1998-2004 IMPORTANT SAFETY NOTICE Memnmdmwwhfinawnmmmmm. CAUTION: MIWMWWIIWWMW. NOTE: Gives helplul information Detailed descriptions of stand-rd workshop procedures. salary principles and service uperations are not included. it is imponlnt to note that this menuel cont-ins lame warnings and caution: egeinst some specific service methods which could ceuu PERSONAL INJWIO service perwnnel or could damage e vehicle or render it unsafe Please understand that those wnrninge could not cover I" conceivable wave In which service, whether or not recommended by Honda, might be done or ol the possibly huerdous consequences of own conceivehle wuv. nor could Honda investigate ell such ways. Anyone using service nroceduree or tools, whether or not recommended by Honda, must seri'sly himsell thoroughly/Met neither personal safety nor vehicle safety will be jeopardiled bvthe service methods or tools selected. HOW TO USE THIS MANUAL Trus sew-Ce manual descrlbes the servlce ptOcedures Im the TRXASDSlFM and TRxasoES/FE. Follow the Mamtenance Schedule (Section 3| recom- mendatrons to ensure Ihal the vehtcle us In peak operatmg condrtron and the EmISSIOn levels are WIII’IIn lhe slandards set bv the CalrIOrnla AIt Resources Board FerIOtmlng {he Ilrsl scheduled marntertance IS very ITVIDOVIBI'II It compensates Iot the lnIIIaI wear that Occurs dullng the breakrln period. Sectlons l and 3 apply In the whole vehtcle Sectton 2 Illustrates procedures IO! temovalunstzllatlon 01 components Ihzl may be IOQuNEd to parlorm sen/Ice descnbed m the IOllowrng sections SeclIOn 4 through 23 descnbe parts Of the vemcle, glouped aCCottIrng l0 localmn Fmd me sectron you want on thts page. then tum to the table at contents on the lust page M Irre SECIIOH Most SECIIOI’IS start WIIIl assembly at system Illustratton, Sen/Ice InImmatIou and Imubleshoottng Ia! the secllOn. The subsequenl pages gIve detatled procedure. II you are no! famlllat wllh Ims vehicle. read the Techtucal Features In sectton 24 II you do not know the source DI the trouble, go to sectron 25. Troubleshootlng ALL INFORMATION, ILLUSTRATIONS. DIRECr ' TIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR 60., LTD, RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANV OBLIGATION WHATSOEVER. NO PART OF THIS PUBLICAHDN MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACOUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS OR ATVS, HONDA MOTOR 00.. LTD. SERVICE PUBLICATION OFFICE ENGINE AND DRAIVE TRAIN CHASSIS ELECTRICAL CONTENTS GENERAL INFORMATION n ’WME/B’ODV PANELS/EXHEI’S’T SYSTEM MAINTENANCE LUBRICATION SYSTEM n FUEL SVSTEM a ENGINE REMOVAL/INSTALLATION u CVLINDER HEAD/CVLINDER/PISTON CLUTCH n GEARSHIFT LINKAGE n ALTERNATOR/STARTER CLUTCH 7“ CRANKSHAFT/BALANCER/ TRANSMISSION ERONT WHEEL/SUSPENSION] 12 STEERING II - REAR WHEEL/SUSPENSION BRAKE SYSTEM 7 V m FRONT DRIVING MECHANISM Ia REAR DRIVING MECHANISM BATTERY/CHARGING SVSTEM IGNITION SYSTEM EECTRIC STARTER LlGHTS/METERSISWITCHES IE - ELECW PROGRAM (ESP) m WIRING DIAGRAM 1] TECHNICAL FEATURES m TROUBLESHOOTING INDEX 7 SYMBOLS The symbols used throughout this manual show specific service procedures. If supplementary information is required 9 pertaining to these symbols, it would be explained specifically in the text without the use 0' the symbols. Replace the partls) with new enele) belore assembly. Use recommended engine all. unless otherwise specified. Use molybdenum oil solurlon lmlxture of the engine oil and molybdenum grease in a ratio oil : 1). Use multipurpose grease (Lithium based multi-purpose grease NLGI '2 or equivalent). Use molybdenum disulfide grease (containing more than 3 $8 molybdenum disulfide, NLGI 01 or equivalent]. Example: Molykote‘BR—Z plus manufactured by Dow Cornlng, U.S.A. Multi-purpese M-Z manufactured by Mitsubishi Oil. Japan Use molybdenum disulfide paste (containing more than to 56 metvbdenum disulfide, NLGI #2 or equivalent]. Example: Molvkote'BR-Z plus. msnulactured by Dow Corning, U.S.A. Honda Moly 60 (USA only) _ Roool ASP menulectured by Rocol Limited, U.l<. Roool Paste manufactured by Sumioo Lubricant. Jepan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 3 or DOT 4 brake fluid. Use the recommended brake fluid unless otherwlee specified. a-gill shed“ Use Fork or Suspension Fluid. 0 '0 1. GENERAL INFORMATION GENERAL SAFETY 1-1 LUBRICATION 8t SEAL POINTS 1.18 SERVICE RULES 1-2 CABLE & HARNESS ROUTING 1-21 MODEL IDENTIFICATION 1-3 EMISSION CONTROL SYSTEMS 1-37 SPECIFICATIONS 1-4 EMISSION CONTROL TORQUE VALUES 143 INFORMATION LABEL 1-38 TOOLS 1-16 GENERAL SAFETY CARBON MONOXIDE USED ENGINE OIL If the engine musl be running to do some work, make sure the area is well ventilated. Never run the engine In an enclosed area. ED The exhaust contains poisonous carbon monoxide gas that can cause loss oi consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. GASOLINE Work in a well veflIIIaIEd areal Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. Awnmwc NEE—H Used engine oil may eause skin cancer II repeatedly left in contact with the skin for prolonged periods. Although this Is unlikely unless you handle used oil on a daily basis. It is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. BRAKE FLUID CAUTION: Spilllng fluid on pain ted, plastic or rubber parts will damage them Place a clean shop towel over these parts whenever the system is serviced, KEEP OUT OF REACH OF CHILDREN. Gasoline ls extremely flammable and is explosive under certain conditions KEEP OUT OF REACH OF CHILDREN HOT COMPONENTS M— Erruine and exhaust system parts became very hot and remain hat lor some time after the engine is run. Wear insulated gloves or wait until the engine and exhaustsystem have cooled before handling these parts. BRAKE DUST Never use an air hose or dry brush to clean the brake assemblies. Use an OSHA-approved vacuum cleaner or alternate method approved by OSHA, designed to mmlmlze lhe hazard caused by alrborne asbestos Ilversl M Inhaled asbestos fibers have been Iound to cause respiratory disease and cancer, 1-1 GENERAL INFORMATION BATTERY HVDROGEN GAS at ELECTRDLVTE _ - mmmmofl-ankupmflmllamu Ind datum away. Provlde edeqmtl ventilation when diamlng. The battery conulm sulllrrlc cold labctrolytol‘ Contact wltlr Iltln or cyu mey cauu unr- buml. Wnr protective dothlrru and I he. lhlold. - ll electrolyte you on your slain. flush wmr wear. - ll electrolyte all! In your em, llulh wltli water lor pt Inn 15 mlnum and call I physlclln Immediately. Electrolylc I: pobonom. - ll swallowed, drink large qulntltlu 0! water or mlllr and follow with mllk of manual. or vegetable all and tall 1 physician. KEEP OUT OF REACH OF CHILDREN. SERVICE RULES 1, Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents, Parts that don't meet HONDA’s design specifications may cause damage to the vehicle. 2‘ Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when servicing the vehicle. Metric bolts, nuts and screws are not interchangeable with English fasteners 4. Install new gaskets, O-ringe, cotter pins, and lock plates when reassemblingt 5. When tightening belts or nuts. begin with the larger diameter or inner bolt first, Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specifiedt 6‘ Clean parts in cleaning solvent upon oisassembly. Lubricate env sliding surfaces before reassemblyt 7r Alter reassembly, check all parts for proper installation and operation. 8. Route all cable and harness routing as shown on pages 1-21 through 1—29 Cable and Harness Routing. MODEL IDENTIFICATION b TRX 450$lFM : GENERAL INFORMATION TRX 450ES/ FE : The Irame serial number is stamped on the Iran! or [he frame. ’ . , ' CARBURETOR NUMBER Yha carburelor Identificauon numbers are slamped on [he leh Side of the carburetor body as shuwn. ENGINE SERIAL NUMBER The engrne serial number IS stamped on upper side a! the rear crankcase named from (he (eh side. {:7 ‘1“ 7» COLOR LABEL m seat as shown. When ordering color-coded pans, always specify rhe designated color code, u 1-3 GENERAL INFORMATION SPECIFICATIONS I 11’98 — '01: TRX‘SDES _ GENERAL After 01. TRX‘SOFE L ITEM SPEUFICATION DIMENSIONS ( Overall length (‘98 — ‘01) 1,961 mml77.21n) (Alter ’01) |,963 mm (77.3 in) Overall width (’98 - ’01) 1,156 mm (45.5 in) (Alter '01) 1,151 mm (05.3 in) Overall height 1.1“ mm (45.0 in) Wheelbase ('98 — '01) 1,271 mm (50.0 in) (After '01) 1,274 mm (50.2 in) Front tread (‘98—‘01) 912 mm (35.9w (Alter '01) 910 mm (35.8 in) ‘ Rear tread 905 mm (35.6 in) Seat height (’98 — '01) 860 mm (33.9 in) (Alter '01) 854 mm (33.6 in) Faotpeg height ('98 — '01) 327 mm (12.9 in) [333 mm (13.1 ln)l (After ‘01) 329 mm (13.0 in) [336 mm (13.2 in)l Ground clearance (’98 ~ '01) 192 mm (7.6 in) (After '01) I98 mm (7.7 in) Dry weight (‘98 — ‘01) 260 kg (573 lbs) [266 kg (585le1] (After '01) 26‘ kg (582 lbs) (270 kg (595 lbsll Curb weight ('98 ~ ‘01) 270 kg (595 lbs) [276 kg (605 Ibsll (After ‘01) 27‘ kg (604 lbs) [280 kg (617 lbsll Maximum weight capacity 220 kg (‘85 lbs) FRAME Frame type Front suspension Front wheel travel Front damper Rear suspension Rear wheel travel Rear damper Front tire size Rear tire sixe From rim sire Rear rim size Tire brand (DUNLOP) FRIRR Front brake Rear brake Toe Caster angle Camber angle Trail length Fuel tank capacity . Fuel tank reserve capacity Double cradle Double wish-bone 150 mm (5.91 in) Double tube Swingarm 150 mm (5.91 In) Double lube AT 25 X 8-12 fl AT 25 X 10-12 ii 12 X 6.0 AT 12 X 7.5 AT KT401C/ '98 - '01: KTIO5C. After ’01 K1128 Hydraulic drum brake Mechanical drum brake Toe-out : 35 mm (1-3/8 in) 3. 0.1' 7 mm (9/32 in) 11010.18 US gel, 2.64 Imp gal) l 2.7 l (0.71 US gal, 0.59 Imp gal) 1-4 G GENERAL INFORMATION - GENERAL (Cont'd) U * ENGINE Bore an; stroke i Displacement Compression ratio Valve train intake valve opens Intake valve closes Q Exhaust valve opens Exhaust valve closes Lubrication system Oil pump type . Cooling system Air filtration U Crankshalt tyne Engine weight Cylinder arrangement (TRXlSDS/FM) lTRX450ES/FE) SPECIFICATION i 90.0 X 68.0 mm [3.54 X 2.68 in) ( 432.5 am (25.40 cu~in) ‘ 8.5: 1 Overhead valve ‘ 6' BTDC 45' ABDC ( 36' BBDC 10‘ ATDC Forced pressure and wet sump l Trochoid Air cooled Oiled double urethane Unit type. two main journals 50.2 kg (110.7 lbs) 52.2 kg (115.1 lbs) Single cylinder, longitudinally installed CARBURETOR Carburetor type CV (Constant Vacuum) type Final reduction Rear Gear ratio 1st 2nd are 4th 5th Reverse Gearshift pattern ELECTRICAL Ignition system Starting system Charging system Regulator/rectifier Lighting system Throttle bore 32.0 mm DRIVE TRAIN Clutch syslem Centrifugal 8i multi-plate, wet Clutch operation system Automatic 1 Transmission Constant mesh, 5-speed with reverse Primary reduction 2.103 (61/29) Secondary reduction 2.100 (42/20) Front (‘93 - '01) (Alter ’01) l 3.153u1/13) l 3231 (42/13) 3.153 (41/13) 4.033 (49/12) 2.388 (43/18) 1.608 (37/23) 1.178 (33/23) 0.848 (28/33) 4.781 (34/12 X 27/16) Lett foot operated return system R—N—1—2—3—4—5 DC — CDI Starter motor and emergensy recoil starter Triple phase output alternator SCR shorted/triple phase lull~wave rectification Battery 1-5 GENERAL INFORMATION — LUBRICA‘HON SYSTEM ”m" '“"‘ ""’ ITEM STANDARDS SERVICE LIMIT Engine oil capacity Al draining 2.0 52.10 US qt, 1.76 Imp qt) — At disassembly 2.7 l (2.!“ US qt, 2.38 Imp qt) i W7- At oil filter change 2.1u2.21 us qt. 1.8501}?th # VRecommended engine oil HONDA GNJ A—stroke oil or equivalent A motor oil A_Pl service classification SF or SG Oil pump rotor Tip claarfle 0.15 (0.006) 0.20 (0.008) Body Elegance 0.15 — 0.21 (0.006 - 0.008) 0.25 (0,010) * Side clearance 0.02 - 0.09 (0.001 — 000‘) 0.11 (0.004) - FUEL SVSTEM ITEM SPECIFICATIONS TCArburetor identification number L53 » ’01: VEBSA I. After '01: VYESSC 7 >Main jat my) man 7 _ FHigh altitude setting _ _ #120 78:01)! jet _ _ 7 7 m 7 Jet meals clip position Jrqgroove (ram top Pilot scraw l Initial opening 7 7 2 — 518 turn: out I High altitude setting; I 2 — 5/8 turns out Float level 18.5 mm (0.73 in) Engine idle weed 1A00 2100 rpm Throttle lever Iree pley fl 3.0 -6.0 mm (1/8— 5/15 “LL , Starting enrichment (SE) valve distance 10 ‘ 11 mm (0.39 - 013 in) 1-6 GENERAL INFORMATION )- CYLINDER HEAD/VALVESICAMSHAFT um“ '“m “"’ ITEM STANDARDS SERVICE LIMIT Cylinder Dewmprusor effected 539 — 034 111‘. (5.5 — 05 kgllcm’. compression 78 - 121 psi) 31450 rpm — Decompressor not affected 1.226 — 1,442 We (12.5 — 14.5 kgI/cml. _ 17B - 206 08081450 rpm Valve. Vatve clearance IN 0.15 (0.008) — Valve gulde EX 0.15 (0.006) — Valve stem O.D. IN 5.475 - 5.490 (0.2156 - 0.2161) 5.45 (0.215) EX 5:455 — 5.470 (0.2140 — 0.2154) 5.43 (0.214) Valve guide (.0. IN 5500 - 5.512 (0.2165 - 0.2170) 5.525 (0.2175) EX 5.500 - 5.512 (0.2165 - 0.2170) 5.525 (0.2175) Stern to guide clearance IN 0010 - 0.037 (0.0004 — 0.0015) 0.12 (0.005) EX 0.030 — 0.057 (0.0012 - 0.0022) 0.14 (0.006) Valve seat width 1.2 (0.005) 1.5 (0.06) Valve spring Inner 38.85 (1.451) 35.00 (1.411) (fee Iangth Outer 41.67 (1.641) 40.42 (1.591) Rocker arm] Rocker arm I.D. 12.000 - 12.018 (0.4724— 0.4731) 12.05 (0.474) shah Rocker arm shaft 0.0. 11.964 - 11.904 (0.4710 — 0.4710) 11.92 (0.489) Rocker arm to shah clelrance 0.016 - 0.054 (0.0006 — 0.002) 0.08 (0.003) Camel-311 and Cam lobe height IN 38.4291 - 36.4291 (1.43421 —- 1.44051) 35.25 (1.427) cam follower EX 35.2670 — 36.4270 (1.42703 — 1.431111) 36.10 (1.421) Cam follower 0.0. IN/EX 22.467 - 22.462 (0.8845 — 0.3051) 22.46 (0.884) Cam Iollower bore 0D. INIEX 22.510 - 22.520 (0.8862 - 0.8868) 22.54 (0.087) Cam (allower to bore clelrence 0.028 — 0.059 (0.0011 -0.0023) 0.07 (0.003) - CYLINDER/PISTON ””"i ""“ “"’ ITEM HANDARDS SEMI! LIMIT Cylinder ID. 9000 ‘ 50.01 (3.543 — 3.544) 90.10 (3.547) Taper i 0.10 (0.004) Out 01 round — 0.10 (0.004) Werpege —— 0.10 (0.004) Piston, Piston mark direction 'IN" mark teclno toward the intake side — piston rings, Piston 0.D. 89.945 - 89.985 (3.5411 - 3.5419) 09.90 (3.539) piston pin Piston O.D. measurement point 10 mm (0.4 in) from bottom of skin — Piston pin 00121.0. 19.002 — 19.008 (0.7481 — 0.7483) 19.08 (0.751) Piston pln 0.D. 18.994 — 19.000 (0.7478 — 0.7480) 18.96 (0.746) Piston-lo piston pin clearance 0.002 - 0.014 (0.0001 — 0.0006) 0.12 (0.039) Piston lingdoJlng Top 0.030 - 0.080 (0.0011 - 0.0024) 0.09 (0.004) groove clearance Second 0.015 - 0.45 (0.0006 - 0.0018) 0.09 (0.004) Piston ring and gap Top 0015 — 0.30 (0.006 — 0.012) 0.5 (0.02) Second 0.370 — 0.450 (0.012 - 0.018) 0.6 (0.02) Oil (sidc (ail) 0.20 — 0.70 (0.008 - 0.028) — Cylinder-to-piston clearance 0.035 — 0.056 (0.0014 — 0.0022) 0.10 (0.004) Einiaing rod smell and 1b. 19.020 - 13.041 (0.7483 — 0.7496) 19.07 (0.7508) Connecting rod-to piston pin clearance 0.020 - 0.047 (0.0008 — 0.0019) 0.10 (0.004) 1-7 GENERAL INFORMATION — CLUTCH/GEARSHIFT LINKAGE ”m" '“"‘ ""' ITEM STANDAIIDS SERVICE LIMT Change clutch Spring free lengm 32.1 (1.26) 31.0 (1.22) Disc thickness 2.62 - 2.76 (0.103 - 0.109) 2.3 (0.09) Plate warpaga — 0.20 (0.008) Clutch omer guide 0.0. 27.359 - 21.930 (1.1007 -1.1016) 27.92 (1.099) 1.0. 22.000 — 22.021 (0.8661 - 0.8670) 22.05 (0.368) Mainshm 0.0 at outer gulda 21.972 — 21.993 (0.8850 - 0.8559) 21.93 (0.863) Centrifugal Drum 1.0. 140.0 - “0.2 (5.51 - 5.52) 100‘ (5.53) clulch Weight lining ihiclmnu 3.0 (0.12) 2.0 (0.08) Clutch spring helghl 3.1 (0.12) 2.35 (0.116) Clutch weight spring (rue lonmh 21.81035) 22.5 (0.89) Plimuy drive (.0. 27.000 - 27.021 (1.0630- 1.0638) 27.06 (1065) our Crankshlh 0.0. I! drive gear 26.969— 26.980 (1.0614 - 1.0622) 26.93 (1.060) GENERAL INFORMATION — CRANKSHAFI’ITRANSMISSION ”m“ "‘"‘ ""’ ITEM STANDARDS SERVICE LHIT Crankshan, Side clearance 0.05 - 0.65 (0.002 — 0.026) 0.8) (0.031) connecting rod Radial clealanca 0.006 — 0.018 (0.0002 — 0.0007) 0.05 (0.002) Runoul *1 0.05 (0.002) Transmission Gear I.D. M4 25.000 - 25.021 (0.9843 —- 0.9051) 25.05 (0.986) M5 20.000 - 20.021 (0.7874 — 0.7882) 25.05 (0.985) C1. C2, C3 28.020- 28.041 (1.1031 — 1.1040) 28.07 (1.105) CR 28.021~ 28.041 (1.1032 — 1.1040) 20.07 (1.105) Reverse (010 18.000 - 19.021 (0.7087 — 0.7095) 18.05 (0.711) Shaft O.D. M4 21.959 — 21.980 (0.0645 - 0.8654) 213310.863) M5 16.983 — 16.994 (0.6096 — 0.6691) 15.95 (0.667) Ravevse idle 13.966 — 13.984 (0.5498 — 0.5506) 13.93 (0.548) Gear bushing C1 0.0. 27.984—28.005(1.1017 -1.1026) 27.93 (1,100) C2 0.0. 27.979-28.000(1.1015— 1.1024) 27.93 (1.100) CR 0.0. 27.979—28.000(1.1015- 1.1024) 27.93 (1.100) M4 1.0. 22.000 — 22.021 (0.3061 - 0.8670) 22.05 (0.368) O.D. 24.959 - 24.980 (0.9820 — 0.9835) 24.93 (0.981) M5 1.0. 17.018— 17.034 (0% —0.6706) 17.06 (0.672) 0.0. 19.966 - 19.984 (0.7961 — 0.7968) 19.93 (0.785) R 1.0 14.000— 14.025 (05515—05522) 14.05 (0.552) 0.0. 17.966 - 17.984 (0.7073 — 0.70%) 17.93 (0.706) Gem-10' M4 0.020 — 0.062 (0.0008 - 0.0024) 0.10 (0.004) bushing M5 0.016 - 0.055 (0.0006 — 0.0022) 0.1010004) clearance C1 0015 - 0.057 (0.0006 - 0.0022) 0.10 (0.004) C2 0.020 - 0.062 (0.0008 — 0.0024) 0.10 (0.004) CR 0.020 — 0.062 (0.0000 - 0.0024) 0.10 (0.004) [:3 0.015 — 0.057 (0.0006 — 0.0022) 0.10 (0.004) Raver“ idle 0.018 ~ 0.055 (0.0006 — 0.0022) 0.10 (0.004) flushing-lo» M4 0.020 — 0.062 (mm - 0.0024) 0.10 (0.004) shun clearance M5 0.022 — 0.051 (0.0009 — 0.0020) 0.10 (0.004) Reverse idle 0.016 — 0.059 (0.0006 - 0.0023) 0.10 (0.004) Shift 107k. Fork (.0. 13.000 - 13.021 (05118—05126) 13.04 (0.513) shaft Claw thickness 4.93 - 5.00 (0.194 — 0.197) 4.50 (0.177) Fork shalt OD. 12.966- 12.094 (0.5105— 0.5112) 12.95 (0.510) GENERAL INFORMATION — FRONT WHEEL/SUSPENSION/STEERING Unit: mm (in) ITEM l‘ STANDARDS SERVICE LIMIT Minimum iirgiraau depth 7' _ 7 7 7 7 7 7 7 4 (0151 Cold tire pressure Standard 25 kPa (0.25 kgflrni. 3.6 psi) 7 :7 7 LN7|inimum 22 W: (0.22 k91/cm1,3.2 psi) 7 i Maximum 28 WI! (0.20 kgf/cm', 4.0 psi) 7 ¥ With cargo 25 kPa (0.25 kgl/cm', 3.6 Pi” i 7 Tia-rod-dislance barween (11970511 (aim; :39 2 1.0 (14.5 2 0,04) 7 i i 7 Toe Toa outz35t 15 mm(1»3l8:9l16 in) ( ¥ Unit: mm (in) — REAR WHEEL/SUSPENSION ITEM STANDARDS SERVICE UMIT read dapth 17 7 i 7 0 (0.16) (Ire Standard 25 kPa (0.275759717071117, 3737s“ 7_7; 7 77 Minimum 22 kPa (0.22 kgI/cm’. 3.2 psi) 1 7 Maximum 28 kPa (0.28 kgI/cmi. 4.0 psi) l 7 i With cargo 25 kFa (0.25 kgf/crn'. 3.6 psi) ( 7 _ BRAKES Unit. mm (In) ITEM STANDARDS SERVICE LIMIT Front brake Drum ).D. 150015.30) 161.0 (6.31) 7 Lining thickness 4.0 (0.16) 2.0 (0.08) Brake panel warpaga — 0.‘ (0.02) 7 Brake panel seal lip waar _ 0.5 (0.02) 7 flater seal lip length 22.0 (0.87) 20.0 (0.79) Master cylinder LD. 14.000 - 14.003 (0.5512 ~ 0.5529) 14.055 (0.5533) Master piston 0.0. 13.957 < 13.984 (0.5‘95 — 0.5506) Wheel cylinder LD. 19.050 ~ 19.102 (0.7500 — 0.7520) Wheel cylinder piston 0.0. 18.997 — 19.030 (0.7479 - 0.7192) Rear hrlke Drum i.D. 160 (6.30) 161.0 (6.34) Lining ihicknoss 5.0 (0.20) To the indicator — FRONT DRIVING MECHANISM um """ "m "EM STANDARDS 1 SERVICE LIMIT Oil capacitv Alter draining 190 cm’ (6.43 us 01. 5.07 Imp 91) (”77 ii At disassemblv 200 cm! (6.76 gs oz, 702 Imp ox) . ‘ 7fia§ommend§g£ii Hypuid gear oil SAE #80 7 i7 Emh spring (ree height 72.65 (0.104)777_ 77 ‘72.5 (0.10) Clutch disc thickness A 2.7 - 2.8 (0.106 — 0.110) l 2.4 (0.09) a 2.3 — 2.4(0091— 0.09977 2.1 (0.0017 Pinion gear (.0. 7 7 12.000 - 12.015 (0.4724 — 0.4731) 12.05 (0.4747) Pinion gear shaft 0.0. 7 11.973 — 11.9074 (0.4714 - 0.4715) 11.75 (0.463) 7 SN): torque 17 — 25 N-m (17 ~25 km, 12 - 18 M10 — Gaar again... 7 0.0751030 (0.002 31.012) 7 0.40 (0.016) 1-10 GENERAL INFORMATION Unit: mm (in) - FRONT DRIVING MECHANISM ('98 - '01) ITEM STANDARDS SERVICE LIMIT 7011 c7apacitv I7AIter drainm7g ‘ 7190 crn7j @375 oz, 6 7 Imp7 uII7 7 * : Wynn“: 20079“: (5_ a U75 972 LQImp oz) 7 Recommended on 77 7 7 7 Hyponggear oil SAE ((7870 7 7 C7|ut7I7:h spripg7l7rie7he7igm 7 2 65 (D 0417 7 2.5 (07.10) Clul7I7:h dISC thickness 717A 2. 77 2. a (o. 106— 0. 110) 2.4 (0.09) 77 77 B 7 7 2.3— 2.4 (0.091 7&9” 7 2.1 (0.08) 7 Pimon gearLD. 7 7 12.00071g07157974724—047371I77 12.05 7:04") Fmion gear shaft 0. . ‘ 11.973 —171.98‘(0.47M — 0171B) 11.750148) Slip torque 7 717 ~ 25 N'm7(1.7 A 7 5 kgfli, 12 — 181191-11) ’ Gear backlash ' 0.05 » 0.30 (0.002 — 0.012) Mo (00161 Unit: mm (InI — FRONT DRIVING MECHANISM (After '01) ITEM STANDARDS SERVICE LIMIT Front TOiI capacity A7fter7Ii7r7almng 241 unis; us 017 55 Imp oz)77 7 7 “i"e'mia' I Afler disassemblv ' 727757;: (9.3 US 02, 9.71I7np oz) 7 Hecnmmended o7il 7 Hypoid gear oil SAE ((80 ‘ 77 Gear backlash 0,05 - 70.25 (0.002 - 0.0170) 77‘ 0.4 (0.02) 7 B7ack7Iash $80717ng 777 7 7 7 0.2 (0.01) 7 7 Slip xorque 14 ~17 N-m (1.45 — 1.75 kgl-m, 12 N-m (1.2 kgI-m. 77 7 7 10 -137IbI-I7n777 779 lug-m . Face cam-to-housipgflslance 6. 3- e. 7 (70. 257 — 0. 26) 6.3 (0.25) DIerremi7a7I7h7ausing cap depth 7 797 557— 7976537 (0 9767 07 37730) 5% (GE Cone spring Iree height 2. 8 (0 11) 2.6 (010) um: mm (in) - REAR DRWING MECHANISM ITEM STANDARDS SERVICE LWIIT Rear, .V i 7 7. 7 iv 7 3-0122)- ,_ Rear fin I OH capacuty . Afiqr draIn7ing77 90c7nv(3.0 US 7372101, ”IPA”, 777 ("We 77 ‘Amisasse7mhly7 7 7 71700¢m’(734US 7 7 7 7_ ‘ Recommended oil 7Hypo‘Id gegr oil SAE7 ((807 7 Gear backlash 0. 05- 0 3010 002— 0.012) 0.00 (0.016) — BATTERY/CHARGING SVSTEM ITEM SPECIFICATIONS Batrerv Cfiily 77 712 V— 12 7A7H7 7 7 Curre7nl Ieakage 7 7 5 mA mg. Voltage 7 Fully charged 173.0 - 13.2 V IZD'CI‘GB'FI 7 Needs charging Belgw 12.3 V 7 7 Charging current I7N707r§Ial 1.2 57157-10 h 7 7 7 7 _Ouic|I 77 75.9 Anon 7 Allernalor 7Capacil7y7 70.3710 kw/EQOO rp7m C7harg71ng call res (M703 (7207 0760' F—7I7 7 0171.070 7 7 fiTgulator/ Type 7 7 {rigIaphaseIIulI-wave renificaupp 77 "mm" Regulaled volIage , 14.7 — 15.5 v at 5,000 rpm 1-11 GENERAL INFORMATION — IGNITION SYSTEM Unil: mm Iinl ITEM SPECIHCATIONS Spark plug Standard DPH7EA — 9 (NGK) X22EPR - U9 (DENSO)7 For cold climate (below 5°C/A1'F) DPRGEA- 9 INGK) XZOEPR — U9 (DENSO) For extended high speed riding _D?RBEA — 9 (NGKI X24EPR — U9 (DENSO) 7561i 7plug7 gap 0.8 — 9.9 mm (0.03 — 0.04 in) Ignition coil peak voltage I00 V mlnmium Ignition pulse generator peaki/ollago k 0.7 V "inmium Ignition liming "F" math 10" PTDC at 1,400 rpm Full advmce 30" BTDC al 5,900 rpm U nit: m m (in) '— ELECTRIC STARTER ‘ n‘EM snumnos ssnvuc: um Sumo! m7olor blush Isngm _ 7275 (0.49) \ 9.010.375; 7 77 7 " LIGHTS] METERS/ SWITCHES ITEM speancnsous 315s Headlight 7 7'9: - '01 77 1gv — zs/zsw x z 7 Mar '01, 12v—3onowx2 Msis! Iliadligm 12v — JSW Taillight 7 W 12v - 5w x 2 , Brake Light (Aharm Quebec province only) 12v - 2 ICF # k7 Indicator IOiIIRsversa/Neulral) 7 LED 7 Fuse Main Iuse 30A 7 Sub (use '93—'01 15AX2. 11:sz Aner‘of77 7 v5Ax2.waa 7 7 _77 MOTOR FUSE (Tnxuio ES/FE only) _ :o A 1-12 GENERAL INFORMATION TORQUE VALUES TORQUE FASTENER 1'er Mm “W“, mm 5 mm hex bolt and nut 5 (0.5, 3.6) 6mm hex bull and nut 10l1,D, 7) 8 mm hex bolt and nut 22 (2.2, 16) 10 mm hex bolt and nut 34 (3.5, 25) 12 mm hex bolt and nut 54 (5.5, ‘0) ) FASTEIER TVFE 5 mm screw 6 mm screw 6 mm flange bolt [8 mm head) 6 mm flange bolt (10 mm head) and nut 8 mm flange bolt and nut 10 min flange bolt and nut TORQUE N-m (km-m, 11:11-11) I ((1.1, 2.9) 9 {0.9. 6.5) 9 (0.9. 6.5) 12 (1.2, 9) 26 (2.7, 20) 39 “.0, 29) - Torque specificatons listed below are for important fasteners. - Others should he tightened to standard torque values listed above. NOTES: 1. Apply sealant to the threads. 2, Apply a locking agent to the threads. 3. Stake. 4. Apply ail to the threads and flange surface. 5. Apply clean engine oil to the O-ring. 6. Apply grease to the threads and flange surface) 7. ALOC bolt: replace with a new one. 8. Do not reuse; replace with a new one. 9. Castle nut: Tighten to the specrfied torque then tighten ta position suitable for cotter pin hole direction. - ENGINE TWO DIA. TORQUE "EM 0"" ) (mm) 1 N-m ikgiqn IbMt) mum‘s Maintenance: ) Oil drain bolt 1 12 25 (2.5 16) Oil filter cover flange bolt 3 i 6 ‘ 10 (1 0, 7) Spark plug 1 i 12 1a (1. B 13) Timing hole cap 1 i 14 i 10 (1.0.7) Valve adjuster lock nut 2 6 17 (1.7, 12) CIutch adjusting screw lock nut 1 8 22 (2.2, 16) Lubrication 5mm: Oil pump rotor side plate screw 1 5 t (0J0. 2.5) ReIief valve cap H 19 [1.9, 14) NOTE 2 Fule System: ' Carburetor cover screw I 5 4 (DJ, 29) Starting enrichment (SE) valve nut 1 14 310.3, 1.8) Insulator band screw fAfter ‘01) 5 I (0.4. 2.3) Cylinder HIId/VIIVM/Clmihl“: Cylinder head flange cap nut ‘ 3 10 39 (4.0, 29) NOTE A Camshaft bearing retainer bolt 1 8 2612.7, 20) NOTE 2 Cam sprocket flange dowel bolt ‘ 2 7 20 (2.0. 14) NOTE 2 Cam chain tensioner litter sealing screw 1 6 410.4. 2.9) Carri chain tensioner mounting bolt 1 2 6 12 (1.2, 9) NOTE 2 Rocker arm holder flange cap nut ‘ 3 10 39 (4.0, 29) NOTE A Rocker arm shaft flange bolt 1 8 7 (0.7. 5.1) clutch/Gnnhm Llnklge: ‘ Gearshift return spring pin ‘ 1 8 22 (2.2, 16) NOTE 2 Shift drum stepper arm bolt 1 E 12 (1.2. 9) Gearshift A arm bolt 1 B 2512.5, 18) Centritugal clutch outer lock nut 1 ‘ 20 11E (12.0. 87) NOTE 3. A Clutch spring bolt t i 6 12 (1.2, 9) ‘ Change clutch center lock nut 1 . IB 108(110. 80) NOTE 3, ‘ Drum shifter and guide plate bolt (’93 - '01) I ‘ 6 12 (1.2, 3) NOTE 2 (After '01) 1 ‘ 6 16 (1.6, 12) NOTE 2 1-13 GENERAL INFORMATION - ENGINE (Cont'd) ‘ THREAD DIA. TORQUE "EM 0'" (mm) N-m rum, IM—l‘tl “M‘RKS Recall Stator: ‘ i Recoil pulley llange ball 1 12 108 (11D, 80) NOTE 4 Altornltorlstartur Clutch: 1 Starter onevway clutch socket bolt 6 8 31 (3.1. 22) l NOTE 2 Stator socket bolt 3 6 10 (1‘0, 7) ‘ lgnltlon System: i Ignition pulse generator socket bolt 2 5 6 (0‘6. 4.3) NOTE 2 UghtslMeters/Swltchn: Neutral/reverse (or gear position) switch l mounting bolt 1 6 12 (112) 9) NOTE 2 on thermo sensor 1 12 ‘ 18 (1.8. 13) Angle sensor (TRX450ES only) 2 6 ‘ 610.6, 4.3) - FRAME v i THREAD 01A. TORQUE "EM 0'" 1mm) N-rn (ital-m. lM-fll “MM“ Frame/Body Panels/Exhaust System: { Muffler bend bolt 2 8 23 (2.3.17) Exhaust pipe protector bolt 3 6 221212. 16) Heat protester bolt 2 6 22 (272,16) Heat guard bolt 4 6 20 (2.0, 14) Step bar mounting bolt 4 8 32 (3.3, 24) Cooling tan shroud special bolt 4 6 1541.3, 13) Fuel tank rear bracket bolt 4 6 l 18 (1.8.13) Carrier mounting bolt (‘98- '01) 14 8 ‘ 32 (3‘3, 24) (After '01) 14 8 37 (318‘ 27) Fuel System: Fuel valve mounting bolt 2 6 l 9 (015, 6.5) Fuel level gauge mounting bolt 2 6 12 (1.2.9) By-starler oap special bolt 1 14 2.3 [0123. 1.6) Hutch/Gavin“! Linkage: Gearshift pedal bolt (’98 — '01) 1 6 16 (1.61 12) (Alter '01) 1 6 20004 14) Ennln- Mountlng: Lower engine mounting bolt (right) 1 10 54 (5.5, 40) Lower engine mounting bolt (left) 1 1D 54 (5.5) 40) Upper engine hanger bolt 1 10 54 (5.5, 40) Upper engine hanger bracket bolt 2 8 32 (3,3. 24) Lower engine hanger bracket bolt 2 a 32 (3‘3. 24) Front Wheel/Suwulon/Stnrlng: Throttle case cover 3 4 4 (074, 2,5) Handlebar lower holder nut 2 1O 39 (4.0, 29) NOTE 3 Steering shalt U~nut 1 14 108 (1110. 80) NOTE 6 Tiered ball joint sell lock nut 4 12 54 (5,5. 40) Tie-rod lock nut 4 12 54 (5.5. 401 Steering shaft holder flange bolt 2 8 ”(13, 24) Upper/lower arm pivot self lock nut B 10 44 (415. 33) NOTE 8 Knuckle ball joint castle nut (’98 - '01) 4 12 29 (3.0) 22) NOTE 9 (Alter ’01) 4 12 32 (3.3, 24) NOTE 9 Shock absorber upper mounting sell lock not 2 10 44 (4‘5, 33) NOTE 8 Shock absorber lower mounting sell lock nut 2 10 44 (415. 33) NOTE 9 Damper rod lock nut 2 10 37 (33, 27) NOTE 2 Front wheel nut B 10 64 (6.5, 47) Front wheel nub castle nut 2 16 78 (8‘0. 58) NOTE 9 1-14 GENERAL INFORMATION - FRAME (Cont’d) 1 . , THREAD BIA. TORQUE ITEM 1 o w ‘ "m", NW (Wm IbMt) REMARKS Bur Wheel/Suspemlen: ‘ Rear axle castle nut Z 20 137 1110. 101) NOTE 9 Rear wheel nut B 10 6‘ (6.5. 47) Shock absorber lower mounting self lock nut 1 10 l u (‘5, 33) NOTE 8 Shock absorber upper mounting sell lock nut 2 10 1 39 (4.0. 29) NOTE 8 Shock absorber lower mounting bolt 1 10 44 (4.5. 33) Damper rod lock nut 2 10 l 37 (3.8, 27) NOTE 2 Swingerrn (en pivot bolt 1 30 113 (11.5. 83) Swingarm right pivot bolt (’98 - '01) 1 l 30 l t (0.104 2.9) (After '01) 1 l 30 1011.0, 7) Swintarm right pivot lock nut 1 30 113 (11.5, 83) Rear axle nousrng and swingerm nut ‘ E l 10 l u (4.5, 33) NOTE 8 Skid plate flange bolt 3 ‘ a 32 (3.3, 24) Sultan: ‘ Rear brake arm pinch bolt/nut 1 8 . 20 (2.0, 14) Rear brake panel drain bolt (’98 - '01) l 12 l 3‘ (3.5.25) (After ‘01) 1 12 12(1.2,9) Master cylinder reservoir cap screw 2 4 7 (0.20, 1.4) Master cvlinder holder SH bolt 2 6 12 (1.2, 9) Brake lever pivot bolt 1 6 1 (010,01) Brake lever orvo! lock nut 1 6 6 (0,6, 43) Brake hose ml bolt 4 10 3‘ (3.5, 25) Brake hose clamp flange bolt 2 6 12 (1.2. 9) Brake panel flange bolt ‘ a 8 29 (3.0, 22) ‘ NOTE 8 Wheel cylinder bolt/washer 4 6 E (0.8, 58) Wheel cylinder nut 4 B 17 (1.7, 12) Wheel cylinder oil pipe I 10 16 (1,6, 12) Brake bleeder valve 2 B 6 (0.64 1.3) Breather hose clamp (knuckle) 2 B 32 (3.3. 24) Brake nose 2an )oint 2 B 15 (1.5, 11) Front Driving Mechanism: Diflerential case mounting bolt/nut, 10 mm 2 1o 44 (4,5, 33) 8 mm 1 E 22 (2.2.15) Differential case cover flange bolt, 3 mm 6 B 25 (2.6, 19) 10 mm 2 10 49 (5.0. 36) NOTE 2 Pinion [Olnl nut (‘98— ‘01) 1 16 1081110 80) l NOTE 2 Pinion bearing lock nut (‘98- '01) 1 GA 98 (10.0. 72) 1 NOTE 3 Diflerontial gear case drain bolt 1 8 12 (1.2, 9) Diflomntial gear case cover oil cap 1 30 12 (1.2. 9) Diflsrential case can torx bolt ('98 — ’01) 6 B 32 (3.3. 24) NOTE 7 Dil'erential case UBS bolt (‘98 — ‘01) 6 8 49 (5.0. 36) Differential ring gear bolt (After ’01) 8 8 49 (5.0. 36) NOTE 8 Speed sensor mountlng bolt (After '01) 2 a ‘ 10 (1.0. 7) final clutch speed sensor mounting bolt (After ‘01) 2 6 10 (1‘0. 7) Final clutch mounting bolt (Alter '01) Cl 8 25 (2.6, 19) Final clutch cover bolt (After '01) 2 6 7 (0.7, 5) flur- Drivina Mosh-mun: Gear case cover flange belt, 5 mm 6 B 25 (2.6. 19) 10 mm 2 10 49 (5.0. 36) NOTE 2 Pinion joint nut ('98 — ‘01) 1 . 15 1001110, 80) NOTE 2 Pinion bearing lock nut 1 ' 64 58 (10.0. 72) NOTE 3 Gear case drain bolt 1 E 12 (1.2. 9) Gear case cover or) check belt 1 B 12 (1.2, 9) Gear case cover oil cap 1 30 12 (1.2.9) 1-15 GENERAL INFORMATION TOOLS NOTES: 1r Newlv designed tool. 2. Equivalent commercially available in USA, 3. Not available in U.S.A. 4. Alternative tooL DESCRIPTION TOOL NUMBER REMARKS ‘ REF. SEC. 7, I Carburetor lloat level gauge 07401 — 0010000 5 Flywheel holder 07725 — 0040000 NOTE 2 10 Rotor puller ‘ 07733 - 0020001 NOTE 4: 10 ‘ 07933 - 39500001U‘SA‘ only) Remover weight 1 07741 - 0010201 NOTE 4: B, 13 07936 — 371020A or 15 (After '01) 07536 < 3710200 Valve guide driver, 5.5 mm 07742 - 0010100 7 Attachment, 37 X 40 mm 07746 - 0010200 11, 12, 13 Attachment, 42 X 47 mm 07746 7 0010300 8, 11 Attachment, 52 X 55 mm 07746 — 0010400 10, I1, 12. 14 15, 16 Attachment, 62 X 68 mm 07746 — 0010500 14, 16 Attachment, 72 X 75 mm 07746 — 0010600 11 Attachment, 24 X 26 mm 07746 — 0010700 , 10. 11 Attachment, 22 X 24 mm (A118! ’01) 07746 — 0010000 15 Driver, 22 mm ID. 1 07746 — 0020100 1 8 Attachment, 15 mm LU. 07746 — 0020200 8 Driver, 40 mm (.D. 07746 — 0030100 , 15, 16 Attachment, 25 mm ID. ('98 — '01) 07746 — 0030200 15, 16 Attachment, 30 mm (D. (A118! '01) 07746 — 0030300 15, 16 Pilot. 10 mm 07746 - 0040100 10 Pilot, 15 mm (Altar ‘01) 07746 ‘ 0040300 15 Pilot, 17 mm 07746 — 0040400 8,11,13,14 Pilot, 20 mm 07746 - 0040500 11, 12 Pilot, 25 mm 07746 < 0040600 11 Pilot, 30 mm 07746 A 0040700 12 Piiot, 35 mm 1 07746 — 0040000 11 Pilot, 40 mm 1 07746 — 0040900 11 Pilot, 22 mm ‘ 07746 — 0041000 11 Pilot, 28 mm 07746 — 0041100 14, 15 Pilot, 14 mm (After '01) 07746 — 0041200 15 Driver 07749 — 0010000 8,10,11,12. 13, 14, '15, 16 Valve spring compressor 07757 ~ 0010000 7 Valve seat cutter NOTE 2 Seal cutter, 29 mm (45' EX) 07780 — 0010300 7 Seat cutter. 35 mm (45' IN) 07780 - 0010400 7 Flat cutter, 30 mm 132' EX) 07700 - 0012200 7 Flat cutter, 35 mm (32' IN) 07780 — 00I2300 7 Interior cutter. 30 mm 160' EX) 07780 — 0014000 7 interior cutter, 37.5 mm (60' IN) 07780 — 0014100 7 Cutter holder, 5.5 mm 07781 ~ 0010101 7 Swingarm lock nut wrench 07908 - 4690003 13 Snap ring pliers 07914 - 3230001 14 Lock nut wrench, 30 X 64 mm ('98 - '01) 07916 - MBODOOZ NOTE 4: 15, 16 07916 ~ M800001 ‘1-16 GENERAL INFORMATION DESCRIP‘HON TOOL NUMSER REMARKS i REF. SEC. Bearing remover set 07936 — 3710001 NOTE 3 ‘ 11 - Remover handle 07936— 3710100 1 ll — Bearing remover, 20 mm 07936 - 3710600 1 i 11 - Remover weight 07741 ~0010201 NOTE 4: 11 07936~371020A or 1 07936 — 3710200 Remover handle 07936 — 3710100 8. 11. 13 Bearing remover. 17 mm 07936 - 3710300 B, 11. 13 Clutch puller 07933 - HA80000 NOTE 4: 8 V 07933 - HBBOOOA Attachment 075‘5 — 3330300 ‘ NOTE 4: 12 07746 — 0010100 Attachment, 20 X 30 mm 079.6 4 1870100 12 Driver handle attachment 1 07949 — 3710001 12 Oil seal driver [Alter ’01) 07965 — KE50100 16 Driver attachment 07965 - KEBOIOD NOTE I: 1 15 ('98 — ’01l, 16 07917 - M50100 Oil seal driver 1 07965 — MC70100 10 Assembly collar | 07965 - VM00l00 ‘ 11 Assembly shalt 07565 — VM00200 NOTE I: 11 07931— ME401OB and 1 07931 - HB3020A (U.S.A, only) Threaded adapter 07965 — VM00300 NOTE 4: l 11 07931 — KF00200 (UrSAr only) 1 Valve guide reamer. 5.5 mm 07984 — 2000001 NOTE 4: ‘ 7 07934 — 200000D (USA. only) ‘ Clutch holder 076MB — HA70101 NOTE 4: 1 8 07GME~HA7010A or ‘ 07GMB-HA7011A and i 07GMB-HA7012A Inspection adapter 07GMJ ~ ML80100 i 20 Peak voltage adapter 07HGJ - 0020100 NOTE 4: 18 Peak voltage tester (U.S.A. only) i Pinion puller set 07HMC - MM80101 NOTE 3 151'98 - '01), 16 — Shaft puller 079317 ME40000 NOTE 4: 15 (’98 , ‘01), 16 07931— ME‘O1OE and 07931 — HB3020A (U.S.A, only) - Pinion puller base 07H MC — MMEOHO NOTE I: 15. 16 07HMC — MM8011A (USA, only) Adjustable bearing puller (After '01) O7JAC — PH80101 15 Remover shaft (Alter '01) 07JAC — P1180200 15 Oil seal driver attachment 07JAD - PH30101 10, 12 Clutch center holder 07JMB ~ MN50300 NOTE 1: 8 i 07HGEVOO101OE and 07HGE - 0010208 (USA. only) Dil'lerential inspection tool i 07KMK - “650101 NOTE 4: 15 i 07KMK — NC5010AlU.S.A1 only) Ball ioint remover, 28 mm 1 07MAC — 5L00200 12, 14 Pilot, 32 mm ‘ 07MAD - PRSOZOO 11, 16 Ball joint installer base 07HAF - SF10120 12 Reooil pulley holder 075MB - HM70100 10 Pinion holder ('98— '01) 075MB — HM70200 15. 