A Few Words About Safety

Service information

The service and repair information contained in this manual is intended for use by qualified.
professional technicians. Attempting service or repairs without the proper training. tools, and equipment
could cause injury to you or others. It could also damage the vehicle or create an unsafe condition.

This manual describes the proper methods and procedures for performing service. maintenance. and
repairs. Some procedures require the use of specially designed tools and dedicated equipment. Any
person who intends to use a replacement part, service procedure or a tool that is not recommended by
Honda. must determine the risks to their personal safety and the safe operation of the vehicle.

if you need to replace a part. use genuine Honda parts with the correct part number or an equivalent
part. We strongly recommended that you do not use replacement parts of inferior quality.

 

For Your Customer's Safety

Proper service and maintenance are
essential to the customer’s safety and the
reliability of the vehicle. Any error or
oversight while servicinga vehicle can
result in faulty operation. damage to the
vehicle. or injury to others.

“WARNING

 

 

Improper service or repairs can create an unsafe
condilon that can cause your customer or others to be
seriously hurt or killed.

Follow the procedures and precautions in this manual
and other service materials carefully.

 

 

For Your Safety

Because this manual ls Intended for the
professional service technician, we do not
provide warnings about many basic shop
safety practices (e. 9., Hot parts - wear
gloves). If you have not received shop
safety training or do not feel confident
about your knowledge of safe servicing
practice, we recommended that you do
not attempt to perform the procedures
described in this manual.

 

AWARNING

Failure to properly follow instructions and precautions
can .use you to be seriously hurt or killed.

 

Follow the procedures and precautions in this

Some of the most important general
manual carefully.

service safety precautions are given
below. However. we cannot warn you of
every conceivable hazard that can arise in
perforrnlng service and repair procedures.
Only you can decide whether or not you
should perform a given task.

 

 

 

important Safety Precautions

Make sure you have a clear understanding of all basic shop safety practices and that you are wearing
appropriate clothing and using safety equipment. When performing any service task. be especially
careful of the following:

. Read all of the instructions before you begin. and make sure you have the tools. the replacement
or repair parts. and the skills required to perform the tasks safely and completely.

- Protect your eyes by using proper safety glasses. goggles or face shields any time you hammer,
drill. grind. pry or work around pressurized air or liquids. and springs or other stored-energy
components. if there is any doubt, put on eye protection.

 

. Use other protective wear when necessary. for example gloves or safety shoes. Handling hot or
sharp parts can cause severe burns or cuts. Before you grab something that looks like it can hurt
you. stop and put on gloves.

. Protect yourself and others whenever you rave the vehicle up in the air. Any time you lift the
vehicle. either with a hoist or a jack. make sure that it ls always securely supported. Use jack
stands.

Make sure the engine is off before you begin any servicing procedures, unless the Instruction tells you
to do otherwise. This will help eliminate several potential hazards:

- Injury from moving parts. If the instruction tells you to run the engine. be sure your hands. fingers

and clothing are out of the way.

Gasoline vapors and hydrogen gases from batteries are explosive. To reduce the possibility of a fire or
explosion. be careful when working around gasoline of batteries.

- Use only a nonflammable solvent. not gasolire, to clean parts.

0 Never drain or store gasoline in an open container.

. Keep all cigarettes sparks and flames away from the battery and all fuel-related parts.

Your safety. and the safety of others. is very important. To help you make informed decisions we have
provided safety messages and other information throughout this manual. Of course. it is not practical or
possible to wam you about all the hazards associated with servicing this vehicle. You must use your
own good judgment.

You will find important safety information in a variety of forms including:
. Safety Labels - on the vehicle

. Safety Messages preceded by a safety alert symbol & and one of three signal words.
DANGER, WARNING, or CAUTION. These signal words mean:

— You WILL be KILLED or SERIOUSLY HURT if you don‘t follow
A DA N G E R instructions.

- You CAN be KILLED or SERIOUSLY HURT if you don't follow
“WARNING instructions.

A CAUTION You CAN be HURT if you don't follow instructions.

. Instructions - on how to service this vehicle correctly and safely.

 

 

 

 

 

 

 

 

As you read this manual. you will find information that is preceded by a [N_QTLC.E_ symbol. The purpose
of this message is to help prevent damage to your vehicle. other property. or the environment.

ALL INFORMATION, ILLUSTRATIONS. DIRECTIONS AND SPECIFICATIONS INCLUDED IN
THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE
AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES
THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT
INCURRING ANY OBLIGATION WHATEVER. N0 PART OF THIS PUBLICATION MAY BE
REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR
PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA
MOTORCYCLES. MOTOR SCOOTERS OR ATVS.

 

HONDA MOTOR CO., LTD.
SERVICE PUBLICATION OFFICE

 

 

III“ III USE THIS MANUAL

Follow the Maintenance Schedule (Section 3)
recommendations to ensure that the vehicle is
in peak operating condition and the emission
levels are within the standards set by the US.
Environmental Protection Agency. Perform-
ing the first scheduled maintenance is very im-
portant. It compensates for the initial wear
that occurs during the break-in period.

Sections 1 through 3 apply to the whole
motorcycle, while sections 4 through 21
describe parts of the motorcycle, grouped
according to location.

Find the section you went on this page. then
turn to the table of contents on page I of that
section.

Most sections start with an assembly or
system illustration, service information and
troubleshooting Ior the section. The sub-
sequent pages give detailed procedures.

If you are not familiar with this motorcycle.
read the TECHNICAL FEATURES In section
23.

If you don‘t know the source ol the trouble,
go to section 24, TROUBLESHOOTING.

 

ALL INFORMATION. ILLUSTRATIONS, DI-
RECTIONS AND SPECIFICATIONS INCLUD.
ED IN THIS PUBLICATION ARE BASED ON
THE LATEST PRODUCT INFORMATION
AVAILABLE ‘AT THE TIME OF APPROVAL
FOR PRINTING. HONDA WTOR CO..
LTD. RESERVES THE RIGHT TO MAKE
CHANGES AT ANY TIME WITHOUT NO-
TICE AND WITHOUT INCURRING ANY
OBLIGATION WHATEVER.

NO PART OF THIS PUBLICATION MAY BE
REPRODUCEO WITHOUT WRITTEN PER-
MISSION.

 

 

 

HONDA MOTOR CO., LTD.
SERVICE PUBLICATIONS OFFICE

 

GENERAL INFORMATION

 

 

LUBRICATION

 

 

MAINTENANCE

 

 

ENGINE

FUEL SYSTEM

 

 

ENGINE REMOVAL/INSTALLATION

 

 

COOLING SYSTEM

 

 

CLUTCH SYSTEM

 

 

GEARSHIFT LINKAGE

 

 

ALTERNATOR

 

 

CYLINDER HEADNALVE

 

 

ORAN KCASE

 

 

PISTON/C RAN KSHAFT

 

 

TRANSMISSION
DRIVE TRAIN

 

 

CHASSIS

FRONT WHEEL/SUSI’ENSION

 

 

REAR WHEEL/SUSPENSION

 

 

HYDRAULIC BRAKES

 

 

 

ELECTRICAL

BATTERY/CHARGING SYSTEM

 

 

IGNITION SYSTEM

 

 

ELECTRIC STARTER

 

 

SWITCH ES

 

 

WIRING DIAGRAM

 

 

TECHNICAL FEATURES

 

 

 

TROUBLESHOOTING

EEEEEEEHHHEeeeeeeeeeeeee

 

 

gale ol Issue October, 1986
QHONDA MOTOR 60., LTD

I. GENERAL INFORMATION

 

 

GENERAL SAFETY

SERVICE RULES

MODEL IDENTIFICATION
9ECIFICATIONS

TORQUE VALUES

TOOLS

CABLE I HARNE“ ROUTING
EMISSION CONTROL SVS‘T EM

1—1
1-1
1—2
1—3
1—5
1—1
1—0
1—14

 

 

5mm sum

l!kmmkmuhn~M.-flrnn
wmbud-mm.flmmlkafluhachul
m. The "AU." MW who mum:
pa.

