC BRAKE. IGNITION SYSTEM LUBRICATION SYSTEM POOR HANDLING POOR PERFORMANCE AT HIGH SPEE POOR PERFORMANCE AT LOW AND IDLE SPEED .. REAR WHEEL/BRAKE/SUSPENSION. TURN SIGNAL LIGHT .. TURN SIGNAL SWITCH VACUUM CHAMBER VALVE CLEARANCE VALVE GUIDE REPLA . VALVE SEAT INSPECTION/REFACING WATER PUMP WHEELS/TIRES WIRING DIAGRAM 22-2