16 Ball joint remover/installer 07WMF ~ HN00100 NOTE 1 12 Universal bead breaker slum—953.0111 12, 13 1-17 GENERAL INFORMATION LUBRICATION & SEAL POINTS ' ENGINE LOCAflOM MA‘I'ENAI. Oil filter cover inside Cylinder bore Cylinder stud bolt threads (at cap nut) Piston pin bore and piston outer surface Piston ring surface Connecting rod small and inner surface Centrifugal clutch outer lock nut threads Cam follower surface Cam chain surface Rocker arm both ends Clutch friction disc surface Clutch lifter plate outer surface Centrifugal clutch outer sliding surface Clutch drive plate one«way clutch sliding surface Transmission bearing and gear teeth surface Transmission bushing Journal surface Main shaft and countershaft journal surface Change clutch center lock nut threads Shift fork shaft surface Shift drum grooves and surface Reverse stopper shaft journal surface Starter idle gear teeth Recoil pulley bolt threads Starter ontway clutch surface Esch ball and needle bearing rolling area Each oll seal lip Crankshaft oil path Engine oil Piston pin outer surface Camshaft lobes Rocker arm shaft (rocker arm sliding surfaoel Valve stem sliding surface Clutch outer guide sliding surface Starter reduction shaft A surface Starter reduction shaft surface Starter motor pinion and Molybdenum disulfide oil is mixture of 1/2 engine oil and 1/1 molybdenum disulfide grease) Cam sprocket bolt threads Cam chain tensioner 6 mm flange bolt threads Camshaft bearing fixing plate 3 mm bolt threads Relief valve 14 mm oat) threads Gearshift return spring pin threads Starter one-way clutch socket bolt threads Neutral/reverse switch 6 mm bolt threads Ignition pulse generator 5 mm socket bolt threads Locking agent Change switch grommet Alternator wire grommet Alternator cover gasket Sealant 1-18 GENERAL INFORMATION — ENGINE lcont'dl ' APPLY spear} APPLY SPECIFIED GREASE LOCATION MATERIAL REMARKS Front cover shift reduction gears Unirex N2 (ESSO) Apply 3 — 59 of recommended (TRXASOES only) Unirax N3 (5550) grease. r equivalent — FRAME LOCAHON MATERIAL REMARKS Steering bushing sliding surface Steering shaft oil seal lip Steering shaft dust seal lip Steering shaft nut threads Steering shaft spline Knuckle dust seal lip and side seal Rear brake cable and Rear brake cam shaft sliding surface Rear brake cam dust seal lip Rear brake panel dust seal lip Rear brake shoe cam contact surface Rear brake shoe anchor pin contact surface Brake pedal shaft sliding surface Brake pedal dust seal lip Brake cover seal lip and side seal Brake lever pivot sliding surface Brake lever parking arm pin sliding surface Rear brake panel O-ring Left axle housing seal lip Left axle housing bearing Front final drive pinion joint oil seal lip Front drive shaft oil seal lip Front differential oil cap O-ring Front differential pinion joint O-ring Front final clutch dust seal lip (After '0” Front final clutch oil seal lip (After ‘01) Front final clutch needle bearing (After ‘01) Front drive pinion spline (After ‘01) Rearfinal drive pinion joint oil seal lip Rear final drive ring gear oil seal lip Rear final drive oil cap O‘ring Rear final drive pinion joint O-ring Cross joing needle bearing Swingarm bearing and grease holder Swingarm bearing dust seal lip Throttle cable end Multi-purpose grease Apply 2 - 3 g of graasa Apply 0.5 — 1‘0 9 of grease Apply 0.5— 1.0 g 0! grease Apply 0.5 — 1.0 g of grease Fill up 3 9 minimum 1-19 GENERAL INFORMATION — FRAME (Cont'd) LOCAflON MATERIAL mums Front brake drum water seal lip and outllda lip inside Multipurpose grease Flll up 14 — 16 g a! grease NLGI N03 Rear axle ahatt epline (left aide) Molybdenum diaulfide (center) grease (right side) Apply grease to 20 mm width of area 0'10 mm away from spline right end an that spline is filled with grease. Rear wheel hub dust seal lip Front di'ferentlal pinlon joint epllna Fill up 5 - 8 a or grease Hear final drive pinion joint spline Flll up 5 —- a g of grease Yoke joints apllna Front propeller shaft ioint spline (Differential aide) Fill up 5 - 8 g at grease (Engine side) Fill up 5 — 8 g 01 grease Rear propeller shall see) lip Frunt propeller shalt seal lip Front drive shaft spline (Wheel side) Frant drive shalt boot inside (Inboard) 40 - 60 g (Outboard) 30 - 50 9 Rear brake Inner cable Cable lubricant Throttle inner cable Flaverse assist inner cable Choke inner cable Front differential cue Hypoid gear oil SAE 200 cc (6.78 01) Rear final drive case 000 100 cc (3.38 oz) Front dlflerential case mating surface Rear final drive case mating suflaoe Liquid sealant (Three—bond 1215 or equivalent) Handlebar grip rubber Inside Handa bend A or Cemedlna 0540 1 -20 GENERAL INFORMATION CABLE 81 HARNESS ROUTING TRXOMS (”401): THROTTLE CABLE CHOKE CABLE REAR BRAKE CABLE aRAKE HOSE REVERSE CONTROL CABLE IGNITION SWITCH WIRE HANDLEBAR SWITCH WIRE COMBINATION METER CONNECTOR 'IRXISOES ['98-'0‘": CHOKE KNOB THROTTLE CABLE REAR BRAKE CABLE BRAKE HOSE IGNITION SWITCH WIRE I I [H ‘ I}? COMBINATION METER ‘71 ~ , ' . CONNECTOR 1-21 GENERAL INFORMATION mm mm '01): CHOKE CABLE REAR BRAKE THROTTLE CABLE CABLE BRAKE HOSE REVERSE SWITCH 2WD/lWD SWITCH WIRE R NTROL IGNITION SWITCH cigELESE co W'RE THERMO , SENSOR 2‘ HANDLEBAH SWITCH WIRE METER SPEED SENSOR ~ CONNECTOR COMBINATION METER CONNECTOR FINAL CLUTCH SPEED SENSOR CONNECTOR FINAL CLUTCH ' 2WD/AWD SWITCH CONTROL UNIT CONNECTOR mm (“In '01): CHOKE KNOB REAR BRAKE CABLE THROTTLE CABLE BRAKE HOSE REVERSE SWITCH 2WD/‘WD SWITCH WIRE REVERSE CONTROL CABLE IGNITION SWITCH HANDLEBAR SWITCH WIRE WIRE THERMO SENSOR CHOKE CABLE COMBINATION METER CONNECTOR METER SPEED SENSOR CONNECTOR 2wo/4wn SWITCH FINAL CLUTCH SPEED CONNEUQR SENSOR CONNECTOR ECU 1-22 GENERAL INFORMATION T'RXMS I‘M-'01): IGNITION SWITCH CONNECTOR ACCESSORY SOCKET CONNECTOR RIGHT BRAKE BREATHER HOSE COMBINATION METER RIGHT BRAKE CONNECTOR HOSE COOLING FAN CONTROL UNIT IGNITION CONTROL LEFI’ BRAKE HOSE MODULE RIGHT BRAKE HOSE RIGHT BRAKE BREATHER HOSE , . 7 LEFT BRAKE BREATHER "055 DIFFERENTIAL CASE BREATHER TUBE HEADLIGHT CONNECTOR IGNITION SWITCH “X45055 “9'49": CONNECTOR ACCESSORV SOCKET CONNECTOR RIGHT BRAKE BREATHER HOSE RIGHT BRAKE /@ HOSE COMBINATION METER CONNECTOR IGNITION CONTROL COOLING FAN MODULE ‘ CONTROL UNIT RIGHT BRAKE HOSE I I LEFT BRAKE HOSE LEFI' BRAKE BREATHER HOSE RIGHT BRAKE BREATHER HOSE SHIFT CONTROL UNIT DIFFERENTIAL CASE BREATHER HOSE HEADLIGHT CONNECTOR 1-23 GENERAL INFORMAflON Tum [All-'01): IGNITION SWITCH CONNECTOR ICM METER SPEED ACCESSORv SOCKET RIGHT “RAKE Sam; on It" CONNECTOR BREATHER HOSE v ‘ COMBINATION METER CONNECTOR RIGHT BRAKE HOSE 2wonwo serCH CONNECTOR LEFI’ BRAKE HOUSE RIGHT BRAKE BREATHER HOSE COOLING FAN FINAL CLUTCH FINAL CLuTCH CONTROL UNIT LEFT BRAKE SPEED SENSOR CONTROL UNrr DIFFERENn - L BREATHER HOSE CONNECTOR CASE BREATHER HEADLIGHT HOSE CONNECTOR mmeE mm '0": [CM IGNITION SWITCH CONNECTOR ACCESSORY SOCKET CONNECTOR COMBINATION METER CONNECTOR COOLING FAN CONTROL UNIT RIGHT BRAKE HOSE 2WDIIWD SWITCH CONNECTOR LEFT BRAKE HOUSE LEFT BRAKE BREATHE" HEADLIGHT LEFT BRAKE HOSE METER SPEED FINAL CLUTCH DIFFERENTIAL SENSOR SPEED SENSOR CASE BREATHER C°NNECTOH BREATHE“ HOSE CONNECTOR CONNECTOR HOSE 1 -24 TRX‘5OS AND TRXOSDES: GENERAL INFORMATION BRAKE BREATHER TUBE BRAKE HOSE TOP VIEW BRAKE HOSE BRAKE BREATHEH TUBE REAR VIEW 1-25 GENERAL INFORMATION “X4506 I'NJMI: REAR BRAKE CABLE FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE BREATHER NOSE IGNITION SWITCH CONNECTOR COMBINATION METER CONNECTOR ACCESSORV SOCKET CONNECTOR HANDLEBAR SWITCH CONNECTOR i TRX‘SOES I‘M-’0": REAR BRAKE CABLE REVERSE SWITCH FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE BREATHER HOSE IGNITION SWITCH CONNECTOR HANDLEBAR SWITCH ONNE COMBINATION ACCESSORV SOCKET C CTOR METER CONNECTOR CONNECTOR 1-26 GENERAL INFORMATION TRX‘SOFM (Am! '01): 2WD/AWD SWITCH WIRE REAR BRAKE CABLE REVERSE CONTROL CABLE FRONT GEAR CASE BREATHER HOSE REAR GEAR CASE BREATHER HOSE / “1—,; ASSIST HEADLIGHT CONNECTOR HANDLEBAR SWITCH METER SPEED SENSOR . CONNECTOR CONNECTOR '4 FINAL CLUTCH CONTROL UNIT IGNITION SWITCH CONNECTOR ACCESSORY SOCKET CONNECTOR COMBINATION METER 2WD/IWD SWITCH CONNECTOR CONNECTOR TRX‘SOFE [AM ‘01): ZWO/‘WD SWITCH WIRE REAR BRAKE CABLE CHOKE CABLE FRONT GEAR CASE BREATHER HOSE REVERSE CONTROL «'7 CABLE REAR GEAR CASE BREATHER HOSE ECU ASSIST HEADLIGHT CONNECTOR f HANDLE EAR swncn ‘ CONNECTOR 2WD/IWD swrrcn CONNECTOR ACCESSORY SOCKET CONNECTOR IGNITION SWITCH CONNECTOR COMBINATION METER CONNECTOR 1-27 GENERAL INFORMA'HON TRX‘SOS ['90—'01 I: CHOKE CABLE THROTTLE (MBLE REAR BRAKE CABIE REVERSE CONTROL CABLE COOUNG FAN MOTOR BREATHER HOSE FRONT BRAKE BREATHER HOSE REAR BRAKE BREATHER HOSE TRXISOES ('MJO‘I ): CHOKE KNOB THROTTLE CABLE REAR BRAKE CABLE REVERSE CONTROL CABLE BREATHER HOSE FRONT BRAKE BREATHER HOSE REAR BRAKE BREATHER HOSE 1 ~28 GENERAL INFORMATION “WWW WNW"? CHOKE CABLE REAR BRAKE CABLE THROTTLE CABLE REVERSE CONTROL 9 CABLE COOLING FAN MOTOR REAR BRAKE FRONT BRAKE ‘ BREATHER HOSE BREATHER HOSE BREATHER HOSE mxm mu: '0": THROTTLE CABLE REAR BRAKE CABLE REVERSE CONTROL 2WDMWD SWITCH WIRE COOLING FAN MOTOR REAR BRAKE FRONT BRAKE BREATHER HOSE BREATHER HOSE BREATHER HOSE 1 -29 GENERAL INFORMATION TRX‘SOSIFM AND WINES/FE: THROTTLE CABLE a FUEL TUBE CHOKE CABLE CRANKCASE BREATHER TUBE SPEED SENSOR WIRE CHANGE SWITCH WIRE STATOR/IGNITION PULSE 1 GENERATOR WIRE I COOLING FAN MOTOR CONNECTORS COOLING FAN MOTOR BREATHER TUBE IGNITION COIL SPARK PLUG WIRE CHOKE CABLE THROTTLE CABLE MAIN WIRE HARNESS 1 -30 GENERAL INFORMATION U on. COOLER LEFT OIL COOLER HOSE RIGHT OIL COOLER HOSE TRX‘GIESIE OIL COOLER RIG ANGLE SENSOR CONNECTOR SHIFT CONTROL MOTOR CONNECTOR 1-31 GENERAL INFORMATION TRX‘EOS {'98-’01}: CAReuRETOR HEATER REGULATOR/RECTIHER CONNECTOR GROUND WlRES REAR GEAR CASE BREATHER HOSE STARTER MOTOR CABLE REAR BRAKE CABLE (HAND BRAKE) REVERSE CONTROL REAR BRAKE CABLE CABLE (FOOT BRAKE) SPEED SENSOR CONNECTOR THERMO STATORIIGNI‘HONPULSE NEUTRAL/REVERSE SENSOR GENERATOR CONNECTOR SWITCH CONNECTOR CONNECT“ TNERMO SENSOR WIRE SPEED SENSOR CARBURETOR HEATER CONNECTOR CONNECTOR THERMO SENSOR STATORIIGNITION PULSE NEUTRAL/REVERSE SWITCH CONNECTOR THERMO GENERATOR CONNECTOR SENSOR CONNECTOR 1-32 GENERAL INFORMATION mm MM '01): CARBUREI’OR HEATER b fiEGULATOR/RECTlHER CONNECTOR GROUND WIRES b REAR GEAR CASE BREATHER HOSE V REAR BRAKE CABLE (HAND BRAKE) b STARTER MOTOR CABLE REAR BRAKE CABLE 1. (FOOT BRAKE) , ‘ REVERSE CONTROL CABLE STATOR/IGNmON NEUTRAL/REVERSE PULSE GENERATOR SWITCH ‘ CONNECTOR CONNECTOR YHERMO SENSOR CONNECTOR THERMO SENSOR WIRE CAHBURETOR HEATER CONNECTOR THERMO SENSOR STATOR/KSNITION PULSE GENERATOR CONNECTOR U NEUTRAunEVERSE SWITCH CONNECTOR THERMO SENSOR CONNECTOR 1 -33 GENERAL INFORMATION NAMES (’H—‘Ml: REGULATOR/RECTIFIER CARBURETOR HEATER CONNECTOR GROUND WIRES STARTER MOTOR REAR GEAR CASE 7 CABLE BREATHER HOSE REAR BRAKE CABLE (HAND BRAKE) REAR BRAKE CABLE (FOOT SRAKEI THERMO SPEED SE SOR SENSOR CONNECYOR CONNECTOR STATOR/IGNITION PULSE GENER‘TOR CONNECTOR GEAR POSITION SWITCH memo SENSOR WIRE a CONNECTOR THERMO SPEED SENSOR SENSOR CONNECTOR CONNECTOR STATOR/IGNITION PULSE “ GENERATOR CONNECTOR GEAR Pos'nON swncu CONNECTOR 1-34 GENERAL INFORMATION mm mm 'on: D REGULATOR/RECTIFIER CAREURETOR HEATER CONNECTOR GROUND WIRES REAR GEAR CASE ’ BREATHER HOSE STARTER MOTOR CABLE REAR BRAKE CABLE 9 (HAND BRAKE] REVERSE CONTROL CABLE THERMO SENSOR WIRE REAR BRAKE CABLE (FOOT BRAKE) GEAR POSITION STATORIIGNITION SWITCH PULSE GENERATOR THERMO SENSOR CON NECTOR CONNECTOR CONNECTOR THERMO SENSOR b GEAR POSITION SWITCH CONNECTER STATORIIGNITION PULSE . > , - 2" ‘ GENERATOR CONNECTOR TMERMO SENSOR CONNECTOR 1-35 GENERAL INFORMATION TRXISOS roe—m I: HARNESS CLAMPS STARTER RELAY CONNECTOR MAIN FUSE BATTERY NEGATIVE (-I CABLE STARTER MOTOR CABLE STARTER RELAY FUSE BOX BATTERY POSITIVE l+I CABLE TRXISOES I'm-'0": STARTER RELAY MAIN FUSE MAIN FUSE HARNESS CLAMPS (CONTROL MOTOR) BATTERY POSITIVE lo) CABLE FUSE BOX 1-36 GENERAL INFORMATION TIXISOFM (Aflu '01): FUSE BOX BATTERV NEGATIVE (—) CABLE b STARTER MOTOR CABLE STARTER RELAY SWITCH BATTERY POSITIVE (o) CABLE TRX‘SDFE (ARC! ’01): FUSE BOX STARTER RELAV STARTER MOTOR CABLE SWITCH BATTERY NEGATIVE (-I CABLE BATTERY POSITIVE b) CABLE 1-37 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The California Air Resources Board (CARB) requires manufacturers to certin that their ATVs comply with applicable exhaust emissions standards during their uselul life, when operated and maintained according to the instructions provided. SOURCE OF EMISSIONS The combustion process produces carbon monoxlde and hydrocarbons Control of hydrocarbons is very important because. under certain conditlons. they react to lrom photochemical smon when subjected to sunlight Carbon monoxide does not react in the same way, but it is toxic. Honda Motor (20.. mt utllized lean carburetor settings as well as other systems. to reduce carbon monoxide and hydrocarbons, EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed 07 a lean carburetor setting, and no adiustments should be made except ldle apeed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. CRANKCASE EMISSION CONTROL SYSTEM The englne is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetorl AIR CLEANER DUST coven “ DRAlN PLUG BREATHER <‘,:w FRESH AIR ma: _ aLow-av GAS 1 -38 GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SVSTEM IS PROHIBITED: US. federal low prohibits or Canadian provincial lows law prohibits the Iollowing acts or the causing thereof: (1) The removal or rendering inoperative by any person. other than tor purposes 0! maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle 1ortha purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use 0' the vehicle alter such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED T0 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 at. or puncturing of any part of the intake system. 3. Lack of grape! maintenance. 4. Replacing any moving pans ol the vehicle. or parts 0' the exhaust or intake system. with parts other than those specified by the manufactuer. EMISSION CONTROL INFORMATION VEHICLE EMISSION CONTROL LABEL INFORMATION LABEL ,\\ The Vehicle Emission Control Information Label is attached on the rear lender. 1-39 FRAME/300V PANELS/EXHAUST SYSTEM BODY PANEL LOCATIONS TRX4508/FM: SEAT REAR CARRIER FUEL TANK COVER FRONT FENDER REAR FENDER FRONT CARRIER FRONT CARRY PIPE REAR MUDGUARD RIGHT LOWER SIDE covER mom INNER FENDER RIGHT SIDE COVER STEP BAR FRONT MUDGUARD TRX‘SDESIFE: R M Am a SEA-r FUEL TANK COVER E c E FRONT FENDER FRONT CARRIER REAR FENDER FRONT CARRY PIPE CENTER MUDGUARD FRONT 'NNE“ FENDER RIGHT LOWER SIDE COVER RIGHT SIDE COVER STEP BAR 2-0 2. FRAME/BODY PANELS] EXHAUST SYSTEM BODY PANEL LOCATIONS FRAME COVER REMOVAL CHART SERVICE INFORMATION TROUBLESHOOTING SEAT/SIDE COVER FRONT CARRIER/CARRY PIPE IFENDER 2-0 2-1 2-2 2-2 2-3 2-6 REAR CARRIER/REAR FENDER 2-10 HANDLEBAR COVER 2-13 CENTER MUDGUARD (TRX450ES/FE) 2-14 E EXHAUST SYSTEM 2-15 FRAME COVER REMOVAL CHART TRX450$I FM: TRX‘SOES/FE: FRAME/BODV PANELS] EXHAUST SVSTEM SERVICE INFORMATION GENERAL 0 Gasoline is extremely flemnublo and Is explollvo under certain conditions. KEEP OUT OF REACH OF CHILDREN. Serious burns may result if the exhaust system LI not allowed to cool before components are removed or serviced i Work in a well ventilated area, Smoking or allowing llamas or sparks in the work area or where gasoline is stored can cause a fire or explosion. This section covers removal and installation at the body panels and exhaust system. Always replace the exhaust pipe gaskets after removing the exhaust pipe lrom the engine. When installing the exhaust system. loosely install all at the exhaust pipe Iasteners. Always tighten the exhaust clamps I I first, then tighten the mounting fasteners. I! you tighten the mounting Iasteners first, the exhaust pipe may not seat property. Always inspect the exhaust system lor leaks alter installation TORQUE VALUES 1 Muffler band ball 23 N-m12t3 kgI-m. 17 “1041) I Exhaust pipe protector bolt 22 N-m (2.2 kgI-m, 16 IbI-fti ‘ Mumer heat protector bolt 22 N-m (2,2 kgf-m, 16 lot-ft) Step bar mounting bolt 32 N-m (3.3 kgl-m, 2‘ IbI'Il) Fuel tank rear bracket bolt 18 N-m (1.8 kgI-m. 13 IbI-It) Front and rear carrier mounting bolt: ‘98 - '0 : 32 N-m (3.3 kgltm. 2‘ lbI-h) 4 After '01: 37 N-m (3‘8 kgI-m, 27 IBM!) ' TROUBLESHOOTING Excessive exhaust noise 1 - Broken exhaust system - Exhaust gas leak Poor peflormlnu - Detormed exhaust system - Exhaust gas leak - Clogged muffler 2-2 FRAME/BODV PANELS/EXHAUST SYSTEM SEAT/SIDE COVER REMOVAL Saar Release the seal lock lever by moving the lever upwardr Pull back and remove the seal. Retalninn Clip Remove the retalning clips as follow: (2) REMOVE (3) INSTALL - Pull up the clip cantor using I snap ring pliers, flu! head screwdriver or equivalenr. — Remove rhe clip assembly (1)PULL UP . Sld. Coven And Full Yank Cover Remove the fuel tank breather lube lrom lha handlebar cover. Mi Gasoline I: nmunaly flammable and explosive under DofllIn conditions. KEEP OUT OF-HEACH OF CHILDREN. Remove (he fuel tank cap by turning It counterclock- wise. Remove the two retaining clips, FUEL TANK CAP Remove the right lower side cover by releasing the LOWER SIDE COVER labs from lhe lrama grommets. ‘ FRAME/BODV PANELS/EXHAUST SYSTEM Removethe two right side cover mounting bolts and RETAINING CLIP ramming CIip. g,- BOLTS Remove the two left side cover mounting bolts and - RETAINING CLIPS two reIainIng clips, then remove (he side/fuel wank cover as an assembly. Side/Fuel Yank Covu Sap-"film Remove the two retaining cups. RETAINING CLIPS Remove me two screws. ReIaase ms sight tabs Irom the both side cover by sliding rearwald than separate the side/fuel tank cove" SCREWS 2-4 FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK COVER SEAT EIGHT SIDE COVER LEFT SIDE COVER FRAME] BODY PANELS/ EXHAUST SYSTEM FRONT CARRIER/CARRY PIPE/FRONT FENDER ”003505 ’F M YRX45DES FE REMOVAL Remove the sidefluel rank cover assembly [page 2, 3) Loosen the two screws and remove the bolt on each 5de Remove rne screw and boil men remove me rnner fender on each Sldev Remove me Irom vendercmud guard srav screw on each srdev Remove rhe honr render rear mounlmg bull on each slde. Remove the (rum Ienderrcenler mudguard sKay screws and relarmng clrps, on each srde. Remove Ihe from fender rear mounting ban on each Sldev MOUNYING EOLT SCREWS FRAME/BODY PANELS/EXHAUST SVSTEM DISCOHHBCI the headlight conneclol. CONNECTOR Remove the upper mounting bolts on each side. ' UPPER MOUNTING EOLT Remove the middie mounting bolts on each side. MIDDLE MOUNTING BOLT Remove the Iowa: mounting bolts on each suds. Remove the Iron! Vander, carry pipe and Mom camer as an assembly. LOWE R MOUNTING BOLT 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM DISASSEMBLY '90-'01: 32 N-m (3.3 kgf-m, 24 thl! FRONT CAREER MIN '01: 37 N-m (3.8 kgf-m, 27 [bf-fl) MUD GUARD oven FENDER ' mxuoes’rs HEADLIGHT GRILL INNER FENDER 32 N-m (3.3Kgf'm.24lefl FRONT CARRY PIPE 2-8 U FRAME/BODY PANELS/EXHAUST SYSTEM TRXlSOEflFE ‘ Install the trout carry pipe and loosely tighten the mounting bolls. NOTE: Do not tighten them yet Install the trout landlrl Install the front and ram mounting bolts, than tighten the rear mounting bolts‘ NOTE: Do not tighten the Iront bolts vet. Install the front carrier and mounting bolts. Tighten the front carry pipe and carvler 8 mm bolts to the specified torque. TORQUE: '98 - '01: 32 "ml [.13 inf-m, 24 IhMt) Mm '01: 37 N‘lll (3.8 ill-m, 27 let) Install and tighten the Iron! carrier 6 mm bolts. Tighten the hunt mounting bolts Install and tighten the inner lender jaint screws. Install and tighten the mud guard screws NOTE: Note the washer locations when installing mud guardt Install the rataing clips on each Slde‘ FRONT CARRV PIPE BOLTS FRONT FENDER FRONT MOUNTING REAR MOUNTING BOLT BOLT FRONT CARRIER 3 mm BOLTS 6 mm BOLT SCREWS FRAME] BODY PANELS/ EXHAUST SYSTEM REAR CARRIER/REAR FENDER 5 "‘m 3°” REMOVAL REAR CARRIER Remove the two 6 mm bolts. Becarelulnollo Remove the m 8 mm buns and rear earner. scratch (/12 rear lender upon Ismova/ REAR FENDER Remove me ngm lower sme cover tpage 23), Remove [he rear carnen Release the talllxgm w 3.1 133 $33; 333 ‘° ”EMS NOTE HOURS 20 100 zoo page . FuEL LINE l u 2 - THROTTLE OPERATION I :H lg - CARBURETOR CHOKE I 3—5 L g AIR CLEANER (NOTE II c (3 er 3 AIR CLEANER HOUSING DRAIN TuaE (NOTE 2) I I 3—7 ; SPARK PLUG l I 17 8 . VALVE CLEARANCE l I I as “g ENGINE OIL R R R 3-H) w ENGINE OIL FILTER R R R 3-I2 - ENGINE IDLE SPEED I I I :4: DRIVE SHAFT BOOTS I I 3-13 REAR FINAL GEAR CAsE OIL AND (H1EVERY I 3-13 DIFFERENTIAL OIL ZYEARS) L z - BRAKE FLUID INOTE :II I I 115 g I» BRAKE SHOE WEAR (NOTE 1) I 115 g BRAKE SYSTEM I I I 3-l6 a . REVERSE LOCK sverM I I I 343 ; SKID PLATES. ENGINE GUARD I I we 8 . CLUTCH SYSTEM I I I 3.19 g . SUSPENSION I I no g . SPARK ARRESTER c I: 320 Z - NUTS, BOLTS, FASTENERS I I 3.21 n WHEELS/TIRES I I I 3-21 b u STEERING SHAFT HOLDER BEARING I 3—21 In» STEERING SVSTEM I 3-22 I- Should be Serviced by an euthorixed HONDA dealer. unless the owner has proper tools end Service date end is mechanically qualified. b '0 In the intereet Dl safety, we recommended these items be serviced only by an authorized HONDA dealer. NOTES: 1. Service more lrequently when riding In dusty ere-I. send or snow. 2, Service more frequently after riding in very wet or muddy conditions. 3. Replace every 2 years. Replacement requires mechanical skill. L» MAINTENANCE FUEL LINE THROTTLE OPERATION Remove the side/fuel tank cover assembly (page 2- 3) Check the luel ltne. Replace it it It shows signs 01 deterioration, dam- age or leaking. FUEL TUBE Check for smooth throttle lever operation wrth com» plete opening and automatic closing in all steering posrtlons. Make sure there is no deterioration. damage or kinking in the throttle cable. Replace any damaged parts. Disconnect the throttle cable at the upper end (page 126). Thoroughly lubricate the cable and pivot point with a commerctally available cable lubricant. Install the throttle cable tn the reverse order of le- moval. Make sure the throttle lever lree play is 3 — 8 mm (1/ ADJUSTER 8 - 5/16 ml at the llp ol the throttle lever. Mlnor adjustments can be made at the upper adjuster. Throttle lever tree play can be adjusted at throttle housing adjuster, Slide the rubber boot off the cable adjuster. Loosen the lock nut and adjust the throttle cable free play by turning the cable adjuster. After adjustment. tighten the lock nut and install the rubber hoot securely. Major adjustments are made With the lower adjuster. ADJUSTER Remove the seat (page 23) Slide the rubber boot 0" the cable adjuster. Adjust by loosening the lock nut and turning the adjuster. After adjustment, tighten the lock nut and install the rubber boot securely. Check throttle operation. install the scat lpage 273). THROTTLE LEVER LOCK NUT 3-4 MAINTENANCE CARBURETOR CHOKE TRXASOS/FM SHOWN: #004505 FM The choke system uses a luel enrtchment curcutt controlled by a starttng enrichment lSEl valve. The SE valve opens the enrichment curcult we a cable when the choke lever on the handlebar ls moved to the left. Check for smooth choke lever ugeratlon and lubeCBIE the chuke cable :6 requtred. lnSpeCt the cable '0! cracks which could allow motsture to enter Replace the cable ll necessary. CHOKE LEVER CHOKE CABLE mxasoEs FE The choke system uses a tuel ennchrnent Cerull TRX‘SOES/FE SHOWN: controlled by a startmg Enflchmenl lSEl valve, The SE valve opens the ennchrnent clrcutt we a cable when the chuke knob on the handle bar cover rs pulled up. Check for smooth choke knob operation and lubricate the choke cable ll tequtred. Inspect the cable for cracks whlch could allow molsture to enter. Replace the cable rl necessary, t ' " CHOKEKNOB AIR CLEANER RETAINING cues Remove the seat lpage 273l. Release the retatntng CIIDS from the alt cleaner housrng cover and remove the cover HOUSING COVER Loosen the atr cleaner element band screw, AIR CLEANER Remove the atr cleaner element assembly from the housmg, MAINTENANCE Remove the element holder by turning It counter— clockwise. Remove the element bend and separate the element from the element core. Dust Cover If the dust cover is dirty, clean It by compressed air, NOTE: Do not shove the dust cover. Wash the element in non-flammable or hlgh huh point solvent. Squeeze out the solvent thoroughly, and allow the element to dry. Apply approximately 32-37 cc (Ll—1.3 all M Pro Hond- Folm Filter OII or an equivalent oil lvom the inside 01 the element. Place the element into a plastic bag and spread the oil evenly by hend~ Piece the element onto the core and replica the ele- ment band Ind holder‘ Install the element In the air cleans! houslnn. and tlghten the band. Install the dust cover. NOTE: Do not shove the dust cover. Install the air cleaner housing cover and secure wlth tho cllpt. Inst-II the see! (page 241). DUST COVER HOLDER ELEMENT CORE BAND ELEMENT WASH SQUEEZE OUT PRO HONDA FOAM FILTER OIL PLASTIC BAG DUST COVER 3-6 0“ & MAINTENANCE AIR CLEANER HOUSING DRAIN TUBE Remove the drain plug from the air cleaner housing to empty any deposits. Install the drain plug and clip. NOTE: Servlce more Irequently when riding in wet or mud- dy areas, SPARK PLUG Disconnect the spark plug cap and remove the spark plug. NOTE: Clean around the spark plug base with compressed air belore removing, and be sure that no debris is allowed to enter the combustion chamber Remove the spark plug and inspect or replace as described in the maintenance schedule. INSPECTION Check the following and replace it necessary (rec- ommended spark plug: page 3-1]. ~1nsulatnrlor damage - Electrodes Ior wear - Burning condition, coloration: - dark to light brown indicates good condition. 7 excessive lightness indicates malfunctioning ignition system or lean mi ure. - wet or black sooty deposit indicates over-rich mixture. DRAIN PLUG SPARK PLUG CAP INSULATOR 3-7 MAINTENANCE REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush or special plug cleaner. Check the gap between the center and side elec- trodes with a wire-type teeler gauge. ll necessary, adjust the gap by bending the side electrode carefully. SPARK PLUG GAP: 0.8 - 0.9 mm (0.03 - 0.0‘ In) CAUHON: To prevent dunno: to the cylinder head, Innd— tIgMon the spark plug helare using a wrench ta tighten to the specified torque. Reinstall the spark plug in the cylinder head and hand tighten< then torque to specification. TORQUE: 18 N-m (1.3 Ital-m , 13 IM-RI REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type Ieeler gauge (see above). CAUTION: Do not avartlghtcn the spark plug. Install and hand tighten the new spark plug, then tighten it about 1/2 pl a turn after the sealing wash~ er contacts the seat a! the plug hole, VALVE CLEARANCE NOTE: Inspect and adjust the valve clearance while the en» gine is cold (below 35 “(1/95 “Fl. Remove the Intel tank and heat guard (page 5—20). Remove the bolts, cylinder head cover, gasket and O-ring, Remove the spark plug. Remove the timing hole cap lrom the right side of the rear crankcase cover. l 0.8 7 0.9 mm (0.03 0.0‘ In) CYLINDER HEAD COVER TIMING HOLE CAP MAINTENANCE Turn the crankshaft clockwise using the recoil starter knob, and align the "T“ mark on the flywheel with the index mark on the rear crankcase cover. Make sure the piston Is at TDC on the compression stroke. It not, rotate the crankshalt 360° (1 full turn) and align the "T" mark with the index mark, Inspect the intake and exhaust valve clearances by inserting a ieeler gauge between the adjusting screw and valve stem VALVE CLEARANCE: INIEX: 0.!5 mm (0.006 In] Adiust it necessary by loosening the lock nut and turning the adjusting screw until there is a slight drag on the leeler gauge. Hold the adjusting screw and tighten the lock nul. TORQUE: 17 N-m (1.7 Roi-m . 12 IM-hl Racheck the valve clearance. inspect the condition 01 the clvinder head cover gas» kat and O-ring. replace them if necessary Install the cylinder head cover and tighten the belts. MAINTENANCE Check that O-ring is in good condition, and install TIMING HOLE CAP the timing hole cap. TORQUE: 10 N-m [to kM-m , 7 Ile) Install the removed pans in the reverse order an re- moval. ENGINE OIL AND OIL FILTER OIL LEVEL INSPECTION Place the vehicle on level ground. Remove the oil fiIIer cap/dipstick and wipe it clean. Reinstall the oil filler cap/dipstick, but do not screw it. Remove the oil I'IIIer cap/dipstick and check the oil Ievel. II the level is below the lower mark on the dipstick, fill the crankcase with recommended oiIi UPPER LEVEL LINE LOWER LEVEL LINE . RECOMMENDED ENGINE OIL: HONDA GNA 4-strake oil or equivalent motor oil API service classification: SF or SO Viscosity: 10W — 40 ens .vuw 5n an guw .Iu NOTE: I.“ mw my Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. war Inw m Reinstall the oil filler cap/dipstick, 3-10 MAINTENANCE ENGINE OIL AND FILTER CHANGE m__ I! the angina mun by running to do wnn work, mak- sum the Am I: well vontllntd. NIVII run the angina In an enclosed n The cxhnun tannins poisanaus carbon monoxide gn that may cause ion a! consciaulnm llId may Ind to duthflun the engine In an opon urn or with en exhaust Ivacunlon system In encloud lru. Warm up the engine. NOTE: Change the engine oil with the engine warm and the vehicle on level ground to assure complete draimng. Stop the engine and remove [he on Iiller cap/dip- stick and drain bolt. DraIn the all completely. CAUHON: Uud lnglnl oil may Mun ukin can“: ”upon-div ion In content with an Ikln Inr pralungnd pounds. Although this [I unlikely uni-u you lundin usnd oil on a daily basis, it I: still advisable to thoroughly wait your hand: with soap and wuu It man I: possibly n hlndling used oil, Remove the bolts and oi! filter cover. Remove the oil filter and spring. Discard the ail filtert OIL FILTER COVER SPRING OIL FILTER 3-11 MAINTENANCE Install the Oil filter spring to the rear crankcase cover. 7' _ ' 7‘ SPRING Install a new onl filter with its "GUY-SIDE (TOWARDS FILTER COVER)" mark lacing out. CAUTION: lmlllng the oil filter backward: will run" in seven englne damnae. OIL FILTER Make sure that the O-rings are in good condition and replace it necessary. Apply oil to the things. Install the oil filter covet and tighten the bolts to the specified torque. TORQUE: 10 MM (1.0 Ital-m , 7 leIl Check that the sealing washer on the drain bolt is in good condition, replace il necessary. Install and tighten the drain bolt. TORQUE: 25 N-m (2.5 ItnI~m , 18 IbMt) Fill the crankcase with the recommended engine oilt OIL CAPACITY: loin-H110 US qt 1,18 Imp qt) alter dralnlng 2‘1 Iltev [2.2! US qt, 1.85 Imp qt) It all filter change Install the oil liller cap/dipstick. Start the engine and let it idle lot 2 to 3 minutes. Stop the engine and check that the oil level is at the wear level line on the dinstick. Make sure there are no oil leaks. 3-12 MAINTENANCE ENGINE IDLE spear) k. M— i! the engine must be running to do same work, make sure tire area is well vom‘linod. Never run tire engine In In enclosed nu. The oxirnust contains poisonous carbon monoxide an that mly mun inn ul :onmiounnm and may lead to death. Run L tire engine in on open nu or with an exit-us! evncuntiorr system in enclosed am. NOTE: . Inspect and adiust the idle speed after all other THROTTLE STOP SCREW L engine maintenance items have been periormed and are withln specifications. . The engine must be warm for accurate idle speed inspection and adjustment. Warm up the engrne Ior about ten minutes. Remove the right lower side cover (page 2-3). Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: IAN : 100 rpm DRIVE SHAFI' BOOTS DRIVE SHAFT BOOTS INSPECTION Check the drive shaft boots ior cuts or other damage. Ii the drive shaft boots are damaged, replace them. See page 153 for boot replacement. REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL OIL LEVEL CHECK Rear Fin-l Gear Case Remnve the oil check bait and check that the oil flows out oi the check bolt hole. CHECK BOLT 3-13 MAINTE NANCE ll there is no oil llow, remove the oil liller cap and OIL FILLER CAP add oil slowly thiaugh the oil filler hole until the oil ' ‘ starts to flow out at the all check bolt holev ' RECOMMENDED OIL: Hypold gear oll SAE no Check for leak ii the oil level was low. Coat a new Owing with gieese and install it onto the oil filler cap. Install end tighten the oil tiller cap‘ TORQUE: ‘2 N~m (1,2 Ital-m, 9 IM-fl) Front Diffenntlel Remove the oil filler cap. Check that the oil level is up to lower edge ol the oil filler hole. Check for leaks. little oil level is low. Pour vecommended oil through the oil liller hole unlil it reaches the lower edge 0' the hole. RECOMMENDED 0|L: Hypoid you all SAE '80 Coat a new o-ring with grease and install it onto the oil liller cap. Install and tighten the oil filler cap. TORQUE: 12 NW! (t2 kg1~m,9|M-k) 3-14 MAINTENANCE OIL CHANGE Rear Flnll Gear Cue Remove the Oil Illler cap and the drain bolt to dram all OII from the gear case. Check that me dram halt sealing washer IS In good Condillon, replace II necessary, Ylghlen me dram bolt to (he specified torque. TORQUE: 12 Mr“ (1.2 kfii-m . 9 IbI-it) Fm xhe Imal gear case wnh the recommended DII. OIL CAPACITY: 90 cm’ (10 US oz, 3.2 Imp 01) liter dvIIniug Check me oil Ievel (page 3-13). From DII‘IonmIII Remove me on filler cap and (he dram bolt to dram all all from the dlflerennal case Check Ihal me drain boll sealing washer Is In good condlllon, replace II necessary. Tighlen the drain ball to the specified torque TORQUE: 12 Man (11 kgi-m‘ 9 Ibl-fl) FIII lhe dliferennal case With [he vecommended OIL OIL CAPACITV [after dralnIng): '58 - '01: 190 cm’ (SJ US 0:. 6.7 Imp ozl Aha"01:2" cm’ (8.2 US 02, 8.5 Imp ozl BRAKE FLUID CAUTION: Do not mix: dill-rent types a! Iluid. as they are not cnmpnlble with each Mlle]. Do not lllaw foreign material to enter the system when filling the nun/air. Amid spilling fluid all painted, plastic or Iubbu p-m‘ Place I my over those parts wnonlvu the system Is sen/ind, Chprk \‘ha hrzkn rn Inspect the float valve tor grooves and nicks. and FLOAT VALVE VALVE SEAT . V “ replace it neoessery. ' . Inspect the operation of the valve. Remove the lollowing: - Meln jet — Needle iat holder - Needle iat - Slow jet ~ Starterjet PlLOT SCREW PLUG MAIN JET Turn the pilot screw in and record the number 00 turns belore it seats lightly. Use (Me as a reference for reinstallation. CAUTION: Dempetompflotmemwfllmwllmpuot mwh tightened against the mt. Remove the pilot screw‘ Inspect the pilot screw and each jet and replace them STARTER JET I ' :gig'ézJET a it they are worn or damaged. PRIMER KNOB Remove the two screws. SCREWS 6 PRIMER KNOB FUEL SVSTEM Remove the primer knob and spring. PRIMER KNOB SPRING Check the diaphragm ior (ears or other damage DIAPHRAGM DIAPHRAGM/VACUUM PISTON SCREWS NOTE: The diaphragm/vacuum piston can be removed without removing the float chamberu Remove the vacuum chamber cover by removing the (our screws. Remove the compression spring and diaphragm] SPRING vacuum piston. Inspect the vacuum piston for weer. nicks. or other damage Make sure the piston moves up and down freely in the chamber‘ DIAPHRA MNACUUM PISTON 5-9 FUEL SYSTEM Push the jet needle holder down and turn it WASHER counterclockwise 90 degrees with a screwdriver. Then remove the needle holder, spring, jet needle and washer from the diaphragm/vacuum piston. «J JET NEEDLE /Lk\/ HOLDER Inspect the jet needle lor excessive wear at the tip DIAPHRAGNWACUUM PISTON J or other damage Check for a torn diaphragm or other deterioration JET NEEDLE ’ A|R CUT OFF VALVE AIR CUT OFF VALVE Remove the screw, air cut olf valve. air jet and O- rlngs. SCREW O-RINGS Blow open all carburetor body openings with compressed airr 5-10 FUEL SYSTEM CARBURETOR ASSEMBLY L ‘ . VACUUM PISTON/DIAPHRAGM JET NEEDLE VACUUM CHAMBER COVER AIR CUT-OFF VALVE SE VALVE JET NEEDLE HOLDER AIR CUTOFF VALVE b TUBE AIR VENT TUBE STARTER JET NEEDLE JET NEEDLE JET HOLDER Q SLOW JET THROTTLE STOP sanw b MAIN .IET PILOT SCREW 8 3% PLATE / \ FLOAT VALVE CARBURE‘I’OR HEATER FLOAT CHAMBER b ‘ 1 ”KW 0% ‘ P .9 @ v ONE -WAv VALVE ——«——’g I PRIMER KNOB \= OVERFLOW TUBE 5-11 FUEL SYSTEM AIR CUT OFF VALVE Install the O-rlngs, air jet and air out of! valve. NOTE: Note the divection of the air iet as shawn. Install and tighten the screw securely, DIAPHRAGM/VACUUM PISTON Install the needle clip on the jet needle. STANDARD SET'I1NG: 3rd groove lvom top lnstall the washer. jet needle, spling and jet needle holder to the vacuum piston. AIR CUT OFF VALVE JET NEEDLE \ eh \‘y NEEDLE CLIP JET NEEDLE DIAPHRAGMNACUUM PISTON WASHER SPRING JET NEEDLE HOLDER 5-12 FUEL SVSTEM Push the jet needle holder in and turn it 90 degrees clockwise. WASHER SPRING JET NEEDLE Install the diaphragm/vacuum piston in the VACUUM CHAMBER carburetor body, aligning the diaphragm lab with COVER the groove of the carburetor body. Hold the vacuum piston up to almost lull open so the diaphragm is not pinched hy the chamber cover. SPRING Install the chamber cover with the spring, aligning its tab with the hole In the carburetor, and secure with at least two screws before releasing the vacuum piston, DIAPHRAGM/ VACUUM PISTON Install the remaining vacuum chamber cover screws. SCREWS CAUTION: Do nut pinch the diaphragm under the chamber cont. ' VACUUM CHAMBER COVER PRIMER KNOB SPRING Install the primer knob with the spring into the float chamber. Do not pinch the diaphragm when installing the screws, %' \ V PRIMER KNOB 5-13 FUEL SVSTEM Tighten the screws securely. SCREWS FLOAT AND JETS Install the lollowing: — Starter jet - Plug - Slow jet — Needle jet, needle jet holder — Main jet CAUTION: Handle all [an WMI can. Thay can easily ba sound or watchad. STARTER JET PILOT SCREW SLOW JET NEEDLE JET NEEDLE JET HOLDER/ /‘i ‘\PLUG Install the pilot screw and return it to its original position as noted during removal. Peflorm pilot screw adjustment if a new pilot screw is Installed (page 5—17) Install the float and float valve in the carburetor body. then install the float arm pin through the body and float. MAIN JET/ 0 After '00 Install the float pin by gently tapping with a suitable pin driver (0.0. 