Gaollu h umuuly flammable and I: cxplodve under
WcmmmmMorwowhmwm
lump-wrung“

SERVICE IIIIIS

Thumdxndymm-Md.mm
on. Mflm.luc-DIWJHW
ad!!! um mldldle/Mynmhmtm

filo bunny puma: hydrogen p1 wild: c- 5: My
"#01100 no! not: arduwflunauwhurdn
hurry. w, M mu.

1. U:- otnulnc HONDA or HONDA-rmmmndod porn and “Antenna 0! "III numlem. Pm: I'm do not moot HONDA'I

anion mcifimions mnv dunno. IM motovcvclo.
. Un (hi will tool! dniomd fol this wodun.

UN

. Us! onry mam: tools Mun naming 1M: motoccvde. Mun: bolls. mm. and m ur- not mum-bl. with Enuhh

ham; TM on 0! income! (ooh me “am may damn! tho unwell.
‘, Install m m. 04w, mu m. lock ohm. etc. when MIN.
5. When “Vol-rung ban: 07 um. book an» mam or mm: Dom hm. and nun-n to m mum-d W Iii-0min.

union I pan-unlit mic! ll woe-lion,

6. Clean um m dun-nu solnm upon dim-ably. Lub'iml my aiding mum Mon mu.
1‘ AM "Why, and: I" out; '0' plow inmlmion an: our-Hon.

1-1

GENERAL INFORMATION

MUDEL IDENTIFICATION

 

BEGINING Frame \Ie SCX7‘I ' EMDOUOOIN The color label <5 attached :0 [he flame behind the left SldE
Eugme \Ju. SC17E 2000001~ count

 

The flame sevial number Is stamped on m: HEM-fig head The vehxcle Idenlihcatvon number (VINI Is on Ihe steermg
nah! :Ich head IeII sida.

 

 

I 7,

The angina senal number is stamped on top of the ugh! The Carbure‘lor Idenhficatzon number is (m the Irom oI
crankcase. me calburelov bcdy,

 

 

1-2

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SPECIFICATIONS
ITEM SPECIFICATIONS ]
DIMENSIONS Ovarall lanoth 2,280 mm I!” In)
Ovanll Md"! 790 mm (31.1 In)
Owall mm 1.185 mm (45.7 In)
W 1.5% mm (62.8 in)
Sill W" 820 mm (37.3 In)
Fact on. him 55 mm (14.0 In)
' Ground than 145 ml 5.7 In)
‘ Dvy WI 25 to (5‘0 h)
‘ cm MW 268 kg I501 b)
F NAME Tvpa Douala an"
anI suspamlon. naval Tami: Iork, I“ mm (5.7 In)
Ru! lulplnIIon. naval Swingarm, 120 mm “.7 In)
Gross which mlghl rating . 453 kg (1010 lb)
Vahicla canadlv load 186 kg (4)0 III)
From (in “an Mild/N48 Tuba).-
fla- 6n nu MIMI? Tabla“ A
Imogen. From 32mi¢225khjfikdun')
«mm-1w new saw (250 m. :50 won‘)
‘1“ “" Up to mm. mm 32 w (225 m, 225 wan'l ‘
""3“" capacity um am 40 as; (275 m. 2.75 wan’)
Fvom bum, IIning map! area Doubla disc. 904 an' I "0.) In W
Rm huh, Ilnlng swam am I Sing): disc, .90 cm’ "6.0 It: In)
Fual capacity 22 mars I58 US gal, O3 Imp gal)
Fual mam tawny 4 mm (1.0 US gal. 05 my pl)
Cam angla 59‘30'
I ma as m (3.7 an
FmMulmv n:maIl5£oz).L:MecIIG.7oa)
Tue: NE I no. I was cool-d «m. 09m: m
I W arr-mm ‘ ‘ cylhdm 90 V
fluoridation 795x553mm Ila-2.18 In)
newt-am: 1,098 an’ I67 cu In)
Companion mio 10.5 : I
VaIva uaIn Sllanl. mulli-IInk chaIn drlva and DOHC with rocker arms
MaxImum ham I18 519.500 mm
Maximum torqu- . 9.93 kwn I713 INN/1.6m mm
on madly 3.5 III-n I17 05m. 3.) Imp at) am: My
3.0 mm 132 us at. 2.6 "no cl) mu dummy ‘
Cool-II cum 32IMI14 USqIZl Input) I
Lam-mien mum Fem-d ovum and not um
Air vim-non um loan
cylm main 1: z 2 wan' nu : 23 an
mun um om vu' mac) \
mom ‘0. IABDCI n I mm um
Exhaml valva Owns 40° IBBDC)
Claus Io“ IATDC)
Vain chant-ca IN/Ex: 0.15 mm (0000 III
Engina mm 90.7 in (2132 a»
Id). wood I Loco—1.100 II!!!

 

 

 

 

GENERAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM SPECIFICATIONS
(‘ARBUR ETION Canny-tot WWII born cvm mm ".42 in)
Idomifinfion rumba VD7IA. California typl: VD74A
PIlmminifid mini Supp-4.11
Float lav-I 7.5 mm (0.29 In)
DRIVE TRAIN Clumh Wu. mum-plot!
Tnnsmmlon 5M with our drive
Primary nducuon 1.707
Secondly ndualon 1153
Final "(Suction 3.182
Gnu "no I 229‘
Gut mic II I319
Gut min III 1.292
60. I“ IV I374
Gav min V 0.897
Our m 0.750
, Gut M mm L." Iood mm mm syn-n, IvN—l-JJ-b—OD
Finddrinwoiluw IWEIBJ 0!!me
I!) a: (4.! on I’m draining
ELECT IICAL [union Full "rumor ignition
Initial timing ”F” m w‘ BTDC u idl-
FuII dune. 37' tame a 3300 rpm
Surfing system Sum: motor
Alt-mum SIM/5.1110 rpm
Imry nap-my IZV— I SAH
spark pm. \ NGK no
Stand-rd DPII OEAD X24EPR-UI
For cold
(a I 5957:!" I on 7EA-9 xmnwo
, 23mm m can xmnwa
I Souk nIul no 08—03 mm tonal—om in)
Firing m 1—2—34
run/Main hm L 10A. 15m
Liam’s Flo-dildo! «nu/m my I eta/sew
Tullhlnplfln smw 3/3? an SAE NO. I157
From Cum signal 3/23?! 3/32 on SAE N0. 1030
fin: tum dun-l 23w 32 up SAE NO. I073
lmtrmmm mm W
Natural Indicator 3W
Tum 3W Indie-tor N
High In." inflate! 39!
on who Indium! 3W
Sun and M NW N

 

 

1-4

 

GENERAL lNFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TONI! "LIES
o E N GIN E
Item 01y Thread Dil. (mm) T010140 N-m (kn-m. Il-lb) ficmulu
m1 1m bud cow 0 0 0-12 Ion—1.2. 50—1101 50-0141 1m
01110001 had 10 5 "1-“ (1.0-1.4. 7—101
0 a 21-25 (11-15. 15—101 005
10 10 40-02 14.0-51.2. H) uos
Nun-m1 1 12 00-100 tan—10.0. 50-721
1 cum cams lock nm 1 25 03-01 10.3—01.40-401
014mm 14 10 43-47 143-41.:11-341 U05
:1 0 21-26 (10-15, 14—10)
14 0 10-14 (1.0-1.4. 7-101 _
Roam .m m 0 22 45-00 (lb-5.0. 32-301 h£ mflfififififi
Canto-’06:“ l 7 10-20 113-211. 13-141 003
Sun- am 1 12 00-100 can-10.0. 50—721 005
Sun. am can :1 a 20—30 12.040. 10—221
Shin lurk can: 1 l 1 10-20 110—20. 12—141
m chin gu'dn A 1 12 21-20 12.1-25.15-101
011 1111.1 1 20 15-20 115-210. 11-14)
Out out car cm '4‘ B 21—25 (2.1-2.5, 15—18) Sock-I bolts.
2 a 21-20 (11-25, 15-101 uas bom
Valvu Idlmmom nut: 16 7 21—25 (2.1—2.5. 15—13) MW all 10 111-
014111 11°11 1 12 30-40 «1.5-4.0. 25-20) 1:33“ "W“
Conn-cling rod mm 0 0 30—34 130-14. 22-251
I Dru-umpo-rvivmnun 1 0 0-12 1011-1250-0111
011 MIMI)! 1 — 10-14 «In—1.4.1401 Tvawm
ou comm! bolt 2 1 a 10-20 110-2013—141 m 1
1 1 10 20-25 «2.0-2.0, 14-101 I
J
O CHASSIS
lum O'tv Throat Din. (mm) Town- N-m (Ira-m, Mb) Remark;
Sub-hm bolts (U000!) 2 10 00-10 (00—70. 43-011
(Lou-11 2 10 3-40 1:15-45. 25—321
Shed mm mm ham/nub
(WI 2 10 40—60 (4.0-6.0. 19—3)
(Low) 2 10 40-00 140-50. 20-301
11.11am nap-r hold" 4 0 30-40 (30-40. 22—201
Rut hula mu 1 0 24-30 12.4—11.0. 17-22)
cum-um 1 0 10-10 (1.0-1.5, 7-111
sw- m 1 10 30-40 (3.0-4.5, 25—32)
511.1114 hm 11qu 2 0 20—30 (10—10. 14-n1
4 10 3-45 135—45, 25—321