2 mm and hammer. FLOAT VALVE Alter '00 SHOWN PRESSFIT SlDEr:> 7 7, , l“ 0,5 t 0.3 mm (0.02 t (Hill in) NEW FROM AIR CLEANER ' . , E 'FOLAT PIN a Mousmc SIDE) FLOAT LEVEL INSPECTION With the float valve seated and the "out arm iust touching the valve. measure the float level with the special tool as shown, FLOAT LEVEL: 18.5 mm (0.73 In) TOOL: Carburetor Mat level gauge 074010010000 The lloat cannot be adiusted. Replace the float assembly if the float level is out of specification. FLOAT LEVEL GAUGE 5-14 FUEL SYSTEM Install the ham: plate. Install I new O-rinn in the float chamberr Install tha llonl chamber, aligning the overflow pipe with the hole in the baffle as shown. a O-RING H OVERFLOW PIPE v BAFFLE PLATE ' ' ' FLOAT CHAMBER Install the (our float chamber screwsr SCREWS FLOAT CHAMBER Install the carburetor heater and collar. CARBUHETOR HEATER Install the overflow tube. ONE-WAV VALVE NOTE: Note the direction of the one—way valvel OVERFLOW TUBE 5-15 FUEL SYSTEM Install the aIr vent tube and all cut off valve lube. AIR CUY OFF VALVE TUBE AIR VENT TUBE STARTING ENRICHMENT (SE) VALVE lnstall the spring over the choke cable and connect lhe cable and to the SE valve. TRXA505 Move the choke lever all the way to the right and lell and make sure that the SE valve operates properly. TRdeaES Move the choke knob all lhe wav to pull and push and make sure that the SE valve operates properly‘ CARBURETOR INSTALLATION Install the throttle cable adjuster to the carburetor body. Connect the throttle cable and to the throttle drum. LOCK NUT ADJUSTER CAUTION: Do not kink or twist the throttle cable, It wlll not opus" smoothly and may stick if It is klnlrcd ar twisted. NOTE: Apply grease to the throttle cable end. Install the carburetor cover and tighten the screw TORQUE: 4 N-m [0.4 kgf-ml 3 lbl-h) CAHBURETOR COVER 5-16 FUEL SYSTEM Apply multI-purpose grease to the SE valve end as SE VALVE AIR VENT HOSE shown. Install the SE valve and trghten the valve nut. TORQUE: 3 N-m (0.3 ltgl-m, 1.8 lbl-ftl Cunnect the air vent hose Into the hole on the heat guard. Install the carburetor by aligning IlS Intake prpe boss wtlh the Insulator groove. Set the pin of the insulator band In the groove of the Insulator and Install the band. Trghlen the Insulator band screwl After 01 TORQUE: 4 N-m (04 kgl-m, 2‘s "1"“) Connect the carburetor heater connector. CARBURETOR HEATER CONNECTOR Route the dram hose carrectly (page l~29lv Adjusl the throttle lever free play (page 3-“. lnstall the removed parts In the reverse order 0! removal. ‘ FUEL SYSTEM PILOT SCREW ADJUSTMENT m______ I! the engine must be running to do some work, rmlr lure In In I: well until-ted. Never run the engine In In enclosed urn. The exhaust contains poisonous carbon manorrlde nu thnt may cauu loss a! consciousness end may lend to death Run the engine In In open I u or with an nth-mt evacuation syltem In enclosed area. NOTE: PILOT SCREW The pilot screw is Iactory preAset. Adjustment is not necessary unless the carburetors are over- hauled or new pilot screws are installed. Then engine must be warm for accurate adjust- ment. Ten minutes oI stop-and~go riding is sullicient. Use a tachometer with graduations tel 50 rpm or smaller that thl accurately indicate 50 rpm change. 1. Turn the pilot screw clockwise until it seats lightly, then back mom to the specification given. CAUHON: Damage to the pun: mw cut will occur II the pllot screw In tightened lglinll the salt. J TOOL: Pllot screw wrench 019084220201 INITIAL OPENING: 2-5/8 turns out . Warm the engine up to operattng temperature. . Stop the engtne and connect a tachometer ac- cording to the tachometer manulacture's instruc- tions. .Srart the engine and adlust the idle speed with the throttle stop screw. mN . IDLE SPEED: 1.400 1 100 rpm THROTTLE STOP SCREW 5. Turn the pilot screw In or out slowly to obtatn the highest engine speed. 6. Readjusl the Idle speed with the throttle stop SCYEW. 7. Turn the ptlot screw in gradually until the engine J speed drops 100 rpm. 8. Turn the DIIOI screw counterclockwise the number 0! turns to the specification given. FINAL OPENING: 1/2 turns out 9. Readjust the Idle speed with the throttle stop J screw. 5-18 FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT MA'N JET SPECIFICATIONS Below Between 5,000 I! 3,000 - 8,000 It (1,500m) (I,000—2,500m) Main jet #130 #120 The carburetor must be adjusted fer high altitude riding (between 3,000 — 3,000 "11,000 - 2,500 m). STANDARD SETTING: Below 5,000 ft (1,500 m) HIGH ALTITUDE SETTING: Between 3.000 - 8,000 ft (1,000 — 2,500 m) The high altitude carburetor adjustment is per- torrned as lollows: Remove the carburetor (page 5-6) and float chamber. Replace the standard main jet with the high altitude W904 HIGH ALTITUDE MAIN JET: 0125 Assemble and install the carburetor. Start the engine and adjust the idle speed at high altitude to ensure proper high altitude operation. m—_ I! tha nulna must ha runnlng to do auma work, makaaun maanalawaflvomt‘latad. Navarmntha annlna In an andosad anal The axhaua-t contalns polsonaua carbon mannxida gas that may cauu loss a! consciouanua and may Iud ta death, nun th angina In an opan area or wlth an axhaust avawatlon systam In undead aru. CAUTION: WWMW5,WOMIL5WMI with the high altltuda uttInga may turn anglna overheating and angina damage. Inatall the standard rnaln [at a d anyuat tha ldla spud with the throttla atop maw, when riding balnw 5,000 feet ".500 ml. STANDARD MAIN JET: "30 IDLE SPEED: 1.400 1100 rpm 5-19 FUEL SYSTEM FUEL TANK REMOVAL lhl-fd 12 N -m (1.2 k FUEL TANK SEAL RUBBER HEAT GUARD 5-20 FUEL SYSTEM AWARMNG _ Gasoline is extremely Ilammnbln and is explosive undo! certain conditions. KEEP OUY 0F REACH OF CHILDREN. Turn Ihe fuel valve all, Remove the Sidelfuel tank cover lpage Z-Al. Remove the fuel tank maunting boltst Remove the fuel tank seal rubber. Remove the luel tank holder bands. 0 FUEL TANK SEAL RUBBER Slightly pull the luel tank up, then disconnect tha FUEL TANK luel tube from the luel valve. Remove the lusl tank. FUEL TUBE Disconnect the carburetov alr vent tube from the luel 1"“ VENT TUBE tank heal guard. Remove the Ihree retaining chps and fuel tank heat guard. 5-21 FUEL SVSTEM FUEL STRAINER SCREEN FUEL VALVE Turn the fuel valve OFF. Remove the iuel tank, Removethe iuel valve mounting bolts and iuel valve. and drain the gasoline into an approved gasoline containert HEMP—4 Gasoline is extremely flammlbie end is uplrulva under certain conditions. Work In I well until-ted em with the malne Itoppld. Do not smoke or IIIUW flame: or spark: In your walking am or when gasoline is stored. Wipe up spilled gasoline at once. STRAINER SCREEN Remove the O-nng and strainer screen, Wash the strainet screen in clean non-flammable or high ilush polnt solventv Retnstall the screen. Install a new 04an into the iuel valve body, Reinstall the iuel valve and tighten the bolts to the specrfied torque. FUEL VALVE TORQUE: 9 N-m (0.9 kgl-m, 5.5 lbi-hl Connect the fuel tube. After tnstalling, turn the fuel valve ON and check that there are no iuel leaks FUEL TANK INSTALLATION AIR VENT TUBE Set the iuel tank heat guard onto the irame, then Install the tram section oi the heat guard lnto the irame. Install the retaining clips. Connect the carburetor an vent tube. NOTE: During heat guard installation, route the iuel tube and carburetor air vent tube properly. HEAT G UARD 5-22 FUEL SVSTEM Connect Ihe Iuel tube In the fuel valve‘ FUEL TUBE Set the (uel lank onto me frame, install and when (he mounnng bollsv Insxall the my tank holder bands and Vuel tank seal FUEL TANK SEAL Rugaen rubbet. ‘ NOTE: Aher Installanon, make sure there are no 'uel leaks‘ 5-23 ENGINE REMOVAL/INSTALLATION 32 N-m (3,3 kgf-m. 24 let) 32 N-m [33 WW“, 2‘ let) 16 NW" [1.8 km-m. 12 let) [Nut '01} 20 N-m (2.0 kgf-m. 1‘ Ibl-m (’98—’01) \_ 5 ? ¢ 1 -,¥@e;/ ‘ | J I 0 0 TRX4505/FM \ (5.5 kgf-m, ‘0 let) 5‘ N-m 32 NW“ (3.3 kgf-m, 24 Ibl-fl) 6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 6-1 ENGINE INSTALLATION as ENGINE REMOVAL 6-2 SERVICE INFORMATION GENERAL . The Iollowvng components requIre engine removal Ior sen/wee , Crankshaft (Section 11) — Transmlssion {Secnon I1) » Gearshm Imkage (Sect-on 9) n - The followmg components can be serwced wuh the engine Installed In the frame. — ClendeI head/valves ISectIon 7) v Camshan (SacIIon 7) 7 Cylinder/piston (SecIIon 7) 7 Clutch (Section 8) - Recon] slaner/alternalor/starter clutch (Sechon IOI - CarbureIor (Secnon 5) - OII pump (Sectlon 4) 7 Control motor lSecIion 2H SPECIFICATIONS ITEM SPECIFICATIONS Engme oil capacny A: dralnlng i a 20 I (240 USql, 1,75 Inup q?) At desassembly 2.7 z (234 USqI, 2.33 Imp an Engine dry weight 50.2 kg (no.7 lbs) TORQUE VALUES Upper englne hanger ball 5‘ N-m (5.5 kgI-m, 40 Ital-fl) Upper engme hanger plate bolt 32 N'm13‘3 kgI-ml 24 Inf-II) Lower englns mountlng bolt (right) 54 N-rn (5.5 kgI'm, ‘0 RIM!) Lower engIne mounting bolt (left) 54 N-m (5.5 kgI-m, 40 IbMI) Lower engnne hanger mounung bolt 32 N-m (3.3 kgI-m, 2t lbI-ft) Gear shII‘t pedal boll ('98 - ’01) 16 N-m (1.6 kgI-m,121bf-ft) [After '01) 20 N-m (2.0 kgf-m. N lbI-Itl ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL EXHAUST PIPE CARBURETOR mums 'FM 557 01 Dram me engine ml (page 3710). Remove me rullowmg- 7 Exhausl pipe/Muffler lpage 215) 7 From lender (page 2»Gl - Alf cleaner housmg (page 54) » Carburetor (page 5-5) » Fuel tank and fuel tank heal guard (page 5-20) Drsconnecr me spark plug cap. Remove me bolls, collars and rrgm engine Side CDVEI. Remove me nul and slaner rumor cablev Remove Ihe bolt and ground cable lermunals‘ Dlsconnecl me allernalar. Igmrion pulse generator ‘98- '01: and neutral reverse swuch conneclors. SPEED SENSOR CONNECTOR DISCDHI’IECI the speed sensor conneclor and connecxor brackel 'rom the frame stayl ALTERNATOR/PULSE GENERATOR CON NECTOR ENGINE REMOVAL/INSTALLATION THXA‘SOES FE 957 01 THXAEOES FE DISCOfinECl the alternator. ngnruon pulse generator and gear posltmn swuclt connectors, DISCOHHECI the speed sensor connector and connector bracket trom the lrarne stay. Disconnect the reverse control cable end [mm the lever. DISCOI’InBCl the Ox] lhermo sensor connector lrom Ihe sensor, Release the lhermo sensor and englne harness wue clamps Remove the wrre clamp from the recall starter cover, Remove the socket bolts, settlng plate, on cooler pipes and O-rmgs. DISCOnnECI the control motor connector (IF whlle) '98 - '01: SPEED SENSOR SSQZESTSOTRON SWITCH CONNECTOR f» 3 ‘ l ’ «.2! ALTERNATOR/PU LSE GE NE RATOR CONNECTOR MIC! ’01: GEAR POSITION SWITCH CONNECTOR REVERSE CONTROL CABLE TRX‘SOES/FE SHOWN: 2P WHITE CONNECTOR lTRXdSOES/FE) OlLCOOLER PIPES / X. \\ SETTING PLATE : ' SOCKET BOLTS 6-3 ENGINE REMOVAL/INSTALLATION Remove the bolts, collars and hair engine side cover. LEFT ENGINE SIDE COVER r i. i E F l mxasosxFM Remove the gearshift pedal. Loosen the swungarm boo! hand screw. SCREW i 1 Remove [he upper engine hanger bolt. " _ HANGER BOLT Remove the hanger bracker bolls. upper hanger plate and mounting rubbers and bracket. '9’“ '0" Remove me bolt and (we retaining clips and propeller shaft cover, PROPELLEH SHAFT COVER ‘ ENGINE REMOVAL/INSTALLATION Remove (he left lower engine hanger boll/nu! collar HANGER BOLT MOUNTING RUBBERS' and engine mounting rubbers. l ‘ ' Remove the bolts and Is" lower engme hanger brackel‘ Remove the rear mounnng boll, Move the from differential forward. Remove (he lront propeller shall. PROPELLER SHAFT Remove the right lower engine hanger ball/nur. _‘l l MOUNTING RUBEERS collar and engine mounting rubhers. HANGER BOLT/NUT ENGINE REMOVAL/INSTALLATION Be (Ia/Blur nor damage me control mural upon erlglne removal and msrarlanon 1 TRXISOFSI Remove the followrng: ~ From drl'lerentral rnuuntmg bolt and nut 7 Front dlflerentlal mountlng bracket bolts and bracket — Upper mountrng bolt, nut and collar Move the engrne lorward, then drsconnect the yoke 10”“ lrom the lmal shalt. Remove the engtne lrom the left Side ol the lrame. ENGINE INSTALLATION When mslal/rng ms anglne‘ loosely msla/I a// or the engme hanger and bracket balls Than lrghlell me calls In the specrfiefl torque as snow bellow Apply molybdenum drsulllde grease to the yoke 1mm splmes. Install the engine from the lelt srde. Move the engine rearward and connect the Intel shaft and yoke Jotnt. Install the mountrng rubbers and lower left englne hanger bracket. Install the bracket bolts. Install the lower left engme hanger bolts and nut, NOIE. Install the mountlng rubbers wrth the wrue srde lowards the engme. Flrst tighten the englne hanger bolt to the specrfied torque. TORQUE: 5A N-m15.5 kgt-m, l0 lbI-hl Trghten the lower hanqer bracket bolts to the speclllea toraue. TORQUE: 32 N-m (3.3 kgI-m. 24 lbI-m UPPER MOUNTING BOLT/NUT/COLLAR (fir voxe JOINT HANGER BOLT . ‘ BRACKET BOLTS 6-6 ENGINE REMOVAL/INSTALLATION Install and lighten the lower right engine hanger _' MOUNTING RUBBERS COLLAR _ mounting rubbers, collar and hanger bolt/nut to the specified torque TORQUE: 54 N-m [5.5 Ital-m, ‘0 Ibl-nl Install the upper hanger plale, engine hanger bracket. bracket bolts, mounting rubbers and hanger bolt, First tighlen the hanger bracket bolts to the specrlied torque. TORQUE: 32 MM (3.! kgi-Im 24 IM-H) Tighten the upper engine hanger bolt to the specnfied torque. TORQUE: 5A N-m (5.5 kgf-m. 4o lM-fl) Apply molybdenum disullide grease tn the propeller shaft splines. Install the front propeller shall. Connect the propeller shalt to the engine over the 04an while pulling back the propeller shaft iornt. Rotate the shalt slightly it necessary to align the splines. Tighten the rear mounting bolt ID the specmsd torque. TORQUE: u N'm “,5 inf-m. 33 IM-ft) 1,". o r f. \ -, REAR MOUNTING BOLT 6-7 ENGINE REMOVAL/INSTALLATION THX‘fiDS’FM Install the upper mounting bolts with the upper UPPER MOUNTING COLLAR/BOLTINUT mounttng collar and nut In the location as shown. ' Ttghten the upper mounllng nut to the spectlied torque. TORQUE: u Mm (4.5 kgI-m. 33 IbI-fll Install the front mounttng bracket and mauntlng bolt then ttghten the bolts and nut to the specified torque, TORQUE: 22 Min [22 Ital-m, I6 lM-RI MOUNTING BOLT/NUT Install the propeller shah cover. RETAINING CLIPS Install the retaining cltps and mounttng bolt, then “ _ ’ tighten the bolt securely. * PROPELLER SHAFT COVER Set the swtngarm boot on the rear crankcase cover properly and Ilghlen the screw. SCREW BOOT Install the gearshift pedal on to the gearshift sptndle GEAR SHIFT PEDAL by aligning the punch marksv ALIGN , , s \ I» 6" Ttghten the bolt to the specified torque, YOROUE: ‘9! - '01: 16 N-m (1‘6 Ital-m. 12 “11-11) Aft" '01: 20 N-m (2‘0 kgf-m. 14 let) ENGINE REMOVAL/INSTALLATION TRX45DES’F E TRXISDS’F M Install the left engine sude cover and collars, then tighten the bolts. Connect the DII cooler pipes using new O-rlngs. Install the setting plate and tighten the socket bolts. Connect the control motor connector (2? Whrte). Route the alternator. ignltion pulse generator. neutral reverse switch and oil thermo sensor wrre properly {page 1-28) and clamp them securely. Connect the reverse control cable and to the reverse selector lever and hook the cable to the cable guide. Connect the thermo sensor wrre connector. Connect the alternator, Ignmon pulse generator and neutral/reverse swrtch connectors. Connect the speed sensor connector and set the connector bracket to the flame stay. ‘7 COLLARSIBOLTS THX‘SOES/FE SHOWN: / /»'\ \ ZPWHITE CONNECTOR (TRXISOES/FE) \/ OIL COOLER PIPES ‘* W571 '%VSCKET BOLl’S SETTING PLATE \\\/5'/ , CLAMPS THERMD SENSOR CORD '99 — '01: NEUTRAL/REVERSE SPEED SENSOR swrrcrg CONNECTOR CONNECTOR ‘ - r x. M». ALTERNATOR/PU LSE GENERATOR CONNECTOR 6-9 ENGINE REMOVAL/INSTALLATION TRdeoES’FE Connect the alternator‘ ignition pulse generator and V '30—'01: P lTl 9"“ p°“"°" “m" °°""°°'°'5' SPEED SENSOR W galfcuogonfigctoa 9&— 01 Connect the speed sensor connectar and set the CONNECTOR \ lv‘ ‘ J connector bracket to the flame stay, ALTERNATOR/PULSE GENERATOR CONNECTOR After '01: , GEAR POSITION SWITCH 0 Connect the engine ground cable terminals and tighten the bolts, Connect the starter motor cable and tighten the nuts. Install the right engine side cover and tighten the bolts. 1 COLLARS/BOLTS 6-10 ; ENGINE REMOVAL/INSTALLATION Inslall the spark plug cap, SPARK PLUG CAP CARBURETOR Install the carbureror lpage 5»16L Install [he removed pans In me reverse order 04 ',, removaL . x‘ .. Fvll the crankcase wnlh recommended engine orl (page 3-18”. Frll the from dmerenual wrrh recommended gear oII (page 3713l' Parlorm rhe following mspecnon and adlusrmem: - Throllle operation (cage 3-4) — Reverse selector cable adjustment {page 118) 6-11 CVLINDEH HEAD/CVLINDERIPISTON 39 N'm “.0 kgf-rn, 29 lei) 35 N-m (4.0 kgf'm, 2901”!) 32 N-m (3.3 kgl-m. 14 let) 7. CYLINDER HEAD/CYLINDER] PISTON SERVICE INFORMATION TROUBLESHOOTING CYLINDER COMPRESSION TEST CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSPECTION 7-1 CYLINDER HEAD ASSEMBLY 7-3 CYLINDER HEAD INSTALLATION 7-4 CYLINDER/PISTON REMOVAL 7~4 CYLINDER/PISTON INSPECTION 7-7 CYLINDER/PISTON INSTALLATION 7-20 7-7 CAMSHAFI'ICAM CHAIN TENSIONER7-22 7-13 7-14 7-16 7-17 SERVICE INFORMATION GENERAL in the frame. inspection. assembling cylinder head. Camshaft servicing require lront crankcase cover removal (section B). When disassembling. mark and store the disassembled parts to ensure that they are reinstalled in their original locations. Clean all disassembled parts with cleaning solvent and dry them by blowing them oil with compressed air before This section covers service 01 the cylinder head, cylinder and piston. These services can be done with the engine installed Rocker erm lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil passages before Be careful not to damage the mating surface when removing the cylinder cover, cylinder head and cylinder. SPECIFICATIONS mm m... (in, ITEM STANDARDS SERVICE LIMIT Cylinder Decompressot eflected 539 - 834 kPa (5.5 ~ 3.5 kgf/cm’, __ compression 78 < 121 psi) at 450 rpm Decompressor not effected 1,226 —1.442 kPa (12.5 - 14.5 kgflcm’, ;_ 17B — 206 psi) at 450 rpm Velve, Valve clearance I IN 0.15 (0.005) — "I“ guide ‘ EX 0.15 (0.003) Vllve stem 0.0. IN I 5.475 - 5.490(01156— 0.2161) 5.45 (0.215) 1 EX I 5.455 — 5.470 (0.2148 — 0.2154) ( 5.43 (01”) Valve gums ”3. IN ‘ 5.500 - 5.512 (0.2165 ~ 0.2170) 5.525(01175) EX I 5.500 - 5.512 (0.2165 - 0.2170) 5.525 (0.2175) ’ 7 Stem to guide clearanc: IN 70.010 — 0.037 (0.0004 - 0.0015) ) 0.1201005) . 7 FX 0.030 - 0.057 (0.0012 ~ 0.0022) 0.14 (0.006) Valve sear width 1.2 (0005) i 1.5 (0.05) Valve spring Inner 36.85 (1.451) 35.84 (1.411) "e" ”9'" Outer 41.67 (1.541) 40.42 (1.591) Rocker arm/ ROCker arm ID. 12.000 — 12.010 (0.4724 - 0.4731) 12.05 (0.474) shaft Rocker arm shaft 0.0. 11.964 - 11.904 (0.4710 — 0.4718) 11.92 (0.469) Rocker arm to 5;an clearance 0.018 — 0.054 (0.0005 — 0.0021) 0.08 (0.003) 7-1 CYLINDER HEAD/cVLINDEH/PISTON Unit: mm (in) ITEM STANDARDS SEEM LIMIT Camilla” and Cam lobe height IN 36.4291— 30.5891 (1.43421 -1.44038l 38.25 (1.427) w" ”I'M" EX 36.2870 - 33.4270 (1.42753 — mam) 38.10(l.421) Cam lollower OD. IN/EX 22.467 - 22.482 (0.8845 -0.8551) 22.46 (0.884) Cam follower bore I.D. lN/EX 22.510 - 22.528 (0.8862 —0.3068) 22.54 (0887) Cam (allower to hora celaarance 0.028 — 0.059 (0.0011 - 0.0023) 0.07 (0.003) Cylinder I.D. 90.00 - 90.01 (3.543 — 3.544) 90.10 (3.547) Taper 0.10 (0.004) Out of round — 0.10 (0.004) Warplge 0.10 (0.004) Piston, Piston mark direction 'IN' mark lacing toward the intake aide 3:32: 23f" Piston o. D. 39.945 - 09.965 (3.5411 - 3.5419; 59.90 (3.539) Piston 0.0. measurement point 10 mm (0.4 in) lrom bottom of akin Piston pin bore ID. 19.002 - 19.008 (0.7401 — 0.7483) 18.08 (0.751) Piston nlrt 0.0. 18.994 - 13.000 (0.7478 - 0.7480) 18.96 (0.746) Flammto platen pin clearance 0.002 — 0.014 (0.0001 — 0.0006) 0.12 (0.039) Piston magic-ring 700 0.030 — 0.080 (0.0011 - 0.0024) 0.09 (0.004) “'°""° ”um“ Second 0.015 - 045 (0.0006 - 0.0018) 0.09 (0.000 Pinon ring and glp Top 0.015 - 0.30 (0.0006 - 0.012) 0.507.172) Second 0.300 - 0.450 (0.012 - 0.018) 0.0 (0.02) Oil (lids rail) 0.20 - 0.70 (0.008 — 0.028) Cylinder-to-pistan clearance 0.035 - 0.056 (0.0014 — 0.0022) 0.10 (0.004) Connecting rad small and (.0. 19.020 - 19.041 (0.7488 — 0.7496) 19.07 (0.7500) Connecting rod-twpiaton pin clearance 0.020 - 0.047 (0.0008 — 0.0019) 0.10 (0.004) TORQUE VALUES (Minder head flange cap nut Rocker arm holder flange cap nut Rocker arm shah flange bolt Cam chain tensioner lifter sealing screw Cam chain tensioner mounting bolt Cam sprocket flange dowel bolt Camshalt bearing retainer bolt Upper engine hanger ball Upper engine hanger bracket bolt 39 N-rn (4.0 kgf-m, 29011-1" 39 NW!) (4.0 “Wm, 29 IM-fl) 7 MI") (0.7 lgf-m. 51 I00“) 4 N-rn (0.4 kgbm, 2.9 IbMt) 12 N-m (1.2 (inf-m, 9 lM-(t) 20 N-m (2.0 kgf-m. 14 (bf-M 26 NM) (2.7 kgl-m. 20 "1"") 64 NW) (5.5 mm", 4001141) 32 MM (3.3 kgf-m. 24 lbf-ft) Apply oil to threads and flange surface Apply oil to threads and flange surface Apply oil to threads and flange surface Apply a locking agent Apply a locking agent Apply a locking agent 7-2 CYLINDER HEAD/CVLINDER/PISTON TOOLS Valve guide driver 5.5 mm 077420010100 Valve guide reamer. 5.5 mm 07584-2000001 or 07984-200000D (USA. only) Valve spring compressor 077570010000 Valve set cutters — these are commercially available in USA. Seat cutter. 35 mm (45“ IN) 077800010400 Seat cutter, 29 mm (45" EX) 077800010300 Flat cutter, 35 mm (32' IN) 077800012300 Flat cutter. 30 mm (32' EX) 077800012200 interior cutter, 3715 mm (60' IN) 07780-001000 Interior cutter, 30 mm (60' EX) 07780-00l4000 Cutter holder, 5.5 mm 07781-0010101 TROUBLESHOOTING - Engine topend problems usually aflect engine performance. These problem can be diagnosed by a compression test or by tracing engine noises to the top-and with a sounding rod stethoscope. - ll the performance is poor at low speeds, check lpr white smoke in the crankcase breather tuba. If the tube is smoky, check tor a seized piston ring. Low compression - Valves: - Incorrect valve adjustment — Burned or bent valve - incorrect valve timing - Weak valve spring - Cylinder head: — Leaking or damaged head gasket — Warped or cracked cylinder head - Cylinder/piston - Worn cylinder or piston ring High compression - Excessive carbon buildup on piston crown or comv bustion chamber Exec-Ive amok- - Worn valve stem or valve guide - Damaged stem seal - Worn cylinder, piston or piston rings 0 Improper installation of piston rings - Scored or scratched piston or cylinder wall Excessive nolu - incorrect valve adjustment - Sticking valve or broken valve spring - Worn or damaged push rod and/or cam lollwer - Worn rocker arm and/or shalt Rough idle - Low cylinder compression - Intake air leak Overheating - Excessive carbon buildsup on the piston head or on com- bustion chamber Knocking or abnormal noise - Worn piston and cylinder - Excessive carbon build—up CYUNDER HEAD/CYLINDER/PISTON CYLINDER COMPRESSION TEST m—_ I! the engine must be running to do come work. make sure the me I: well ventilated. Never run the engine In an enclosed area. The exhaust contains poisonous carbon monoxide gel that may cause lea ol consciousness and may lead to death Run the englna In an open area or with an exhaust evacuation system In enclosed em. Warm up the engine. Stop the engine and remove the spark plug. Install a compression gauge. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rlsmg. Compression pronoun: 539 - 334 kPl (5‘5 - 8.5 Itg'lcm', 78 — 121 p5” It ‘50 rpm ll compression is below then the standard, loosen the exhaust valve lock nut and turn the ediusting screw H/Z turn and recheck the compression. Companion pressure: 1226 - 1.442 RP! "25 ~14.5 Inf/cm“ I78 -206 psi) It 450 rpm Low compression can be caused by; CYLINDER HEAD COVER — Blown cylinder head gasket ‘ - Improper valve adjustment - Valve leakage — Worn piston ring or cylinder High compression can be caused by: - Carbon deposits in combustion chamber or on piston head CYLINDER HEAD REMOVAL CYLINDER HEAD COVER REMOVAL Remove the fuel tank and luel tank heat guard (page 520). Remove the bolts and cylinder head cover. Remove the O-rlng and cylinder head cover gasket. CVLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD REMOVAL \ |NDEX MARK ..1 Remove the timing hole cap. Turn the crankshaft with the recoil starter and align the 'T" mark on the flywheel with the index mark an the rear crankcase cover. Make sure the piston is at TDC of the compression stroke by moving the rocker arms I! it the rocker arms are light, turn the crankshaft one tull turn and realign the '1" mark with the index mark. Remove the lollowing: — Exhaust pipe (page 2-15) — Carburetor (page 5-5) — Spark plug cap Remove the bolts and carburetor insulator. Remove the upper engine hanger bolts. bracket bolts and engine hangert SPARK PLUG CAP " NSULATOR Remove the left fuel tank bracket mounting bolts FUEL TANK BRACKET and bracket BOLTS Remove the 6 mm cylinder head mounting bolts. ROCKER ARM HOLDER Loosen the six cylinder head can nuts in e crisscross pattern in 2 or 3 steps, Remove the washers, Remove the rocker arm holder assembly. ,_ _ , ., ‘ !_ CAP NUTS/SEALING WASHERS CVLINDER HEAD/CVLINDERIPISTON Remove the dowel pins. Mark the push rods so they can be reinstalled in their original position. Remove the push rods. CAUTION: DoMtWhthopuahrmIfyoudo,“ m-pushmdsnmulry. Remove the cvlinder head. Remove the gasket and dowel pins. ROCKER ARM HOLDER DISASSEMBLV Remove the rocker arm shah retaining butt. Mark the rocker arms so they can he reinstalled in their original positions. Remove the rocker arm shah and rocker arms. ROCKER ARM HOLDER INSPECTION Inspect the rocker arms and shaft for wear or dam- age. Measure the LD. of each rocker arm. SERVICE LIMIT: 12.05 mm (0,414 in) Measure the 0.0. of rocker arm shalt. SERVICE UMIT: 11.92 mm (0169 inI Calculate the rocker arm-to-shalt clearance. SERVICE UMIT: 0.08 mm [0.003 In) CYLINDER HEAD ROCKER ARM SHAFT PUSH RODS DOWELNPINS ROCKER AFIMS 7-6 ._. ..... _.........___- _. ...._..-.._._w mw-W-. Nn-‘-v--rm CVLINDER HEAD/CVLINDER/PISTON VALVE SPRING COMPRESSOR CYLINDER HEAD DISASSEMBLY U Mukulpans Remove the valve spring collars, retainers, springs WW am and valve using the special iool as shown. so they can be Pl“? M 'n M TOOL: ~ Wyndham. VIIvc spring comprmr 077514010000 b enunou: To provanl In.“ of (Milan. do not compuu (In VIM springs mm than uncanny ta nmava tho canon. ‘ Ramava lha valve stem seals and valve spring seats. STEM SEAL OUTER SPRING COTTERS VALVE SPRING SEAT ‘ INNER SPRING ‘ SPRING RETAINER CYLINDER HEAD INSPECTION CYLINDER HEAD Avoiddammgme Remove carbon deposits from the combustion 935*“ SMBOG- chamber. Check the spark plug hole and valve areas for cram. Check the cylinder head for warpape with a slraighi sdga and Ieelar gauge. l SERVICE LIMIT: 0.10 mm [0.004 In) VALVE SPRING Measure the free length ofme Inner and outer valve L springs. SERVIG LIMITS: mm Inn-r: 35.34 mm (1.411 in) Outer: «m mm (1.591 In) Replace the springs iI they are shaner than me servi- ce limits. CYLINDER HEAD/CVLINDER/PISTON VALVE/VALVE GUIDE Inspect each valve for bending, burning or abnormal stern wear. Check valve movement in the guide. measure and record each valve stem OD. SERVICE LIM‘I’S: IN: 5.“ mm (0.215 In) EX: 5.“ mm (0.2" In) Ream the guides to remove any carbon deposits belora checking clearances. lnaen the reamer Irom the rocker arm side of the head and always rotate the reemer clockwise. TOOL: Valve guide reenter. 07“!»2000001 or 5.6 mm (1me (USA. only) Measure and record each valve guide LD. SERVKI LIMIT: INIEX: 5.525 mm (0.2"!) In) Subtract each valve stem 0.0. from the correspond— ing guide LD. ro obtain the stemmguide clearance. SERVICE LIMTS: IN: 0.12 mm [0.005 in) EX: 0.14 mm (0.000 In) mm the valve II the stem-lo—guide clearance exceeds Ihe service sure whenever!» limits, determine if a new gulde with standard di- "Mom W mansions would bring the cleerance within toler- W ance. II so. replace any guides as necessary and (Page 7-91- ream to fur. II the stem-tu-gulde clearance exceeds the service lirnim with new guides also, replace the valves and guides. CYLINDER HEAD/CVLINDERIPISTON VALVE GUIDE REPLACEMENT Chill the replacement valve guides in the Ireezer section a! a refrigerator for about an hour. Heat the cylinder head to 100 - 150'C (212 — JOZ'F) with a hot plate or oven. m— Yo avoid harm. weer heavy ploy-a when henfliny till heated cylinder head. CAUTION: Banana-torch mhutthecyfindulnwltmy cairn warping. Support the cylinder heed and drive out the valve guides from cambustian chamber side of the cylin- der hand using the special tool as shown. TOOL: Valve guide fiver. o17n-oa1o1oo 5.5 mm Replace a new O-ring on the new valve guide. Drive in the guide hom the top ol the head using the special real as shown. TOOu Vale wide driver. 0770241010100 5.5 mm Let the cylinder head cool to room temperature. Ream the new valve guide altar installation. Insert the reemer item the combustion chamber side ofthe head and also always rotete the reamer clock- wlse. TOOL: Valve nulde reamer, 079044000001 or 5.5 mm 079041000000 (USA, only) NOTE: Use cutting oil on the reamer during this operation. Clean the cylinder head thoroughly to remove any metal particles. Retace the valve seat (page 7-10). VALVE GUIDE DRIVER VALVE GUIDE REAMER CYLINDER HEAD/CVLINDER/PISTON VALVE SEAT lNSPECTION/REFACING Clean the intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to the valve some. Tap the valves and seats using a rubber hose or other hand-lapping tool. Remove and inspect the valves. CAUTlON: The velvet cannot be ground. I! e n e hoe ll burned or bedly worn or if It come I the ant unevenly. realm the valve. inspect the width of each valve seat. STANDARD: 1.2 mm (0.” ln) SERVICE LMT: 1.5 mm (0.06 in) if the seat is too wide, too narrow or has low zpots. the seat must be around. VALVE SEAT HEFACING NOTE: - Follow the relacer manulacture's operating In- struction. - Relace the valve seat whenever the valve guide has been replaced. - Be careful not to grind the seat more than neces- sary. , HANDLAPPING TOOL \ . “w WE“ TOOLS: VIM uet cutter. x mm (32‘ IN) 017004012300 VINO net um. N mm (32' EX) 077M122” VIN. Ill! cutter. 35 mm “5‘ IN) 07780-00104” VIN. out cutter. 23 mm “5‘ BO 01780-0010300 VIM soot cutter. 37.5 nun (fir IN) (mammoo Valve sent tamer, 3) mm [80‘ EX) 017800014000 VIM ”it can. holder. 5.5 mm 0778141010101 or equivalent commercially available In USA. VALVE SEATCUTTER .v ' «(I 7-10 b Ramayana! midi-degree Murmurs!- Vin/99ml: W Use 3 45699126 cunar to "move any roughness or irragularlties (mm the seal. Use a 32-deglee cuner lo remove the mp 11‘ of (he existing valve seal material. Use I ”degree cutter [0 remove [he bonom 11‘ of the old seal. Remava the cutter and Inspect "In an“ you have related Install a Afr-degree finish cutter and cul (he sent to the player widm. Make sure lhal all pitting and irragularllias are re- moved, Refinish if necessary‘ CYLINDER HEAD/CVLINDERIPISTON ROUGHNESS 3 OLD SEAT w1 DTN 32 L; OLD SEAT WIDTH 60' if 'f 1.2 mmlOJJSinl ‘5'5 : 7-11 CYLINDER HEAD/CVLINDERIPISTON Thclocab‘ona/lfn Wmlm Mmhmevllva flfl'Bvlly Wham seem-lg. Apply a thin calling oi Prussian Blua to the valve seat. Press rho vulva lhrnugh lire valve guide and cum the soar in make a clear pattern. If the comract area is loo hlgh on the valve, the seal must be Iowared using a 32-dearee flnr cutter. If the contact am Is loo low on ma valvl. ms 333! mu! be raised using A ”degree inner cunar. Refinish the seal to speciflcmions, using I Mme finish cunor. Altar culling lhe seal, apply lapping compound lo the valve 1m, Ind lap the valve using lighl pressure. Do minnow Alter lapping, wash all residual compound elf the WW cylinder head and valve. in anlar the garden. CONTACT TOO HIGH OLD SEAT WIDTH 32' CONTACT T00 LOW OLD SEAT % WIDTH 50° an HAND-LAPPING TOOL 7-12 CYLINDER HEAD/CVLINDER/PISTON CYLINDER HEAD ASSEMBLY CYLINDER HEAD COTTERS SPRING RETAINER OUTER SPRING ”In. Alter ’01: a INNER :7 SPRING STEM SEAL SPRING I . SEAT \Q I VALVE , GUIDE % go-RING\° \ I EXHAUST VALVE INTAKE VALVE Clean the cylinder head assembly with solvent and SPRING SEAT blow through all all passages with compressed air. Install the valve spring seats. Install the new stem seals, OUTER - t ‘ SPRING Lubricate the valve stems wrth engIne oil and Insert the valve Into the valve guide, To avoid damage to the stern seal, turn the valve . slowly when inserting. a v “\\v STEM SEAL In. INNER SPRING SPRING RETAINER Install the valve springs with the tightly wound coils lacing the combustion chamber. Install the valve Spring retainer. 0 U FACING THE COMBUSTION cnmaen 7-13 CVLINDER HEAD/CYLINDER] PISTON Install the valve cotters using the special tool as VALVE SPRING COMPRESSOR shown. TOOL' Valve spring commoner 017570010000 CAUTION: To prevent loss a! tension. do no! campus: the valve aprlng more than necessary. Tap the valve stems gently with two plastic hammara as shown to seat the ootters firmly. CAUTION: Support the cyllnder head above the work bend! surface to prevent possible valve damage. CYLINDER HEAD INSTALLATION Install the dowel pins and a new cylinder head gasket as shown. Install the cylinder head. NOTE: Do not install the gasket upside down. Install it as shown. ROCKER ARM HOLDER ASSEMBLY Lubricate the rocker arm and rocker arm shaft with molybdenum disullida oil. Place the rocker arm into the rocker arm holder, then insert the rocker arm shalt. BOLT NOTE: ll reusing, install the rocker arms in their or locations as marked. Turn the rocker arm shaft using a screwdriver to align the hole between the rocker arm holder and shalt, Apply oil to the thread and flange surface ol the racks! arm holder bolt. Install and tighten the bolt to the specified torque. TORQUE: 1 N-m (0.7 infirm. 5.1 let) ROCKER ARM SHAFT ROCKER ARMS 7-14 CYLINDER HEAD/CYLINDER/PISTON ROCKER ARM HOLDER INSTALLATION Properly install the push rods into the center groove 0! the cam lollower. NOTE: If reusing, install the push rods in their original loca- tions as marked. Install the two dowel pins. knob, and align the 'T' mark on the flywheel with the index mark on the rear crankcase cover. Make sure the piston is at TDC on the compression stroke. It not, rotate the crenkshah 360° (1 full turn) and align the 'T' mark with the index mark. Install the rocker arm holder onto the cylinder head. Install the new washers and cap nuts, Tighten the cap nut in a crisscross pattern in 2 — 3 steps. TORQUE: 39 Mom (4.0 light". 