 

 

 

 

 

 

 

 

GENERAL [NFORHATION

 

 

 

Swinoom Ml pivot bolt
Swing-rm right pivot hon
W ohm lock nut
Fiml par can run
Snoring Inn: M

From vork loo pinch In":
From M bottom pinch bola
Swing sum pinch hon
From uh

From “I. pha- bolt
aw “In

Gnnhm new pivot

Fun! rm mm

 

 

—.......-‘~N_u—.n-a—nb~uub-nnbu~a

w

10

12

18

 

 

00-120 (mo—n.0, 85—37)
16-20 (1.6-2.0.12-14)
lm-IN (10.0—13.0. 72—94)
”—70 “0-71). 43—5"
fl-Im ‘89-! 29. 56-87)
0-43
15—55
M

Ian 0'», Thad Di; (m) Tenu- Nm 0:”. h—Gb)

lulu ho- bolu 19 25-35 (2.5—3.5, 18-25)
cum-I nlv Mood bolt 7 4-7 (OJ-0.7. 2.9—5.1)
luk- mm cvllnduv holds! 8 10-14 [LO-11, 7—10!
cum mum cylindu how 8 10—14 (1.0—1.4. 7—10!
Axle pm bolt 8 20-30 (2.0-3.0. “-22!
PM but tubular 8 13-2! (1.8-2.3. 13-20) I
Urdu mut- Mind-r up 4 1—2 «ll—0.2. 0.7-1.4) ‘
(:1mewa 4 1-2 «1.1-0.2. 0.7—1.4)
Find pr oil mm: av so 10—14 (1.0—1.1,7-10)
From allow 10 M tan-49. 22—29)
ROI! brake xoraun rod 8 13—26 (1.8—2.5. 13—18)

10 3°40 (3.0-4.0. 22—29)

30

so

an

10

24

009-13. 7—9'
“5—5.5. 32-401
(2.0—3.0. 14—22)
55—85 (5.5—8.5. 4H7)
13-30 (1.8-3.0, ‘3—22)
35-105 (BB-10.5, 81—76)
18-25 (1.8-2.5.13—181
27—0! 0.7-3.5. 20—25]

 

 

mewwamnvalmmommuumwnmwvmw

W.

0 STANDARD TORQUE VALUES

 

 

 

 

 

 

 

""" "mg-0:) """ «W472;
5 m Ml N III! I“ ”AM... 3—4) 5 mil W 3.5—5 “335-05. 2-4)
0mw1adnm l—l!(0.t—|.1.H) 0mm 7-1H0.1-I.1.Hl
.mw‘mflrul IO-anJ-IJ. 13—18) Bmmm-flm 10-14 (LO—11, 7-‘03
m m bolt «.1 m 30—40 tan-4.0. 22-20) 3 mm a... we and an 20—30 (2.0—3.0, "—22;
12 mm bolt ms nu: so-oo «so-m. 39—43) 10 mm M... ball a nut 30—40 «3.04.0. 22-22»

 

 

 

GENERAL INFORMATION

 

“Ills

 

 

 

 

 

0 SPECIAL
F I '
cum-mow Mun-n Anem'nve wanna um net

on mm m own-cum! 1
Vic Mum om- own-com Cflm'fiTMUW my" :
Gut-arm" pnlol am much ‘ amt-4mm J
VIN with drum 07762-00162“ IO
Swim-7m um run much nmo-auoom Lon um much {fimafl'jm II
VIII. Idlumng munch onus-moowo :
flown- wmlch OWN—46”!“ M
sauna. our: 1 01911423000» 5.3%.“ ‘°°' W" 1.1:,"
SIC-um nun Incl-I (”9|“an ll

‘ um. um mu onus—42m 1
Lou nu ma. 30/54 «In onus-um u
Lotti-summaMn-n ' omoanunoo I:
can rum onnm {wmwn ‘ u ‘
mu m mun—mm u
Mud M '0‘ ‘ amt-m I.

‘ Mm ‘ omu-um Mun-whim ems—um n

0'
‘ halon m and omI—am
Mm mun m1 um mm M
Dunn u" mm mummm amt-4mm II Fort all dim GNU—11‘0"}! I4
I Anth. :1 : 40 «mu—comm 1:

Human: Mndll onu-mmoo
Hut-now mm! 071“ #10101 lam. rumour m 01336—31!” HI
Bum. "mm. 17 mm ems-mono 13
MM. m M 0M.” 1|
I-awmn‘ ‘ onus-alum M"'m'3°"'" mm ‘ u
Dvmv' mono—anon: 0mm 01949.11qu 1:
no.“ on- own—mm yum vu- are. ova—comm Io ‘
mu m. n mm mm {W W m H
mm om u
u- m- m amt-mum | u
Ila-"n an m m ‘ 'I
you am can 07917me is

‘ For! no: cum mum-m 0190-!"me Is

’ flu:- um magnum omwuoooa u“ may ? u
All-tum! ”C'“ MISC—JIM M
VIM luldl mom-r mun—m 10
Flwml com omnwooo ‘ J
Amermm onto-mono ‘ v
m Incl: mm: comnmnv 0795947000” u
hw- nuflva STAN-INC? C
Vmum mum n-Amawcv 3' U’“ W” 4
Muum (mu—anon: ‘ u
Mum-- omo—uamoo ‘ H
mm ‘A‘ onu-Mlxnoo ‘ u
mm outs—amour: I.
on an arm mun u
SIG! m m ‘ omI—mnm l U.“ only I.
awn mo- ‘ ems-mam 1 :

 

 

 

GENERAL INFORMATION

 

 

 

 

 

 

 

0 COMMON
oucmmou NUMBER Auunnw: NUMIBI an, sect

Hm lml mp ‘ om: 4mm 4
on mum moo ‘ 073054000000 2
0|! m M W ‘ ovum-4229200 2
mm M W! 1 emu—mm 3*“.me a
Lad-In assign-320nm own-m fl
Em n- omo-m J us
u».— w ova—m 7w unu- ‘ onus-com u
m pun- own-mo: m pun-v 0mm: ‘ 0
Vin on. m. 5.5 mm «ma-amoral: ‘0
v». gum- mm: ova-mm Io
Mum-nu. 32 x 36 mm 071M101!” u
Ami-mm, :7 x to mm ova—0mm u, no
Arum. a2 . 41mm ‘ onto-comm 7.1: u u
Arum-u. u - u m ‘ onwmoo 1:. u, :5
Amman.” nun-m \ ova—0mm nu
ma, u m ‘ onus-comm ‘ II
mm, H m unto-m 2:
man. an m Wyn—m a
Not. an m ‘ ova—comm 13,14
amum mus-macaw ‘ 7.1:
cm: one-ovum om ‘ om—onm 1
am: 011mm ‘ u, u
mm. 25 mm 01145-003200 ‘3' m" onu—a‘nom ‘ u
Anna-mu. 30 mm own—comm H
mm. mt mu 011mm m. I:
l-m m m. '5 m onto-moo fzm“;‘fi.f""““" u
m M has. 20mm ems-cow a
V“ m m own—mum m

 

 

 

GENERAL INFORMATION

 

GAIL! I: HARNESS WTIIIG

Now the fotlawinq Mun routing abb- Ind win
humans.

A minimmmouorMIImhufflvhu-d.
Ammumuuwhwnilk
WM.

0 Do not man Mr- mm: (M wold or one o!
in cfilmp whan a Mid-on clamp is and.

o Scam wlmwwlnmmmhm
with III-it munMnthv-dnuwud
mum. Ti'mn m bands an M aw m-
imulmnd urinal com-cl the wu- ov win
hm

0 Rows humans In any In no! pullnd um ov
hm cumin slack.

o Prom wins and humane: with doctrinal up.
ornahlflhcvmccmmumnupor
comm Chm IN machine when mmly
Wminnm

0 Do wxmwlmumfimnmm
minor. Emit by wrlwinn M with I m
[min In or «pl-cu m.

0 Room win ham-mu to Hold mm «In or
comm.

ommmm-‘aoomu
m

0 Km win human may how human: pips
mu arm no! mm

0 Be sure grown-u In and in mm groom
won-fly.

o Ammmmmmum
muitkmlnwmmfimmmmu
amp-m

o ANIr routing, chock mu m. wir- hum-n on
not twin“ or ktnkod.

0 Win hm: round lbfll the Mull-hm
ileum not bu pun-a nut. Mn “mm slack
In 96061.6,th with din-nova»
Wmhulmwfim.

 

 

GENERAL INFORMATION

 

 

1-10

 

 

 

RELAY

IGNITION
SVIITO'I WI RE
COUPLER

 

mam 5109

same» WIRE

counsn ‘ 7

P

r igl."i.l I ‘ ‘
DI 21

‘_!illlllrrlrlllligi7!<§l:

mun);

FUSE BOX

  
       
 

 

POSITION

TURN SIGNAL
CANCEL WIRE

. COUPLER

DIMME R
SWITCH
COUPLER

VEED SENSOR
WIRE COUPLER

GENERAL INFORMATION

 

    

- Va»
FRONT BRAKE HOSE

SPEED

SENSOR wme . 4 .1 k
Play (3
«Er Era}
‘5 V

 

, ‘o/rgf‘r} OILPRESSURE/PULSE
’ GENERATOR WI as

 

1-11

GENERAL INFORMATION

 

REAR BRAKE REAR CUSHION
RESERVOIR TANK AIR VALVE HOSI'

    

FUEL VALVE _-
FUEL FILTER
REAR

BRAKE HOSE RADIATOFI OVERFLOW TUBE BATTE'W
BHEATHEFI TUBE

BATTEIW NEGATIVE “VERY POSITIVE
CABLE

  
 

. f ,:. ’ . ’, 7
\J ,. ’ a ' " SYARTER MAGNETIC swn'cu

FUEL NM? RELAY

GROUND CABLE ‘ «77m BREATHER TUBE
ALTERNATOR was CABLE
STARTER MOTOR cam

 

1-12

GENERAL INFORMATION

 

1-13

GENERAL INFORMATIM

 

EMISSION CIIITIIDI. SYSTEM

Tho U.S. Environmenul Function MIMY and Colifomll Al Roman Board (CARE) nquin mnnulncmnu to unify
Ihll Muir motorcycles comply with Ipplvcnbln oxlnust Minion land-rm duvlng the" unlul Illa. Mun opemcd md
malnulmd warding In me imrucliom provided. and mu molovcvcm hum may January 1, 1083 comply with walkable
nolu cmlislon mdads lot on. you ol 6.000 km (3.730 «mm am- the lime cl sale to the ullimm purchmr. when
wound Ind mlnuinod accordmg no on Instructions wavldcd‘ Commune. will: the terms of flu Diwibuw‘n Wmnfies
lot Hm. Mmorcvde Emission Control Synm h mm In only to hug me unlulon warmty ln off-ct.

SOURCE OF EMI$IONS

mmmmnmmmmwmnmw ConWoIhyaoc-Mnurymtm.

und- cumin conditions. they vast In lonn Wis-I than «an outboard to sunlight. Cotton monoxide does not
mInWWw'y,buH!hwlkL

Honda Motor Co.. Ltd. utllim lun urouvnor mums a well an own! Ivsmvu. to Mace cubon mononldl and hydrocarbons.

EXHAUST EMISSION CONTROL SYSTEM

Thu can-um minim antral wlum 'n comm oi Inn wbumov umnm. and no adimumnu would be and: except
ldlo land column": mm m- chroma «on w.

CHANKCASE EMISSION CONTROL SYSTEM

mmnhwmlmmmmmmammmggmmmmolmmam.m
MphmmmmfimwthmmdwIndium-«or.

AIR CLEANER

   

¢== PRES! AIR
0— : BLOW-BY GAS

BREATHE R SEPARATOR

 

1-14

GENERAL INFORMATION

 

EVAPORATIVE EMISSION CONTROL SYSTEM (California (vat)
‘I’Ml modtl complies with CaMombn Air Resourm Bord requirmnu Ior unwell" emission vmmlom
Fuol vapov Iram (ha luol unk nnd cnrhumo: i; routed Into I ehucoal uni-m whore it is .130th and norod while the angina

II noppul. Winn the min: II running and [M purge cum-0| dinpmm nlvn I: open, lual "not In the unusual unism ls
arm Into 1M Incin- through m. what-tot.

       

FUEL TANK

 

 

 
 
 
   

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FUEL/VAPOR
SEPARATOR
FORGE CONTROL VALVE
PURGE PORT
CARBURETOR AIR CLEANER
'0 ATMOSPHERE
1
Am VENT CONTROL <1: mesa Am
VALVE
_1—l
fl
INTAKE PORT «:1
CHARCOAL CANISTER
T0 DRAIN

NOISE EMISSION CONTROL SYSTEM

TAM'ERING wrrH THE NOISE CONTROL SVSTEUI ts PROHIBITED Fm law 010'”qu m- Mining ms or u:
taming MI: (I) The maul ov rendering Imperuive by any canon. one! "an for puma" 01 mm. up". a
unite-mm. of m deuce 0' ohm! 04 down unmounted "no any run which for III! purpofl ol mm ml prior to its
an or delinry to the ulmuu puvmm 0: MM: it n. m uw; 0! I2! m use a! the which II"! and: dlvaa or lie-nun ol
damn has born ternand av undead inoperative bv "Iv “Hon

AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAW’ERING ARE THE ACTS LISTED BELOW

1 Human! M. or puncturing m. mum", bafllu, Mada: gnu w my olhov oomponont which condufll “Must can.

2. Ramoul oi, ur puncturing 0! any pm of m: Intake system

3. Lock 0! pvoper maintenanc-

4. Replacmn any movmg pun of m "luck. or mm o! m- anhunt m mute system. mm pm. omit "an m:- we“
bv 1M mundxmnv.

 

1-15

GENERAL INFORMATION

 

EMISSION CONTROL lNFORMATlON
LABEL

An Eminion Cantrol Intelmaxion Label is located
on the Vrame as shown, Ix gives basic tune-up
specifications,

VACUUM HOSE ROUTING DIAGRAM
LABEL (California type)

The Vacuum Hose Routing Diagmm Label I: attach-
ed to the air cleaner case cover behind me fuel tank.

 

  

EMISSION CONTROL
INFORMATION LABEL

VACUUM HOSE
ROUTING DIAGRAM LABEL

    

MEMO

LUSRICATION

—— '_ E.
:7;- -g- ca
—‘"‘ ‘- snou‘rcvuuoan
m
12‘ -— EX.CWAFT
(c, I S?