23 lblvm Install and tighten the cylinder head mounting 6 mm bolts. Install the upper engine hanger bracket, and tighten bracket bolts and the hanger bolt. TORQUE: Bracket bolt: 32 MM (3.3 “but, 24 Ital-It] Hanger bolt: 54 MM [55 hut-m. no Ital-m Check the O-ring is in good condition, install the carburetor insulator. Tighten the insulator bolts. Install the luel tank bracket and tighten the bolts. PUSH RODS _ WASHES (LARGE on.) (CAP NUTS UPPER ENGINE HANGER INSULATOR FUEL TANK BRACKET BOLTS 7-15 CYLINDER HEAD/CVLINDERIPISTON Install the lollowlng: EXHAUST PIPE ~ Spark plug cap " - Carburetor (page 5-16) - Exhaust pipe (page 246) Install a new cylinder head cover gasket. Install a new O-ring into the groove of the rocker arm holder. Install the cylinder head cover and tighten the bolls. Install the fuel tank heat insulator and fuel tank (page 5-21). CYLINDER/PISTON REMOVAL cvuosn REMOVAL Remove the cylinder head (page 74L Remove the cylinder bolts and cylinder. CVLINDER SPARK PLUG CAP_ CVLINDER HEAD COVER 7-16 CYLINDER HEAD/CVLINDER/PISTON Remove the cylinder gasket and dowel pins. DOWEL PINS PISTON REMOVAL Do notler trap-stun Remove the piston pin clip with pllers. pin d'va MI Wu "K WNW“- Press the piston pin out of the piston and remove the piston. CYLINDER/PISTON INSPECTION CYLINDER Inspect the cylinder bore (or wear or damage. Measure the cylinder ID. in X and Y axis at three levels. Take the maximum reading to determine the cylin— der wear. SERVICE LIMT: 90.10 mm (3.547 MI Calculate the piston<15 » SHIP-r DRUM _ 6807 20 x 25 x ‘2 11-10 CRANKSHAFTIBALANCERITRANSMISSION ASSEMBLY/INSTALLATION NOTE: - Apply oil to the shifter gear groovesr - Always install the thrust washers and snap rings with the chamlered (rolled) edge facing away from the thrust load. Alter installing the snap ringl slightly open the ring and rotate it in in groove to be sure it is lully seated. Do not used worn snap ring which could easily spinning in the gmovev They may be too loose to properly seat in the groove. - Align the gap in the snap ring with the groove 01 spline, - Align the oil holes on the shafts and bushings ~ The countershaft must be installed with the inside oll teed hole to the back, and the outside oil holes to the item as shown. TRXASOSIFM MAIN SHAH: M5 GEAR (SST) M3 GEAR (ZJT) M4 GEAR i28T) THRUST WASHER M2 GEAR (1ST) BUSHING THRUST WASHER M1 GEAR (12T) SPLINE SNAP FIING WASHER M4 GEAR M3 GEAR M5 GEAR M, H — || SPLINE SNAP RING THRUST WASWR WASHERS 11-11 CRANKSHAFI'IBALANCERITRANSMISSION mummsum: REVERSE IDLE GEAR 134mm y :1 | ® J11 - < ; ® ca GEAR (371') THRUST WASHERS c2 GEAR um CR GEAR (2m Cl-REVERSE COUNTER SHIFTEfi C1 GEAR (191') ’ ‘ BUSHING , ’ COUNTEHSHAFT @ ’ \ SPLINE ® / COLLAR / FINAL DRIVE GEAR (201') CI-REVERSE COUNTER SHIFT'ER C5 GE“ ‘23“ COPPER WASHER c1 GEAR ca GEAR c2 GEAR Install lha countenhoh with the inside C 4 GEAR oil had hole facing tho rur crankcase. c3 GEAR cs GEAR C747 7 7 77 7 A u / FINAL DRIVE GEAR COPPER WASHER THRUST WASHER 11-12 CRANKSHAFT/BALANCERITRANSMISSION mums/FE mm M5 GEAR 1331) M3 GEAR (2m M4 GEAMZBT) 7 M2 GEARHET) _ ” A > ' ' ' THRUST ,: WASHER 121 ‘ , M1 GEAR! ) . THRUST BUSHING WASHER SNAPRING SPLINE WASHER BUSHING MAIN SHAFT M4 GEAR M3 GEAR M5 GEAR L M 1 , , , T 1 SPLINE SNAP Rmc THRUST WASHER WASHERS 11-13 CRANKSHAFTIBALANCERITRANSMISSION COUMERSHAFI‘: REVERSE IDLE GEAR a (swan y L c: GEAR «3m 7 c2 GEAR (41m YHRUST WASHERS CR GEAR (271') C1-REVERSE COUNTER SHIF‘rER SPLINE ® COLLAR C1 -REVERSE COUNTER COPPER 5mm" c5 GEAR (22m WASHER c1 GEAR C1 GEAR (497) COUNTERSHAFT FINAL DRIVE GEAR (201) CR GEAR (:2 GEAR . . . Ct GEAR C3 GEAR ”131]” the coumarshah With the mania on feed hobs facm the rear crankcase. FINAL DRNE GEAR COPPER WASHER THRUST WASHER 11-14 CRANKSHAFT/BALANCER/TRANSMISSION Install the mainshaft end washer into the crankcase. MAINSHAFT/COUNTERSHFT ASSE MBLV Install the mainshaft and countershaft as an assembly. Verify that the top end of the countetshaft does not have an oil feed hula. Assemble the final drive gear and shaft, then install FINAL DRIVE SHAFT the drive shaft assembly into the rear crankcase. Install the shift drum, Install the rear shift fork into the M2 shifter gear groove with its "RR" mark facing up, Install the center 5 ift fork into the C3 shifter gear groove with Its "C" mark lacing up. Install the front shift fork into the counter shifter groove with its “FR" mark lacing up. Make sure all of the shift fork pins are aligned with the grooves In the shift drum. Install the shift fork shaft. SHIFT DRUM SHIF‘f FORKS Assemble the reverse idle gear] bushings, washer and shaft, m0 WASHER BUSHINGS IDLE GEAR 11-15 CRANKSHAFT/BALANCER/TRANSMISSION Install the reverse idle gear aligning the pin on the shalt with the crankcase groove. Install the washer. Install the CI gear bushing making sure oil passages are aligned, C1 gear and copper washer CRANKSHAFUBALANCER REMOVAL Remove the transmission (page 114). Remove the crankshaft and balancer from the rear crankcase using a hydraullc press. If the rear cranksha't bearing remains on the crankshalt, remove it with a commercially available bearing separalor (4. 1/2 in) as shown. If the bearing remains in the rear crankcase, drive it out lrorn the outside. Discard the rear crankshaft bearlng. NOTE: Always replace the rear bearlng with a new one whenever the crankshaft is removed horn the rear crankcase. l ' , REVERSE IDLE GEAR ASSEMBLY Cl GEAR BUSHING -6 CRANKSHAFT 11-16 I i l i CHANKSHAFT/BALANCER/TRANSMISSION INSPECTION Set the crankshaft in a stand or V-blocks and read the runout using dial indicators at the A and 8 points as shown. SERVICE LIMIT: 0105 mm I0.002 In) Measure the side clearance between the connecting rod big and and the crankshaft weight with a teeter gauge‘ SERVICE UMIT: 0.00 mm “1.03! In) Measure the radial clearance at the connecting rod big and, at two points in the directions indicated by the arrows. SERVICE LIMIT: 0.05 mm (0002 In) Check the balancer gear teeth (or abnormal wear or damage. 11-17 CRANKSHAFT/BALANCER/TRANSMISSION BEARING REPLACEMENT Turn the inner race 0! each bearing with your finger. The bearings should turn smoothly and quietly. Also check the outer race at each bearing fils tightly in the crankcase. Drive our the crankshaft bearing, Pull the balancer bearings out ofthe crankcase using the special tools as shown. TOOLS: Rumour hlndll 07936-3710100 Eurlng "mover. 17 mm 0733644710300 Rumour weight 07741-001020! or 07939-17 10200 or 07935-37 1020A lU.S.A. only) Drive new bearings In usmg the l‘cllowmg toalsv TOOLS: Cnnklhm blaring: Driver 07749—001000!) Attachment. 72 X 75 mm 07746-0010600 Pllm, 40 mm 077450040900 Balancer burlng: D'ivlr 07749-0010000 Afllchmont. 37 X 40 mm 0774641010200 Pl|ot, 17 mm 077450040400 INSTALLATION Temporarily install the balancer and crankshaft in the tram crankcase and align their timing marks. BEARING REMOVER DRIVER ‘DRIVE GEAR 11-18 CRANKSHAFI'IBALANCERITRANSMISSION CRANKCASE ASSEMBLY Install the rear crankcase on (he lrunl crankcase. THREADED ADAPTER Install the threaded adapter on [he crankshaft. ‘ TOOL: Inn-dud adaptor onssvmoom or 07931-KF00200 (USA. only) Draw the crankshah into the rear crankcase using the Speclal lools. TOOLS: Assembly collar MSSGVMOMM Asumblv shah C'IBSS-VMMZOO or D7931-ME40‘IOB and (USA. only) Spud-l nm 0793l-HB3020A ASSEMBLY COLLAR _ SPéCIAL NUT Remove the lronl crankcase and make sure me index marks on (he balancer and crankshaft are aligned. lnslalllherransmassionlpage11-11), TIMING MARKS DOWEL PINS Install the dowel pins and new gasket. GASKET 11-19 CHANKSHAFT/BALANCERITRANSMISSION Install the front crankcase onto the rear crankcase. REAR CR AN KC ASE NOTE: Make sure that the gasket stays in place. Make sure the bearing holder/cam chain tensioner arm is on the correct side nf the mainshen. Refer to page 7-2310r proper positioning Make sure that the oil pump shaft is correctly aligned. Install and tighten all the rear crankcase belts in 2 or 3 steps in a crisscross pattern. Tighten the front crankcase bolts. Install the new O-ring onto the final drive shaft. FRONT CRANKCASE Install the engine hanger bushings and dust seals. DUST SEALS NOTE: When installing the engine hanger bushing dust seals, install the dust seal lips to the outside as shown Reinstall the removed pans in the reverse order of removal, 11-20 MEMO FRONT WHEEL/SUSPENSION] STEERING u NJ" “.5 kgl-m, 33 leI) to MIT! (4.5 kgf-m, u N-m (1.5 kgV-m‘ 33 ltd-fl) 33 lbI-h) 108 N-m (“‘0 WM". 50 IbM!) 'H - '01: 29 N-m (3.0 kgbm, 22 RIM!) AM '01: 32 N-m (3.3 kgfom, 2‘ thK) 12 N-m (1.2 kaf-m, 9 lbf-h) 15 N-m (L5 kgf-rn, '1 lM-fi) 29 N~m (3.0 Raf-m. 22 "1”!) 78 N-m (8.0 WM", 58 lbf-fl) 84 N~m (6.5 Raf-m, 47 Ibf'ft) 1 2-0 12. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 12.1 TIRES 12-8 TROUBLESHOOTING 12-2 TIE-ROD/KNUCKLE 12-12 HANDLEBAR 12-3 UPPER/LOWER ARMS 12-20 THROTTLE HOUSING 12-6 STEERING SHAFT 12-23 FRONT WHEEL 12-8 FRONT SHOCK ABSORBER 12-29 SERVICE INFORMATION GENERAL Av- It, A cont-min-rod brake drum or shoe reduce: slapping pawn. Disuld contaminated shine and clean a contaminated drum with a high nullity brake dcumsing agent. - A jack or other support is requred to support the vehicle. - Adjust toe whenever the tie-rod. knuckle or steenng shalt are replaced or removed (page 3-22). - Do not lwisl or bend the Drake hoses and pipes when removing them (tom the knuckle or upper arm. SPECIFICATIONS > UnIl: mm (In) ITEM ( STANDARDS ‘ SERVICE LIMIT Mimrnum tire tread depth ' ‘ 410.2) Cold Iire pressure Stantard | 25 kPa (0.25 kgI/cmz. 3.6 psi) Minimum 22 kPa (0.22 kgf/crn', 3.2 psi) Maxnnum . 28 kPa (0.28 kgl/cm‘, 4.0 psi) With cargo 25 kPa (0.25 kgl/cm’, 3.6 psi) Tie-rod distance between the ball joints 369 : 104.5 : 0.04) Toe Toe-out: 35 : 15 mm (1-3/8 3 9/16 in) TORQUE VALUES Handlebar lower holder nuI Steering shalt U-nut Tiearod ball )oint sell lock nul Tlerod lock nut Steerlng shah holder flange bolt Upper/lower arm pivot self lock nut Knuckle ball [0)!“ castle nul (’98 - '01) (Amer ’01) Shock absorber upper mounting self lock nut Shock absorber lower mounting sell lock nut Fronl wheel hub castle nut Front wheel nut Throttle case cover Brake hose 2 way jaunt nut Brake hose clamp boII Brake panel bolt 39 N'm (4.0 kglem, 29 Ibf-(l) 108 N-m (11.0 kgfem, 80 Ibf~m 54 N-m (5.5 kgf-m, 4O lbf-ft) 54 N-m (5.5 kgl-m, 40 lbl-(t) 32 N-m (3.3 kgf‘m. 24 Ibt-ft) 44 N-m (4.5 ngm, 33 lbi'ftl 29 N-m (3.0 kgl-m, 22 Inf-ft) 32 N-m (3.3 kgf-m, 24 Ibl-(t) 44 N-m (4.5 kgf-m, 33 Ibl-fi) u N-m (4.5 kgI-m. 33 Ibl-m 78 N-m (8.0 kgl-m, 58 (bl-(t) 64 N-rn (6.5 kgf'm, 47 (bl-ft) 4 N-m (0.4 kgf-m, 2.9 (bl-(t) 15 N-m(1.5 kgf-m,11lbf'hl 12 N-m (1.2 kgl-m, 9 lel) 29 N-m (3.0 kgl'm, 22 lbf'h) U-nut Castle nut Castle nut Castle nut Do not reuse Do not reuse: Do not reuse; DO not reuse: Do noI reuse; Do noI reuse; replace With a new one. replace mm a new one. replace with a new one. replace with a new one. replace WIth a new one. ; replace mm a new one. 12-1 FRONT WHEEL/SUSPENSION/STEERING TOOLS Unrversal bead breaker Bell joint remover Oil seal driver attachment Driver Attachment Driver Attachment, 37 X 40 mm Attachment. 52 X 55 mm Pilot, 30 mm Pilot, 20 mm Ball joint remover/installer Attachment, 28 X 30 mm Ball joint installer base TROUBLESHOOTING Nerd nemng - Damaged steering shaft hearing and holder bushing - Steering shalt halder to tight - Insufficient tire pressure Stun ta one side a! does not track straight ' Bent tie—rod ~ lnsutflcient tire pressure GN-AH-SSB-BB'I 07MACvSL00200 07JAD~PH30101 07549-3710001 079454330300 or 077460010‘00 07749-001 0000 07746-001 0200 077‘5v0010‘00 077‘6-00‘0700 077050040500 07WMF-HN00100 0795-1870100 07HAF-SF 10120 Soft suspenslon - Week spring Herd sup-mum - Bent shock absorber Suspension noise ~ Loese fasteners - Bent suspension arm; frame or wheel installed incorrectly - Incorrect wheel alignment - Weak lront shock absorber Front wheel wobbllnn - Bent rim - Worn hunt drum bearing - Faulty tire - Axle nut not tightened properly 1 2-2 FRONT WHEEL/SUSPENSIONISTEERING HANDLEBAR REMOVAL Remove the Iron! fender and handlebar cover (sec- tmn 2). Remove the wire bands. WIRE BANDS Remove the two screws and "name huusmg. THROTTLE HOUSING Remove me two bolts and masks! cyllndal. MASTER CYLINDER Remove the two screws and rear brake lever brackel‘ REAR BRAKE LEVER BRACKET FRONT WHEEL/SUSPENSION/STEERING Remove the two screws and swrtch houslngv SWITCH HOUSlNG TRX4505’FM Drsconnect the choke cable. only Remove the four bolts and upper holders, UPPER HOLDERS Remove the handlebar. INSTALLATION UPPER HPLDERS‘ Place the handlebar on the lower holders, Alrgn the punch mark on the handlebar wrlh the top at the lower holders. Install rhe upper holders on the handleuar with their cover bosses lorward. Trghren the lront tmlts lrrst, [hen trghten the rear bolts, PUNCH MARK II the handlebar guns were removed, apply Honda GRIP END Bond A or Honda Hand Grlp Cement 1U.S.A. only) to [he rnsrde olthe grrp and lo the clean surfaces of the rrght and left handlebar, Wart 3A5 mrnules and lnslall the grrp. Arrow Ins adhesrve Rotate the gun for even applrcatmn of the adhesrve. Ia dry rm an hour DMD/G "SW Install the gnp end and nghlen the bolt. 12-4 FRONT WHEEL/SUSPENSION[STEERING TRX45US'FM Connect the chocke cable to the chocke lever, SWITCH HOUSING only Install the left handlebar swuch by allgmng its locating pin with the hole In the handlebar, Trghten the upper screw first, then the lower screw. SCREWS Install the rear brake lever bracket With the punch TRX450$ SHOWN: TRX‘SOES SHOWN- mark on the holder lacing up. p NCH MARKS Alrgn the end althe holder With the punch mark on U SCREWS rhe handlebar, Tighten the upper screw first, then the lower screw, SCREWS PUNCH MARKS Install the master cylinder by aligning the end of MASTER CYLINDER PUNCH MARK the master cylinder with the punch mark on the handlebar. Install the master cylinder holder Wlll’l the “UP” mark facing upr Tighten the upper bolt llrsl, then the lower bolt. TORQUE: 12 Nrm (1.2 kglcmr 9 [bl-kl “UP” MARK 12-5 FRONT WHEEL/SUSPENSION/STEERING Install the throttle housing by aligning rhe line on THROTTLE HOUSING the throttle housing with the and o! the master cylinder. LINE Tighten the throttle housing screws securely. SCREWS Secure the wire with the wire bands. install the handlebar cover and lront lender (section 2). WIRE BANDS J THROTTLE HOUSING SCREWS DISASSEMBLV Remove the three throttle housing cover screws and the cover. Remove the gaskel, HOUSING COVER 12-6 FRONT WHEEL/SUSPENSION/STEERING Slide the rubber boot off the cable adjuster. Loosen the throttle cable adjuster. THROTTLE ARM Bend down the lock washer tab and remove the nut and lock washer. Disconnect the throttle cable lrorn the throttle arm. Remove the throttle arm, spring and throttle lever lrom the throttle housing. LOCK WASHER ASSEMBLY THROTTLE CABLE SPRING Connect the throttle cable to the throttle arm. Install the throttle arm spring and arm onto the throttle lever by aligning the slot. v LOCK WASHER Install a new gasket, then install the throttle housA a GASKET ing cover, v Install and tighten the three screws. Adjust the throttle lever free play (page 374). HOUSING COVER 12-7 FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL TIRES REMOVAL Loosen the wheel nuts. Place a support block under the engine to raise the lront wheels off the groundr Remove the wheel nuts and wheel. INSTALLATION Install the front wheeL NOTE: Do not interchange the right and left tires. Install the wheel nuts with their curved (tapered) sides lacing inward and tighten to the specified torque TORQUE: M N-m (6.5 Itaf'm, 47 IM'M REMOVAL NOTE: ~ This service requires the Universal Bead Breaker lGN-AH-SSE-BB‘I). - Remove and install tires from the rim side opposite the valve stem, Remove the core from the valve stem CAUTION: . Uu oi the bud bunker tool in required in! tire removal, - Do not damage the bud seating am aim rim. - Uu a Conn 220 Tire Changer or equivalent to remove the the irarn the rim. lie tire changer in not err-liable, rim protectors and tire iron: may be used. Install the blade iur 9/11" rim: onto the breaker arm assembly. Slide a piece of I I12" In x 3" length rectangular tubing over the end oi the breaker as. aemblyr CAUTION: Una oinnirnpmperaiubiademeyruuitindemem to the rim, tire or blade. FRONT WHEEL FRONT CURVED SIDE BLADE PRESS BLOCK BREAKER ASSEMBLY 12-8 FRONT WHEEL/SUSPENSION] STEERING Place the proper size adapter onto the threaded shaft and then put the wheel over the threaded shaft and adapter. Lube the bead area with water. pressing down on the tire sidewall/bead area in several places to allow the water to run into and around the bead. Also lube area where the breaker arm will contact the sidewall oi the tire. m— Uuonly wet-rue Iubrlam‘renmvlng amounting tires. Soap or some mounting lubricants may leave a slippery residue which can cause the tire to mm on the rim and [use ll! mum during riding. While holding the breaker arm assembly at an approximate ‘5‘ position, insert the blade ol the breaker arm between the tire and rim. Push the breaker arm inward and downward until it is in the horizontal position with its press block in contact with the rim. With the breaker arm in the horilontal position, place the breaker press head assembly over the breaker arm press block. Make sure the press head bolt is backed out all the way and than position the nylon buttons on the press head against the inside edge 0! the rim Insert the threaded shaft through the “I hole in the breaker press head assembly and then tighten the lever nut until both ends of the breaker press head assembly are in firm contact with the rim. Tighten the press head bolt until the reference mark on the press block is aligned with the top edge ol the press head It the rest ol the bead cannot be pushed down into the center ot the rim by hand. loosen the press head bolt and the lever nut. Rotate the breaker arm assembly and breaker press head assembly 1/8 to we the circumference ol the "mt Tighten the lever nut and then tighten the press head bolt as described. Repeat this procedure as necessary until the remainder of the bead can be pushed down into the center of the rim. Assemble the Universal Bead Breaker on the other side ofthe wheel and break the bead lollowing the same procedures. Remove the tire from tha rim using a tire changer machine or tire irons and rim protectors. Remove tire lrorn the rim side that has the smallest shoulder area to simplify removal. BREAKER ARM ASSEMBLY TIRE RIM ADAPTER THREADED SHAFT USE 11' LEVER NUT RIM HOLE 1-1/2 X B' TUBING PRESS HEAD BOLT REFERENCE MARK TOP EDGE OF PRESS HEAD ll! HEAD BLOCKS 1 2-9 FRONT WHEEL/SUSPENSION/STEERING Bewelilnoltn pmhlneplwell mewaE-mlhe fiebprevenlil mmm. TIRE REPAIR NOTE: Use the manufecturer'e instructions for the tire repair kit you ere using. If your kit does not have Instructions. use the procedures provided here. Check the re lor Iereign objects. Chalk mark the punctured eree end remove the foreign object. Inspect end measure the Injury. Tire repairs tor Injuries larger than 15 mm (5/8 In) should be e section repair. Section rep-Ire should be done by I proleeilonel tlre repair ehop. If the injury le emeller then 15 mm (5/8 in). proceed with the repair as described here. Install e rubber plug Into the Injury ee Iollowe: Apply e cement to e plug Inserting needle and work the needle into the Injury to clean and lubricate it. Do this three times. Do not let the cement dry. Insert end center I rubber plug through the eye of the Inserting needle. Apply cement to the rubber plug. Push the Inserting needle with plug into the Injury until the plug ie slightly above the tire. Twist the needle and remove it from the tire; the plug will my in the tire. Trim the plug 6 mm (114 in) above the tire surlaoe. Repeat the ebove procedure if the puncture is Ierge. Do not nee more than two plugs per injury. 12-10 FRONT WHEEL/SUSPENSION/STEERING Allow the repair to dry i Drying time will vary with air temperature. Refer to the tire repair kit manufac- turer‘s recommendations. lnllate the tire and test the seal by dabbing a small amount ol cement around the plug. Escaping air will cause a bubble In the cement. If there in leakage. remove the tire (page 12-9) and apply a cold patch to the inside ol the tire as described. If a plug has been Inserted, trim it even with the inner tire surface. Temporarily place a rubber patch that is at least twice the site at the puncture over the injury. Make a mark around the patch. slightly larger than the perch ltsell. Roughen the area marked inside the tire with a tire buffer or a wire brush. Clean the rubber duel lrom the buffed area. Apply cement over the area marked and allow it to dry. Remove the lining from the patch and center it over the injury. Press the patch against the inlury using a special roller. NOTE: - Allow cement to dry until tacky belore applying patch. - Do not touch the cement with dirty or greasy hands. ASSEMBLY Install the tire onto the rim. where the rim shoulder width is the narrowest, to simplify installation. Clean the rim bead seat and flanges. Apply clean water to the rim flanges, bead seat and base. m—_ Ute only wetelue lubricant when mounting tires. Soap or some mounting lubricante may leave a slippery realdure which can cauu the tire to alum on the rim and lose all pm during Ildlng. Install the valve core in the valve stem. Install the tire and inllate it to seat the tire head. 11'. preaaurm Deflate the tire. Wait 1 hour and Inflate the tire to FRONT/HEAR the specified pressure. Standard 25 kPa (0.25 kgllcm’, 3.6 psi) Minimum 22 kPa (0.22 kgllcm’. 3.2 psi) Maximum 28 We (0.28 kgllcm’. 4.0 psi) With cargo 25 kPa (0‘25 kgl/cm'. 3.6 psi) Check lor air leaks and install the valve cap. 12-11 FRONT WHEEL/SUSPENSION/STEERING TlE-ROD/KNUCKLE \ ' ' BRAKE DRUM REMOVAL NOT The tie-rod can be removed without removing the brake drum, Remove the front wheel (page 12-8). Remove the two bolts. Remove the brake drum. Remove the lollowing: — Cotter pin — Axle nut — Wheel hub Remove the brake hose guide mounting nut. . BRAKE HOSE Remove the breather tuba 1mm the tube guides Remove the lam belts and brake panel lrom the BREATHER TUBE knuckle. NOTE: - Do not disconnect the brake hose from the brake panel. The brake system will have to be bled ii the brake hose is disconnected. Do not operate the front brake lever after removing the brake panel. It you do, the pistons will be forced lrom the cylinder, CAUTION: Support the hr. 0 panel so the! It does not hang from the hr a hose. Do not twist the brake hon. BRAKE PANEL 12-12 FRONT WHEEL/SUSPENSION/STEERING Remove the cone! pins, Hold me rie~rod ‘oinrs and remove me nuts. Remove the tierrod. Remove the comer prns. Loosen the castle nurs. bur do not remove them. Apply grease lo the ball juinr puller on the are as shown, This will ease rnsm|lation ol the tool and prevent damage to (he pressure boll rhraads, Inserr rhe laws carelully, making sure {her you do not damage the ball joint boot. Adjust the 18W spacing by turning the pressure bolt. NOTE: ’— If necessary, apply penenaung Iype lubncnnr to loosen the ball joint. #— COTTER PINS/ CASTLE NUTS ——_——1 APPLY GREASE HERE PRESSURE BOLT g FRONT WHEEL/SUSPENSION/STEERING Once the tool is in place, turn the adjusting bolt as necessary to make the jaws parallel. PRESSURE BOLT Then hand-tighten the pressure bolt and recheck the jaws to make sure they are still parallel. Tighten the pressure bolt with a wrench until the ball joint shaft pops loose. ADJUSTING BOLT Remove the knuckle from the upper and lower arm, BALL JOINT REMOVER using the special tool according to the above instructions TOOL: Bell joint remover, 28 mm 07MAC»SL00200 Remove the castle nuts. INSPECTION BALL JOINT RUEBERS Inspect the tie-rod Ior distortion or damage. Inspect the ball joint rubbers for tears or other damage by moving the ball joint ends. They should move freely and smoothly. Replace the ball joints i! necessary. Inspect the knuckle Ior damage or cracking. BALL JOINT Russell Inspect the knuckle ball joint rubber Ior tears or other damage by moving the ball joint and It should move lreelv and smoothly. Replace the ball joint it necessary. 12-14 FRONT WHEELlSUSPENSION/STEEFIING BALL JOINT REPLACEMENT Remove the snap rung and dust seal. Set the knuckle and special tools, with “A" marked side on the tool facing the ball jaunt. m a vise as shown. TOOL‘ Bell lolm removOr/lnet-ller 07WMF-HNoo1oo Anlchmenl, Z! X 30 (”S‘s-1870100 Press the ball joint out at the knuckle by tightemng the VISB‘ Set the knuckle, a new ball jam! and special tools, with "B" marked side on the tool faced to the bell joint, in a vise as shown. TOOL: BIII IoInt "mover/install" o7WMF-HN00100 Bill iolnt inlilllaf hil- OTHAF-SF‘IO‘IZO Press the ball joint Into the knuckle by tightening a visa as Shawn. CAUTION: I! you In! the ball joint Ive-d pressing aynhut the visa, «on tlnhtenllw. Reset the enechment of the tool so Met the bell ioim head can go into the hollow of the etuchnnnt and try retighte . Install me snap ring securely in the ball loint groove. Install the dust seal (page 12717L SNAP RING DUST SEAL BALL JOINT , //”" / ,——\_flr: \ _ ,t'f / A \\ BALL JOINT \ REMOVERIINSTALLER AWACHMENT BALL JOINT ,/7 TV a]? '15" _‘, ’ in ~ " I '/ 6 BALL JOINT BALL JOINT REMOVER/INSTALLER INSTALLER BASE SNAP RING DUST SEAL 12-15 FRONT WHEEL/SUSPENSIONISTEERING KNUCKLE BEARING INSPECTION] REPLACEMENT Turn the inner race of the knuckle bearing with your finger. The bearing should turn quietly. Also check that the bearing outer race fits tightly in the knuckle. Remove and discard the bearing it the race does not turn smoothly and quietly at it it fits loosely in the knucklet Remove both dust seals from the knuckle. Remove the snap ring‘ Drive the bearing out oi the knuckle. Pack the new bearing cavity with grease. Install the bearing squarely, TOOLS: Drive! 071490010000 Attachment 019l5«3330300 or 07746-001040!) Pilot. 30 mm 077‘8—00‘0100 OUTER DUST SEAL INNER DUST SEAL SNAP RING ‘_,—— DRIVER ATTACHMENT 'r—1'. 7‘ A L PILOT 12-16 FRONT WHEEL/SUSPENSION/STEERING Install a snap ring securely In the knuckle groove. Install new ouler dust seals using the special lools. Apply grease to the dust seal lips, TOOLS: Drivel 01149-0010000 Anlchmenl. 52 X 55 mm 077090010400 Film, 30 mm 077460040700 |nslal new Inner dust seals using the specual tools‘ Apply grease 10 [he dust seal lips. TOOLS: Drlvcr 077090010000 Oil seal drlvev 07JAD-PH80101 Pilot. 30 mm 0775—0040700 SNAP RING Momvsn ' 7 i 1.. ATTACHMENT —L IE E211, , : —‘\PILOT DRIVER / 0|L SEAL / DRIVER 12-17 FRONT WHEELISUSPENSION/STEERING TIE-ROD ASSEMBLY lnstan the unmarked ball tutnt and gold colored nut J on the llal side at the harm. and the ”L“ marked ball lolnl and sllver nul an the opposrte Slde. Set the drstance between the ball lornts as specified * below, STANDARD SETTING: ' LOCK NUT-TO-THREAD END DISTANCE A AND B: l k W - '01: 15 mm [0.1tln), ARI! '01: 5.5 mm (0.2 in) B: '98 - '01: 3.5 mm, Aha! ’01: 5.5 mm (0.22 in) ; AVE less than or equal to 3 mm 40,1 tn) Ttghten the lock nuts securely. LOCK NUT ’ KNUCKLE INSTALLATION KNUCKLE Connect the knuckle to the upper arm Install the castle nul. Ralse the upper arm and Insen the drive shaft mm the knuckle Connect the knuckle to the lower arm. Install the castle nut. Ttghten the castle nuts to the spectfted torque CASTLE NUT! J roacue; ’93 - '01: 29 N-m (3.0 kgf-m, 22 lbl-ft) COTTER pth Aha! ‘01232 N-m (3.3 mm, 24 lbl-fl) Install the new collar pins. TIE-ROD INSTALLATION Install the tterrod wtth IlS flat end at the knuckle. Hold the ball JDII'II and ttghten the ball pom! nuls to the specrlted torque TORQUE: 54 N-m (5.5 kgl-m, w lbfcfl) 12-18 FRONT WHEEL/SUSPENSION/STEERING Install new cotter pins. Adjust the toe (page 3-21). v COTTER PINS ll you removed the brake panel, install the brake BOLTS panel onto the knuckle. Install brake panel mounting bolts and tighten them to the specified torque. TORQUE: 29 N-m (34) kgl-m. 22 Ibl-fl) - BRAKE PANEL Clamp the breather tube into the clamps BRAKE HOSE *‘ . Install the brake hose clamps and tighten the nut, TORQUE: 15 MM (1.5 k91~m, 11 let) install the wheel hub. Apply grease to the castle nut flange and threads. then install the nut. Tighten the axle nut to the specified torque. TORQUE: 18 Nail (8‘0 Itgf-m, 58 lbl-m Install a new cotter pin. It you disconnect the brake line, bleed the system (page 143). Install the hon! wheel lpage IZ-B) FRONT WHEEL]SUSPENSION/STEERING Install the brake drum and tighten the two bolts, BRAKE DRUM UPPER/LOWER ARMS answer: was REMOVAL rheupperand Remove the knuckle (page 1242). rower arms can be removed wrthout up", An“ ”WW9“ Remove the brake hose guide mounting nut and tre—rod boltt BRAKE HOSE Remove the breather tube from the tube guidesv Remove the shock absorber lower mounting bott/ LOWER MOUNTING BOLT NUT nutt r Remove the upper arm mounting bolts/nuts and arm ' BOLTS/NUTS Discard the upper arm mount-n9 nuts and shock absurber mounting nuL 12-20 FRONT WHEEL/SUSPENSIONISTEERING Lower Arm .. BOLTS/NUT Remove the lower arm mounnng bolls/nuls and ‘ arm, Discard the lower arm mounting nuxs. LOWER ARM INSPECTION BALL JOINT RUBBER ausumes Inspect me ball lornr rubber Ior (ears or orher dam age by movrng rhe ball Jornr end. I! should move Ireelv and smoome Check the prvot bushing Ior damage‘ Replace the ball 1mm If necessary. ’ BALL JOINT REPLACEMENT SNAP RING Upper Arm Remove the snap ring, Ser rhe upper arm and ball .orm removen‘insrauar with rhe “A" marked srde an the tool faced lo the bail 1mm, m a press as shown. TOOL’ BI“ joint rumour/Installer 07WMF-HN00100 ATTACHMENT Annzhmtnt, 28 X 30 mm 07546-187010!) Press (he ball JOIN our DI the upper arm, \ BALL Jomr REMOVER/ INSTALLER 12-21 FRONT WHEEL/ SUSPENSION] STEERING Set Ihe upper arm. a new ball joint and ball joint remove/insraller with the "B” marked side on me Iool laced lo the ball joim, In a press as shownr TOOLS: Ball ioinl remover/Installer 07WMF-HN00100 ‘ BIII ioim install" b-u 07MAF-SF101ZO Press the ball joint into the uppev alm‘ CAUTION: I! you In! strong resistance when lowering (In BALL JOINT pros: nap. film the lmchmnnt of the tool so mu REMOVERI Um ball/01m hand can go Into the hollow of (In INSTALLER cruel-men! llld try ngnln‘ SNAP RING VJ InsraII the snap ring to groove of the ball ioim securely, INSTALLATION g NUTS/BOLTS I Uppu Arm Install Ihe upper arm, Dolls and new nuts. UPPER ARM lnslalI the shack absorber lower mouming bull and a NUT/BOLT new nut, [hen lighten It to the specified lorque. v TORQUE: M N-m “.5 kgI-m, 33 IM-h) 12-22 FRONT WHEEL/SUSPENSION/STEERING Install the knuckle (page 12-18). Instal the brake hose and breather tube clamp. Tighten the clamp bolt to the specified torque. TORQUE: 12 N-m (1.2 Raf-m. 9 [bl-ft] Install the brake hose clamp and tighten the nut. TORQUE: 15 MM (15 Ilfif-m. H lbl-ft) Lower Arm LOWER ARM Install the lower arm, bolts and new nuts. Install the front wheel (page 128). then place the vehicle on level ground, Tighten the upper and lower arm mounting nuts to the specified torque. TORQUE: u N-m [4.5 Ital-m. 33 lbl-fl) UPPER/LOWER ARM PIVOT NUT STEERING SHAFT HEADLIGHT BRACKET REMOVAL Remove the trout fender (page 2-6). Remove the bolts and headlight bracket, FRONT WHEEL/3USPENSION/STEERING Remove the handlebar lower holder nuls, washers LOWER HOLDERS and handlebar assemblyv Discard the handlebar lower hulder nuts‘ NUTS/WASHERS Remove the steering shah holder bolls and holder. STEERING SHAFT HOLDER Remove me lollawing: - Coner pins - TIe-rod ball joint nuts 7 Tlarrod Remove (he coner pin and steering shah U-nut. STEERING ARM Remove the steering shah. STEERING SHAFT NUY 12-24 FRONT WHEEL/SUSPENSION/STEERING INSPECTION BUSHING Remove the steering shaft bushing. Check the steering shalt bushing (or wear or damage. Check the steering shaft distortion or damage. STEERING SHAFT Turn the inner race of steering shatt bearing w-th your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly m the frame Remove and discard the hearing it the race does not turn smoothly. quietly or it it tits toosely in the trams, BEARING REPLACEMENT DUST SEAL Remove the dust sealt FRONT WHEEL/SUSPENSION/STEERING Remove Ihe snap ring Remove me dust saaL 01 frame usmg (he spemal tool TOOLS; Burina nmovor at 079368710001 — Bearing remover, 20 mm 079364710600 - Remover handle 015364710100 — quovu weight 077047010201 or 07536-37 10200 Pack the healing cavllv Wllh gvease‘ Install the beating wim Ils sealed side up using me special lools. YOOLS: Drivnr hlndll 077450010000 Anachmum, 37 X M] mm 07746-00I0200 Pilot, 20 mm 07746-00405“) 1 ATTACHMENT 12-26 FRONT WHEEL/SUSPENSIONISTEERING Install the snap ring in the groove securely. Apply grease to new dust seal. Install the dust seals. Apply grease to new dust seal. Install the dust seal. v DUST SEAL INSTALLATION WIDE TOOTH WIDE CUTVOUT Apply grease to the steering shall spline, Assemble the steering shall and steering arm by aligning the Wide cut-out oi the steering arm with the wide tooth of the steering shaft. 12-27 FRONT WHEEL/SUSPENSION/STEERlNG Apply grease to the steering shaft bushing cavlttes. E BUSHING ‘ Install the bushing with its “UP” mark facing up. Install the Sleerll’lg shaft in the frame. Install the staenng shalt holder and tighten the STEERING SHAFT HOLDER holder bolts to the specified torque. TORQUE: 32 MM (33 kM-m, 24 [bl-ft! Apply grease to the flange and threads of the steering shaft nut. Install the steering shaft and tighten the steering shalt nut to the specified torque. TORQUE: 108 N-m (11.0 kgf-rn, 80 Ilel Install a new cotter pin. STEERING SHAFT NUT/v COTTER PIN ‘ Install the tierrods on the steering shaft (page 12- 18D. 12-28 FRONT WHEEL/5USPENSION/STEERING Install me handlebav assembly on the steering shah LOWER HOLDERS and ligmen the new Iowa! holder nuts with washers lo the specified torque. TORQUE: 39 N-m [4‘0 Incl-m, 29 lbf-fl) WASHERS/v NUTS Install ma headlight bracket and tighten (he bolts. HEADLIGHT BRACKEY Adjusl me me (page 3-22). FRONT SHOCK ABSORBER UPPER MOUNTING REMOVAL Support the vehicle with a support block under me engine to raise the lronl wheels off the ground. SHOCK ABSORBER Remove the Vollowing: - Shock absorbev mounnng bolls/nuts — Shock absorbev Discard the mounting nuts. LOWER MOUNTlNG ~ 30m ”NUT v — Inspect the dampev rod lor distortion and signs of SHOCK ABSORBER oil leakage, Inspecl (he spring and spling guide lo! damage. 12-29 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION UPPER MOUNTING BOLT/ ”NUT Apply grease to the shock absorber lower pivor v collar. Insrall me shock absorber and tighten rhe mounting bulls and new nuts re the specified quue. Do not reuse me nurs. TORQUE: u Mom (4!, kgl-m, 33 mph, ABSORBER LOWER MOU NTING BOLT/ NUT ’6‘ $9— 12-30 MEMO REAR WHEEL/SUSPENSION '90-'01: ‘ N'm (OJ kgl-m, 2.9 ADM!) “I‘M: 10 N-m 11.0 kgf'm. 7 let) / 113 NW" 111.5 kgl-m‘ / // u N-m «‘5 mm. 33 mm 1 7' ‘ “z ,. . ‘ V / as an (Ln kgf-m, ,. ‘ , _ , . 29 lbw!) \ I, 1 ,7 N‘ ' " r u N-m (1.5 NM“, 33 lbf-R) 32 N-m (3‘3 kgfim. 2.111140 137 Mm (140 kgl-m, 101 Ibf-R) 65 Nm (5.5 kgf-m. 47 1M) 1 3-0 13. REAR WHEEL/SUSPENSION SERVICE INFORMATION 13-1 REAR SHOCK ABSORBER 13-3 TROUBLESHOOTING 13-2 SWINGARM 13-4 REAR WHEEL 13-3 SERVICE INFORMATION GENERAL A contaminated brake drum or shot reduces stopplnn power, Discard contaminated anon Ind clun n cunnmlnnud drum with l high quulhy brake dew-fling monk - A lack or other suppon Is requlred to suppon me vehIcle. SPECIFICATIONS Unit: mm (in) ITEM ‘ STANDARDS SERVICE LIMIT Minimum (ire (read dEplh V ‘ ———7 V 7 7 4 (0.217 Cold me pressure Standard I 25 k; {025 kgI/cm1.3.s ps7) — I Minimum 7 i; 22 kPa (0‘22 kél/c;1,3,2 nsil ¥Maxlmum 28 I}; (0428 kgf/cm7, 4.0 psi) r with 0:987 25 kPa (0.25 kgilcm1,3.6 psi) V TORQUE VALUES Rear axle castle nur Rear wheel nul Rear shock absorber lower mounllng boll/nur Rear shock absorber upper mounring nut Damper rod lock nul Swingarm lah pivot boll Swingarm ngm vaol Doll (’98- '01) (Aflar '01] Swingarm right vaot bol! lock nul Rear axle housing and swingarm nuI Skid plate flange hall TOOLS Swmgarm lock nu! wrench Remover handle Bearing remover, 17 mm Remover weugm Driver Anachrnenr. 37 x 40 mm film, 17 mm 137 N-m (14.0 kglrm, 101 IbI-fl) 84 N'm (6.5 kgl-m, 47 Ibl'h) u N-m “.5 kgl-m. 33 IbI-m as N-m (4‘0 kgf~m. 25 Ihl-h) 37 N‘m (3.5 kgI'mi 27 "2'4" n3 N-m ms kgI-mi 33 Ibf'hl 4 N-m (or: kgI-m, 2.9 IbI-m 10 N-m no kgf-m, 7 [bf-fr) 1|3 N-m (1 L5 kgIvm. 83 IBM!) 44 N-m (4.5 kgI-m, 33 Ibl-m 32 N-m (13 kgf-rn, 24 Inr-m Do noI reuse; replace MIN 3 new one. DO nor reuse; replace WIlh a new one‘ Apply a locking agent. 