    
    

I: m'(‘I’O REAR CYLINDER!

|‘—OIL PIPE SHIFT FORK SHAFT

 

J 1quer
._ J
I. ma

 

 

 

, , mums?
2::

“Mn

, ' ooumeasnan
$§i~§~=fl \ou. pump
~ will J

   

ODL FILTEI

 

 

2. LUBRICATIIIN

 

 

TROUBLESHOOTING
ENGINE OIL LEVEL

 

SERVICE INFORMATION

ENGINE OIL & FILTER CHANGE
OIL STRAINER CLEANING

2—1 OIL mamas CHECK 2—4
2—2 OIL PUMP 2—5 I
2-: FINAL DRIVE on. 2—10
2—3 CONTROL CABLE LUBRICATION 2-10
2—4 LUBRICATION POINTS 2—11

 

 

SERVICE INFORMATION

GENERAL

To sunk: the oil pump, it in necessary to nmov- me right ids cover Ind mm pump assembly. Sn action 6 for war pump

removal in! lnmllnuon.

SPECIFICATIONS
Engine oil

 

Oil cup-city

3.0 liur (3.2 US an. 2.6 Imp q!) lfter draining
3.6 liter (3.7 US ql. 3.1 Imp qt) llrer disuwmblv

 

Oil recommendation

Uu HONDA 48TROKE OIL or squwalanl.

'84

OIL VIMITIES

 

API SERVICE CLASSIFICATION: SE or SF.
VISCOSITY:

SAE ION—40

Other vuscmiues shown In th- chart may b.
used when thl average lemonralura in your
riding am II wnlhin lhl lndicaud rangl.

«n

n u I1 It"
40 40 -II n w l )0 tot

 

E

 

A

her '84

 

 

‘E

IE
I

arc-Inca
l_4—l_..__

N ‘00
’20 -IO 0 I) 20 )0 ‘0 'C

 

 

 

Oil prawn
In all press-m swilch)

5.4 2 0.7 kg/cm’ m :10 pscl n 5,000 rpm l80°C/l76°Fl

 

Oil pump dellverv

 

28.8 lirer (3114 US qll/m n. a! 5,000 rpm

 

Oil pump service data

 

STANDARD

SEEVICE LIMIT

 

Rotor rip clnranct

0.15 mm (0.006 in)

0.20 mm (QM in)

 

Pump body clearance

0.15~022 mm (ODDS-0.009 in)

0.35 mm (0.014 in)

 

 

Pump 0nd clear-nee

 

0.02—0.07mm loom-0.003 inI

 

 

0.10 mm (0.“)! in)

 

 

2-1

LUBRICATIM

 

 

 

Final drive your
Oil cup-city 1mm: (6.! cl.) that «may
no at (4.4 at.) am: daining
Rmmm oil "young-non 5‘5 #30

 

 

 

TORQUE VALUES

Englno oil drain plug
Engine on mm

Onlmuildl

TOOLS

”an

Oll wanna gauge

Oil mm M mailman!
Oil film mndl

Oll Incl loo m

I. Slum-l oll lulu

2. Worn pkmn vlnu

3. Wom um pm or ml

OHM

H N-In (3.5—4.0 kw. 25—29 "46)

16-20 N-m [1.5—2.0 Ira-m. ll—M h-b) — Apply Local. 0' Quinlan! to cheer-uk-
cue bolt and;

lo—Il Malta—1.! I‘m. 7-10 01-h) - WV Hondn W Lock. 3 BOND.“
in tantalum to If. boll that.

3:23;?" }. u mmrciollv walla». Quinlan.

DEW—611“!"

I. Oilov nmmwomm

3. Mod calm MW
3. Vlam pimn ring:

Low Oil pmum
I . Oll lav-l low

2. WMMVIQ” [Moon

3. Plan-d oil pidwp m
4. Oil mm
B. Exmmloil ldu

"I'm! mu

1. Imam mm um mad: am

2. lend oil lilm, gall-w, ov mowing will“

3. lneovrncl all being uud

Molly's-In
LOSIInIllo-r

2. Oél main vain brain

3, Oil wmp bully
l. lam oil In“

 

2-2

 

ENGINE OIL LEVEL

Pm me momuyclr un :15 cenzev firm qr \-.r
ground Sun the mgm and In n rrfi‘e try 3 3
mmutu Yum 0" [hi rug-n: Remove t'v _ m. I

mp: I! clan and Inse'l 1! wnhnu: suewrg I: H

Human: m: dewck and check me n‘ IeveI

II m. luvul 1| bvlow the lower level mavk rwuuvr
m Iulln cap and full to m: upper Ievel mark.

Check [he uII ureuuve w-II- the wan-Aw ludxcawv
Mild" II!” "vs enqme warm, The mdmotov would
no a" fill! one 0! Mn secnnd;
II It doe: nnl non the ungmo and chwk Y"P m'
pump Iuncmm ind’ov m1 cwruv!

ENGINE OIL & FILTER CHANGE

MOVE

Chino: snow. o‘l mm me engm-
Ub- malo'cvcll on m cenlsv Him: tn um»-
complom Ind mum dram wg

3..“ and

 

Slop mu lngum

Ramon "w on Mlvr up. cyimdex wean om mam
ptuql cnulne bmlom ml dmm plug and mam ma u-‘.
Ramon: (he ml Iclxuv wnh a Imer wrench and.) I»! Um
"mum-no ml dram out Discard the DII hum

Mala mrl "W" "‘9 “film; washers rm th: (Eu n
plum Me "1 good condmun and vrsuil IhL' nluga

TORQUE:
DRAIN PLUG 35—40 19-!!! c1540 m m,
25—29 mm
cvunoen HEAD DRAIN PLUG:
10—u N'm H.044 kq‘m‘
7-10 mm

AIlIv comp'c'ely dumrg the av raglan? 2"!
an wnh l ncw one Che-J max me on ‘ 1r! I2“
.x m good canamon. anc :03: v. a m 3 Ix:
mmn no .I Con! the on Mm ma? mrh m!
Inn-ll "1: ml Mm With an ml Ht-zr wrencr~
TORQUE: 15—20 N-m (IS—2.0 kgm,
11—14 beI
F|II (hm cmnkcnw wuh 30 1mm 13 2' L4 S at.
2 6 Im a!) M 2hr: recommended all (Dagu 2— I;

 

Sun "u wanna Ind In! H IdIE 'm 27"; mnum
men map In Mum:-

Mokl cure lhn the 041 lava! ,, n my moan lru‘
mom

Makv mu "m they. n no on an

 

 

LUBRICATION

I
Q—I‘JOPER

1“-l_QWER

F'LLEP (3-19

OIL FIL YER LERE‘IKN ()7QI261ICXXJI

'v H.7En H:»‘«[I MFA!" Pug

 

2-3

LUBRICATION

[Ill STRAINER CLEANING

NOY!

TM ml uumev can be Vrn/Jvud wth me
L engine mouMod m the frame

 

Roman the from exhauu Dopei
Dram lhl «mom! on (page 2—3)

Ramon thl Ol' pln bans and o.‘ par

Rumovo and cum the N V1 "‘5'

Check "1! omnl‘on 0‘ I”! p'essu's '9 ‘2' .zwu
Mike In" lhe 01mg w ~ war crmtmur- «hm
over ma ve Inf um: q lemon-d

Inn-II "1. ml mama: and a 1 pa"

Install "u "Mun IND“

Flu ma cranium w‘m mo vecommcnded ovl (cage

21)

OIL PRESSURE CHECK

Wmm [he angina up w novm)’ “rperanng xemper
llurl (looloxmumlv BO‘C 176’“

Stop me whom: and discwmec‘ the DH prcnuvt
swulchwuu

Remuv- mu m! rue-.urr- watch and connect an
oil pranum gluon In [he uvessura xw‘tch hola
(pla- 2 5)

Check them mm

2-4

 

OH PA\

0"- STRAWEF’

m

   

Hf LIEF VALVE
1') RYNI‘,

H:LLU VALV

 

OIL PQESSLWE 5.2mm

LUBRICATION

 

Start the engme and check the ad pqessure ax 5,000
mm
OIL PRESSURE:
5.4 1 0.7 Icy/cm: (77 1 10 mi) at 5,000 rpm
(80"C/‘I761'FI

Slop me engme‘
Apva 3~BONDF: seaiam m ecu mien: :0 (He
pressute swflch {breads and Irma“

TORQUE: 10-14 N~m(1.0—-1.4 Ito-m, 7—40 fl-lb)

Connzcl the oil pressure swath wne.