079084690003 079363710100 079364710300 077M»00I0201 Or 07936—371020A [U.S.Ai only) or 079363710200 (U.S.A only) 077490010000 077460010200 07746-0040400 13-1 REAR WHEEL/SUSPENSION TROUBLESHOOTING Wm M Vlbnflon In MM. - Bonl rim - Loose brake panel bearing - Faulty tlre - Axlu not lightened properly - Swinnarm bearings worn Son truncation - Weak spring Hard Won - Bent shock absorber - Improperly tightaned swingarm pivol - Faulty plvot bearing Sum nolu - Flour shock absorber damper binding - Loose lameners 13-2 REAR WHEEL/SUSPENSION REAR WHEEL REAR WHEEL REMOVAL Loosen the wheel nuts. Raise the rear wheels off the ground with a jack or block under the engine. Remove the wheel nuts and wheel. For tire removal, repair. and installation. reler to page l278. INSTALLATION Install the rear wheel with the tire valve lacing out so that the tires show a "V' pattern when viewed from front. NOTE: I . . _ :) 4- ' Do not interchange the right and left tires. ‘ " Install the wheel nuts with the curved (tapered) sides lacing inward and tighten to the specified torque. CURVED SIDE TORQUE: 64 N-m (6‘5 ltd-m, l7 "3th UPPER MOUNTING NUT/WASHER REAR SHOCK ABSORBER “Flag! REMOVAL Raise the rear wheels off the ground by placrng a jack or block under the engine. Remove the rear shock absorber lower mounting bolt. Remove the Ielt shock absorber upper mounting nut and washer, then remove the shock absorber. Discard the nuts. Remove the muIIler (page 2715). Remove the right shock absorber lower mounting bolt and nut. Remove the right shock absorber upper mounting nut and washer, then remove the shock absorber. Discard the nuts. K igggfiafin UPPER MOUNTING NUT/WASHER LOWER MOUNTING BOLT/NUT 13-3 REAR WHEEL/SUSPENSION INSTALLATION ; .. UPPERMOUNTiNG _ WASHER/”NUT ' v Position the rear shock absorber into the lrame, and install washer and the new upper mounting nut. Tighten the new upper mounting nut to the specified torque. Do not reuse the nut. TORQUE: 39 Na" (4.0 Ital-m, 29 tht) Left shock absorber: Install and tighten the lower mounting bolt. TORQUE: 44 MM “.5 kgf-m, 33 lM-fl) ngm shock lbtorhu: UPPER MOUNTING Install the lower mounting bolt item the outside. ' WASHER/a NUT |nsta|l and tighten the new lower mounting nut to / the specified torque. Do not reuse the nuts. tonouz: u um (45 kgt-m, 33 let) snocx AB BE Install the muffler lpage 2717), 503 H LOWER MOUNTING eoLT/ gNut SWINGARM REAR MUD GUARD REMOVAL Remove the (allowing: — Rear wheels (page 13-3) — Rear brake (page 1445) ~Axle shaft, axle housings and final drive (section 16) Remove the screws and retaining cllps and rear mud guards (page 2-10). ' b d w. Loosen the swrngarm oot ban sore SCREW 13-4 REAR WHEEL/SUSPENSION Remove the swingarm pivox cap (each side). Release (he breather tubes from [he swmgarm clamps, Remove the left plvol bolt usmg the commercially available lool as shown. Remove the right pivot lock nut using me special LOCK NUT WRENCH loo! as shown TOOL: Swlng-vm lock nut wrtnch 079084690003 Remove the ngm plvm ball usmg a commercially available lool, Remove the swingarrn 1mm me (tame. HEAR WHEEL/SUSPENSION 957111 98- 0! AM! ‘OV Remove the yoke [OInUdrIve shalt lrom the swmgr 3"“. INSPECTION Remove the dust seals from the swrngarmv Check the dust seals for wear or damage. Turn the lnner race a! each plvot bearing With your finger. The bearmgs should turn smoothly and qmetlv‘ Also check that the outer race ms tightly in the swingarm pivot. Replace them if necessary (see nexx page)‘ Remove the plvm heanngs lrom the swungarm, Check the dust seals {or wear or damage Turn the Inner race of each pivot bearing With your linger. The bearings should turn smoothly and quietly‘ Also check that the outer race Iits lightly m the swingarm DIVOI Replace them If necessary. YDKE JOINT DRIVE SHAFT DUST SEALS l @‘ g PIVOT BEARINGS 13-6 J v) U REAR WHEEL/SUSPENSION PIVOT BEARING REPLACEMENT Remove the swingarm pivot bearing using the special tool. TOOLS: Romavnr hundk 079301710100 marina romovcr, 17 mm 079384710300 Rcmovor weight 071010010201 or 07338-371020A (USA. only} or 078304710200 (USA. only) Drive the grease holder into the swing arm using special tools. TOOLS: Annehmlnt. 24 X 26 mm 077060010700 Drlvu 077090010000 Pull out the pivot bearing outer race using a commercially available 3/5 in X 16 sliding hummar and special tooll TOOL: Adjustable bearing puller. 25 - 40 mm 07738-A010003 Install the grease holder in the swingarm pivot. Install new pivot bearings (Altar ‘01: outer races) using the specual mnls. TOOLS: Drivor 077490010000 Amchnunt, 37 X ‘0 mm 077400010200 ’58-’01 : IF LEFT PIVOT BEARING ”\ I :‘T GREASE HOLDER 1f BEARING FULLER I I I I , ? BEARING OUTER RAC DRIVER ATTACHMENT 13-7 REAR WHEEL/SUSPENSION INSTALLATION 95' 01 Pack the grease holders and bearing cavmes wuh grease, My 01 App|y grease to the pwot hearings and dust seal hps. Install the pwct bearings Into the swrngarm pivots. GD PIVOT BEARING ' 987 01 Apply grease to the dust seal IIDS, and lnSlall the dust seals in the swmgarm USll’Ig the specual tools. TOOLS: Drlvu 01749-001000!) Anlchmlm, 37 X ‘0 mm 077‘60010200 DUST SEALS a Install the swingarm boot securely wrm us "HNO" marked tab lacing up. “HNO” MARK Apply molybdenum dusullrde grease to me drive shaft Splines and tnslall the yoke loml/drwe shaft unto the swingarm‘ \m a YOKE JOINT DRIVE SHAFT 13-8 Posmon the swmgarm In the frame by aligning the Spllfle between the lmal dnve shaft and yoke [Olntt Install and nghten the lefl pivot bolt usrng a comr merclally available tool as shown. TORQUE: 113 Mm (115 kgl-m. 83 Ibf-hl Install and hghlen the right pivot boll “Slug 3 cammermallv available tool. TORQUE: '98 — '01: 4 N-m (0.4 kgi-m, 2.9 lbl-hl After 'Ol: 10 N-m [1.0 kgl-m, 7 lefl Move the swungarm up and down several IImES. Retlghten the rlght pwol bolt to the specifieo torque [see above). Tlghlen lhe ugh: pwot lock nut Whlle holding the prDK bull usung the specxal tools as shown, TORQUE: 1‘3 N-m (11.5 kgl-m, M lbf'hl Torque wrench scale reading: 103 "mi [10.5 kgl-m, 7S lbl-flll using I 50 cm (20 in) long torquu wrench. TOOL: Swing-rm lock nut wrench 079034630003 lnstall (he swingarm DIVOI caps REAR WHEEL/SUSPENSION VOKE JOINT/DRIVE SHAFT SWINGARM PIVOT CAP 13-9 REAR WHEEL/SUSPENSION Attach the swingarm boot to the engme and tighten the boot clamp screw securelyt figure the bvaathev tubes and clamp them on the swingarm clamps, Install the tollowtng: — Final drwe, axle housings and axle (page 16-16) — Rear brake (page “-19) » Hear mudguatds (page 2-10) 4 Rear wheels [page 13-3) SCREW 13-10 i i l E MEMO BRAKE SYSTEM 0 fl 0 fl m m . m M Mm n. a. “m m w a: w m m n. M N u a u m m M N u u. 16 N-m (1.6 kqf-m.1ZIM-k) 137 N-m (".0 kgl-m. 101 Inf-fl) 29 N-m (3.0 kgl‘m4 22 lbf'fl) 78 N-m (5.0 kgf-m. 53 lel) 14-0 1 4. BRAKE SYSTEM SERVICE INFORMATION 14-1 BRAKE SHOES/WHEEL CYLINDER] TROUBLESHOOTING 14-2 ADJUSTER ”'7 BRAKE FLUID REPLACEMENT/AIR REAR BRAKE "'15 BLEEDING 14—3 BRAKE PEDAL 14.23 MASTER CYLINDER 1+5 SERVICE INFORMATION GENERAL m A cannmlnnnd buli- drum or time reduce: napping power. Dl-cud contaminated than Ind clean I contaminated drum with a high quellty broke doom-elm 0900!. CAUflON: Avoid spilling brak- lluld on palm-d, pint]: or rubbu pans. le - rug or chop tom! over then pans whenever the symm is serviced. This section covers maintenance ol the front hydraulic brake and rear drum brake systems. A jack or other support is required to support the vehicle. Once the hydraulic system has been opened. or it the brake feels spongy, the system must be bled. Do not allow foreign material to enter the system when filling the reservoir. Always use (rash DOT 3 or 4 brake fluid from a sealed container when servicing the system. Do not mix diflerent types of fluid as they may not be compatible. Always check the brake operation belore riding the vehicle. Apply multipurpose grease INLGI No.3) to the front brake waterprool seal lip. SPECIFICATIONS U"... m... (I... ITEM STANDARDS SERVICE LIMIT Front brake Drum I.D. 160.0 (6.30) 161.0 (6.34) Lining thickness 4.0 (0.16) 2.0 (0.08) Brake panel wnrpage — 0.4 (002) Brake panel seal lip wear 7 0.5 (0.02) Water seal lip length 22.0 (0.87) 20.0 (0.79) Master cylinder ID. 14.000 714.043 (0.5512 ~ 0.5529) 14.055 (0.5533) Master piston 0D. 13.957 — 13.584 (0.5495 — 0.5506) 13.954 (0.5490) Wheel cylinder ID. 19050 419.012(0.7500 - 0.7520) 19.12 (0.753) Wheel cylinder piston OD. 18.997 - 19030107479 — 0.7492) 18.81 (0741) Rear brake Drum ID. 1600 (6.30) 181.0 (36.34) Lining thickness 5.0 (0.20) To the indicator 14-1 BRAKE SYSTEM TOROUE VALUES Rear brake arm pinch ball/nut Rear brake drain bolt ('98 — ’0 ' (After ’01): Master cylinder reservoir cap screw Master cylinder holder SH bolt Brake hose nil bolt Brake panel flange bolt Brake hose clamp flange bolt Brake lever pivot bolt Brake lever pivot lock nul Brake bleeder valve Brake wheel cylinder nut Brake adjuster bolt/washer Front wheel hub castle nut Rear wheel hub nut Wheel cylinder oil pipe Brake breather hose clamp Brake hose 2-way ioint TOOLS Snap ring pliers D'War Oil seal driver Attachment. 52 X 55 mm PllDL 28 mm Attachment 62 X 58 mm TROUBLESHOOTING Front wheel wobbllng and nolu - Worn brake shoe - Loose wheel bearing Poor brake pedomum Brake not adiusted properly Warn brake shoes Brake fluid leak Water in the front brake drum Contaminated brake shoe Worn rear brake cam Warn rear brake drum incorrectly installed rear brake arm 20 N-m (2.0 kgl-m, 1t lbi-ftl 34 N-m (3.5 kgf-m. 251121-11) 12 NW! (1.2 kgl-m, 9 "#40 2 N'm (0.2 kgf-m, 1.! lbl'ft) 12 N-m (1.2 kgl-m, 9 let) 3‘ N-m (3.5 kgl-m, 25 lbt-ftl 29 N-m (3.0 kgf-m, 22 Ibl-tt) Do not reuse; replace with a new ans. ‘2 N-rn (1.2 kgl-m, 9 lbl-ftl l N-m (0.1 kgf-m, 0.7 le‘tl 6 N~m (0.6 kgf-m. ‘3 Inf-ft) 6 N~m (0.5 kgt-m. 4.3 "mm 17 N-m (1.7 kgt-m, 12 ”114!) 8 N‘m (0.3 kgl-m, 58 Ithl 7B N-m (8.0 kglrrn, 58 lbf-ftl Castle nut 137 N~ml1l,0 kgl-m, 101 Ibl-lt) Castle nut 16 N-m (16 kgf-m,12lb1-ftl 32 N-m (3.3 kgf-m, 24 lbf-ft) 15 N-m (1.5 kgI-m, 11 let) 079 1 #323000 1 077A9-00 l 0000 07965-MC70100 077‘6-0010‘00 07746-001110!) 077450010500 1 4-2 BRAKE SYSTEM BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING CAU110N: - Do mallow foreign meterini to Into! the system when filling the rmrvoll. - Avoid spilling fluid on painted, plutic. or rubber pun Piece - reg over these pens whenever the Iystern ll serviced. With the fluid reservoir parallel to the ground remove the reservoir cover and diaphragm. Connect a bleed hose to the bleed valve Loosen the bleed valve and pump the brake lever. Stop pumping the lever when no more lluid flows out of the bleed valve. BRAKE FLUID FILLING Fill the reservoir with DOT 3 or A brake fluid from a sealed container. CAUTION: Do not mix different types oi fluid, They Ire not comp-tibia Connect a commercially available brake bleeder to the bleed valve Pump the brake bleeder and loosen the bleed valve. adding lluid when the lluid level in the master cylinder reservoir is low UPPER LEVEL MARK NOTE: Check the fluid level oltan while bleeding the brakes to prevent air irom being pumped into the system‘ When using a brake bleeding tool, follow the manufacturer‘s operating instructions. Repeat the above procedure until air bubbles do not appear in the plastic hose. NOTE: ll air is entering the bleeder from around the bleed valve threads, seal the threads with Tellon tape. II a brake bleeder is not available, fill the master cylinder and operate the brake lever to lill the system, Close the bleed valve. Next. pertarm the BLEEDING procedure lpage ”-4). 14-3 BRAKE SYSTEM BRAKE BLEEDING Connect a clear bleed hose to the bleed valve. Pump up the system pressure with the lever until there are he air bubbles in the lluid flowing out at the master cylinder and lever resistance is lelt. 1. Squeeze the brake lever. open the bleed valve 1/2 turn and then close the valve. NOTE: Do not release the brake lever until the bleed valve has been closed. 2. Release the brake lever when the bleed valve has been closed. Repeat steps 1 and 2 until bubbles cease to appear in the lluid coming out at the bleed valve. Fill the lluid reservoir to the upper level. upPER LEVEL Reinstall the diaphragm and reservoir cover, and tighten the screws. YOHOUE: 2 N-l'l'l [0.2 Raf-m, 1.‘ IM‘") BRAKE HOSE/BRAKE PIPE BRAKE HOSE INSPECTION Remove the lront lender {page 2-5). Check the brake hose and brake pipe for damage and brake fluid leaks. Check the front brake breather tubes lor secure connections and damage. A disconnected breather tube means that. the Hunt brake drum can lill with water. BREATHER TUBE 14-4 MASTER CYLINDER DISASSEMBLV Remove the reservoir cover, diaphragm and float. and soak up the brake fluid lrom the reservoir. Disconnect the brake hose lrom the master cylinder by removing the bolt/two sealing washers. Fix the brake hose to prevent the limo lrom flowing OUI. CAUTION: Avoid spilling fluld on plinted, plum, or rubbol pnm. Flu;- I rug on! than pm: wit-non! the In"!!! is "wind. Remove the lront brake lever nut, pivot bolt and level, Remove the bolts from the master cylinder holder and remove the master cylinder. Remove the boot. Depress the piston and remove the snap ring from the master cylinder body, using the special tool as shown. TOOL: Snap ring pIiMS 07914»3230001 BRAKE SYSTEM BRAKE LEVER SHAKE HOSE MASTER CYLINDER MASTER CYLINDER HOLDER BOOT SNAP RING PLIERS 14-5 BRAKE SVSTEM Remove the oil seal, piston and spring, OIL SEAL Clean the inside of the cylinder and reservoir with I, V brake fluid. , SPRING Check the oil seal, piston boot, primary cup and secondary cup Ior fatigue ur damage. Check the master cylinder and piston for abnormal scratches. PISTON Q . PRIMARY CUP SECONDARV CUP INSPECTION Measure the master cylinder LD. SERVIOE LIMT: “.065 mm (0.5633 In) Measure the master cylinder piston 0.0. SERVICE LIMIT: 13.845 mm (0.5m InI ASSEMBLY OlL SEAL cnunou: " SPRIN G Keep the pleton, cum, spring, snap ring and beat uamdonotwbnmn-lndhddualplm. PISTON Coat all parts with clean brake fluid beIore assem- th. Install the spring to the piston. Install the oil seal and piston assembly. cwnou: ‘3 ~ When Installing the cups, do not allow "In Ilps to PRIMARY CUP SECONDARY CUP turn lnelde out. Instill the snap ring. p rlng la firmly uatod In the SNAP RING PLIERS 1 4-6 BRAKE SYSTEM Install the boot. / .- 0 BOOT Place the master cylinder on the handlebar. MASTER CYLINDER Install the mastet cylinder holder with the “UP” mark lacing up. Tighten the upper bolt first, then tighten the lower bolt loosely. YOfiCtUE: 12 N-m ".2 Itg1-m. 9 lbl-fl) Align the end of the mastev cylindal With the punch mark on the hendlehart Tighten the lower bolt. TORQUE: 12 MM [11 Ital-m, 9 “5”!) "UP" MARK HOLDER Install the brake hose between the stoppers with the bolt and new sealing washers. BRAKE LEVER BRAKE HOSE TORQUE: 3‘ Mn! (35 lint-m. 25 lhf-hl Install the brake lever. Install and tighten the pivot boll. TORQUE: 1 NW! (0,1 kgf-m. 0.7 lbl-hl Hold the pivot bolt and tighten the nut, TORQUE: 6 Man (0.6 kuf-m. 4.3 IM-hl Fill the reservoit to the upper level and bleed the brake system (page NJ). BRAKE SHOES/WHEEL CYLINDER/ ADJUSTER DISASSEMBLY Remove the following: — Front wheel (page 12-8) ~ Bolts 7 Blake drum 1 4-7 BRAKE SVSTEM Measure the brake drum LD. SERVICE UMIT: 161 mm (5.34 In) Remove lhe following: - Wheel hub and O-ving — Dust seal For from brake waterproof seal inspection/replace— ment, see page 14~1L Measure Ihe brake lining thickness SERVICE UMIT: 2.0 mm (0.08 In] FD! brake panel inspection, see page "-10. For brake panel inspection, see page “~10. V , PINS/PIN HOLDERS "/ Remove the [allowing . / ~ Pins — Pin holdels erk the brake — Brake shoes and shoe springs shoes '0 Uldlclll their miginar Positions. SHOE SPRINGS Remove the cone! pin and hub nut. ' CUTTER PIN Remove the wheel hub. ' WHEEL HUB 11' 14-8 BRAKE SYSTEM Drain the brake fluid (page 14-3). HOSE BOLT/SEALING WASHERS Remove the following: — Brake hose by removing lhe brake hose boll — Breather lube from brake panel — Brake panel bolts and hrake panel — O»ring CAUTION: Discard the panel bum. Do nut msn the panel bolts Mum their threads m lpocially dry-mud In! waterproofing. BRAKE PANEL Loosen the joinl nuls and remove me brake piper Remove the wheel cylinder assembly A and B by removing the bells and nuts. Clean any sealanl malarial lrom the cylinders, balls and brake panel. VI WHEEL CYLINDER A n) 1 4-9 BRAKE SVSTEM WHEEL CVIJNDERIADJUSTER INSPEC‘HON Disassemble the wheel cylinder assembly A and 8. |nsaect the wheel cylinder bore and piston lor scoring or greaving. inspect the piston cup and piston boot for wear or fatigue. inspect he adjuster body and adjuster nut tor wear or damage. Check the lock spring for fatigue or damage. Measure the wheel cylinder LD. SERVICE LIMIT: I9t12 mm (0.753 In) Measure the wheel cylinder piston 0.0. SERVICE LIMIT: [8.81 mm (0.741 In) FRONT BRAKE PANEL INSPECTION Remove the wheel hub from the brake drum and temporarily install the hub on the axle shalt, Tighten the axle nut securely. Install a suitable steel plate to the wheel hub and tighten the plate with the wheel nut securely. Clean any grease item the brake panel. M Green on the brake llnlnys reduces ltopplng power. Keen gum all the Ilnlngl. Measure the brake panel on the points attached to the waterpreol seal lip lor warpage as shown. using a dial indicator. SERVKZ LIMIT: 0.4 mm (0.02 In! Replace the brake panel iI warpage is greater than the service limit, ADJUSTER Q; i» PISTON CUP BOOT U LOCK SPRING BRAKE PANEL STEEL PLATE AXLE NUT WHEEL HUB 14-10 BRAKE SYSTEM FRONT BRAKE WATERPROOF SEAL INSPECTION Check the waterproof seal for damage. latigua or laulty installation. Measure the front brake waterproof seal lip length. SERVICE LIMIT: 20 mm (0.19 In) FRONT BRAKE WATERPROOF SEAL REPLACEMENT Remove the waterprool seal lrom the brake drum by prying open the seal edge. Remove the wheel hub. CALCULATE THE CLEARANCES BETWEEN THE DRUM AND SEAL Measure the drum and seal at a, b, c and d as shown, Calculate the clearances A and 3 between the drum and seal. A- a — c B: d — b Anply water to the entire new waterproal aeal. Place the waterprool seal on a clean surface plate, and press the brake drum into the waterprool seal. making sure that the clearances between the seal and drum will reach the calculated clearance (we previous step). CAUTION: - Prm the mm onto the an] evenly, lo the lips will not be damaged. I! m. ml Ia damaged or mla-lnetalled. removeltandtryagaln wltlu new ml - PI alaal plat bout "0 mm (5.5 in) in dlamata and more than 10 mm (0.4 In) In tIrIdrrrml on the brake turn, or the brake turn will be warped or damaged. Dry the seal thoroughly and pack the lips cavily with multipurpose grease (NLGI No.3) as shown. AMOUNT OF GREASE: 14 -16 910.5 - 0.6 all m—_ Dnnotapplypremtommmolmbnh drum. Grease on tha Innar surface olchrm reduces napping power. Keep grease on ma drum. WATERPROOF SEAL BRAKE DRUM BRAKE DRUM T‘ A e Ti“— b B — .1 C fir SEAL BRAKE DRUM APPLV WATER SURFACE PLATE APPLY WATER DO NOT DAMAGE DO NOT APPLY GREASE .‘l (NLGI No.3) 14-11 BRAKE SYSTEM ASSEMBLV f 17 N-m (1.7 kgI-m. 12 lbl-ll) ®@ a N-m (0.3 kgbm. 5.8 IbI-le Q ®© SHOE RETAINER PIN WHEEL CVLINDER A 8 BRAKE PIPE 5 spam G Chg @ ERAKE snos ‘ 9 V BRAKE PANEL WHEEL CVLINDEH B SHOE RETAINER Clean ell parts, excluding the boots, tharuughly with ADJUSTER BOOT BRAKE FLUID only. Blow out passages with compressed eir. Install the plstons Into the wheel cyllnder body without ellowlng the Ilpe to turn Inside out Install the boots on the cylinder body. ”51-0” Apply silicone grease to the adiuster nut. Install the adjuster nut. screw end lack Iprlng on the edluster body. A I 6‘ LOCK SPRING Apply Ioellnt to the cylinders mounting locations r.“ on the bre e panel. v 14-12 BRAKE SVSTEM lnstall the cylinder assembly A and B, and tighten WHEEL CYLINDER E the bolts, washers and nuts. TORQUE: 6 mm bolt: 8 N-m (03 kul-m, 6 lbl-ftl 3 mm nut: 17 MM (1.7 kul-m,12IM-ft) Install the brake pipe as shown by tightening the NUTS jaunt nuts. A' r' TORQUE: 18 N-m [1‘6 Hal-m. 12 lbl-hl lama PIPE Install a new O-ving on the knuckle, ' OVRING v |nstal| Ihe front brake panel assembly and tighten the new brake panel balts, YOROUE: 29 N-m (3‘0 Ital-m. 22 Ibl-ltl CAUTION: Discard the uudpmal balm Do not nun m. panel Dom bmuu than threads In spatially drymtod In! waterproofing. Apply silicone grease on the metal contact area indicated. BRAKE SVSTEM Install the brake hose to the cylinder assembly A HOSE sou/a SEALING WASHERS _ and tighten the brake hose bolt with new sealing " " ' ' washers. TORQUE: 3‘ Na“ (3.5 tot-m, 25 lbl-fl) Securely install the breather tube to cylinder assembly A, NOTE: Route the brake hose between the stoppers. Install the wheel hub and tighten the hub nut to the spec-lied torque, TORQUE: 7B N-m (8.0 ltqf~m. 58 Ibl-fll Install a new cotter pln. Face the nuns: Install the brake shoes in their original positions with «1995 01"" 50095 the shoe springs as shown. to mecylmdar. Apply oil to the tension pin seals. Install the tension pins. tension pin seals, seal caps and pin holders, m_— - Donotgetgnmonthobruadrumouhmor uopplng power will be reduced. - Din-rd contamlnlnd than And clun l tontlmlnund drum WI": 1 high qlnllty huh demo-slug calm. ' ’ .1 BRAKE SHOES/ ’ _—— - SPRINGS Seat an O-ring carefully in the brake drum. O-RING 14-14 BRAKE SYSTEM Install the brake dtum. ‘4 NOTE: . Make sure the waterprool seal lip is packed with multipurpose grease (NLGI N03) (see page H- 11). AMOUNT OF GREASE: ‘ll — 16 g (0.5 , 0.6 01), L Make sure any grease is cleaned elf the inside of the brake drum and brake shoe. V Install and tighten the wheel hub mounting bolts. TORQUE: 10 N-m (1.0 Ital-m, 7 lbl-ltl Apply grease to the dust seal and install it in the wheel hub. Fill the reservcur to the upper level with new brake fluid (page 1&3)‘ Bleed the brake system (page 1L4), Install the front wheel (page 12-3). Adjust the brake (page 347), REAR BRAKE : coma Pm REMOVAL/DISASSEMBLV Remove the following: — Right rear wheel (page 13-3) — Right rear axle nut and wheel hub (page 1673) L WHEEL HUB Remove the bolts and brake dtum cover. BRAKE DRUM COVER 14-15 BRAKE SVSTEM Remove me brake drum cover O-ring. Remove [he brake dlum. BRAKE DRUM Measure the brake drum I‘D. SERVICE LIMIT: 1511) mm (6.31 In) Inspect the brake drum Ior scoring. cvacks and out of mundness, Check the brake drum cover dusl seal for weal or DUST SEAL damage‘ Drive il out of the drum cover iI necessary. For the installation aflhe dust seal, see page 14-22. Remove the make cables from (he brake arm. BRAKE ARM 14-16 Remove the (allowing: BRAKE SHOES/ — Cotter pin SPRIN — Washer — Brake shoes and shoe springs NOTE: Mark the brake shoes to indicate their original positions belore removing them, Remove the lollowing: — Brake arm pinch bolt/nut — Brake arm — Return spring — Indicator plate — Brake cam — Felt seal < Dust seal Remove the brake panel nuts and brake panel. Discard the brake panel nuts‘ Remove the O-ring. BRAKE SYSTEM BRAKE PANEL BRAKE SVSTEM Tum tha innar rm 0' the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the outer race at the belting fitt tightly in the brake panel. Raplaea ll nmmvy. Check the dust seal for wear or damage. Remove the dun sul. Remove the map ring. Drlva the baring out of the brake panel. Drlvn the new bearing into the brlka panel with it: named tide fixing out (facing tho axle housing) using the Ipecial tool: I: Ihown. TOOLS: Driv- on‘mmooo Amen-mm. 52 X 55 mm 077M104“ PM 28 mm onus—mum 14-18 CCC BRAKE SYSTEM Install the snap rlng inlo the groove socurely. ASSEMBLV/INSTALLATION zo N-m (2.0 kgf-m. u two DRUM covea mmcm’on PLATE RETURN spams ‘2? , . BRAKE CAM BRAKE ARM I BRAKE DRUM ‘8 O SHOE BRAKE PANEL 3‘ N-m (3.5 kgf‘m, 25 (bf-ft) Pack tho dust saal lip with grease and install It in DUST SEAL the panel with the lip facing up using the special lools. Align the upper surfaces ml the dust seal and braka panel. TOOLS: 01W" «1149-0010000 Amman-m. 62 X 60 mm 0776401“ BRAKE SVSTEM Install an Owing In the brake panel groove securely. Tnghten the brake panel dram boll I! removed. TORQUE: ‘93 - ’01: 34 N-m [3.5 hut-m, 25 tht) Mu! ’01: 12 Ntm (1,2 kgl-m, 9 lbl-h) Install the brake panel onto the axle shaft. Install and ughlen the new nuts to the spectfted torque. Do not reuse the nuts. TORQUE: 44 Null (‘5 Ital-m. 33 IM-h) Apply grease to the dust seal, Apply OII to the felt seal. Install the dust seals and fell seal. Apply grease to the anchor pIn and brake cam. Install the brake cam lrom the outside E PANEL .A ERAK DRAIN BOLT FELT SEAL BRAKE CAM 14-20 BRAKE SYSTEM Install the veturn spring and then install the indicator , RETURN SPRING plate, aligning the wide tooth on the plate with the " t wide groove on the brake cam. Install the brake arm, aligning the punch marks on BRAKE ARM the brake arm and cam Hook the return spring and onto the brake arm. Tighten the brake arm bolt. TORQUE: 20 MM (2.0 Ital-m, M Ibl-h) Instal the make shoes in their original positions with the spring as shown. M Eonumlnnod but. lining: "duet stopplng pow-Iv Kup gm» all (In lining; wipe execs groan of! th' elm. Install the anchor pin washer with its chamlered side (rolled Edge side) facing in. Install new cotter pins as shown. 14-21 BRAKE SYSTEM Install the brake cables to the brake aim. Apply grease to the brake drum splines. Install the brake drum. Install a new O-ving onto the brake panel. BRAKE DRUM Apply grease lo the dust seal lipt Oll. SEAL DRIVER‘ Install a new dust seal into the dtum covet usan the special tool as shown. TOOL: OI| sell drive: 07365 22 N‘m [2.2 kgl'm, 16 IbI-h) 15-1 FRONT DRIVING MECHANISM SERVICE INFORMATION GENERAL 1 Replace all oil seals and O-rings whenever the Iront differential assembly is disassembled, - Check the tooth contact pattern and gear backlash when the lront differential hearing. gear set end/or gear case are replaced. Mn! '01: - Replace the ring and pinion gears as a set. - Replace the cam lollowers (12 pieces) as a set, and the cam tollawers, lace cams and differential housing halves as an assembly il the lace cam. ditlerential housing or up Is faulty. SPECIFICATIONS ('98 - ’01) Unit: mm (in) ITEM ‘ STANDARDS SERVICE LIMIT Oil capacity ( After draining 190 cm: (6.1 US 01, 6.7 Imp oz) —— l At disassemblv . 200 cm3 (6.8 US 02, 7.0 (mp 01) —— Recommended oil Hypoid gear oil SAE #80 — Clulch spring lree height 2.65 (0.10‘) 2.5 (0.10) Clutch disc thickness TA 2.7 - 2.8 (0.106 ~ 0.110) 2.4 (0.09) E 2.3 ~ 2.. (0.091 — 0.090) 2.1 (0.08) Pinion geafw. 12.000 — 12.013 (0.4724 — 0.4731) ‘ 12.05 (0.4741 Pinion gear shalt OD. ”.973 V 11.98! (0.47" — 0.3710) 11.75 (0.163) Slip torque 17 — 25 N-m (1.7 — 2.5 kgf-m, l! -18|bt-lt) Gear backlash 0.05 — 0.30 (0.002 — 0.012) 0J0 (0.016) SPECIFICATIONS (After '01) Unit: mm (in) ITEM i STANDARDS sanvtcs um Oil capacity Alter draining 2A1 cm3 (6.2 US 01. 5.5 Imp oz) —— At disassemblv 275 cm3 (9.3 US 01. 9.7 Imp oz) — Remmmended ail Hypuid gear oil SAE #80 —— Gear backlash 0.06 - 0.25 (0.002 - 0.010) 0.4 (0.01) Backlash difference — 0.2 (0.01) Slip torque I 14 — 'I7 N-m (1.45- 1.75 kgl-m.10—13lbf'fll 12 N-m (1.2 kgt-m. 9 Ibl-ltl Face cam-to—housing distance 6.3 - 6.7 (0.25 — 0.26) 6.3 (0.25) Diflerential housing can depth 9.55 - 9.05 (0.370 — 0.330) 9.55 (0.376) Cane spring rm height 2.8 (0.11) l 2.6 (0.10) 1 5-2 FRONT DRIVING MECHANISM TORQUE VALUES Differential case mounting bolt, 10 mm 44 N-m (4.5 kgf—m. 33 Ibf-ft) 8 mm 22 N'm (2.2 kgf-m, 16 lbftft) Differential case cover flange bolt, 8 mm 25 N-m (2.6 kgf-rn, 19 (bf-ft) 10 mm 19 N-m (5.0 kghm, 36 Ith) Apply a locking agent. Pinion ioint nut (’98 — ’01) 108 N-m (11.0 kgf-m. 80 Ibf-ft) Apply a locking agent. Pinion bearing lock nut (’93 — ’01) 98 NW" (100 kgf-rn. 72 lbf-ft) Differential gear case drain bolt 12 N-m (1.2 kgf-m, 9 Ibf-ft) Differential gear case cover oil cap 12 N'm (1.2 kgl-m, 9 Ibf-ft) Differential case cap Torx bolt ('98 — '01) 32 N-rn (3.3 kgf-m,21lbf-ftl Replace with new ones. Differential case USE bolt ('98 - ’01) A9 N-m (5.0 kgf-m, 36 Ibf-ftl Differential ring gear bolt (After '01) O9 N-m (5.0 kgf~m, 36 MO") Replace with new ones. Speed sensor mounting bolt (After '01) 10 Mint (1.0 kgf-m, 7 let) Final clutch speed sensor mounting bolt (After '01) 10 N-m (1.0 kgf-m, 7 lbf-ft) Final clutch mounting bo|t (After '01) 25 N-m (2.6 kgf-m. 19 lbf-h) Final clutch cover bolt (After ‘01) 9 N-m (0.5 kgf-m. 7 Ibf-ftl TOOLS Differential inspection tool 07KMK-H050101 or 07KMKvHCSO1OA (U.S.A. only) Pinion holder (’98 — '01) 07SMB-HM70200 Lock nut wrench. 30 X 54 mm ('98 - '01) 07916-MBOW02 or 0791EM300001 Pinion puller set (‘98 — '01) 07HMC-MM80101 not available in U,S.A. — Shaft puller 07931-ME40000 or 07931-ME40103 and 07931-H33020A (U,$.A. only) — Pinion puller base 07HMC-MM80110 or 07HMC-MM8011A (USA only) Driver attachment (‘98 - ‘01) 07965-KE80200 Ball jaunt remover, 28 mm 07MAC-SL00200 Driver 07749-0010000 Attachment, 52 X 55 mm 077450010400 Pilot, 25 mm 077460041100 Driver. 40 mm ID. ('90~ '01) 07746w0030100 Driver, 22 mm 1.0. (After '01) 0770647020100 Attachment, 25 mm ID. ('98 - ‘01l 077060030200 Attachment, 15 mm ID. (After '01) 077460020200 Film. 15 mm (After ‘01) 077490000300 Pilot. 14 mm (After ’0” 07745-0041200 Attachment, 22 X 2‘ mm (After '01) 07745-0010800 Attachment, 30 mm (D. (After ‘01) 0770600303100 Oil seal driver (After '01) 07965-KE50100 Adjustable bearing puller (After '01) 07JAC-PH80101 Remover shaft (After ‘01) 07JAC-PH80200 Sliding weight (After ‘01) 07701-0010201 1 5-3 FRONT DRIVING MECHANISM TROUBLESHOOTING Consistent noise durlng cruising Oil level too low - Foreign matter contaminating gear oil - Improper tooth contact between ring gear and drive pinion Worn or damaged ring gear hearing Worn or damaged ring gear and drive pinion Worn pinion shaft or pinion gear side washer Deformed ring gear or differential case Chipped or damaged gears Gear noise: while running ~ Oil level too low 4 Foreign matter contaminating gear oil - Chipped or damaged gears - Improper tooth contact between ring gear and drive pinion Gear nolm while ooutlng - Damaged or chipped gears Bearing noise: while running and mutlng - Cracked or damaged drive pinion bearing or ring gear Abnormal nolul when turning ('98 - ‘01) - Worn iexcessive play) or damaged ring gear bearing - Damaged side gear. pinion or pinion shalt - Worn clutch disc/plate - Worn clutch spring - Worn or damaged slots of me differential housing Abnormal noiua when tumlng (After ’0" r Worn or damaged ring gear bearing ' Worn or damaged lace cam and cam follower - Worn or damaged differential housing groove - Worn cone spring or shim Abnormal not“: at nan or during acceleration -Excessive backlash between ring gear and drive pinion Excessive pinion gear backlash Worn di erential splines Loose pinion joint nut ('98 - '01) and other fasteners Worn clutch disc/plate {’98 — '01) Worn clutch spring ('98 ~ ’01) Worn cone spring or shim (After '01) Oil leak - Oil Ievelteo high - Clogged breather hole or tube - Worn or damaged oil seal - Loose differential cover oolt Overhutlng ~ Oil level too low - Insufficient backlash between ring gear and drive pinion 1 5-4 CCC i i I 1 i FRONT DRIVING MECHANISM FRONT DRIVE SHAFT REMOVAL Remove the (allowing: — Front wheel (page 12-3) , Front brake drum (page 1477) - Cotter pins Loosen the castle nut. but do not remove It. Separate the knuckle from the lower suspension arm. according to the page 1244 instructions. TOOL: Ball laint remover, 28 mm OTMAC-SLOOZDO Remove the castle nut. Disconnect the breather tube from the brake panel. Separate the knuckle/brake panel assembly from the drive shaft. CAUHON: Support the knuckle/brake penal monthly so that it do“ not lung from the brake hm. Do not twkt the brake hon. NOTE: Do not operate the trout brake lever alter removmg the knuckle/brake panel assembly. It you do ut, the pistons are pushed lrorn the cylinder. Pry the driveshalt assemhly with a screwdriver to lorce the set ring at the driveshah and past the groove. Hold the inboard joint as shown and pull the dnve shalt out of the dilterentlal. CAUTION: To prevent damage tn the diflerential all seal. hold the Inboard iolnt harlzantnl until the drive shaft is clear a! the dllhrontlal. it straight to avoid damning the differential oll seal. Us: can when prying out the nun-My, and pull COTTER PIN/ CASTLE NUT BREATHER TUBE BALL JOINT REMOVER KNUCKLE . E lNE/OARD JOINT J 15-5 FRONT DRIVING MECHANISM INSPECTION Check the boot Ior cuts or other damage; replace it necessary. Check the drive shalt ioints Ior excessive play or noise by moving the joints in a circular direction. lithe outboard joint seems to be worn or damaged, the drive shaft must be replaced. To service the inboard joint. Ioliow the DISASSEMBLY steps below. DISASSEMBLV NOTE: To replace the outboard boot, first remove the inboard boat as described In these steps. Then remove the bands and pull the outboard boot off the inboard end of the shaft. Loosen both boot bands on the inboard side, and remove boot band A. Pull the boot on the inboard joint. Remove the stop ring and inboard joint. NOTE: The outboard ioint cannot be disassembled. Remove the snap ring and bearing. Remove the boot band B and pull the boot off the drive shaft. NOTE: Replace the bands with new ones whenever removing them. OUTBOARD BOOTS BOOT BANDS INBOAHD INEOARD BOOT STOP RING INBOARD JOINT ‘ BEARING SNAP RING 15-6 FRONT DRIVING MECHANISM Check the following (or wear or damagel BEARING CAGE — Bearing cage — Bearing Vacs ~ - Steal balls BEARING RACE STEEL BALL L ~ Inboard join! INBOAHD JOINY NOTE: Replace the bearing cage‘ bearing race. steel bans ¥ and inboard join! as an assembly‘ ‘- , ASSEMBLY DRIVE SHAFT OUTBOARD BOOT BEARING INBOARD 800T 15-7 FRONT DRIVING MECHANISM NOTE: The boms are marked 'BJGBL“ for the outboard join! and "BJSE' Ior ma inboard joint. II the outboard boot was removed. insrall ir on the drive shah with a new boo! band B (1 pieces). Install xhe inboard boot with a boot band B‘ Do nor lighten Ihs bands at this lime‘ NOTE: Now (he direcrion 01 (he boot bandsr Install the bearing race in me bearing cage as shown. 'BJSB" MARK '6J68L" MARK INBOARD BOOT OUTBOARD BOOT BOOT BAND 8 OUTBOARD BOOT FORWARD DIRECTION BOOT BAND WIDE LD, SIDE BEARING RACE BEARING CAGE FRONT DRIVING MECHANISM Push the steel balls into the bearing cage‘ STEEL BALL Install the bearing an the drive shaft with the small SNAP RING end of the bearing lacing the inside ol the drive shaft. Install the snap ring securely in the groove of the drive shaft Apply molybdenum disulfide grease to the bearing STOP RING and inside of the inboard joint. Install the inboard joint to the drive shaftl Inslall the stop ring in the joint groove. Pack the boots with molybdenum disulflde grease and pull them on the joints. GREASE CAPACITV: Inboard boot: 40-60 5 (1.4-10 ozi Outboardboot: 30—50 a ".1 - 1.1 oz) (m BOOT FRONT DRIVING MECHANISM Adjust the length olthe drive shaftta the (guts given below, DRIVE SHAFT LENGTH: Rlcht : 342 — 352 mm I115 - 13.9 in) Loft: 382 - 382 mm (15.0 —15Jlnl Install the bands wllh their tabs faclng tearwatd. Secure the new boat bands as follows: 1, Bend down the tab 0! the boot band. 2, Secure the bent down tab With the locking clips and tap them with a plastuc hammer. Install a new step nng in the groove on the Inboard jmnt. Apnlv molybdenum disullida grease to the splines ol the lnboam jaunt. INSTALLATION Install the dnve shah In the dlflerenual whlle holding the inboatd IOII'IL After installlng, pull the jaunt a IIIIIE to make sure that the stop ring IS locked m the differential Slde gear groove, CAVITV LOCKING CLIPS ”STOP RING v : Y -' INBOARD JOINT 15-10 FRONT DRIVING MECHANISM Install the knuckle/brake panel assembly. Tighten the castle nut to the Specified torque. TORQUE: 29 N-m [3.0 an-m, 22 IbI-h) Install a new cotter pins Connect the breather hnser lnstall the Iollowrng: - Front brake drum (page 14-15) — Front wheel [page 12-3) FRONT DIFFERENTIAL Alla! 01 '95 - '01 REMOVAL Dram the front differential ml (page 3-!3) Disconnect the Iollowmg connectors: v Iront Iinal clutch speed sensor - meter speed sensor - Iront final clutch Remove the Iollowlng: A All venl hose - One Iront dI‘IVE shah (page 15-3) , Front Iender (page 26) Remove the bolt, retaining CIIDS and propeller shaft caver, Remove the following: - Upper mountmg nut, bolt and collar - Front dIerrennal maunnng bolt and nut ~ FVOTII differential mounting bracket bolts and bracket BREATHER HOSE CASTLE NUT/vu COTTER PIN FRONT FINAL CLUTCH SPEED SENSO CONNECTOR FRONT DRIVING MECHANISM — Rear mounting bolt Push the iron! diflerential forward. Pull the propeller shalt jomt forward. then separate the propeller shah lrom the engine. Remove the propeller shalt [mm the Iron! differentiall Remove the front differential. Separate the other drive shaft horn the drflerential as you lemons it. INSPECTION PROPELLER SHAFT DUST aoor 3 Remove the dusl bum‘ Check the propeller shaft lor wear or damage. Check the dust seals for wear or damage. replace if necessary. 