Sun xhe enginel

Opevate the warning ind'vcalor switch,

Check that the oil pressure warning lndlCiIIUI goes
uutafxur une or two seconds,

II the on pressure warnsng IndICaTOF nay; on, stop
the EnglnE rmmt’dlalelv and determine the cause

OIL PUMP

REMOVAL

NOTE

 

The on] pump can be removed With me engine
mourned In the I'ame‘

 

Drain the engine oiL Remove the exhausx system
Ramove the thI sxde cover

Homove [he ovl pump dnvcn sp'ockel by vemovrng
1m: bol! and washm

Remove the waxev pump assembw {page 6-10),

Remove {he ml sva‘ner (page 274) and me o~
Dass DID!
Make sure the O-rmgs are m good candmon

OIL PRESSURE GAUGE
07505-3000000 (Not avuiiame m U‘SAVI
Commercualiv JVaI'dL‘HE n U.S‘A‘

OIL PUMP DRIVEN SPROCKET

OIL PASS PIPE

 

    

 

LUBRICATION

f

Ramon the Ul' pump by vrv-uu ng me mom-I‘m;
balu

SXWun Ind rtrnove the pm hold-no Ihe ml
mlimv Iuy
Rum" "I! ml saline! nlv

Mill! w" the 041an are m good mud! n

DlSASSEMBLY

RImm/I th ml pump body cove! Ind umovr vhe
dowol om
Rtmon the dme pm ‘ram tn- vmo- mm

    

OIL PUMP

f“ “Al‘iEH SYAY

 

LEL ‘uJ'v’p BODY COVE?

 

MOUNTING BOLT

ORING

DOWEL PIN

 

 

Measure (he volor tip clearance.

STANDARD: 0.15 mm I0.000 in)
SERVICE LIMIT: 0.20 mm (0.008 in)

Men."- the pump body clearance.

STANDARD: 0.15—0.22 mm (ODDS—0.009 In)
SERVICE LIMIT: 0.35 mm (0.016 in)

Remove the rotor shah and musure the pump
and charancl.

STANDARD: 0.02—0.07 mm (0901-0903 In)
SERVICE LIMIT: 0.10 mm {0.004 Inl

 

LUBRICATION

 

 

 

2-7

LUBRICATION

 

ASSEMBLY OIL PUMP 500v OUTER ROTOR

Infllll m. on!!! rotov unto Ina body In! mun (M
rotav shah
Insert m- am: pm Into the rotor shift

     
  

DRIVE PIN

ROTOR SHAFT

Ahgn the sin" m m- mmr mm! mm the am. pm

 

DRIV PIN INNER ROTOR

DOWEL PIN
Install mu dowtl pin and oil pump body com

 

 

2-8

1NSTALLATION

Imull ma dowel nuns and 01mg and Insult me
on pump

|nnul| (he "rains! stay with a new pm ind Install
m. onl pipe.

NOYK

Malt mm the Dung, m ”mum an we
www any and o 1 mp!

I-umH (N: ml ma-ner awqmng my hon on the mu
am we cm on 0‘ we marer

lmult nu- ml pan

Pm. me ml pump driven wrockc! lnlo me dnve
chum
No"

The "W" mark on the dnun mode: would
he. the Genius:

Imam the trvllnwng
Um walher and hghllr 'lw boH.
, Hu- dowel pins and a «uw gauu-z
the ngm side cuvev,
Me water pump any (page 6<l l)‘
— ma exhaust pxpe.
FM the rhyme waf- the rucomrnuv-tim 01 inane
2 “

LN, .K‘EL F'mE

A?» .'L'. Cwnflm'i

O H v 5. G

 

LUBRICATION

 

 

LUBRICATION

 

 

FINAL DRIVE OIL . OILF'LLER CA

CHECK

Place the motorcycle on its center stand on level
ground.

Remove the oil filler cap‘

Check that the oil level reaches the lawn Mg: (II
the oil filler cap hole.

Check tor leaks, If the level IS Iowt Pour fresh oil

throufl‘l the oil tiller hole until it reaches the lower
edge.

CHANGE

 

Remove the OII filler cap and dram bolt to drain all
oil from the final gear case,

Install the drain bolt securely.

Fill the gear case with the recommended oil up to
the correct level (above).

OIL CAPACITY: 130 at: (4.4 oz)
RECOMMENDED OIL:

HYPOID GEAR OIL SAE 1380

 

OIL LEVEL

CONTROL CABLE LUBRICATIDN

PQrIOdICBIIV. disconnect the throttle cables at then
opp-t m4; Thorowhly IUb'lCi‘e the cables and
their prOl points with a commercially avmlabla
cable Iubrtcant or a lig’tt weight oil.

 

 

2-10

LUBRICATION

lUBRICATIflN POINTS

, 7,,7 , W, THROTTLE GRIP SWING ARM
o: {CABLE LUBRICANfl PIVOT a
l

      
 
 
   
      

THROTTLE AND ,6 I DRIVEN FLANGE
CHOKE CABLES BRAKE I SPINDLES AND
PEDALI PIVOT I I’LIII'ISHIUM BASED
I
CLUTCH AND BRAKE I I fl MULTIPURPOSE
LEVER PIVOYS I FOOT PEG GREASE)
/ ’ PIVOT /
I I

fl

STEERING
HEAD
BEARINGS

 

FINAL DRIVE

  

GEAR AND SHAFT

I
I
I
I
I
I
I
I
I
I

6! ' 5'05 AND IHYPOID GEAR OIL
.6” “fly CENTER 5“ m,
SPEEDOMETER 5mm- FOOT PEG STAND '6‘
DRIVE GEAR PEDAL PIVOT PIVOT PIVOT DRIVESHAFT
FRONT FORK JOINT
IATF.) ILITHIuM BASED
MULTIPURPOSE
GREASE)

 

2-11

 

MEMO

3. MAINTENANCE

SERVICE INFORMATION 3-1 CYLINDER COMPRESSION 3-13
MAINTENANCE SCHEDULES 34 EVAPORATIVE EMISSION CONTROL

I < ENGINE > “575" 3-13
FUEL LINES 3—4 < CHASSIS>
FUEL FILTER 3-4 BATTERV 3.14
THROTTLE OPERATION 3-5 BRAKE FLUID 3.14
CARBURETOR CHOKE a—e BRAKE PAD WEAR 3-15
AIR CLEANER 3—3 BRAKE SYSTEM 3-15
SPARK PLUGS 3—7 BRAKE LIGHT SWITCH 3—10
IGNITION SYSTEM 3—3 HEADLIGHT AIM 3.15
VALVE CLEARANCE 3—8 CLUTCH 3-1.
CARBURETOR SYNCHRONIZATION 3-10 SIDE STAND 3."
CARBURETOR IDLE SPEED 3—11 SUSPENSION 3.11
RAOIATOR COOLANT 3—12 wHEELS 3-19
RADIATOR CORE 3-12 STEERING HEAD BEARINGS 3—20
COOLING SYSTEM HOSEs NUTS. BOLTS. FASTENERS 3-21
B CONNECTIONS 3—12

 

SERVICE INFORMATIUN

GENE HAL

O Enam- OII Sn mo- 23
o Enema OII IIIIIV Soc no: 2-3
0 PIA-lama pm ml SOIDOQIIIO

SPECIFICATIONS

 

 

 

 

 

 

 

< Eng-no >
Souk now:
7 é‘lfldlfd For Gold CIII;MC [balm E'C. II'FI For "Landed high I906 twin.
NGK I W _NO NGKV T m _ND NGK ND
DPRBEAIC J X24EPR-U9 DPR7EA-9 i X2259R~U9 DPRDEA-B X27EPR-U9

 

 

 

 

 

Snark pluc DID OCR-03 mm (0031—0035 In)

MAINTENANCE

——_————-

 

 

 