95- 07 Turn the drfleremial drive pinion [Olnl With your finger: It should turn smoothly and quietly‘ 15-12 FRONT DRIVING MECHANISM After or Install and hghten the 6 mm bolt on the drive pinion, DRIVE PlNION V 5/51 The 5 mm bolt III/Ill [wit the b mfieIenIraI so It can be Inspected 6 mm BOLT ‘ Alter DI Turn the 6 mm bolt on the drive pinion and check that the gear turns smoothly and quietly without bindmg. Inspect the following ll the drive pinion does not turn smoothly and quIetly. — Dullerentlal case - Ring gear bearings - Drive pinion - Ring gear Proceed with the detailed Inspectron procedures that follow and replace faulty parts/assemblies as required. I Remove the 6 mm holL BACKLASH INSPECTION ('98 - '01) DIFFERENT,“ CASE Remove the oil filler cap. Set the differential case In a vise and hold the pinion joint as shown. TOOL: Pinion joint holder 07SMfl-NM70200 L Set a horizontal type dial indicator on the ring gear, PiNIDN JOINT through the ml liller hole. Install the difierential inspection attachment into the rlghl side 0' the dellerential gear and rotate the dlflerentlal assembly/ring gear by turning the dIfferential inspection tool by hand until gear slack . is taken up. Turn the ring gear back and (0th to read the backlash STANDARD: 005 - 030 mm (0302 - 0.0121") SERVICE LIMIT: 010 mm (0.018170 b TOOL: ' Din-until! inspection tool 07KMK-HCW101 or ‘ 07KMK-NC5010A lUtStAt only) |NSPECT|0N TOOL 15-13 FRONT DRNING MECHANISM Remove the dial indicator. Turn the ring gear and measure the backlash. Repeat this procedure once more. Compare the difference of the three measurements. DIFFERENCE 0F MEASUREMENT SERVICE LIMIT: 0.25 mm (0.0“) in) If the difference in measurements exceeds the limit it indicates that either the bearing is not Installed squarely, or the case is deformed. Inspect each hearing and case. If backlash is too small, repIace the ring gear left side spacer with a thicker one. Backlash is changed by about 0.06 mm (0.002 in) when thickness of the spacer is changed by 0.10 mm (000‘ in). RING GEAR SPACERS: Twenty-three lowers lfrorn A to W). are an ble In thlckneu Intervals of 0.05 mm. - Standard: 100 mm (0.039 In) - Thinnest 0.50 mm (0.020 In) - Thickefl: 1.00 mm (0.063 In) Replace the right side spacer with a spacer that is the opposite thickness of the new left side spacer. For example. if the left spacer was replaced with a 0.10 mm (0.004 in) thicker spacer. repiece the right spacer with one that is 0.10 mm (0.004 in) thinner. BACKLASH INSPECTION (After ’01) Hold the pinion gear with the 6 mm bolt. Set the differential case into a jig or Visa wrth soft jaws. Install the differential Inspection tool into the right side of the differential. YOOL: leferential inspection tool 01KMK-H650101 or 07KMK-H05010A IU.S.A. only) Remove the oil filler cap and set a horizontal type dial indicator on the ring gear through the finer hole. Turn the ring gear back and forth to read the backlash, STANDARD: 0.05 - 0.25 mm (0.002 — 0.010 In) SERVICE IJMIT: 0.4 mm (0.02 In) Remove the dial indicator. Turn the ring gear 120° and measure the backlash. Repeat this procedure once more. Compare the difference of the three measurements. SERVICE LIMIT: 02 mm (0.01 In) RIGHT RING GEAR SPACER LEFT RING GEAR SPACER INSPECTION TOOL 15-14 II the dilferance in measurements exceeds the service limit, it indicates that the bearing is not installed squarely, or the case is detormed. Inspect the bearings and case. ll the backlash is excessive, replace the ring gear left side shim with a thinner one, II the backlash is too small, replace the ring gear left side shim with a thicker one, Backlash changed by about 0.06 mm (0.002 in) when thickness of the shim is changed by 0.") mm (0.004 in). NOTE: FRONT DRIVING MECHANISM - Shims are available in 23 diflerent thicknesses, from 050 mm (shim A) to 1.80 mm (shim W) in increments of 0.05 mm. fllng near shims: A (thinnestl: 0.50 mm [0.020 Inl- K: (standard): 1.00 mm (0.039 In) — W: lthlnnletl: 1.00 mm [I363 lnl - Replace the right side spacer with a spacer that is the opposite thickness at the now left side spacer. For example, if the left spacer was replaced with a 0.10 mm (0.00: in) thicker spacer, replace the right spacer with one that is 0.10 mm (0.0m in) thinner. DIFFERENTIAL CASE DISASSEMBLV ('98 — '01) Remove the cover bolts in two or three steps in a crisscross pattern ta prevent differential case warpage. Carefully prv the cover oil the case using a screw- driver at the pry points as shown. 10 mm BOLTS 3 mm BOLTS PRV POINTS FRONT DRIVING MECHANISM Remove the diflerenllal assembly and the adjusl- DIFFERENTIAL ASSEMBLV ment spacers from the dlflerenllal case. - RING GEAR SPACERS DIFFERENTIAL CASE DISASSEMBLY COVER (After '01) Remove the [mks and fina| clutch cover. BOLTS ' Disconnect the final clulch connector‘ V Remove the bolls. slay and meter speed sensor. CONNECTOR STA SPEED SENSOR Remove the bolls, cover and Iran! final clutch speed BOLTS COVER sensor. . FRONT FINALVELUTCH SPEED SENSOR 15-16 FRONT DRIVING MECHANISM Remove (he final clutch mounting bolts and final clutchl FINAL CLUTCH Remave the cover bolts m a cnsscrcss pattern in BOLTS several steps. Pry the cover at the prying points using a screwdriver and remove me case cover. Remove the diflerential assembly and shims‘ DIFFERENTIAL ASSEMBLY FRONT DRIVING MECHANISM BEARING INSPECTION Turn the inner race of each ring gear bearing with your finger. The bearings should turn smoothly and quietly. Also check that the outer race firs tightly in the case and cover. Remove and discard the bearings if the races do not turn smoothly and quietly, or H they fit loosely in the ease or cover. For ring gear bearing replacement, go to page 15-30. For drive pinion removal and disassembly, go to page 15-27. GEAR TOOTH CONTACT PATTERN D'FFERENTIAL ASSEMBLV CHECK ('98 - '01) Install the original ring gear spacers onto the differential assembly. RING GEAR SPACERS Apply a thin coat cI Prussian Blue to the pinion gear Apply pm” n Blue teeth tor a gear teeth contact pattern check. Clean all sealing material off the mating surfaces of DIFFERENTIAL ASSEMBLV'W r» - the differential case and covert I NOTE: - Keep dust and din out DI the diflerential case‘ - Be caralul not to damage the mating surlace. Install the difierentiel assembly with the spacers into the differential case. SPACERS 15-18 Tighten the cover bolt: in two or three steps until the cover evenly touches the gear case. Then. while rotating the drive pinion, tighten the bolts to the specified torque in two or three steps In a crisscross pattern. TORQUE: 10 mm bolt: ‘3 "ml (5.0 Ital-m. 36 I014!) 0 mm bolt: 25 N-m (2.6 Irwin. 19 lM-ft) CAUTION: h in Important to turn the plnlon while tightening the bolts. I! the ring any spacer la too thick, the pun wlll lock that only Ilght tlphmnlng Remove the oil filler cap lrorn the differential case. Rotate the ring gear several times in both directions of rotation. Check the gear tooth contact pattern through the oil Iiller hole. The pattern is Indicated by the Prussian Blue applied to the pinion before assembly. Contact is normal if the Prussian Blue is transferred to the approximate center but slightly to the heel side of each tooth and to the flank side. It the patterns are not correct. remove and replace the pinion spacer with one of an alternate thickness. Replace the pinion spacer with a thicker one it the contact Is too high, toward the lace. Replace the pinion spacer with a thinner one if the contact is too low, to the flank side. The pattern will shift about 0.5 — 1.0 mm (0.02 — 0.04 in) when the thickness of the spacer is changed by 0.12 mm [0.005 in). PINION SPAQRS: L: 1.64 mm (0.064 in) C: 1.90 mm [0.076 In) M: 1.70 mm (0.007 In) D: 1.00 mm [0.079 In) N .76 mm [0.009ln) E: 2.06 mm [0.001 In) A mm (0.072 In) F: 2.12 mm [0.003 Inl B .88 mm 10.074 In) 6: 2.18 mm [0.000 inl For pInion spacer replacement. go to page 1517. FRONT DRIVING MECHANISM 10 mm BOLTS 8 mm BOLTS TOE HEEL/TOE \ HEEL [9 Q1 ‘ DRIVE COAST SIDE SIDE TOO HIGH: FACE DRIVE SIDE 1/ i SPACER COAST SIDE TOO LOW: FLANK I Q % 'FLAN DRIVE SIDE COAST SIDE 15-19 FRONT DRIVING MECHANISM K690 dust and am am of In. case and cover It :5 important to turn the pawn Mule tightening the bolts II the Img gear shim I5 I00 Mick. the gears will lock after only light Ilghfamng GEAR TOOTH CONTACT PATTERN CHECK (After ’01) Install the final clutch and tighten the final clutch mounting bolts. TONGUE: 25 NM! (2.6 Ital-I11, 19 Ibf-fl) Clean sealing material offthe mating surfaces of the differential case and cover, being careful not to damage them. Apply a thin coat of Prussian Blue to the pinion gear teeth for a tooth contact pattern check, Install the ring gear shims onto the differential assembly. Install the differential assembly into the gear case. Install the case cover and tighten the bolts in several steps until the cover evenly touches the gear case. Then, while rotating the pinion gear, tighten the bolts to the specified torque in a crisscross pattern in several steps TORQUE: 10 mm bolt: 49 N-m l5.0 kgf‘m, 36 Ibf-f!) 8 mm bolt: 25 N-m (2.6 kgf'm. I9 Ibf-ft) Remove the oil filler cap Rotate the ring gear several times in both directions of rotation Check the gear tooth contact pattern through the oil filter hole. The pattern is indicated by the Prussian Blue applied to the pinion, Contact is normal it the Prussian Blue is transferred to the approximate center of each tooth, but slightly to the heel side and to the flank side. If the patterns are not correct, remove and change the pinion shim with one of an alternate thickness. FINAL CLUTCH Apply Prussian Blue LEFT SHIM DIFFERENTIAL ASSEMBLY RIGHT SHIM 10 mm BOLTS CASE COVER 3 mm eons nonMAu HEEL [m ‘ TOE TO HEEL .. :9 DRIVE SIDE E ‘~ HEEL QM COAST SIDE 1 5-20 Replace the pinion shim with a thicker one it the contact pattern is too high. toward the lace. Replace the pinion shim with a thinner one il the contact pattern is too low, toward the llank. The pattern will shift about 0.5 - 1.0 mm (0.02 - 0.0! in) when the thickness at the shim is changed by 0.12 mm [0.005 in). Plnlon shims: : 1.84 mm [0.054inl [: B: 1.70 mm [0.067 In) D 2.12 mm [0.003 ml J: 2.1! mm [0.006 MI C: 1.76 mm 10.009an K: 224 mm [0.088 In) D 1.82 mm [0.012 in) L: 2.30 mm [0.001 In] E: .88 mm [0.074 in) M: 2.36 mm [0.093 In) . .54 mm [0.070 In) N: 2.02 mm l0.095 in] G .00 mm [0.07901] 0: 1.48 mm [0.098 In) H: 2.06 mm [0.001 in) For pinion shim replacement, see page 15-27. DIFFERENTIAL ASSEMBLV INSPECTION [’98 - ’01I Inspect Iunction: Install the differential inspection tools to both sides of the differential. YOOL: Dmeromlal impaction tool o7KMK-H650101 or OTKMK-HCSOIOA [U.S.A. only) Hold the chamlered side with a bench vise as shown. Place a torque wrench on the other tool and measure the limited slip torque. using the special tool. SLIP TORQUE: 11 - 25 NM! [1.7 - 2.5 Raf-m, 12 - 18 [bl-“I ll the limited slip diflerentiel WIII be disassembled or i[ the slip torque is out of specification, perform the lollowmg: NOTE: - A visual inspection must be done [or each clutch pack [plate, discs, springs and seat). - Always install each clutch pack assembly in its original location In the alflerential. - Do not interchange components between the two clutch pack assemblies. FRONT DRIVING MECHANISM TOO HIGH: PINION SHIM DRIVE SIDE ' ' 3.. COAST SIDE FACE FACE T [7 Q I T00 LOW: DR'VE 5'05 COAST SIDE I FLANK' I FLANK ’ , 7 INSPECTION TOOL 15-21 FRONT DRIVING MECHANISM Remove both differential caps and clutch pack assemblies (page 15-23), Inspect the clutch pack assemblies (page 154‘). Then, Install one of the differential caps onto its clutch pack assembly. Check the slip torque on the reassembled clutch pack using the procedure specified above. If the slip torque is out of specification, the clutch spring seat is worn. Remove the inspection tools. Remove the differential cap and the clutch pack from the differential. Select a clutch spring seat ofthe required thickness. II the slip torque is below specification, replace the spring seat with a thicker one. If the slip torque is above specification. replace the spring seat with a thinner one. Select the clutch spring seat from the list below. A: 1.0 mm (0.039 in) B: 1.2 mm (0.047 in) C: 1.4 mm (0.055 in) D: .6 mm (0.0m In) E: 1.8 mrnlo.071 In) Hecheck the slip torque. Next, inspect the remaining clutch pack assembly in the same way. DIFFERENTIAL INSPECTION (After '01) Install the inspection tools into both sides of the differential. YOOL: Difluontial inspection tool o7KMK-HCSMM or 07KMK-HCSO‘IOA (USA. onIyI Hold the flat surface of the tool With a bench vise. Attach a torque wrench to the other tool and measure the limited slip torque. STANDARD: 14 - 17 N0!“ (1.45 - 1,15 kfl-m. 10 - 13 leII SERVICE LIMIT: 12 MM (1.2 kgI-m, 3 lM-hl If the slip torque is out of specification, disassemble the oillerantial and perform the components inspection (page 15-26) since the differential may be laultv. CLUTCH SPRING SEAT INSPECTION TOOLS 15-22 FRONT DRIVING MECHANISM DIFFERENTIAL DISASSEMBLV TORX BOLTS (’98 - '01) Remove [he Iollowing: — Tovx bolls — Difierennal case rear cap SPRING SEAT REAR CAP — Clutch pack (spring seax. springs. discs and plale) . ~ Side gear — Washer — Bolts 7 Ring gear BOLTS - Clutch pack (spring seal. springs. discs and plaIEI SPRING SEAT — Side gear — Washer 1 5-23 FRONT DRIVING MECHANISM - Spring pin — Pinion shalt ~ Pinion gears - Canter collar — Side washers DIFFEREN11AL INSPECTION CLUTCH Measure and record the height a! the civic" spring. SERVICE LIMIT: 2.5 mm (0.10 mm) Check the clutch discs for scoring or discoloration. Measure the thickness of each disc. SERVICE LIMITS: DISC A: 2.4 mm 10.09 Inl Disc 3: 2.1 mm [Ml In) NOTE: Clutch disc 5 has two laces: one side is a steel plats, the other side is a friction surface disc. Inspect the clutch plate surlacs Ior estsiva scores or discoloration (Purple) and replace iI necessary. "MON Measure the pinion gear LD. and pinion shalt 0D. SERVICE UMITS: UNION GEAR LD.‘ 12.05 mm (017‘ In) PINION SHAFT 0.0.: 'l 1.75 mm (0.483 In) Check the side washsr for wear or damage. 'CLUTCH DISC SPRING PIN CLUTCH PLATE 15-24 FRONT DRIVING MECHANISM DIFFERENTIAL HOUSING SLOTS DIFFERENTIAL HOUSING Check me slots for wear or damage. DIFFERENTIAL DISASSEMBLV DIFFERENTIAL (After '01) Remove me six bolls, men place the differential assembly wnh me housing side down. and remove [he ring geavl 8 mm BOLTS Remove the following CAP - differential cap - cone sprung — shim FACE CAM CONE SHIM SPRING - Ieh Iace cam CAM FOLLOWERS A AND E - six cam followers A and six cam Vollowers B - right lane cam FACE CAM 15-25 FRONT DRIVING MECHANISM lithe dlllalenllal Musing, cap and lace tam are IeuIIy, replace one alNerenIIs/ as an assembly Heplace the cam IDIIOWOIS as a sel (12 places) DIFFERENTIAL COMPONENTS INSPECTION (After '01) DIFERENTIAL CAP Check the sliding surface ol the cap for damage or discoloration. Measure the depth of the cap lrom the mating surface as shown. SERVICE UMIT: 9.55 mm (0.378 in) DIFFERENTIAL HOUSING/FACE CAM] CAM FOLLOWER Check the sliding surface and grooves olthe housing for damage or discoloration. Check the shim, lace Cams and followers (or damage Temporarily assemble the differential housing, lace cams and cam followers (page 15-38). Measurethe height olthe lace cam tram the housrng mating surface as shown while applying a load ol 1,17 kN (150 kgl) ID the lace cam buss using a hydraulic press SERVICE LIMIT: 5.3 mm (025 In) "the height exceeds the limil. replace the differential as an assemblyt L47 IN (150 kgfi Housms 6 FACE CAM mé CAM FOLLOWERS 9 15-26 l l l FRONT DRIVING MECHANISM SIDE CONE SPRING Check me sprlng for damage. Measure the height 0! the cone spnng. SERVICE LIMIT: 2.6 mm [0‘10 In) SPRING DRIVE PINION REMOVAL ['98 - '01) lnslall Ihe plnlon holder on the pinion lomt and secure in a vuse as shown. TOOL: \ Pinion holder 075M$HM702M Remove the pinion [OInI nut‘ then remove the pinion holder and pinion joint‘ Remove the ml seal and O-ving, I _A OIL SEAL ,. \ GRING Unstake the plnion bearing lock nut with a drill or ‘7 BEARING LOCK NUT grinder. Be carevul that metal particles do not enter the bearing and that the threads are not damaged. U NSTAKE 1 5-27 FRONT DRIVING MECHANISM Remove the pinion bearing lock nut with the lock LOCK NUT WRENCH nut wrenchi YOOL: Lock nut wrench. 30 X 64 mm OTBIB-MBOODOZ or UNIS-M30000! Install the pininn puller attachment tool onto "16 PINION PULLER SET diflerential easel Screw the shah puller onto the threads of the drive pinion, Turn the 23 m spec-3| nut counterclockwise with a 23 mm wrench while holding the shaft With a 17 mm wrench to remove the drive pinion from its hous-ng, Remove the drive pinion assembly nsmg the special tools. TOOLS: Pinion pullu set 07HMC~MM00101 - Shah pull" 07931-ME‘0000 - Plnlnn pull-v halo 01HMC-MM801ID or USA only: sum pull-v 07931‘ME40105 pngss Dan/ER Spodll nln 07831-Hm20A Pinion puller bl“ 'A' 07HMCMM801‘IA DRIVE PINION REMOVAL (After '0‘" Press the drive pinion out lrom the final clutch using the special tools. TOOL: Dllvar 077490010000 Film, 15 mm 077‘6—004M00 Heal the final clutch l0 1003C (212 ’Fii BEARING FULLER U m—__ To avoid bums. m heavy glove: when Inndllng the leld final clutch. REMOVEH SHAFT Remove the drive pinion bearing train the final clutch using the special tools TOOL: Adjufllblc hearing pull-I 01JAc-PI'I80101 Rumovnr shah 07JAC-PH80200 Sllding weight 07741HM701M Remove the pinion joint nut, then remove the pinion holder and pinion joint. Remove the pinion joint and O-ring. Remove the oil seal. Unstake the pinion bearing lock nut with a drill or grinder, Be carelul that metal particles do not enter the bearing and that the threads are not damaged. TOO HIGH: PlNlON _ 0 SPACER l %i , FACE r; \\\ FACE T l DRIVE SIDE COAST SIDE Too LOW: ’ PINION SPACER FACE FAYCE :7?) i; ‘ DRIVE SIDE COAST SIDE U NSTAKE C‘C 16-10 REAR DRIVING MECHANISM Remove the pinion bearing lock nut using the special tool as shown. LOCK NUT 1001; Lock nut munch, 30 X 84 mm OHIO-MW or 0731G-MW‘I Install the pinion puller attachment tool onto the PINION FULLER SET our case Screw the shalt puller onto lhe threads of the drive pinionr Turn the 23 mm spacial nut counterclockwise with a 23 mm wrench while holding the shalt with e 17 mm wrench to remove the drive pinion lrom its houslngt Pull the drive pinion lsurriblv a" with the shaft puller‘ TOOLS: Plnlon pull. u! OTMWIM - Shah pull" WWI-HEW - Plnion puller been o‘INMGMMW1 10 or U.S.A. Only: Shaft puller OHM-KOO“)! Speclll run 07931-"83020A I, Pinion puller be“ 07W!" 1A Blow compressed air through the hrenther hole in the gear case, BREATHER HOLE DRIVE PINION DlSASSEMBLVI BEARING BEARING FULLER ASSEMBLY * “ Pull the bearing of! the shaft with a hearing when Remove the pinion adjustment spacer. REAR DRIVING MECHANISM To reassemble. first install the pinion spacer. BEARING ‘ NOTE: C When the gear set, pinion bearing and/or gear case has been replaced. use a 2.0 mm (0.08 In) thick spacer. monem /01 g SPACER Apply #50 gear ml to the bearing. Press the bearing onto the drive pinion with its groove Side facing out using the special tools as DRIVER, 30 mm 1.0. C shown. TOOLS: I Drlvlt. 40 mm ID. 077W30100 _' Attachment. 25 mm ID, OTIWMZW PINION NEEDLE BEARING REPLACEMENT Remove the stopper ring by rotating it until the end at the stopper ring appears in the access hole. Bend up the end at the ring with a screwdriver. Grasp the and a! the ring with needle-nosed pliers and pull the stopper ring out through the access hole. Heat the final gear case to we (175T) and remove the pinion needle bearing by using the special tool. TOOLS: Beerlng remover, 14 mm 07WMC-KF60100 Remover shaft, 15 mm 07936-KC10100 Remover welght 0774143010201 USA only: ' Beerlng remover. 15 mm orgas-chzoo , Remove eheft. 14 mm orvMCemoroA ! Remover weight 07936-311020A er 079353110200 Remover handle 07536<37I0100 M V” STOPPER RING Be sure to weer heavy glans to even! bume when 0 handling the heated gear cent I . I l . 1 Remove the bearing cage and bearings from the I inside ofthe pinion bearing to allow the specral tool to grip the hearing. I l . CAUTION: 0 Uslng e torch to heel the gel! cue any cause wupage. PINION NEEDLE BEARING 16-12 ‘98 — ‘01 Merm: Alterat- Inst-ll the stopper ring into the groove in the bearing. Install the bearing into the compressor until the bearing is flush with the end oi the TOOL Piece the driver on top 0' the bearing and tape the driver to the compressor. Place the assembly into a freezer lot at least 30 minutes. TOOLS: Driver 077M‘I 0000 Dm-runI-I bearing 1an oTVMEHNonA comer-nor Amhrnem 25 X 28 mm urns-0010100 Amamnm 22 X 2‘ mm OHM—001m Pilot. ‘4 mm INTIW‘IZOO Heat the gear case to BO“C l176°FL Remove the needle hearing and tool assembly from the Ireezer and drive the bearing into the geer case using the special tools. Only strike the driver once. If you strike it more than once. the ring may slip out of the groove. If this happens, remove the ring and bearing, and install e new one. Make sure that the stopper ring is securely set in the groove of the final year case. CASE BEARING REPLACEMENT Remove the oil seal. Drive the ring gear hearing out at the case. REAR DRIVING MECI’ANISM I COMPRESSOR BEARING / DRIVER ATTACHMENT a , ©3t .77 J PINION NEEDLE BEARING , I { ST6P R m; \ REAR DRIVING MECHANISM Drivo the ring gear boarlng Into the cover using the Ipecill tool: Is shown. TOOLS: Drlvll' 07740-0010” Attachment. 02 X 08 mm 07746-001500 Film. 35 mm 071mm deo a new all soul into the cover using the special tools. TOOLS: DIMI' 077M10N0 Attachment, 52 X 55 mm orrmrm Apply groaso to the oil soul llps. Inst-ll the ring our with the spam Into the cover. Measure the claoranoe between the flue gear and tho ring our atop pin with a feeler gauge. CLEARANCE: 0.30 - 0.00 mm (0.012 - 0.024 In) Ramovu the ring gear. I! tho cloarnneo «coeds rho stand-rd. hut the cover to approximately BO’C (175T) and remove the stop pin by unplug the Dover. m— Mmylwurglomwhonhondflnglhomm Ithubnnhut-dlommbumlngyourhm CAUTION: Dommotorohtohntthlcomflmyuuu W. Install I stop pin shim to obtain tha correct clurance. SHIM muss: A: 0.10 mm (0.000 In) B: 0.15 mm (0.000 In! Install the shim and drive the slap pin Into the cover. STOP PIN 0.30 - 0.60 mm (0.012 41.024 in) RING GEAR 0“ SYOP PIN 16-14 REAR DRIVING MECHANISM DRIVE PINION INSTALLATION DRIVER A‘I'rACHMENT Place the drive pinion assembly into its housing and drive it into the gear case. TOOL: Driver machmom 07985-KE80200 ov 078‘7-“50100 NOTE: Keep the driver centered with the bearing outer race during instanaticn. Install and tighten the pinion bearing lock nut usmg the special tools as shown. LOCK NUT tonoue: 93 Num no.0 “pm, 7: "Mn WRENCH Wnnch sell. vending: 88 N-m [3.1 kgI-m, 66 IhI-fl) using n 50 cm [20 In) long torque wrench YOOL‘ Lock nut wunch, 30 X 64 mm WSW—M30000! or , 0791wm1 ‘ ' Stake the pinion bearing lock nutl Apply grease to the new drive pinion oil seal lips, Install the new drive pinion oil seal on the case. lnstall the Orring onto this pinion shalt. '98— '01 Apply a locking agent to the pinion threads install the pinion joint and joint nut. Me! ‘01' Install the pinion joint. "l orRING PINION JOINT 16-15 REAR DRIVING MECHANISM '98— 'DY.‘ Attach the pinion holder on the pinion joint and secure in a vise. Tighten the pinion joint nut to the specified torque. Took I’lnIon hold-r WSMB-MMNIIOO TORQUE: 1M Nvm H 1.0 knf'm. I) lM-fl) Remove the pinion holder‘ PINION HOLDER GEAR CASE ASSEMBLY CASE SPACERS DRIVE PINION LOCK NUT P|NION JOINT RING GEAR OIL SEAL CASE COVER SPACER '93 - '01: PINION JOINT NUT 16-16 REAR DRIVING MECHANISM 3 mm sour : 25 N-m (2,6 kgfim, 19 Ibf-ft) 10 mm eon : 49 N-m (5A0 kgr-m, 36 let) '6' 10mm BOLT: Que —" Km dust-MUM eulollnewr case. 98 N-m (10.0 kgf-m. 72 lat-hi fits—am NOTE: When the bearing, gear set and/or gear case has been replaced. check the tooth contact pattern (page 16-91Ind gear backlash (page 1&7). Install the ring gear spacers onto the ring gear. Install the ring gear. with the spacers, into the final drive case. Apply liquid sealant to the mating surface 01 the gear case covert Apply a locking agent to the threads 0! the to mm bells. Tighten the cover belts in two or three steps until the cover evenly touches the gear case. Then. while rotating the drive pinion. tighten the bolts to the specified torque in two or three steps in a crisscross pattern. TORQUE: 10 mm bolt: 68 Nm (5.0 inf-m. 36 lM-ftl I turn bolt: 25 "mi [2.6 Ind-m. 19 IhMt) CAUTION: It I: Import-n! to turn the pinion while tightening the bane. I! the ring you m In ten thick. the gears will Ind: after only light tightening. ’98-'01: on 108 Mm (11.0 mm. 30 tht) 16-17 REAR DRIVING MECHANISM GEAR CASE INSTALLATION Install a new Owing on the swingarm Apply grease to the O-ring. Install the swing in the drive shaft joint‘ SPRING Apply 5- 8 9 0' molvbdenum disullide grease to BHEATHER Tue; 0 FINAL DRIVE CASE the pinion joint spline Install the final drive case to the swingarm. I Loosely install the new nuts, Do not reuse the nuts, Connect the breather tube to the case. Install a new O-ring on the final drive case. Apply grease to the O-ring. Install the right axle housing to the final drive case and install the mounting bolts and new nutst Tighten the linal drive case joint nuts and axle housing nuts to the specified torque. TORQUE: 44 Ill-m (4.5 Ital-m, 33 IM-hl Install the right tear shock absorber lower mounting bolt and new nut. Tighten thn nut to the specified torque. TORQUE: 44 MM [4.5 Ital-m, 33 IMJII RIGHT AXLE HOUSING 16-18 REAR DRIVING MECHANISM REAR AXLE INSTALLATION Apply grease to the axle splines. 20 mm (0.8 mi 73153:! 10 mm (0 A in) Install the rear axle from the right side while aligning the splines ol the final drive install a new O-ring on the brake panel. Apply grease to the Owing. Instal and tighten the new brake panel mounting nuts to the specified torque. TOROUE: u N-m (4.5 kgl-m, 33 lM-hl REAR DRIVING MECHANISM Install the brake drum and drum cover (page 14- RIGHT WHEEL HUB 22). Clean the dust sell mating Iurleca ol the wheel huh. Apply grease to the axle shaft spline. Install the rlght wheel hub. Temporarily tighten the right axle nut, AXLE NUT Install a new O-ring on the final drive case. Apply grease to the O-rlng. Install the collar ante the rear axle REAR AXLE NOTE: Note the dlrection at the collar. Install the left axle housing. Install the left wheel hub and Mt, while centering the axle shaft. k: LEFT AXLE HOUSING 16-20 REAR DRIVING MECHANISM Install and tighten the new left axle housing LOWER MOUNTING BOLT mounting nuts to the specified torque. ' TORQUE: M N-m “.5 Ital-m, 33 let) Install and tighten the left rear shock absotber lower mounting bolt. TORQUE: u Min “.5 Ital-m, 33 letI Install the final gear case skid plate and tighten the three bolts. Tighten the axle nuts to the specified torque. TORQUE: 137 NW“ (11.0 kgI-m, I01 lM-m NOTE: ll cotter pins cannot be installed after torqutng nuts due to alignment at axle hole, tighten nut lurther until cotter pin can he installed. Do not loosen the axle nuts alter torquing them to install cotter pins as shown. Install the new cotter pins. AXLE NUT Install the rear wheels (page 13-3). Fill the final drive with the recommended oil (page 3-1”. 16-21 REAR DRIVING MECHANISM REAR DRIVE SHAFT REMOVAL Remove the swingarm (page 134). Pull the yoke joint/drive shell out of the swingavm and disassemble it. VOKE JOINT DRIVE SHAFT INSPECTION fl fl DUST SEAL Inspect the yoke iolnl bearings Ior excessive play or damage. Apply molybdenum disulflde grease to the spline. Apply 5 — 8 g of molybdenum disullide grease to fl Ihe spline. VOKE JOINT i0 PROPELLER SHAFT INSTALLATION Assemble xhe yoke loin! and drive shaft. _ Insall the yoke joinlldllve shaft lmo (he swingarm. luslall me swingarm (page 13-7). VOKE JOINT DRIVE SHAFT 1 6-22 MEMO BATTERY/CHARGING SYSTEM MEGS/M: NAMES/E BATTERY BATTERY 7 ALTE RNATOR REGULATOR/RECTIFIER ALTERNATOR REGULNGFVRECTIFIER REGULATOR/ RECTIFIER VV" 5 R FUSESOA i BATTERY RNATOR HARGING I ALTE C CO L ‘ Rad Green -Yellow 2‘5”.” 17-0 b L 17. BATTERY] CHARGING SYSTEM SYSTEM DIAGRAM 17-0 CHARGING SYSTEM INSPECTION 17-8 ‘ SERVICE INFORMATION 17-1 ALTERNATOR CHARGING COIL 17-10 TROUBLESHOOTING 17-3 REGULATOR] RECTIFIER 17-11 BATTERY "-5 SERVICE INFORMATION GENERAL The battery gives all explosive gases; keep sparks, flames end cigarettes ewey, Provide edequate ventilation when charging. The battery contains sulfuric acid lei-ctrolytei. Contact with skin or eyes rrrey cause severe burns. Wear protective clothing and a face shield. - ll electrolyte gets on your sltin. flush with water. - II electrolyte gets in your eyes, flush with weter for at Inst 16 rnlnutu end call 1 physician immediately. Electrolyte is poisonous. - II ewe/lowed, drink Ierge quantities nl weter or milk end all a physician immediately. Always turn ott the ignition swrtch betore disconnecting any electrical component. CAUTION: Same electrical components may be damaged it terminals or connector: ere connected or disconnected while the ignition switch is ON and current I: present. - For extended storage. remove the battery, give it a full charge. and store il in a cool, dry space. For maximum service Iile, charge the stored battery every two weeks. - For a batter remaining in a stored vehicle, disconnect the negative battery cable tram the batter term-nal. NOTE: The maintenance free battery must be replaced when II reaches the end of its service lile. CAUTION: The battery caps should not be removed. Attempting to remove the sealing caps from the cells ntey damage the battery. The battery can be damaged il overcharged or undercharged. or it lelt to discharge for long period. These same conditions contribute to shortening the 'lile span' of the battery. Even under normal use, the perlormance ol the battery deteriorates after 2 -3 years. Battery voltage may recover alter battery charging, but under heavy load, battery voltage will drip 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. ll one at the battery cells is shorted and battery voltage does not Increase, the regulator/rectilier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. Belore troubleshooting the charging system, check (or proper use and maintenance at the battery. Check If the battery IS frequently under heavy load, such as haying the headlight and taillight ON lot long periods oI time Without riding the vehicle. 17-1 BATTERY/CHARGING SYSTEM - The battery will salt-discharge when the vehicle is not in use. For this reason, charge the battery every 2 weeks to prevent sultation from occurring. - Filling a new battery with electrolyte will produce some voltage, but in order to achieve its maximum performance always charge the banery. Also, the battery life is lengthened when it is initially charged. - When checking the charging system, always follow the steps in the troubleshooting flow chart (page 17-3). Battery charging This model comes with a maintenanceAlree lMF) battery. Remember the following about MF batteries. — Use only the electrolyte that comes with the battery — Use all at the electrolyte 4 Seal the battery properly - Never open the seals again CAUTION: For battery charging, do not exceed the eharalna current and time specified on the battery. Uae of excessive current or charging time may damage the battery. BATTERY TESTIM Refer to the battery tester's Operation Manual for the recommended battery testing procedure. The recommended battery tester puts a "load“ on the battery so the actual battery condition at the load can be measured. Recommended battery teeter BIN-210A", BM-Z‘Io or BATTERY MATE SPECIFICATIONS ITEM I SPECIFICATIONS Battery ‘ Capacity 7 7 12 v — 12 AH Current leakage 5 mA max. Voltage (ZD'C/SB‘F) Fully charged 13.0 — 13.2 V ‘_Needs charging Below 123 V VCharging current Normal 1.2 NS — 10 h Quick 5.0 N1.0 h Alternator Capacity '98 — ’01 0.310 ltw/5.DOO rpm After '01 0.326 Itw/5,000 rpm Charging coil resistance (20'C/68'F) 0.1 — 1.0 I) Regulator/rectifier regulated valtage » ".7 — 15.5 V at 5,000 rpm 17-2 ‘CG BATTERV/CHARGING SYSTEM TROUBLESHOOTING BATTERV IS DAMAGED 0R HAS LOW POWER F————’ Remove the battery (page 17-5). Incorrect l Check the battery condition using the recent» 43qu battery mended battery tester. . RECOMMENDED BATTERV TESTER: r BM-210-AH. BM-ZIO or BATTERY MATE or equivalent l ‘ Correct j—_— [_—__——r——‘ ‘ Installthe banerylpa 9175), ' Drscmnect the regulator/rectifier connector and r 9 Incorrect Check the battery current leakage (Leak test: recheck the battery current leakage, page 178). r Correct Incorrect - shorted wtre harness Correct - Faulty ignition switch ' '———> - Faulty regulator/rectifier U (—1. l Check the alternator charging coil {page 1740]. Incorrect r »——-———A—> - Faulty charging coil ' STANDARD: 02 - 0.5 u maze/ears) Correct r l ‘ Measure and record the battery voltage using a ‘ digllal multimeter (page ”6!. r Stan the engine. ' ‘ Measure the charging voltage (page 17-8). Compare the measurement to the result at the followth calculation. Mounted battery voltage < Matured charging r STANDARD: volun- < 15.5V U Incorrect 9 Correct - Faulty battery 17-3 BATTERVICHARGING SYSTEM Incorrect $ Check the voltage and resistance at the regula- Incorrect . _ > _ tor/rectifier connector (page 174 1)‘ —‘~—’ ' 0”" WW" "1 WIN” WIN - Loose or poor contacts at related termlnal - Shoned wire harness Correct [‘5’ - Fanny regulator/rectifier 17-4 BATTERY/CHARGING SVSTEM BATTERY REMOVAL] INSTALLATION Remove the seat (page 2-3). Remove the two bolts and battery holder bracket Drsconnect the negatlve cable and then the positrve cable, and remove the battery. Install the battery tn the reverse order at removal wrth the proper wrung as shown. BATFERY BRACKET NOTE: Connect the posrtlve termmal first and then the negative cables POSITIVE gABLE After lnslalllng the battery, coat the terminals with clean grease. Rernstall the removed parts VOLTAGE INSPECTION Measure the battery voltage usrng a drgital multr» meter. VOLTAGE: Fully charged: ‘10 — 13.2 V NEGATIVE CABLE Under churned: Below 12.3 V TOOL: DigIt-l multimeter Cummarcinlly null-hie BATTERV TESTING Always clear the work area of flammable materials such as gasoline, brake fluid, electrolyte, or cloth towels when uperatmg the tester, the heat generated by the tester may cause a fire. BAWERV Remove the battery, Securely cu nnect the tester‘s positive 1+) cable first, then connect the negatrve l») cable. TOOL: Battery tater BM-ZW—AH or BM-210 (USA. only) 17-5 BATTERY/CHARGING SYSTEM For accurate test results. be sure the tester's cables and clamps are In good womng m- dlnon Ind Ina! a secure connection ran be nude at the battery. FD! the firs! cheek Do NOT charge the battery bolero Iesnng. test 1' m an ‘na ‘5‘ candl- nan Set the temperature switch to "HIGH' or "LOW" depending on the ambient temperature, Push in the appropriate test button tor 3 seconds and read the condition of the battery on the meterl To avoid damaging the tester] only test batteries with an amperage rating of less than 30 Ah. Tester damage can result tram overheating when: — The test button is pushed in for more than 3 seconds — The tester is used without being allowed to cool for at least 1 minute when testing more than one battery — More than ten consecutive tests are performed without allowing at least a 30-minute cool-down Period, The result at a test on the meter scale is relative to the amp. hour rating of the battery. ANY BATTERY READING IN THE GREEN ZONE IS 0K. Batteries should only be charged it they register In the VELLOW or RED zone. BATTERY CHARGING Remove the battery (page 17—5). Clean the battery terminals and position the battery as tar away lrom the charger as the leads will permit Do not place batteries below the charger — gases from the battery may corrode and damage the charger. Do not place batteries on [up u! the charger. Be sure the air vents are not blocked. {nib Eooooosao HIGH: 15 'C (60 'F) or higher LOW: 15 'C (60 'Fl or lower TEST B TTONS VE LLOW Rio (-1) GREEN (—3. —2) (+1, +2. +3) 17-6 BATTERY/CHARGING SYSTEM The charge; my automatically SWIM" la the 'ankle' made alter the sel charg~ ing mne has elapsed YOOL: Christie buttery charger Mcrmz/z (USA. only) 1. Turn the power Switch to the OFF position, 2. Set the battery Amp. Hr. selector Switch for the size ol the battery being charged. 3. Set the Turner to the position indicated by the Honda Battery Tester; RED — 3, RED — Z or YELLOW 1. If you are charging a new battery, set the switch to the NEW BATT positinn. 4. Attach the clamps to the battery terminals: RED ta Positive, BLACK to Negative. Connect the battery cebles only when the Power Switch is OFF, 5, Turn the Power Swttch to the ON position 6‘ When the timer reaches the ”Trickle" position, the charging cycle Is complete. Turn the Power Switch OFF and disconnect the clamps 7‘ Let the battery coal for at least 10 minutes or until gassing subsides after charging. at Retest the battery using the Honda Battery Tester and recharge il necessary using the above steps. BATTERY AMP HR SELECTOR SWITCH D 15 to 5.0 15 to 15.0 W“ Iljtow + Set the appropriate ampt hour rntlng. TIMEfi Trickle NEW BA‘I'I' 0 RED YELLOW ' ‘ 17—7 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION NOTE: When inspecting the charging system, check the system components and lines step-oyrstep according to the troubleshooting on page 17-3. Measuring circuits With a large capacity that exceeds the capacity of the tester may cause damage to the tester. Eeiore starting each test. set the tester at the highest capacrty range first. then gradually lower the capacity ranges until you have the correct range. When measuring small capacity circuits, keep the ignition switch off. lithe switch is suddenly turned on during a test , the tester ruse may blow. REGULATED VOLTAGE inspection m— il the engine must ba- running to do some work make sure lira or" is well-ventilated. Never run the engine In an enclosed araa, Tir- uirauxt contains poisonoue carbon monoxide gas tit-t may close lose a! consciousness end may lead to duth. Run the engine in an opan aru or with an exhaust ovuuntion system In an ancioaad u. NOTE: Be sure the battery is in good condition before performing this test. Warm up the engine to normal operating tempera- Kuiet Stop the engine, and connect the multimeter as shown. CAUTION: - Topmonta short, meira Absolmolyuflaln which m are positive Ind nognivo terminal: or cabin - Do not disconnect the battery or any cable In the chnrainy cyst-m without first switching all the ignition switch. Failura to follow this precaution can damage tho tutu or electrical camponantc. Restart the engine. With the headlight on Hi heam, measure the voltage on the multimeter when the engine runs at 5,000 rpm, STANDARD: 14.7 -15.5 V It 5.000 rpm 17-8 BATTERY/CHARGING SYSTEM The battery is normal it the specified regulated voltage is displayed on the multimeter. NOTE: The speed at which the voltage stans to rise cannot be checked as it varies with the temperature and loads at the generator. A frequently discharged battery is an indication that it is deteriorated even it it proves normal in the regulated voltage inspection. The charging circuit may be abnormal it any or the Iollowing symptoms is encountered. Voltage does not used to regulated voltage: - Open or short circuit in the charging system wire harness or poorly connected connector. ~ Open or short ot the alternator. ‘ Faulty regulator/rectifier. (N. Regulated voltage is too high: - Poorly grounded voltage regulator/rectifier. - Faulty battery. - Faulty regulator/rectifier. CURRENT LEAKAGE INSPECTION Turn the ignition swrtch oft and disconnect the negative bettery cable Irorn the battery. Connect the ammoter to) probe to the ground cable and the ammeter (-l probe to the battery H terminal, With the ignition switch all, check for current leakage. NOTE: - When measuring current using e 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 tuse in the tester. While measuring current, do not turn the ignition on. A sudden surge ot current may blow out the tuse in the tester. SPECIFIED CURRENT LEAKAGE: 5 «IA "Ill. it current leakage exceeds the specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. NORMAL CHARGING VOLTAGE HEGULAT‘ED VOLTAGE BATTERV VOLTAGE VOLTAGE -> I I I I I I 3 . —r—T—‘—t—r—l—t ENGINE SPEED —’ rpm « ABNORMAL CHARGING VOLTAGE l I OLTAGE —' I l“ ENGINE SPEED "* rpm AMMETER GROUND CABLE 17-9 BATTERY] CHARGING SYSTEM ALTERNATOR CHARGING COIL NOTE: it i: not necessary to remove rha stator coil to make rhls test. INSPECTION Disconnea the regulator/rectifier 5P connector, Check the resistance belween Yellow terminals. STANDARD: 0.1 - 1.0 fl l20'C/BB'F) Check for continuity between Yellow terminals and Ground. There should be no continuity. ll lhe reading ls out o! specification check the resistance at the alternator connector. Disconnect the alternator 5P lNaturall connector. Check the resistance betwem Vellow terminals. STANDARD: 0.l - 1.0 n (ZO'CIOB'H Check for continuity between Yellow terminals and Ground. There should be no continultv. II readings are still fer beyond the standard. or ii any wire has continully to ground. replace the alternator stator. Refer to section in for stlmr removal. REGULATOR/RECTIFIER CONNECTOR REGULATOR/RECTIFIER 5P CONNECTOR ALTERNATOR CONNECTOR 5P CONNECTOR 17-10 BATTERV/CHARGING SYSTEM REG ULATORI RECTIFIER SYSTEM INSPECTION Disconnect the regulator/rectifier connector, and check it lor loose contact or corroded terminals. It the regulated voltage reading (see page 1743) is out 0! the specification, measure the voltage between connector terminals (wire harness side) as lollows: Item Termifl Eoocification Battery Red (v) Batterv voltage charging and should register line i ground H 7 7 Charging Yellow and 0.1 — 1.011 coil line Yellow (fiLZO‘C/GS'F) , Ground line Green and Continuity ‘ ground should exrst It all components olthe charging system are normal and there are no loose connections at the regulator/ rectifier connectors, replace the regulator/rectifier unit. REMOVAL/INSTALLATION Disconnect the connecton Remove the regulator/rectifier unit mounting bolts and regulator/rectifier. lnstall the regulator/rectifier unit ln the reverse order of removal. REGULATOR/RECTIFIER CONNECTOR REGULATOR/RECTIFIER CONNECTOR BOLTS 17-11 IGNITION SYSTEM TRX‘SOSIFM: TRXASOESIE IGNITION SWITCH IGNITION CONTROL MODULE IGNITION SWITCH IGNITION CONTROL MODULE IGNITION COIL SPARK PLUG IGNITION COIL SPARK PLUG IGNITTION PULSE GENERATOR IGNITION PULSE GENERATOR ALTERNATOR BATTERV BATTERY NEUTRAL/REVERSE GEAFI POSITION SWITCH SWITCH ALTERNATOR 1 : Aha '01 To nEouuron/ IEO‘I'IHER ‘ YO srmtn ‘. ELAV mm“ 9&1ch v V v am my : Bllcl launou Pum'e ALVERNATON ; Gm" «Newton (We can) Yellow .B‘lgofia :L Ivm raga , Gr-y : 013nm 53 Apply battery voltage to the starter motor directly and check the operation. i 1 Normal Abnormal i - Poorly connected motor cable - Faulty starter relay switch (page 137) - Faulty starter motor (page 19-3) - Faulty neutral/reverse or gear position switch (page 20-18 or page 21-23) - Loose neutral/reverse or gear position switch connector - Faulty ignition switch (page 2047) - Faulty starter switch (page 20-17) ~ Open or short clrcuit in wire harness - Faulty starter relay switch N - Loose starter relay switch connector Starter motor turns origin- slowly . Low hattery voltage - Excessive resistance in circuit - Binding in starter motor Slener motor turns. but engine does not turn - Faulty starter clutch (see section 10) - Faulty starter reduction gears (see section 10) Starter motor and englne turns, but engine does not start - Faulty ignition svslurn (set: section 1a) Engine emblems (see section 3.7} — Low compression — Fouled spark plug 1 9-2 ELECTRIC STARTER STARTER MOTOR REMOVAL M When the Ignition switch OFF, "move the marlin cable at the battery bolero urvlclng the starter motor. Remove the right engine side cover (page 62L '\ Disconnect the starter cable from the starter motor. e \ Remove the two mounting bolts and the starter STARTER MOTOR motor. FRONT coven DISASSEMBLV Remove the two starter motor case bolts and remove the front cover, motor case and armature coil. Record the number and location or shims for correct assembly. BOLTS INSPECTION COMMUTATOR BARS Inspect the commutator bars (or discoloration, Bars discolored in pairs Indicate grounded armature coils‘ in which case the starter motor must be replaced. Check for continuity between individual commutator CONTINUITV N0 CONT‘NUWV bars; there should be continuityr Also. check for continuity between individual commutator bars and the armature shaft; thorn should be no continultvr ELECTRIC STARTER Check for continuity between the cable terminal end CONTINUITV N0 CONTINUITV the brush wire lthe light blue colored wire or the insulated brush holder). There should he continuity. Check lor continuity between the rear cover end the bm-h wire (the light blue cover wire or the insulated bruth holder). There Ihould be no continuity. G (v BRUSH HOLDER Disassemble the rear cover. a | Inspect the brunhet lot damage Ind meeeure the bruth length. SERVICE LIMT: 0.0 mm “$.35 In) Check the bushlng ol the rear cover for weer or dam-9e. BUSHING a Check the needle benring oi the lront cover for DUST SEAL smooth rotetlon. Check the dust seal for weer or demeae. NEEDLE BEARING 19-4 ELECTRIC STARTER ASSEM BLV REAR COVER 9 e O 3} WASHERS 2 ® BUSHING SHIMS BRUSH HOLDER LOCK WASHER NEEDLE BEARING FRONY COVE R BRUSHES Insmll the brushes in the brush hoiders as shown. InstaH the brush holder assemny to lhe rear cover. BRUSH HOLDER ASSEMBLY aligning the lab at the holder with the groove o! the V937 COVE'. ELECTRIC STARTER Install the shims to the terminal and ermeture call In the correct positions II recorded. Install the armature in the rear cover. install the O-ring on the motor case. Assemble the motor case and rear cover. aligning the index marksl NOYE: Hold the armature coil shalt. or armature might be drawn out by the magnetic field. INDEX MARKS Apply green to the dust seal oi the front covert SHIMS Instnll the shim: to the shaft In the correct position: as recorded‘ and O-ring to the case. CAUTION: Donotdanugetlulmntoowmaul. Align the index marks of the front cover, motor case and rear cover. Tighten the bolts securely. Apply all to the O-ring Ind install it on tho lront cover. ARMATURE LOCK WASHER FRONT covea e 0 1 9-6 ELECTRIC STARTER INSTALLATION J STARTER moron Install the starter motor with the two mounting bolts / “ Connect the starter cable to the motor. Install the right engine side cover (page 8-10). STARTER RELAY SWITCH OPERATION INSPECTION Remove the seat and battery holder bracket. Depress the starter switch button with the ignition switch ON. The coil is normal if the starter relay switch clicks. STARTER RELAV SWITCH VOLTAGE INSPECTION STARTER RELAY I CONNECTOR II the switch “CLICK" is not heard, disconnect the relay connectorr Measure the voltage between the Yellow/Red M and Light green i») wire terminals of the wire harness side. The battery voltage ahould be indicated when the starter switch button is depreaaed with the ignition switch ON and the transmission in neutral, CONTINUITV INSPECTION 5T ART R RELAV Connect an ohmmeter to the starter relay switch large terminals. Connect a lully charged 12V battery to the starter relay switch connector terminals (Yellow/Red and nght greenll Check for continuity between the starter relay switch ‘ terminals. There should be continuity while 12V battery is “—1 connected to the starter relay switch connector ‘—-BA1TERY terminals and there should be no continuity when the battery is disconnectedt LIGHT S/METERS/SWITCHES TRX‘SOS ('98-'01): IGNITION SWITCH COOLING FAN MOTOR COOLING FAN CONTROL UNIT BA‘I'I'ERV SPEED SENSOR OIL THERMO SENSOR TRX‘SOES ['90-'01]: COOLING FAN MOTOR 'GN'Y'O“ SW'TCH COOLING FAN CONTROL UNIT BATTERY SPEED SENSOR 0|L THERMO SENSOR 20-0 20. LIGHTS/METERS/SWITCHES SERVICE INFORMATION 20-2 ACCESSORY SOCKET 20-15 TROUBLESHOOTING 20-2 IGNITION SWITCH 20-17 HEADLIGHT 20-8 HANDLEBAR SWITCHES 20-17 ASSIT HEADLIGHT 20-9 NEUTRAL] REVERSE SWITCH 20-18 TAILLIGHT 20-11 COOLING FAN CONTROL UNIT 20-19 COMBINATION METER 20-12 OIL THERMOSENSOR 20-19 SPEED SENSOR 20-13 CARBURETOR HEATER ZO-Zfl Am: ’01: IGNITION SWITCH 2WD/4WD SWITCH COOLING FAN MOTOR COOLING FAN CONTROL UNIT FRONT FINAL CLUTCH SPEED SENSOR METER SPEED SENSOR OIL THERMO SENSOR 20-1 LIGHTS/METERS/SWITCHES SERVICE INFORMATION GENERAL - A continuity cheek can usually be made without removing the part from the vehicle by simply disconnecting the wires and connecting a continuity tester or voltmeter to the terminals. SPECIFICATIONS ITEM SPECIFICATIONS Bulbs i Headlight ’93 — '01 12 V - 25/25 W X 2 AIter'DI 12V—30/30WX2 Assist headlight 12 V — ISW Taillight IZV—SWXZ Fuse Brake light (After ’01: Quebec pruvmce only) ‘2 V - 21 CP indicator (Oil/Reverse/Neutrall LED , Main iuse 30 A Subluse '98—'01 15AX2,10AX2 lAItur'Ol 15AX2.10AX3 MOTOR FUSE (TRXASOES only) 30 A TORQUE VALUES Neutral and reverse switch mounting bolt 12 N-m (1.2 kgl‘m, 9 lell Apply a locking agent to the threads. Oil thermo sensor 18 N-m (1.8 kgf-m. 13 lbl-lt) Speed sensor mounting bolt (Alter '01) 10 N-m (1.0 kgf—m, 7 Ibtvft) Final clutch speed sensor mounting bolt (Alter '01) 10 N-m (1.0 kgt-m. 7 lbf-I‘t) Final clutch cover bolt (Alter ’01) 7 N~m 40.7 kgt-m. 5 lot-It) TOOLS Inspection adapter 07GMJ~ML80100 Light does not some on when light switch I: turmd rm . Bulb burned out - Faulty switch - Wiring to that component has open circuit Nudllght bums do not shift when dlmmor owlteh is owned - Faulty dimmer switch - Bulb burned out . Wiring to that component has open circuit 20-2 b b b LIGHTS/METERS/SWITCHES TROUBLESHOOTING comammon METER '98 - '01: Bus: .1; are! "A ramhon mm mourn-m. u-u u-vm Hun - Susan Altar '01: can-um um. FWI : Block : Green : Blue E Fink : Dung: : Brown 2°1=gnz z a The ope-domltor taper-tn normally, but the hour motor or odometu/tripmotor do“ not own-t - Faulty combination meter The hour mom or odometer/trlpmotar opera": normally. but the spudomotor does not mate. — blown mam or sub luse — loose or corroded terminal of the connectors - discharged battery —% Chock for loose or poor contact of the \ Abnormal speed sensor 3P connector. With the ignition switch on, measure the voltage at the (After '01: motor) speed sensor connector. Connection: BIIelt/bluo (o) and body ground l-l ‘ Standout Emory volt-go Normal , - Lease or your contact of related terminal. I - Open crrcuit in black/blue wires. Remove the (Altar ’01: meter) speed ADHOHHal sensor and cried: for damage oi the (Altar ’01: meter) speed sensor (page 20-13). Normal l - Faulry (After '01: meter) speed senson 20-3 LlGHTS/METERS/SWITCHES Connect the inspection adapter. '9! - ‘01: Measure the output voltage (sensor signal) at inspection terminal with the ignition switch on while turning the speed sensor shalt by your finger Connection: Graen to) and White (-l Standard: Repeat 0 to above 5 V M"! ’01: Place a support block under the engine to raise all of the wheels off the ground. Place the vehicle in founwheel driver Turn the ignition swrtch on. Rotate the iront wheel by hand and measure the output voltage (sensor signal) at the inspection terminal. Connectlon: Green (4-) and White (-l Standard: Repeat 0 to above 5V Special tool: Inspection adapter 07GMJ~ML80100 Remove the speedometer, but do not disconnect the speedmeter connac» tor (page ZCHZL With the ignition switch oft measure the voltage at the bottom of the speedometer terminal. Connection: Red M (After '01: Red] Black M) and body ground l-l Standard: Battery voltage Normal With the ignition switch on, measure I the voltage at the bottom of the i speedometer terminalr 1 Connection: Block/brown hi and body ground“) Standard: Batter voltage Normal r _—Y—_ With the ignition switch on. check tor the continuity between the Pink/green wire at the speedometer. Connection: Pink/green Standard: Continulty i Normal - Faulty speedometer Abnormal - Faulty (Alter '01: meter) speed sensor. (No input voltage) INSPECTION ADAPTER PINK/GliEEN GREEN WHITE 43 RED pmx GREEN~> ¢- GREEN a BLACK/BLUE Abnormal "BLACK - Loose or poor contact of related terminal. - Open circuit in red/black wires between the conmhination meter and battery Abnormal - Loose or poor contact oi related terminal. - Open circuit in Black/brown wires between the combination meter and battery Abnormal - Loose or poor contact all related terminal. - Open circuit in Pink/green wires between the combination meter and (Alter '01: meter) speed sensor 20-4 0 0 U LlGHTS/METERS/SWITCHES OIL COOLING SVSTEM FAN comROL to CONGINATION (—6.” Marie Fu se IONIYION 30A swncn e a .5. —r:i Normal Connect the control unit 16? connector, Turn the ignition switch ”OFF“ Disconecl the control unit 5? connector. Install a jumper mm between the Block/Orange terminal oi the control unit 5P connector (harness side) to the positive battery terminall With the ignition switch "0N“. measure the voltage between the Red/Vellow connector terminal of the wire harness side and berry groundl /\ A ~ \\ Tl ECU 5P CONNECTOR ' OONIEC'TION: Red/Yellow lol - Body ground l-l STANDARD: 11 V minimum Normal Disconect the control unit 5P connector. Wllh the ignition switch "OFF', check for the continuity between the Green connector terminal of the wire harness side and body groundl 7 . CONTROL UNIT 5P CONNECTOR CONNEC‘HON: Green lol - Body ground (-l STANDARD: Comlnuhv ‘ Normal ELECTRIC SHIFT PROGRAM (ESP) - Open circuit in Black/Green wire - Loose or poor contacts at related terminal Abnormal , , ‘ , - Open circuit In Red/lelow wtre - Loose or poor contacts of related terminal Abnormal . . , , - Open circuit in Green wure - Loose or poor contacts a? related terminal 21-5 ELECTRlc SHIFT PROGRAM (ESP) Connect the ECU 5P connector. Abnormal Disconnect the control unit 16F connector. With the ignition switch ”OFF", measure the resistance between the Black/Red and Blue/Green connector terminal of the wire harness side. ,4, . \ 7 a CONTROL UNiT 16? (BLACK) CONNECTOR CONNECTION : Block/Red lo) - Blue/Green (-) STANDARD : 4—6 It!) Disconnect the control ‘unit 16? and angle sensor 35‘ (natural) connector. Check for continuity between the control unit 1GP connector and angle sensor 3P connector terminal at the wire harness side. CONNECTION: Block/Hod - BIIcklflod Vlllowllluo- Vollflw/BIue Blue/Green - Blue/Green STANDARD : Contlnutty Not Continuity - Open circuit in related wire - Loose or poor contacts 0' related terminal Continuity Normal Connect the control unit 16F connector. Abnormal Disconnect the angle sensor 3P (natural) connector, With the ignition switch “ON”. measure the vlotage between the Black/Red connector terminal of the wire harness side and body ground. \ p _ ANGLE SENSOR 3P CINNECTOR CONFECTION : Black/Red (+) - Body ground 1-) STANDARD : 4‘15 - 5.25 V Normal Remove the angle sensor (page 21-26). Visually inspect the angle sensor shalt hole and gear shift spindle (or damage ANGLE SENSOR GEAR SHIFT SHAFT HOLE SPINDLE l Normal Abnormal Disconnect the control unit 16? and angle sensor 3P (natural) connector. Check for continuity between the control unit (GP connector and angle sensor 3? connector terminal of the wire harness side. CONNECHON: Black/Rod - Block/Rod STANDARD : Continuity Normal - Faulty control unit A bnormal .—. ~ Open circuit in related wire - Loose or poor contacts of related terminal - Replace the angle sensor (page 21-25) - Replace the sub gearshift spindle (section 9) 21-6 ELECTRIC SHIFT PROGRAM (ESP) I Normal Remove the angle sensor (page 21-26). Measure the resistance between the Vellow/BIue and Blue/Green connector terminal at the sensor side while turning the sensor shaft slowly with yor finger. ANGLE SENSOR CONNECTION : VellowlBluo- Blue/Green STANDARD : Humane- chines: smoothly Normal Connect all connectors that were disconnected lot the previous procedure. Disconnect the 5th switch 3? (natural) connector. With the ignition switch "0N", measure the voltage between the Black/Red connector terminal of the wire harness side and body ground. BRACK/HED TERMINAL OONIIECTION : luck/Rod (cl - Body ground H STANDARD 7 ‘15 - 5.25 V Abnormal Abnormal - inspect the angle sensor (page 2143) Normal Inspect the shfit switch (page 2149). Disconnect the control unit 16F and shift switch 3P (natural) connector. Check (or the continuity between the control unit 16? connector and shilt switch 3P (natural) connector terminal at the wire harness side. CONNECTION 1 White/Blue - White/Blu- WhItn/Yallow - WhII-IVIIIW STANDARD : Continuity l Normal Abnormal Abnormal Disconnect the control unit 165' and shift switch 3P (natural) connector. Check Ior continuity between the control unit 16F connector and shift switch 3P (natural) connector terminal of the wire harness side. CONNECTION : Neck/Rod - Black (Red STANDARD : Continuity Normal - Faulty control unit Abnormal _. - Open circuit in related wire - Loose or poor contacts oI related terminal - Faulty shift switch - Open circuit in related wire - Loose or poor contacts at related terminal 21-7 ELECTRIC SHIFT PROGRAM (ESP) Normal Inspect the change SwllCh (page 21-29). Normal Disconnect the control unit (ECU) 16F and gear position switch 4? connector. Check lor continuity between the control unit 16F connector and gear position switch 4P connector terminal of the wire harness side. CONNECTION : Gray - Grlv nght green/Hod — Light green/fled Whltl/Grun — White/Green Llollt blue — “in blue STANDARD : Continuity Normal Connect a fully charged ‘1 V battery to the control motor 2? connector. Control thOI lUHIS - Faulty control unit Abnormal Abnormal Control motor does not turn - Faulty our position switch - Open circuit in related wire - Loose or poor contacts of related terminal . Faulty control motor 21-8 ELECTRIC SHIFI' PROGRAM (ESP) ELECTRIC SHIFT MALFUNCTION DURING VEHICLE OPERATION - The engine run normally — Speedometer operates normally Inspect the following beiore diagnosing the system. Reler to Electric Shift Does Not Operate troubleshooting section {page 2L3). Normal Inspect the clutch operation. Normal Inspect the angle sensor lpage 21-25lt Normal Disconnect the control unit 16F and Ignition control module 4? connector. Check lot continuity between the control unit 16F connector and Ignition control module 4P connector terminal of the wire harness sidet CONNECTION : Blue/Yellow - Blue/Yellow STANDARD : Continultv i \ Normal Disconnect the control unit (ECU) 16F and speed sensor 3? (natural) connector. Check Ior continuity between the control unit 16? connector and speed sensor 3? connector terminal 01 the wire harness side. WNMCHON : nItIGnen - Plnlthrun STANDARD : Continulty Normal - Faulty control unit Slipped Abnormal Abnormal Abnormal - Inspect the clutch (section 8) - Faulty angle sensor . Open circult in related wire - Loose or poor contacts 0' related terminal - Open circuit in related wire - Loose or poor contacts of related terminal 21-9 ELECTRIC SHIFT PROGRAM (ESP) GEAR POSITION INDICATOR OPERATES ABNORMALLY - inspect the following before diagnosing the system, ~ Make sure the battery is fully charged and in good — Clutch adjustment oonditont — Blown main (30A). motor (30A) or sub fuse (Light (15A), ignition (toAii. — The engine runs normally - Speedometer operates normally Set the parking brake. Stan the engine, then shift through the all gear positions and check the gear position indicator operation, Start the engine and check for proper clutch operation. Abnormal NON“al - Faulty clutch Remove the angle sensor (page 21v26i. Visually inspect the angle sensor shaft hole and gear shift spindle for damage ANGLE SENSOR GEAR SHIFT SHAFT HOLE SPINDLE Abnormal Normal - Replace the angle sensor inspect the angle sensor (page 21-25it Normal Shift indicator operates abnormally at lst, neutral. 5th and/or reverse Inspect the gear position switch (page 21-29it Abnormal Normal - Faulty gear position switch Disconnect the gear position switch 4F connector and combination meter HP connectort Check for continuity between the change switch JP connector and combination meter HP connector terminal of the wire harness side. CONNECTION : Grey - Guy Light gran/Rod - Light groan/Rod White/Gran - White/Green Light biuolWItito- Light blue/White STANDARD : Continuity (page Zl-Zsit - Replace the sub gearshift spindle (section 9) Abnormal 1 Normal - Faulty combination meter Abnormal _. - Open circuit in related wire - Loose or poor contacts of related terminal - Faulty angle sensor 21-10 ELECTRIC SHIFT PROGRAM (ESP) l Normal Disconnect the control unit 18F and Ignition control module tP connector‘ Check for continuity between the control unit 16F connector and Ignition control module 4? connector terminal oi the wire harness side. CONIECI'ION : lino/Vellum: - BlullVoilow STANDARD : Continuity Normal Disconnect the control unit 16F and speed sensor 3? connector. Check lor continuity between the control unit 16F connector and speed sensor 3? connector terminal a! the wire harness sidet CORRECTION : Plnlthnen — Pink/Green STAMARD : Continultv Normal - Faulty control unit Abnormal Abnormal - Open circuit in related wire - Loose or poor contacts 01 related terminal - Open circuit in related wire - Loose or poor contacts of related terminal 21-11 ELECTRIC SHIFT PROGRAM (ESPI ELECTRIC SHIFT DOES NOT OPERATE WHEN ENGAGING THE REVERSE GEAR - Inspect the Iollowing beIore diagnosing the system. - Make sure the battery is Iullv charged and in good conditonr — Clutch adjustment — Blown mam (SOAL motor (30A) or sub ruse (Light (15ml ignition (10All. i Turn the ignition switch "OFF". ‘ Shift the gear manually using the gear change tool, GEAR CHANGE TOOL Normal '1 Inspect the reverse shift switch (page 21-30). Normal Disconnect the control unit 16F and reverse shih switch 2P (red) connector. Check for continuity between the control unit 16F connector and reverse shift 2P iredl connector terminal of the wire harness side. CONNECTION : Guy/Red - Guy/Rod STANDARD : Contlnuity Normal Disconnect reverse shift switch 2P (red) connector. Check for continuity between the reverse shift swrtch 2P (real connector and body grondt CONNECTION : Green — Body ground STANDARD : Comlnullv 1 Normal - Faulty control unit Abnormal Abnormal Abnormal Abnormal - Faulty transmission or gearshilt linkage (section 9/11) - Faulty reverse shift switch - Open circuit in related wire - Loose or poor contacts oI related terminal - Open circuit in related wire - Loose or poor contacts of related terminal 21-12 ELECTRIC SHIFT PROGRAM IESPl CONTROL MOTOR TURNS WHEN THE SHIFT SWITCH IS PUSHED DOWN WITH THE REVERSE SELECTOR NOT OPERATED - Inspect the following before diagnosing the system. — Make sure the battery is lully charged and in good conditon. v Blown main (GOAL motor (GOA) or sub Iuse (Light USA). Ignition (ION) Abnormal Inspect the reverse shiIt switch (page 2130). —* - Faulty reverse shift switch Normal ‘ Disconnect the control unit 16F and reverse shift ‘ Abnormal - Open circuit in related wire switch 2P (red) connector. V - Loose or poor contacts of related terminal Check lor continuity between the control unit 1GP ‘ connector and reverse shift 2P (red) connector terminal 01 the wire harness side. CONNECTION : Gray/Rod - Guy/Rod STANDARD : Continuity Normal .—I—c ‘ Disconnect reverse shift switch 2? (red) connector. Abnormal _ . , 7 a - Open circuit in related Wire Check Ior continuity between the reverse shirt ' Loose or poor comm“ 9' related ”mm“ switch 2P (red) connector and body grand, CONNECTION ' Green - Body ground i STANDARD : Continultv ‘ mi ‘ Normal V - Faulty control unit 21-13 ELECTRIC SHIFT PROGRAM (ESP) TROUBLESHOOTING lAfter'01) BEFORE TROUBLESHOOTING When the Electric Control Unit lECU) detects a system abnormality, the ECU has a built-in self~diagnostic function that stops the Electric Shift (ES) system or resets the systems entirely liust as when the ignition switch is turned from ”OFF” to "0N”l. If the ECU detects an E5 system failure, the ECU stops the ES system function end records a problem code. The ES system will not operate, even after the ignition switch is turned to "OFF". To reset the ES system, turn the ignition switch from “0N" to “OFF” and back to ”ON” again. However, if the ECU still detects a problem, it Will continue to deactivate the ES system function. When this occurs, the gear position indicator will blink a certain number of times to indicate the appropriate problem code. The ECU is able to record system failures and outputs these as problem codes that are shown on the indicator (ii a” the ”N“ blinks a designated number of times). TROUBLESHOOTING PROCEDURE When the operator detects an abnormality. check the following before proceeding with the diagnosis: li Check the battery voltagel 'nimum spec. 12.! V) and any blown fuses. 2. Turn the ignition switch to "ON". If the gear indicator blinks, record the number of blinks, since this indicates the type of failure. Then troubleshoot the indicated failure. Refer to the appropriate problem code within this chapter. If no ES system failure occurs (the indicator does not blink), perform the following: I. Make sure the gear position indicator blinked codes to the user. Check the problem code as described below. a) Turn the ignition switch to "OFF“ bl Place the transmission in neutral. cl Apply the parking brake so the vehicle does not move. d) Turn the ignition switch to ”ON” while pushing both electric shift switches (UP and DOWN]. Make sure the "N" appears to indicate that the transmission is in neutral. 3) Wait 5 seconds and then push both electric shift switches again, and hold them for at least 3 seconds lithe code number could not be checked (the indicator did not blink), repeat steps 2 and I. .ll a failure is still not indicated (i, 5., the ”N“ does not blink), the problem is as follows: al Electric shift does not operate (page 2146) and/or b) Faulty gear indicator (e. 9., does not indicate the problem, keeps indicating the same gear position, indicates a different gear position than what the transmission is in) 4. After performing the above troubleshooting steps and repairing the problem, delete the codes as follows: 3) Turn the ignition switch to ”OFF". In) Place the transmissron in neutral. cl Apply the parking brake so the vehicle does not move. dl Turn the ignition switch to ”ON” while pushing both electric shift switches (UP and DOWN). Make sure the 'N" appears to indicate that the transmission is in neutral. e) Wait 5 seconds and then push both electric shift switches again, and hold them for at least 3 seconds. fl While the indicator is showrng the problem code (i ., blinking with the transmission in neutral), push both electric shift swflches to delete the problem code number. 9) Turn the ignition switch to "OFF”. am ONE BLINKS OLD PROBLEM CODE ONE BLINKS LATEST PROBLEM CODE GEAR POSITION INDICATOR 21-14 ELECTRIC SHIFT PROGRAM (ESP) Diagnosis table v ggxsmdlcator Check part and system Probable faulty part aegis/9 0 No problem No problem 7' 1 EUC (writing and recoding circuit] ECU 21-18 2 ES shift switch system (up and down) Shift switch or related wire harness or ECU 21—18 D 3 Angle sensor system Angle sensor (abnormlry Installed) or related wire 21-19 harness or ECU 4 Gear position switch system Gear position switch or related wire herness or ECU 21-21 5 ECU motor driver circuit ECU 21-22 6 ECU lal|~safe relay circuit ECU 2143 U 7 ECU voltage convent circuit ECU 2123 8 Angle sensor system Angle sensor or control motor or related wire harness 21-19 or ECU 9 Angle sensor system Angle sensor (short or open) or related wire harness 21-19 or ECU 1O Ignition pulse generator system Ignition pulse generator or related wire harness 21~24 _ 11 Speed sensor svstem (vehicle speed) Speed sensor or related wire harness or ECU 21-25 12 Gear position switch system Gear position switch or related wire harness or ECU 21-21 21-15 ELECTRIC SHIFT PROGRAM (ESP) ELECTRIC SHIFT DOES NOT OPERATE - Inspect the following belore diagnosing the system — Make sure the battery is Iully charged and in good condition — Clutch adjustment - Blown main (30A), motor (30A) or sub (use, ignition (10A) Turn the ignition swttch "OFF“. sum the gear manually using the gear change tool, ' GEAR CHANGE TOOL Normal Check the gear indicator, Indicate the gear position GEAR INDICATOR PROBLEM - No indication oi gear position ~ Keeps indicating same gear position ~ DiIIerant gear is indicated Make sure the ECU, combination meter, gear position switch and ground wires are properly connected Normal Abnormal Faulty Abnormal 4' ' Faulty transmission or gearshift linkage (section 9/11) - Troubleshoot the gear position switch system (page 2141) —> ~ Troubleshoot the ES shift switch system (page 21-18) . Loose or poor contact of related circuit. Abnormal Disconnect the ECU connector (ZZP/Blueit Turn the ignition switch ”OFF”. Check Ior continuity at the ECU connector oi the wire harness side as Iollows: CONIiECTIONS : - Light greenIRed M - Body Ground (—1. when shitting to neutral - White/Green (ti - Body Ground l-l. when shifting to 1st gear ' Pink/Bin! I0) - Body Ground (-I. when iiian to 2nd gear - Blue/White to) ~ Body Ground l-l. when shifting to 3rd geer - Yellow/Oren” lo) - Body Ground l-l, when ehitting to lth gear - Light Bin/White lo) - Body Ground l-l when ehiftlng to 51h geer - Grey M — Body Ground l—ii when shitting to reverse STANDARD: Continuity l Normal Disconnect the gear position switch connector (8?). Check for continuity at the gear position switch connectors as Iollowing: CONNECTIONS : - Light green/Red lrl - Body Ground (-l. when shifting to neutral ~ White/Green M - Body Ground (-1. when shifting to 1st gear - Pink/Bloc is) - Body Ground (-I. when shitting to 2nd year - Blue/White l1») - Body Ground 1-]. witch “lifting to 3rd year - Yellow/Orange (o) - Body Ground (-i, when ehmlng to lth Deer - Light Blue/White lo) - Body Ground l-) when shifting to 5th gear - Guy I.) - Body Ground l-I. when shitting to reverse STANDARD: Continuity i Abnormal - Faulty gear position swrtch _. - Loose or poor contact oI related circuit 21-16 ELECTRIC SHIFT PROGRAM (ESP) Disconnect the combination meter connector (HP). Check for continuity of the Gray/Black wire between the ECU connector and the combination mater connector terminals. CDNIECTION: Guy/Block (s) - Grey/Block l-l STAMARD: Comlnulty ML. . Open circuit in Gray/Black wire - Loose or poor contact 0' related circuit Continuity Shilt the transmission into neutraL Check lor continuity between the Gray/Black terminals of the combination meter and body ground with the igniton switch "0N". m - Faulty combination meter Continuity ————> - Replace the ECU with a new one and troubleshoot again 21-17 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 1: ECU (writing and recording circuit) Delete the problem code numberi Check the ES system leilure (the gear indicator blinks) when turning the ignition switch lrom ”OFF" to ”ON'X Blinks - Replace the ECU with a new one and troubleshoot again No blinks ———-——> - No problem (temporary lailure) Problem Code 2: ES Shift Switch System (Up And Down) Check the connectons of the ECU, gear shift switch and related circuit. M - Loose or poor connections in related circuit, Normal Discunnectthe ECU connector (22P/Bluelt Abnormal Check lor mud or water in the left handlebar Check for continuity at the wire harness side switch housing. connector while pushing the shift switches up or Normal Abnormal - Clean the Ielt handlebar switch housing Disconnect the left handlebar switch connector. Check for continuity while pushing the shilt switches up or down. CONNECTION: Shift up switch: Block/Light blue lo] - White/Blue l-l CONNECT'OM slim down twitch: Black/Light blue 1+) - Shllt up switch: Black/unlit blue [cl - White/Vellow l-l "hm/3"" H STANDARD: c r ' sum down when: Block/light blue M - M "m" While/Vollow H N A snumno: Continuity °""“' Wm“ - Replace the Ian handlebar switch | Norma 4. - Loosa or poor contact of related circuit ' Open or short of related circult Check the ES system lailure (the gear indicator —-—>B""ks ' “90'3“ "‘8 ECU with i new one and troubleshoot blinks) when turning the ignition switch lrom "OFF" to "ON'V again No blinks —> - No problem ltemporarv lailure) 21-18 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 3. B, 5: Angle Sensor System Check the connections of the ECU, angle sensor and related circuit. Normal Turn the ignition switch “OFF", Disconnect the ECU connector (HP/Blue), Measure the resistance between the Black/Rad and Blue/Green terminals ol the wire harness side. Normal Abnormal Abnormal - Loose or poor contact at related circuit Ff Make sure the angle sensor is correctv installed to the engine ‘ ‘ 7. ANGLE , , SENSOR CONNECTOR Abnormal Normal Disconnect the angle sensor connector (SP). Check lor continuity between Iha Yellow/Blue terminals of the ECU connector and the angle sensor connectori CONNECTION: Yellow/Blue (cl - Yellow/Blue l-l STANDARD: Conflnultv Ahnormal 1 Normal ———>. __.. Disconnect the angle sensor connector ISP). Check for continuity tor the ECU and angle sensor connectors. CONNECTION: Black/fled (cl - Black/Red l-l Blue/Green (cl - Blue Green (—l ANGLE SENSOR CONNECTOR Normal Abnormal ~ Open or shon ol related circuit —> - Faulty angle sensor Loosen the angle sensor mounting bolts. Open or short 0! related circuit 21-19 ELECTRIC SHIFT PROGRAM (ESP) Connect the ECU connector (HP/Blue) and angle sensor connector (3Plt With the ignition switch 'ON", measure the voltage between the Black/Red and the Blue/Green terminals. CONIEC'HON: Block/led (vl - Blue/Green (-1 STANDARD: £75 - 5.25 V Normal Turn the ignition switch ”OFF", Disconnect the ECU connector (HP/Blue). Measure the resistance between the Vellow/Blue and Blue/Green terminals 01 the wire harness side while shifting through all the gears list, 2nd, 3rd, lth, 5th, Reverse) CONNECHON: Yellow/Blue (o) - Blue/Green l-l STANDARD: 0 - 5 H) A——.