Ionkion tlmlng a
At idle: to BTDC
Adv-nu mm: 10‘ BTDC at 1,500 rpm
Full dance: 37’ BTDC at 3300 rpm
Valvo dunno:
Cold (Balm: 35°C. 95°F): madam“: o 15 mm (0.0061nl
ldlnspud: 1.000—1,1001pm
Cnrbumar synchronizuion: All curhumou wmfln 60 mm (2.4 in) Ha
eynmr commubn: 13 t 2 wcm’ 1184 : 28 psi)
TMom: grip fin play: 2—6 mm NIB-1M in)
< CHASSIS >
Tm:
From Rear
Tire size
Mun/9MB M130/90—17
k l '
33° 9° ' (200 b" 32 (225. 2.25) 361250.250)

Cold tire pm", pal (kh. kglcm’)

 

90 RI (200 lbs) load

 

 

 

 

 

 

 

to "Male WHY load 32 (2‘25. 225) 40‘ (275. 2.75)
The band Dunlap F11 K827
From Vovk alr prawn: 0—8 {:55 (0—40 “’5. 0—0.4 ko/cm’)
Hm MMnflon air pressure: 0.57 mi (0400 km, 0—4.0 kg/cm’)
TOOLS
Special
View!!! an»: a! ONCE-0030000 or M9378—021—XXXXX (U.S.A. only)
Carburetor piIot sum wand! 01908-422020!
Compvmion gauge attachment 07510451800101 Commercially availabie in USA
Valve adlusting wrench 07908-M300100
Flvwml on"! ones-M54000!)
Camshaft hdder 07979—MK30000

 

3-2

MAINTENANCE

 

MAINTENANCE SCHEDULE

PerImm The PRE—RIDE INSPECTION in the mer's Manual at and! schedulad mnlnunancn period.

I: INSPECT AND CLEAN, ADJUST. LUBRICATE. OR REPLACE IF NECESSARY.
C: CLEAN. R: REPLACE. A: ADJUST. L: LUBRICATE

   

  
  
   

 
   
 

WHICHEVER ODOMETER READING (NOTE 3)

COMES

FIRST g

   
 

F R EOU ENCY

\

\

      
     
    
  
   

   
  
   
    
   
  
   
  
  

   
 
  
 
  
  

Refer to page
3.4
34
3-5
3-6
3-6
3-7
3-8
2-3
2-3
3—10
3-1 1
3-1 2
3-12

3-12

ITEM
FUEL LINES
FUEL FILTER
THROTTLE OPERATI9N7
CARBURETORCHOKE
AIR CLEANER
SPARK PLUGS
VALVECLEARANCE
ENGINE OIL 77 . 7
ENGINE OILWEILTER
CARBURETOR-SYNCHRONIZATION
CARBURETOR-IDLEfi-Pfl
RADIATOR COOLANT
RADIATOR cone

COOLING SYSTEM HOSES 81
CONNECTIONS

EVAPORATIVE EMISSION
CONTROL SYSTEM

FINAL DRLYEQIL
aAT-rEnv

   
  
  
  
  

    
  

  
   

    

O

    
    

  
 
 
 

110
I

  
  

     

 
    
  
  

    
   
   
 

   
  

 
     

  

EMISSION RELATED ITEMS
————xx—rn—-
--—::;u-:nn-—
-£—-:na-:nn-zz—

   
  
   
  
 
 

  

     

      

   

      

  
  
 
    

  
    

     

      

3—13

2-10
3-14
3-14
3-15
3-15
3-16
3-18

3-1 5

3-18
3—1 7
317
3-21
3-19
3~20

  
 
  
 

   
    
 
 

       
  
  
   
 

BRAKE FLUID
BRAKE PAD WEAR
BRAKE SYSTEM

BRAKE LIGHT SWITCH
HEADLIGHT AIM

CLUTCH FLUID

   
   
   
    
 

   
     
  
  

     

  
 
  
    

     

  
  
   

CLUTCH SYSTEM
SIDE sTAND_
- SUSPENSION

.__+__—_
- I NUTS. BOLTs.:ASLENERs

‘ ~~ WHEELS
.. STEERING HEAD aEARING

' SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER. UNLESS THE OWNER HAS PROPER TOOLS AND

SERVICE DATA AND IS MECHANICALLY QUALIFIED.
" IN THE INTEREST OF SAFETY, WE RECOMMENDED THAT THESE ITEMS BE SERVICED ONLY BY AN AUTHOR-

IZED HONDA DEALER.

NOTES: 1. SERVICE MORE FREQUENTLY WHEN RIDING IN DUSTY AREAS.

2. CALIFORNIA TYPE ONLY.
3. FOR HIGHER ODOMETER READING, REPEAT AT THE FREQUENCY INTERVAL ESTABLISHED HERE.

  
      

   

NON-EMISSION RELATED ITEMS

      
 
   
 
 

  
  

 

 

 

 

  

 

 

3-3

MAINTENANCE

 

FUEL LINES

Remove the left and ngm and: covers.
Remove the sea! by remnvmg the moummg «ache!
bolt;

Check Ihe fuel Imes .nd IUDIICL' auv Dam wh‘ch
mow drierroratlon, damage In Inlays

lmul me sea: and wit com”

SC H E W

FUEL FILTER

Remove the seat

Tum the Iuel valve "OFF?

Remove m. fueI hue! how the holdev by remosmu
mo Icrew.

cllp [he ‘qu III'IeS,

Disconnum m: Iuel Ilnu horn Iho Illtav,

Rem-ca the Iuel Iiller mm a nnw one when decm
ed by "w mauuenlnce wN-dule See page 3-3!
Unczlu the fuel imes

Imml me Iuel film and hghven the men seamen

\ Gala/In: lo flammable and It “plan's! mu!"
«null: condition: I)“ rm! mink: or III/"h
[lawn a! spark: in your working arm

 

AIlcv mnallmg, check the! (hem ave no fues leaks. :UEL l INCS

- 4.

3-4

FUEL LINFS

MOUNTING BOLT

HI l‘ Die-3‘

 

MAINTENANCE

 

THROTTLE OPERATION

Check for smou'?‘ Thrown ghp (ui‘ c-pemrg and
aulomnhc Yull :Ionng m a‘l Hemmg pos‘tvnm
Check the "name Labia: and veplaca them .4 they
are delenoraxed, kmked 0' damageo

Lubncmc me xhvoulz came; (page 2 H), v! mrome
opevaflcm Is no! smooth

Maisv'e [Nettle gnp free play a! 1m 31011:: 9er
flange.

FREE PLAY: 2% mm (1/8—1/4in)

Adjustments can be made a! Etther and GI me
[muille mtnbe Minor amnsrmum; are 1 ‘11-.- ‘.-.'.Hv
the JODE‘ ad‘zmav 3rd mam! ac‘usmmms we madc-
wnh me ‘awer adiuste’.

Remove vhe seat.

Remove, the fuel xanw (page :1 i8:

Adiusl hv {oosemrn mp Huck mi and [mung l‘lt‘
adjuster

Ttghxen ma lock nu ma ‘A—chuclv w rm'lu Uu': "Um:
Remstall the remmar. par: u 'h- e-w mdex 0'
disassemblv and cry-ark (moxie trap 915» Once more

 

“W’E F finJLSTE R

 

FUEL VALVE

FUEL LINE

 

LOWER ADJUSTER

LOCK NU

    

\

T

 

3-5

LUBRICA‘I’ION

CARBURETUR CHOKE

":5 V65 wmr- ”new“ ma. 5 he. E’WCh-Enmq
mun Lu'1m ‘cdtzv e zz‘n'a-tw' .aN-r '"izusta'tr

 

 

.‘alm mum's 1hr n"
the man mm or m. Myanmar :5 nulleri dowr
ChrL- Mu mnnm :rvr-ev c 0'” Wu» opfi'aha"

mmg v, m»: «a caste whe'v

Chen {M mumm upnm move “an" npurdhun
Luuvlcaw I'u- \hnhv 1.1km, M Mr: noe’anan ‘5 no!
smooth,

Rurnovv mr hu-I mm mane 4718!