>Ab"°""a' - Replace the ECU with a new one end troubleshool again Abnormal —. - Faulty angle sensor Normal Check the ES system lailure (the gear indicator hlinksl when turning the ignition switch lrorn "OFF" lo 'ON", —>B""k5 - Replace the ECU with a new one and troubleshoot again No blinks “a - No problem (temporary failure) 21-20 ELECTRIC SHIFT PROGRAM (ESP) Problem Codes 4 or 12: Gear Position Switch System swrtch and related Ceruii. Disconnect the ECU connector (ZZP/Blue). Turn the rgnition swrtch “OFF". Check for continuity at the ECU connector of the wire harness srdo as lollows: CONNECUONS : . Light green/Red (o) - Body Ground l-i, when shifting to neutral - White/Green lei - Body Ground I-L when shifting to I51 gear - Plnk/Blue (+1 - Body Ground l-l, when shifting to 2nd gear - BIue/Whhe M - Body Ground (-1. when shifting to 3rd goer - VellowIOrange lb) - Body Ground [-1. whon shifting to lth geer - Light Blue/White M - Body Ground H. when shifting to 5th gear - Grey M - Body Ground l-l. when shifting to reverse STANDARD: Continuity ——l—— ‘ Normal Check the connections of the ECU. gear posuion Normal Abnormal Abnormal ' Loose or poor coniaci or related circuit —___i_—__, Connect the ECU connector (HP/Blue}. Disconnect the gsar position switch connector (BF), Turn the Ignition switch ”0N". Measure the voltage at the gear position switch connector ol the wire harness side as same connections as above procedure. STANDARD: 5 V Normal blinks) when turning the Ignition switch lrorn "OFF” to 'ON“. ‘ No blinks Check the ES system lailure (the gear indicator Blinks Disconnect the gear position swutch connector laP), Check for the continuity at the gear position swttcn connector as lollows: CONNECTIONS 2 - Light green/Red lo) - Body Ground l—l. when shifting to neutral - White/Green lo) — Body Ground l-l. when shitting to in gear - Pink/Blue l6) - Body Ground l—l. when shifting to 2nd gear - Blue/White (o) - Body Ground l-i, when ehltlng to 3rd geer - VellowlOrenge lo) - Body Ground (-1, when shifting to 4th our - Light Blue/Whlte l-l — Body Ground l—l when shifting to 5th gear - Grey (vi - Body Ground l-). when shining to reverse SYANDARD: Continuity Normal l Aborrnal - Faulty gear position switch ——> - Open or short circuit in related circuit MM» - Replace the ECU unit wrth a new one and troubleshoot again —————> ' Replace the ECU with a new one and troubleshoot again A _V——> - No problem (temporary lailure) 21-21 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 5: ECU Motor Driver Circuit Check the connections at the ECU, motor and related circuit Ab‘___.norrnal - Loose or poor contact of related circuits Normal Disconnect the ECU connector (SP/Brown). Measure the voltage between the Red/Yellow terminal and body ground. CONPEC’HON: Red/Venom l9) - Body ground STANDARD: 11 V minimum Normal M- Loose or poor contact of related circuits - Blown luse - Open circuit in Red/Yellow wire Check for continuity between the Green terminal and body ground. '9 CONNECTION: Green lo) - Body ground t-l STAIDARD: Continuity __.Abnorrnal - Loose or poor contact 0' related circuits - Open circuit in Green wire Normal Disconnect the motor connector (2?). Check for continuity between the ECU connector and motor connector, OONIECTIONS: Orange M - Orange 1—) Green/Blue M - Green/Elna i-I STAMARD: Confluultv —.Ab"°"“" - Loose or poor content of related circuits - Open or loose circuit in Orange and/or Green] Blue wire 1 Normal 21 -22 C G ELECTRIC SHIFT PROGRAM (ESP) Connect a iuliy charged connector terminalsr battery to the motor 2P w. . Faullv motar Motor turns Check the ES system la ilure (the gear indicator blinks) when turning the ignition switch from "OFF“ to "ON". —~—9"“kS—> ‘ Repalce the ECU With a new one and troubleshoot again No blinks - No problem (temporary failure) Problem Code 6: ECU Fail-Sate Circuit or Problem Code 7: ECU Voltage Convert Circuit Check the ES system iailure (the gear indicator blinks) when turning the ignition switch from 'OFF' to "ON". m» - No problem (temporary failure) Blinks Bill‘s other than Check the number 0' number) blinks (problem code So 7tmea ' I - Troubleshoot the problem code Six or seven blinks —-———’ - Replace the ECU with a new one and troubleshoot again 21-23 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 10: Ignition Pulse Generator System Check the connection ol the ECU. Ignition pulse generator and related circuit. m. - Loose or poor contact ol related circuit Normal Check the connections ol the ground cables. _A___’bnormal . Loose or poor contact ol ground cablelsl Normal Disconnect the ECU connector (HP/Blue) and pulse generator connector (5F)r Check ior continuitv in the BIue/Vellow wire between the ECU and pulse generator connector terminals. CONNECTION: Blue/Yellow (oi - Bow Yellow I-l STANDARD: Continuity ML- Open circuit in Blue/Yellow wire - Loose or poor contact ol related circuit Normal Check the ignition system (page 184). ,AL'EL'L‘L'- - Ignition system lailure Normal Gear Indium! Check the number of gear indicator blinks while drivmg in lst gear over 6 ltm/h l4 mi/hl tor more than 6 seconds L» - Replace the ECU with a new one and troubleshoot again No blinks ~—_> - No problem (temporary lailurel 21 -24 ELECTRIC SHIFT PROGRAM (ESP) Problem Code 11: Speed Sensor System (Vehicle Speed) Check the vehicle speed Indicator during low speed driving. M» ~ Check the combination meter (page 202) Normal Check the connection ol the Pink/Green and Black/Blue wires Between the ECU and the meter speed sensor. Abnormal - Loose or poor contact 0' related terminals Normal Turn the ignition switch "OFF". Disconnect the ECU connector (22P/Bluel and speed sensor connector. Chuck lor continuity in the Pink/Green wnre between the ECU connector and meter speed sensor terminals. Ff it. .. 5:1 _l f: :14 CONhEC'HON: Flak/Green (cl - Pink/Green (—I STANDARD: Continuity m. Open circuit in Pink/Green Wire Continuity 6w indicator Check the number cl gear indicator blinks while driving In 1st gear over 6 km/h (4 mill” for more than 6 seconds, L - Replace the ECU with a new one and troubleshoot again No blinks —_> - No problem (temporay lailure) 21-25 ELECTRIC SHIFT PROGRAM (ESP) ANGLE SENSOR INSPECTION ‘I. Neutral Resistance Turn the ignition switch OFF. Remove the angle sensor cover (page 21-27). Disconnect the control motor 3? connector. Measure and record the resistance between the Black/Red and Blue/Green connector terminal ol the control motor side. Neutral Resistance Connection : Black/Red - Blue/Green Standard : 4-6 I) 2. Shift-up Resistanos Measure and record the resistnce between the Blue/Green and Yellow/Rad connector terminal ol the control motor side while upshilting the gear manually using the gear change tool. shlfl-up Resistance Connection : Blue/Green - Vellowl Red Measurlng Condition : At Upshlft 3. Shut-down Resistance Measure and record the resistance between the Blue/Green and Yellow/Red connector terminal a! the control motor side while downshilting the gear manually using the gear change tool. Shut-down Resistance Connection : Blue/Green . Yellow/Red Meesurlng Conditlon : At Dowmhltt t. Cabal-ted Result Comparison Compare the above measurement to the result of the following calculations. At ShIIt-Up: Measured shift-up resistance in step 2 / Neutral Resistance In step 1 < 0.4 The sensor is normal if the result of the calculation is less than 0.4. At Shutdown : Measured shift-down refinance In step 2 1 Neutral Resls‘unee In step 1 > u The sensor is normal it the result ol the calculation :5 greater than 0,6. BLUE/GREEN TERMINAL BLUE/GREEN TERMINAL BLACK / RED TERMINAL C YELLOW / RED TERMINAL \ f2» ANGLE SENSOR 21-26 ELECTRIC SHIFT PROGRAM (ESP) REMOVAL Remove the the two bolts and cover. Disnennecl the angle sensor connecor [mm the sensor. Remove the two bolts and angle sensor. INSTALLATION Inslal the angle sensor aligning cutout with angle sensor shall and gear shin spindle. Tighten the two bolts and connect the angle sense. TOROUE : 5 MM (0.6 kgl‘m. Alibi-h) |nstall the cover and tighten the two bolts. CONNECTOR CONNECTOR ANGLE SENSOR WASHER 21-27 ELECTRIC SHIFT PROGRAM IESPI CONTROL MOTOR REMOVAL Ramave the angle sensor (page 21~27). Disconnect the control motor 2P connector. Remove the two bolts and control motor. Remove the O-ring and dowal pint Disassemble the reduction gears. INSTALLATION Thoroughly clean and apply the specified grease to the reduction gear shaft sliding surface as shown RECOMMENDED GREASE : UNIREX N2 GREASE (ESSOI or UNIREX N3 GREASE (E580) or equiv-hm BOLTS DOWEL PIN REDUCTION GEARS APPLV SPECIFIED GREASE 21 -28 ELECTRIC SHIFT PROGRAM (ESP) Thoruugllly clean and apply the specified grease to the reduction gear contact area as shown. RECOMMENDED GREASE 2 UMREX N2 GREASE lESSO) or UNIREX N3 GREASE (E850) or equlvllent Install the reduction gears (HT/1M and 40T/12TL Install the reduction gear (7T) by aligning the punch marks an the reduction gear UT) and gear shift :pindle. install a new O-ring and dowel pin, Install the control motor and tighten the bolts. Connect the control motor 25' connectort Install the angle sensor (page 21-27). APPLY SPECIFIED GREASE REDUCTION GEAH(41T/10T) REDUCTION GEAR (7T) REDUCTION GEAR MOT/127) ALIGN 00sz Pm \ CONTfiOL BOLTS \ 2P lNA‘rURAL) CONNECTOR 21 -29 ELECTRIC SHIFT PROGRAM (ESP) GEAR POSITION SWITCH INSPECTION Remove the roght lower srde cover (page 2-3), Disconnect the gear pusmon swrtch connector Check for contrnulty between the 993! pOSIUOn swnch 4P connector and body ground, Contrnmty should exrst between the color coded wue terminals as Iollows when m the appropriate gear. It Is recommended to pertorm 16 tests to properly Inspect the swrtch. Make sure that the CIfCuIIS wrth Continully and wtthout COHIII’IUIIY are OK. The same hotds true Ior the Altar ‘01 switch‘ However, tor thts switch you need to pertorm ‘9 IESISV ['98 — '01:) BODY Gr LG,’H W/G LB GROUND REVERSE ‘O—';' C NEUTRAL 5 IST 9 5TH ‘3 (Mn: ‘01:) After '01: ' Gr Lgnfi W/G P'Bu REVERSE , C " VNEUTRAL a _v5 Eu/W BODV wo WW Gamma 21-30 ‘ '1 ELECTRIC SHIFT PROGRAM (ESP) SHIFT SWITCH INSPECTION Q Remove the Item lender (page 2A6): Disconnect the shiti switch connector. Check tor the continuity between the shift switch 3P connector terminal of the switch side. U Continuity should exist between the color coded wire terminals as follows. 1 1 :1:1::f w~ :.:::: 1 ? A,l:v . . .._ U FREE ‘ V1 . V a i i- 1 DOWN T H REVERSE SHIFT SWITCH INSPECTION Remove the trout fender (page 26). Disconnect the reverse shift switch 2P (rent) connector. Check for the continuity at the reverse shift switch 2? lred) connector terminal of the switch side. There should he continuity with the reverse selector GREEN GRAY / RED ‘ operated and no continuity with it released. MAIN RELAY (’98 - ’01) commum/ INSPECTION Disconnect the connector lrorn the main relay. Connect an ohmmeter to the Red/Yellow and Red] White terminals. Connect a Iullv charged 12V battery to the Black] Orange and Green wire terminals. There should be continuity while ‘IZV battery is connected to the main relay connectortarminels and there are should be no continuity when the battery ‘ is disconnected. MAIN RELAV 21-31 SELECT ABLE 4WD SYSTEM (After ’01) SELECTABLE 4WD SYSTEM (After '01) ’Wm‘WD SW'TC“ FINAL CLUTCH CONTROL UNIT FINAL CLUTCH SPEED SENSOR METER SPEED SENSOR \‘\ 7 ’ FRONT FINAL CLUTCH IEflHfll filial (roe) um um FUSE e 3 1m \—' FUSE = ' ° — we a a - IOA mm 5 _ I a “ESSaai’aau m ”m -— to son mu “'0" I: wo— —EI/0_——J SPEED P _ —P/Bl 52m '—Bl Km? 1? 5 — —6 SPEED “0'" - m — —l/v ' p/G— —p senses mm mm mm mm r0\O—R—O’\/O—n7, e 65?» alum — BI — ‘l/R Gr mslm m - Loose or poor contact on wrre harness - Temporary lailure (electromagnetic obstruction or noise) Three blinks Check for loose or poor connections on wire harness Abnormal . , —> - Loose or poor connections on Wire harness Normal Replace the FCC unit with a new one and troubleshoot again 22-6 SELECTABLE 4WD SYSTEM (After '01) 4WD Indicator Problem Code 4: FCC Unit System Voltage - Inspect the lollowing beiore diagnosing the system. b v Make sure the battery is fully charged and in good condition. — Engine idle speed Check the connections oi the FCC unit, luse box, M» - Loose or poor connections in related circuit battery and related circuit. Normal Turn the ignition switch “ON” and check the M19 - No problem (temporary failure) number oi times the 4WD indicator blinks after 30 I seconds. tour time blinks Ab normal Turn the ignition switch ”OFF“. —> - Short or open circuit between battery and FCC unit Disconnect the FCC unit connector. - lithe related wire is OK, check the charging system With the ignition switch "ON", measure the (section In voltage between the Red/White and Green connector terminals ol the wire harness side, CONNEC'HON: Rod/White (Oi - Green (-l STANDARD: 11 - 16 V 1 Mom. ‘ Replace the FCC unit with it new one and troubleshoot again 22-7 SELECT ABLE 4WD SYSTEM (After '01) 4WD Indication Problem Code 5: FCC Unit Driver Check the connections ol the FCC unit. final clutch speed sensor and related circuit: VAbnormaI Normal Turn the ignition switch ”ON". Check the number of time the 4WD indicator blinks: No blinks Five blinks Turn the ignition switch "OFF”. Disconnect the linal clutch control (FCC) unit connector and lronl final clutch connector: Check lor continuity between the White/Yellow land White/Red) terminals of the FCC unit connector and lront linal clutch connector: CONNECTION: White/Yellow 1+) - MRI/Yellow l-l With/Rod (9) - WWI/fled H STANDARD: Contlnulty Normal Check loi continuity between the White/Vellow (and White/Red) connector terminal ol the wire herness side and body ground, CONNECTION: Vinita/Voila“! M - Bow mud l—l While/Nod is) - 300' MM H STANDARD: No Contlnultv Abnormal Abnormal 1 Normal ' Loose or poor connections in related circuit - No problem (temporary lailure) - Open circuit in White/Red and/or White/Yellow wire ——> - shorted White/Vellow and/or White/Red wire 22-8 U SELECTABLE 4WD SVSTEM (After '01) Measure the resistance between the White/Rad and White/Yellow terminals of the hunt tinal clutch. CONIVECTION: While/Venom l+l -Wh'tll/Rld l—) STANDARD: 3 - 7 L] M. - Faulty tront linal clutch l M———v - Replace the FCC unit with a new one and troubleshoot again 4WD indicator Problem Code 6: Alternator Check the connections at the FCC unit, alternator and related circuit. Abnormal , . Loose or poor contact of related circuit Normal Check the number at two indicator blinks when driving in two over 10 km/h 16 milhl for more than Ito seconds. m. - No problem (tamnorarv lailurel Six blinks Turn the ignition swilch "OFF'. Disconnect the tinel clutch control (FCC) unit connector and alternator connector‘ Check for continuity between the Yellow terminals of the FCC unit connector and alternator connector. CONNECTION: View (0) - Velow [4 STANDARD: Continuity Abnormal r Open circuit in Velow wire 1 Normal 22-9 SELECTABLE 4WD SYSTEM (After '01) Check for continuity between the Yellow M- ShonedVellowwiie connector terminal of the wire harness side and body ground. DONl‘ECflON: Volow M - Body wound l-l STANDARD: No Continunv Normal Check the battery/charging system (section 17) Apnormal - Faulty battery/charging system I M———+ - Replace the FCC unit with a new one and troubleshoot again 22-10 TRXISOS ('98 - '01) leumou swrrcn n__ 855? neumou q??? CONTROL IIII monumucu) quoron “‘5 mm @z w 55 >555 cansumon HEATER NEUTRAL INDICATORLED 8 L OIL pg Innlcggmeo _ 3:; :33# “:5 :M— ammo :3” 11 £25 5:; 3552*” ——5.§§ 25,, Dian/mm 5:17 “5 [Li M rm HI oz: '1 *W —a M 0,_ J3 s: E J Assnsr HEADLIGHT 12v45w (LOW) zc no I], min: was NEUTRAL/ memo tins“: Revanss SWITCH SENSOR W 11 IGNmoN swrrcn umswncn gggggflg am) DC BAT1BA‘I’ we on o——o o——o cm L} LIGHTING/STARTER! OFF on: ENGINE WHO” ma m P a BI :33. am 23. WIRING DIAGRAM SPEED SENSOR START MAGNETIC swncn ‘ 0g?- ! REGULATOR/ ‘ ‘ 0 RECTIFIER 0 :; ' © (-3 ’ ’ * ‘ ‘ BATTERY 1 '3” N” g: 12mm 1 \ J u [ : , STARTER K j w”: i'u— wan MOTOR 5 9 E K i T ‘ E é. , gs; > ,_ w ENGINE mo ENGWE \ WF 2» 1 K, ' \ H P 7, > :- T 1 . ' FUSE BOX 7 § 11 7“. inzifimlt-W l In ,F :5,- mm+ru kwma 'fimr we 7 am 7 “‘91 m ' G 71774 \1 V3 '2 i 7 7 4 i a. 436— av __ if 7 4 I F, E ‘ ‘ a: m a , T '5. ‘ ‘ bi :. m a g — G —D 5° $5 ‘ TAILLIGHT [ 112V5Wx2b k ‘ 6:5 ‘ J. 9 " § ' ‘7 ‘ ENGINE FRAME FRM FRM gig: in T \ l 1 a wv wv mm mm Bl BLACK B BROWN FAN CONTROL 1% 3.15,, 0' ORANGE I ’ ‘ ’ Bu BLUE Lb UMUE §NGINE ENGINE ENGINE G GREEN Ll UGHTGHEEN 7 fig?" ALTERNATOR (ST—fin £7 $7 GENERATOR commons Gmmmmm : DIMMER swrrcn ENGINE STOP STARTER swncu 3 V_S__WITCH ;i (H|) Lg J‘L ' am 16 \ am ST I LO 0‘0 3F FREE \ 1 (N) o——0——o fl”: _:>——c PUSH 0—443 :_ HI 0 3 on: m}. avadwn ‘ Rm T w m: “g. aI/G aI/w 00302-HNO-A000 WIRING DIAGRAM TRX‘SOES ('98 — '01) wt: _ 8:3: mm FEED )1? m9 MEL $5."? ‘11! new .., G (#3:... L.- ,_ WM {gm : :_—E— P I. , [M ii an 35° 5 CAHBURETOR —": ': HEATER u—m—o #— l n—cD—N fig: :3: ‘3']; VD VI) m an (IV E n n- 38% —m m— m M m M I I I. n —R E II: In REVERSE p- " ° swrrcu o__,,_ u m— u- u.— n «— "Mi—F; 1%? Cw TEE: EE A8615"! n W m ill GEARPOSITION My? 4% SW m is” LIGHTING/81m 7 7 7 ENGNESTOPMFTSMTCN mans mm IGNITIONSWI'I’OH LIGHHNGSWITCH umswnm ENGiNESTOP STARTE swrrcu BAR DC BA“ BAT BAT! TL (HL) (HI) LO Fl 8A1" K! on o——o o——o on o——o——o L0 o——o on me: orr or; (N) o——o—~o mono PUSH “REP H H 33.591315! K O 0 OFF :35. gr. 1» wmmmw —J TART MAGNETIC EWTCH REGULATOR] RECTIFIER ELECTRONIC CONTROL UNIT 3,} igizggfiéifiasss l I 1 ans: £§§e§s§§325§§§ _ w __ an v1 V? n n a -— fl —(:l<)— fl — D - av —a<— I — Iv 3 LI —G Iv —C)Q— i — I R a m Q ~ 5 —- 0 —D TAILLIGHT \ mar (1mm) WAYERPKY ga 03 593 53‘“ an efia: Lu 6 6 hip? 9%» #- 0 $1 #H W T . °° W 33‘” ENGINE ran: “a, T FAN ® ssttEm F“ - UNIT TOFI ran an m 3: BROWN v mow 0 came: an nu: Lb mgg_ IGNITION PULSE ALTERNATOR 6 am La Lien-rm GENERATOR 7 T 54 nsn 3 gm ENG” mmmmommm SWITCH SHIFFSWITCN 1'3 ST UP VCCDOWNVGC up o——o o——o FFIEE wn DOWN (yo é?- W 3"" W" 3"" 003OZ-HNO-A100 |_J TRX‘SOFM (After '01) mm FIIIL '1an mm mm eLurcu . , man SPEED SEW ; 3 SPEED SE , an m ‘Q "° comm. um um um n . .g . ... $53. massm .m_ “ i“ ‘ " a some! - » '. 1mm 5|le [Ely m- v n mam "wen u n :l . E— : g ml lam .. n u. m. um x-Iuv- I. m .1.— "mn- ~.~ =.- L w tlv DIGITAL IETER _ CPI! '5‘; .53, “...”. m L_.__I _ _ u—m—oa—u : mutton ooIL - ' SPAM PL .l _ 4 grain“ "‘3'“ a." season Slum ASSIST mum {.5555 _ mm "' = ‘ JLLl fill any; "W 5‘“?! menu mu LlamIIIa/SHRTEI/ Iaurlm slum mens smut mm film! nun: slw mm: stow/sum sum 9"“ luv: DC Ian m hm] n {In on m m hm u “I 00 00 a 0-0-0 Lo 00 on on an (In 000 M '0 : gm. ; - .. E-‘W .. m w En m” . w law- WIRING DIAGRAM myw 5mm name Kenna! ”W u 3) TAILLIEI" I 'm (Ile) I 00302 - HNO - 6700 23-3 WIRING DIAGRAM TRX450FE (After ’01) mm mm. CLUIUI ram FINAL cum»: IEIER SPEED siusun é é man x- cm m . m mum mm um um , .. Aootssm "- I . g sown ' 1 ”a . S “—klr : [L mu m 'f'fii'f‘ mm mm q;- 1: CARIIREYOR mm E— .. m u :1 . fi . . .m— . FM! NTDR m n ~90- u a ”um-."flh. “Z 3.}— j m n. mm“. m. m , was mm. M um I u 1 menu. mm 5'," ( I. .11; .5 mm... m. u “hm—u. , l n ‘ — ‘ mam sum c ”2132” v 5 no mm ‘. #:1131333: g I: hlu- hm Mr J u u - :_ name"! E ' : SE} : l " man/son: “j . :83: . ( E . _ . . I .9. n ME my Y ‘“ h :, “1.31:3; Posmuu mmn ( “—m ,. .. sum season _f_ SPARK mm mm __ _ an"! mas! m = 9...! gag m 9“" "“i’l "Iis manna In: LIBIIIIIG/SIMIER/ IBIIYIOI HIT“ LIWIIG “”61 DIII SIVDI “I! SW mu: swwsmn suntan 9”“ 11 0: an»! Inn IL on on U: m um u '- 0'0 0-0 I 0-00 "I 00 an w! 1" 0'0 55 u- . . .. 2.5.. - mu m 23-4 mo: “mm, 5mm mm mnnm mm 1‘ ELECTRONIC CONTROL WIT O O B. ..'.— $118!? I a-» 11$ 1mm :0“: nahzimliimea ’ ”ms: é 4, .W ""' lam ” 55 v "=9: §E§§5§J§§§S§5§55§ E u..- a: 5"" m 55 '5 m_ Fuse Box '-” l": 75' u. M 4th...“ ?.+M: m mm m M m m: I—CN—l I 1:”—°°" ._; mum! V :—g . I, (maxi) —l—C|°—I—I I—cl -g 55... 5- .. $3” :5 ”i: .. I, 55’” _ I'I m 'E =,,,;_ .3; 03.2,“— . ME T1201! H“! mm com mum nus: umm run: 02mm : _ a“ m‘m “In!“ ”In HUN HUD! Hulls! u! mludm I! 00 00 I .. u haul 0-0 Ill-Inw- "F"! J l I 00302 - HNO - 7700 24. TECHNICAL FEATURES ELECTRIC SHIFT PROGRAM (ESP) 24-1 SELECTABLE 4WD SYSTEM 24-5 (Afler '01I ELECTRIC SHIFT PROGRAM (ESP) The electric shih program (ESPI Is designed to make gearshift operation easner by replacing the Iooroperated shift pedal wnh a swnch Iocated near the operalor’s left hand. '98 — ’01 SHOWN: SHIFT SWITCH REVERSE SHIFT SWITCH IGNITION PULSE GENERATOR ANGLE SENSOR SPEED SENSOR MAIN RELAY ELECTRONIC CONTROL CONTROL MOTOR UN'T GEAR POSITION SWITCH 24-1 TECHNICAL FEATURES COMPONENT DIAGRAM SHIFT SWITCH COMBINATION METER CONTROL MOTOR IGNITION PULSE GENERATOR \ I SHIFT DRUM $593,“ I $83 I l I :I Z n [ | 5" g l , O o I I l— E I I REVERSE n » SHIFT | I r‘. I SWITCH ' I \J - ‘ I I a l I l l I I l I ”C j ‘ .1 MAIN RELAY I'ee - '01) ANGLE SENSOR (:9, _ '01) IGNITION swncn mum-I TRANSMISSION Shift Poeltlon Indlcator The shift position indicator incorporated in the combination meter indicates the gear position, detected through the gear posnion swnch (operated by an electric on and oh swutch to detect reverse, neutral, ‘lst, and 5thgearsl and ECU signals (calculated Irom the signals Irom both the engine speed and vehicle speed to detect 2nd, 3rd, 4th gears). Alter ‘01, all gears are detected through the gear position switch. Shlfl Switch When the operator pressing the shift switch that is installed on the lett handlebar, it sends a corresponding shift-up or shiftAdown signal to the ECU. Reverse Shift Switch The reverse shift switch that Is located above the rear brake lever bracket, turns on when the reverse selector is operated. Mlln Relay ('98 - ‘01) The mam relay that Is located inside the rear lender. shuts o" the electric current for the control motor when the ECU detects an error. Electronic Control Unit (ECU) The ECU that is located under the tram lender, controls the system by processing the signals coming lrom each switch and sensor. It also operates the control motor. InnItIon Pulee Generator The pulse generator that is located on the rear crankcase cover, controls the ignition system and also sends an engine speed alone! to the ECU. Control Motor The control motor is located on the Iront crankcase cover. and rotates the sub~gearshilt spindle depending on the voltage lrom the ECU. 24-2 0 CCC CCC “n- “ I—~ TECHNICAL FEATURES Angle Sensor The angle sensor that is located on the control motor, converIs the direction of rotation, rotating angle and rotating speed ol the sub-gearshift spindle into voltage and speed signals, and outputs them to the ECU. Beer PoaItlon Switch The gear position switch that is located inside the rear crankcase. controls the starter relay switch and also sends gear signals (For '98 - ’01: reverse. neutral lst, and 5th — Alter '01: all pears) to the ECU. Speed Sensor The speed sensor that is located on the rear crankcase. sends a vehicle speed signal to both the combination meter and the ECU. DESCRIPTION OF MAJOR COMPONENTS Angle Sensor REDUCTION GEARS ANGLE SENSOR SUB-GEARSHIFT SPINDLE The angle sensor shatt is connected to the end at the suogearshift spindle. It converts the direction at rotation. rotating angle and rotating speed at the sutrgearshitt spindle, into voltage and speed signals and than outputs these signals to the ECU. The rotation ol the angle sensor shalt changes a variable resistance value, thereby changing the out-put voltage to the Electronic Control Unit lrom the angle sensor. Electronlc Oomrol Unit .4 f. a ‘ . (V Y, t. ELECTRIC CONTROL UNIT (ECU) Consisting of the CPU, a motor drive circuit and gear position (2nd, 3rd and 4th gear signals) output circuits, the Electronic Control Unit calculates the signals Irom each switch and sensor and controls the ESP system. The Electronic Control Unit has a seIIAdlagnoslic Iunction (though it does not have the capability to display the results) which checks the whole system. It any error is lound as the result of sclfrdiagnosis, it shuts a” the electric current to the main relay (‘98 - ’OI). smpping the ESP. If the error is temporary, turn the ignition switch to "OFF" to erase the saltdiegnostic results. Then, restart the engine to resume the system. 24-3 TECHNICAL FEATURES TRANSMISSION CLUTCH LEVER SUB-GEARSHIFT SFINDLE CONTROL MOTOR MASTER ARM SHIFT DRUM The shift control motor actwates the clutch and shaft changes. It rotates the clutch Ievev. master arm and shift drum via the reduction gear and sub-gearshih spindle, It activates Ihe clutch and shin changes The shape ana number at the transmission gear dogs have been changed to cope with faster speed cl gear shifting by a shun control motor in place at the convenhonal foot-operated shift mechanism 24-4 TECHNICAL FEATURES SELECT ABLE 4WD SYSTEM (After '01) CONSTRUCTION This mechamsm controls the selectable 4WDI The rider selects either 2WD or AWD on the 2WD/‘WD switch that Is located an the "th handlebart Selection is possible when driving. This compact mechanism is Operated by an electromagnetic mechanical clutch lelectromagnetlcnlly activated bl—direcllonal roll-r clutches) and drives a built~in from diflerential pinion gear. This system provides lor smooth and quiet operation Vou can also shIlt smoothly between 2WD and 4WD, ALMATURE PLATE RETAINER DIFFERENTIAL CASE "WELLER SHAFT SWITCH “0&2“ SPRING CAM “'"G CONNECT ROLLER PLATE DRIVE SHAFT RING GEA CAM RING Roma GUIDE ARMATURE ROTOR PLATE ouTER RING ”MON GEAR K CONNECT PLATE ROTOR GUIDE . RING ELECTROMAGNETIC GEAR FIELD COIL a PINION GEAR DIFFERENTIAL CASE 24-5 TECHNICAL FEATURES OPERATION in front dMItentllll 1. 2WD torque transmission: Engine Prgpeller shalt SWITCH ROLLER Outer ring ._._ OUTER W RING WM \ ROLLER K RETAINER CAM RING 2. two torque transmission: When ‘WD is selected, voltage is applied to the lield coil. This creates a magnetic lield that magnetizes the rotor, The magnetic force pulls the armature plate against the rotor and rotates the roller retainerl This mnvas the rollers 1mm their center neutral position on the cam ring causing them to bind between the outer ring and the cam ring This allows power to flow to the drflerential and iront wheels. When power to the field coil is switched o", the switch spring moves the roller retainer to the neutral position tor 2WD operation. Engine Prépenu shah PUSHING C- THE SWITCH SPRING AND Outer ring THE RETAINER LOCKS THE R n if" 9' [D ( aouens Cum ring ’ Pinion gear v. Rina gear Diiterential case Drive shaft was Frent tires LOCK 24-6 25. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEED 25-1 25-2 25-3 POOR PERFORMANCE AT HIGH SPEED 25-4 POOR HANDLING 25-4 ENGINE DOES NOT START OR IS HARD TO START in .Start by Iollowmg normal procedure . Test cylinder compressmn Fuel reaching carburetor Good spark Remove and inspect spark plug Good Engine does not start Poulblo nun . Check the luel flow to carburetor — Fuel not reaching carburetor —> - Clogged fuel line and lilter - Clogged luel valve - Clogged Iuel Iill cap breather . Perform a spark test —Weak or no spark —> - Faulty spark plug - Fouled spark plug - Faulty ignition control module ~ Broken or shorted spark plug - Faulty ignition switch wi re - Faulty ignition pulse generator - Faulty engine stop swnch - Loosen or disconnected ignition svs» tam wires Fouled plug —-> - Flooded carburetor - Throttle valve open - Air cleaner dirty - Improperly adjusted pilot screw - Starting enrichment (SE) valve stuck open or damaged Engine starts but stops—> - Improper choke operation - Carburetor incorrectly adjusted - Intake pipe leaking - Improper ignition timing (Faulty igni- tion corl or ignition pulse generator) - Fuel contaminated Low compression — - Valve clearance too small - Valve stuck open - Worn cylinder and piston ring - Damaged cylinder head gasket - Seized valve - Improper valve timing TROUBLESHOOTING ENGINE LACKS POWER Possible cause 1, Raise wheel oil the gound and spin Wheels do not spin freely—» - Brake dragging by hand - Worn or damaged wheel bearing Wheel spins freely 2. Check tire pressure Pressure law - Faulty tire valve I - Punctured tire Pressure normal 3‘ Check lor slipping clutch Abnormal ——> - Clutch slipping | - Worn clutch discs/plates Normal - Warped clutch discs/plates - Weak clutch spring - Additive in engine oil 4. Accelerate lightly Engine speed does not—> - Fuel/air mixture too rich or lean increase - Clogged air cleaner Engine speed increase - Restricted luel flow - Clogged muffler - Pinched luel fill cap breather 5. Check ignition timing Incorrect - Faulty ignition control module - Faulty ignition pulse generator Correct 6. Test cylinder compression incorrect —> - Valve stuck open - Worn cylinder and piston rings Normal - Leaking head gasket - Improper valve timing 7. Check carburetor (or clogging — Clogged ——> - Carburetor not serviced frequently I enough Not clogged at Remove spark plugs Fouled or discolored—> - Plugs not serviced lrequantlv enough Not fouled or discolored - Spark plugs are the incorrect heat range 9. Check oil level and condition Incorrect—u - Oil lever too high ~ Oil level too low Correct ~ Contaminated oil ll), Remove cylinder head cover and Valve train not Iubricated—> - Clogged oil passage inspect lubrication properly - Clogged all control orillce Valve train lubricated properly 25-2 b TROUBLESHOOTING l Feasible cause 11. Accelerate or run at high speed —-Engine knokcs‘u - Worn piston and cylinder - Wrong type of tuel - Excessive carbon buildup in Engine does not knock combustion chamber ~ Ignition timing too advanced llaulty ignition control module) ' Lean Iuol mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check carburetor pilot screw — Incorrect adjustment - See section 5 Correct 2. Check lot leaking intake pipe Leaking———> - Faulty insulator O-ring i - Damaged insulator Not leak at Parlorm spark test Weak or interminent —> - Faulty carbon or wet fouled spark spark plug - Faulty ignition control module Good spark - Faulty ignition coil - Broken or shorted spark plug wire - Faulty engine stop switch - Faulty ignition pulse generator - Faulty ignition switch - Loose or disconnected ignition system wires L Check ignition timing Incorrect - improper ignition timing (faulty ignition control module) 25-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED Possible came 1. Disconnect luel nose at carburetor — Fuel flow restricted - Clogged fuel line - Clogged fuel fill cap breather . Faulty luel valve Fuel (lows lreelv - Clagged fuel filter 2. Remove the carburetor and check—— Clogged ——> - Clean [or clogs | Not clogged 3. Check valve timing Incorrect - Cam shalt net installed properly Correct 4. Check ignition timing Incorrect - Faulty ignition central module - Faulty ignition pulse generator Correct 5. Check valve spring Week - Faulty spring Not weak POOR HANDLING Posslble can-e 1. ll steering is heavy - Steering shaft nut too tight - Damaged steering shalt bearings ~ Damaged steering shaft bushing 2. ll either wheel is wobbling - Excessive wheel bearing play - Bent rim - Improper installed wheel hub - Swingerrn pivot bearing excessively warn - Bent lrarne 3_ ll the vehicle pulled to one Slde ————_—v ~ Tire air pressure incurred - Faulty shock absorber - Bent tiered - Incorrect tie-rod adjutment - Bent swingarm - Bent frame - Improper wheel alignment 25-4 I I I , I 26. INDEX ACCESSORY SOCKET AIR CLEANER AIR CLEANER HOUSING AIR CLEANER HOUSING BREATHER DRAIN TUBE ALTERNATOR CHARGING COIL ALTERNATOR INSTALLATION ALTERNATOR REMOVAL ANGLE SENSOR ASSIST HEADLIGHT BATTERY BODY PANEL LOCATIONS BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE PEDAL BRAKESHOE WEAR BRAKE SHOES/WHEEL CYLINDER/ADJUSTER BRAKE SYSTEM CABLE £1 HARNESS ROUTING CAMSHAFTICAM CAHIN TENSIONER CARBURETOR ASSEMBLY CARBURETOR CHOKE CARBURETOR DISASSEMBLY CARSURETOR HEATER CARBURETOR INSTALLATION CARBURETOR REMOVAL CENTER MUDGUARD (TRX‘SOES/FE) CENTRIFUGAL CLUTCH CHANGE CLUTCH CHARGING SYSTEM INSPECTION CLUTCH SYSTEM COMBINATION METER CONTROL MOTOR COOLING FAN CONTROL UNIT CRANKCASE ASSEMBLY CRANKCASE SEPARATION CRANKSHAFT/BALANCER CYLINDER COMPRESSION TEST CYLINDER HEAD ASSEMBLY CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSPECTION CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL CYLINDER/PISTON INSPECTION CYLINDER/PISTON INSTALLATION CYLINDER/PISTON REMOVAL DRIVE SHAFT BOOT ELECTRIC SHIFT PROGRAM (ESP) EMISSION CONTROL INFORMATION LABEL EMISSION CONTROL SYSTEM ENGINE IDLE SPEED ENGINE INSTALLATION ENGINE OIL AND OIL FILTER ENGINE REMOVAL EXHAUST SYSTEM FLYWHEEL/STARTER CLUTCH FRAME COVER REMOVAL CHART FRONT AXLE REMOVAL FRONT CARRIER/CARRY PlPE/FENDRE FRONT CRANKCASE COVER INSTALLATION FRONT CRANKCASE COVER REMOVAL FRONT DIFFERENTIAL FRONT DRIVE SHAFT 3-10 6-2 2-15 10-9 16-3 26 8-18 8-3 15-10 15-4 FRONT SHOCK ABSORBER FRONT WHEEL FUEL LINE FUEL STRAINER SCREEN FUEL TANK INSTALLATION FUEL TANK REMOVAL GEAR POSITION SWITCH INSPECTION GEARSHIFT LINKAGE INSPECTION GEARSHIFT LINKAGE INSTALLATION GEARSHIFT LINKAGE REMOVAL GENERAL SAFETY HANDLE BAR HANDLE BAR SWITCHES HANDLE BAR COVER HEADLIGHT HIGH ALTITUDE ADJUSTMENT IGNITION COIL IGNITION PULSE GENERATOR IGNITION SWITCH IGNITION SYSTEM INSPECTION IGNITION TIMING LUBRICATION A: SEAL POINTS LUBRICATION SYSTEM DIAGRAM MAIN RELAY ('98 — '01) MAINTENANCE SCHEDULE MASTER CYLINDER MODEL IDENTIFICATION NEUTRAL/REVERSE SWITCH NUTS, BOLTS. FASTENERS OIL COOLER OIL PUMP OIL STRAINER SCREEN OIL THERMO SENSOR PILOT SCREW ADJUSTMENT REAR AXLE INSTALLATION REAR BRAKE REAR CARRIER/REAR FENDER REAR DRIVE SHAFT REAR FINAL DRIVE 12-29 12-8 34 5-22 5-22 5-20 21-30 54 9-4 9-2 1-1 12-3 20-17 2-I3 20% 5-19 18-7 18-7 20-17 18-4 18—8 1-18 4-0 21-31 3-3 1&5 1-3 20-18 3-11 #2 4-2 l-I? 20-19 5-17 16-19 1A-I5 240 16—21 16-6 REAR FINAL GEAR CASE OIL AND DIFFERENTIAL OIL 3-13 REAR SHOCK ABSORBER REAR WHEEL RECOIL STARTER REGULATOR/RECTIFIER RELIEF VALVE REVERSE LOCK SYSTEM REVERSE SHIFT SWITCH INSPECTION REVERSE STOPPER SHAFT SEAT/SIDE COVER SELECTABLE 4WD SYSTEM SERVICE INFORMATION (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (BRAKE SYSTEM) (CLUTCH) (CRANKSHAFT/BALANCER/TRANSMISSION) (CYLINDER HEAD/CYLINDER/PISTON) (ELECTRIC SHIFT PROGRAM) (ELECTRIC STARTER) (ENGINE REMOVAL/INSTALLATION) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT DRIVING MECHANISM) 13-3 13-3 10-2 17-11 l-‘II 3-15 2131 9-7 2-3 2&5 10-1 17-1 “-1 INDEX SERVICE INFORMATION (FRONT WHEEL/SUSPENSIONISTEERING) (FUEL SVSTEM) (GEARSH(FT LINKAGE) (IGNITION SYSTEM) (LIGHTS/METERS/SWITCHES) ILUBRICATION SVSTEM) (MAINTENANCE) (REAR DRIVING MECHANISM) (REAR WHEEL/SUSPENSION) (SELECTABLE 4WD SVSTEMI SERVICE RULES SHIFT SWITCH INSPECTION SKID PLATES/ENGINE GUARD SPARK ARRESTER SPARK PLUG SPECIFICATIONS SPEED SENSOR STARTER MOTOR STARTER RELAV SWITCH STEERING SHAFT STEERING SHAFT HOLDER BEARING STEERING SYSTEM SUSPENSION SWINGARM SYSTEM DIAGRAM (BATTERY/CHARGING SYSTEM) (ELECTRIC SHIFT PROGRAM) (ELECTRIC STARTER) (IGNITION SYSTEM) (SELECTABLE 4WD SYSTEM) TAILLIGHT THROTTLE HOUSING THROTTLE OPERATION TIE-ROD/KNUCKLE TIRES TOOLS TORQUE VALUES TRANSMISSION TROUBLE SHOOTING (FRAME/BODY PANELS/EXHAUST SVSTEM) (ALTERNATOR/STARTER CLUTCH) (BATTERVICHARGING SVSTEM) (BRAKE SYSTEM) (CLUTCH) (CRANKSHAFTIBLALANCER/TRANSMISSION) (CYLINDER HEAD/CVLINDERIPISTON) (ELECTRIC SHIFT PROGRAM) (ELECTRIC STARTER) (ENGINE DOES NOT START OR IS HARD TO START) (ENGINE LACKS POWER) (FRONT DRIVING MECHANISM) (FRONT WHEEL/SUSPENSION/STEERING) (FUEL SYSTEM) (GEARSHIFT LINKAGE) (IGNITION SVSTEM) (LIGHTS/METERSISWITCHES) (LUBRICATION SYSTEM) (POOR HANDLING) (POOR RERFORMANCE AT HIGH SPEED) SJ 3-1 1&3 20-1 4~1 254 25—4 (POOR PERFORMANCE AT LOW AND IDLE SPEED) 25-3 (REAR DRIVING MECHANISM) 1&2 (REAR WHEEL/SUSPENSION) (SELECTABLE ‘WO SVSTEM) UPPER/LOWER ARMS VALVE CLEARANCE WHEEL/TIRES WIRING DIAGRAM (TRXA‘SOS: ‘98 - 'OI) (TRXlSOES: '98 — ‘01) (TRX‘SOFM: Afier '01) (TRXASOFE: Afler ’01) (TRX‘SOFM: Canadian Model: After '01) (TRX‘SOFE: Canadian Model: After ’01) 134 22.2 1240 3-2I 234 234 23-3 234 23-5 23-6 26-2