Pull mu rhokn luvm on thn handlebav all the way
down 1-3 lullv um" Makr surr the choke valve 45
open by nymu m mr-vl: "w nnoke Ievev cm the
EB‘thFlnv

ThFrr mnuld be no ‘19! L a»

Auflsv 4‘ rrcmu'. :r. «)st r2: "2% :hohe can‘t!
camp (2'1 'ne (rt. 1"‘lu' 4'": ”\Qw‘g its, mo"
cama- :asmg 10 mo ('1V):~?\~'~.‘W ;, . My (mew

quhtuv‘ mm mm

9mm ma (nuke law-v .v mu way u: 1-3 mm, dosed
Muir my" Hm r'mk- who: w 'le Nosed by check
mg iuv Hm- Na" d m» cahw hum-em the may on
[hr cwlmtr-mv am! rnhlr raan

Rmmlnll Hm mrmwn umh m I'm: vwc-rsa order m
msasxrmhly

AIR CLEANER

Hrmnw UH: 'ual link mag: 418v

Rama»! #1: an durum cast: covey by ”Hum-n9
th screwy

Removu mo ulnmen: wnmg plat? B and the element

    

 

CABLE CLAMP

 

CHOKE CABLE

A'r‘ ClFANCF
CASE COVER
\

scam-s

ELEMENT SEYYING PLATE 8

 

3-6

MAINTENANCE

 

M the «cm-m m nonllammlble or man flash
paint ”ham. Squeeze out the am when! and
m: I! cry.

Sock lhI ohm-M In on: 0-! (SAE M) and
snub". out 1h! unis:

Insull ml umowd pom in (he rams: old-t o! du-
mummy,

 

 

 

 

neeommoeo ”ARK noes
NGK ' no I
‘ Sundm 1 DPROEA-O xzasnwn [
l , ,
4:215:11?" DPR7EA-9 menu
:3.me if,“ omens x27evnm

 

 

 

 

 

Dhconnm the walk plug up“

Clun any dun lvom lrouna m spark plug bun.
lem and dlwud {M spurt plugs.

Mouun MI mw ml"! plug pups who u wan-wpa
lulu on...

‘PARK PLUG GAP: 0H) m (0331—0335 Inl

Adlun by bonding the fid- mumm.
WM the plug wail-r m. thud um M
plug In by m to pawn! «Mm-dung
Timummmuupm ”Imam”
M pungncnlommpluam,
Com-«I Mow-rt mam.

CLEANING
SOLVENT
I

ALLOW TO \ ’
.. $* W @ .. $
I

  

ElEMENT squeeze GEAR OIL SOUEEZE ‘
TIGHTLY (SAE ‘80-‘90) TIGHTLV

J

CENTER
ELECTRODE SIDE ELECTRODE

.a-os mm
(0.0314035 m)

 

3-7

MAINTENANCE

 

 

FLYWHEEL COVE ‘4
O7998MB40000

\‘r

IGNITION T|M|NG CRANKCASE MATlNG SURFACE

Wipe of? the oil from the flywheel.
lnstall a flywheel cover [07998 MBdOOOOl

Connect the tummy hght to the hogh tension wire
0! the No. 1 cvlinden
Start the engine Ind lot It idle.

IDLE SPEED:1.000-1,IOO run

   
   
   

The timing 6 correct It the ”F" mark on the fly.
wheel aligns with the crankcase rear mating surfact-
or the flywheel cover aligmng mark

FLYWHEEL 7 “l>"MARK ALlGNlNG MARK

VALVE CLEARANCE nggfirvscou CVLINDER HEAD COVER

NOTE

 

lnspect and adjust valve Aclelranca Whll! the
engine is cold» (Below 35°C, 95°F)

 

Remove the heat guard, radiator cap and dram bolt.
Drain coolant Irom engine and frame (page 6-3).

MOVE.

Drain the coolant into n cleln container r37
reuse. Scheduled coolant replacement is every
2 years or 24,000 mules (38,600 km).

 

Remove the "9"“ and left heme side covers and
remove the seat

Remove the luel tank [page 4—18).

Remove the radiator lpage 6—6). INSULATOR COVE R

Remove the spark plug caps.

Remove the Ignihon CDIIS with lhatr bracket and T1 3 MARK
remove the Insulator cover. '
Remove the iron! and rear cylinder head cover bolts

and both cylinder head covers,
Remove the alternator and loft crankcase covers. ‘

 

  

INSPECT ION

Measure and adjust the intake and exhaust valve
clearances while the englne l5 cold. ‘

Rotate the crankshalt clodtwtse to Illgfl the T13
mark wrth the crankcase mating surfaces.

Make sure the No. 1 pmon li at TDC (Yup Dead ‘
Center) on the compression stroke. ‘

CRANKCASE MATING SURFACE

f -

3-8

MAINTENANCE

 

 

Install the cumin." hold-c KOCH
Slud- m ‘claw" undo! "I end of the cur-shah RING ‘
Slothc"rmo"ovn ml Madnhha comm pou- ‘
ma! boll

Fmoor “ohm IM canning knob This will ruin
the camchm no mm In. camshaft hold“

CAUTION l

Owrligluufilvrvm I)" alI/IIIfiIIg knob may damn”
III! loot

 

 

 

 

 

 

 

 

 

 

 

 

 

 

\ ADJUSTIN
Chock lhl vuIvc clurlncu Icr the No, I cylindcv | G K05

Hung two Iulu gluon Ior ouch par of v“; on:
Io: uch um that shares a common rocker arm 6

I
VALVE CLEARANCE (IN. EX): 0.1 5 m (0.006 In) / ‘e’ ’ ’

-—

cuw cmsum mo
cmsuAn nouarsn onn—maoooo

 

nmmummJoosenmloet null and
tum IN can-1mg term umimnnllnhldng
on both Icolor snug-II Both Inlet gauges shodd
lama-n murud ammo Idmtrmm.

FEEL R GAUGES

Ramon [hi all nine hon Ind on pipe If necessary
Hold mo odquumg tcrnwl and ughmn m- Iock mm
TORQUE: 11 —25 N-m 12.1 —2.5 kg-m, 15-1. 8-.»
CAUTION:

The lad null will name low! 1/ no! lighlened (a
the WI Iorqw value. ‘

 

 

 

Mock 1M valve chance

 

VALVE ADJUSTING WRENCN ones—maoouoo

 

Roux. Iho eunuch“! 270' dodmisn to IN" the
T“ mm: mm m cunkusc mating sum and
chodt IN “I" clnllneu In! tho No. 2 cylmdlv.

Adiun was I?» moo-dun: Iov the No. I clendIr.

T1,! mm: with m. suntan mating lumen and
and tho vllvc clumncu Iot th- No. 3 cylindov.

 

Rom. (ha mnklhm 90" clockwin to align m ‘

Minn mine m- proudum Iov the No. I cylindor.

Rom. m mnkunn 270' dodmin to align m
12.4 mm: with the autism Ming airbus and
and! tho "I" durum Io: the No. l whiny.

 

Minn whom-um- an'afl-No. I
Mind-v.

 

 

 

FEE ER GAUGES

 

MAINTENANCE

 

 
 

CYLINDER HEAD
COVER BASE

     
    

REAR CYLINDER HEAD COVER
Install the removed parts, except the radiator cap‘
in the reverse order 07 d-slssemblv.
Be sure the cast mark inside the rear cylinder head

cover, and the tab of the cover base face the from

 

CAST MARK TAB

FRONT CYLINDER HEAD COVER

Be sure the tabs 0' the front cylinder head cover
lace the rear.

Check the engine orl levelt
Fill the radiator w-th clean coolant to the specified
level.

NOYE_

After filling the radiator, star! the engine and
rev It at least three times to remove any air .
bubbles from the cooling system Add more
coolant mixture as necessary ‘

 

Install the radiator cap

 

CARBURETDR SYNCHRflNIZAllON . N° ‘CYUNDERHEAD?0”TPLUG

NOTE:

 

‘ Synchronize the carburetor: with the engine '
at normal operating temperature, the trans‘
mission in neutral and the motorcycle on the
center stand. i

 

Remove the plugs lrom the No. 1. 2. 3 and 4 cylin
dar heed ports and install the vacuum gauge adipA
t‘ers.

Connect the vacuum gauges

No‘ 2 CVLINDER HEAD PORT PLUG

 

3-10

MAINTENANCE

 

 

vacuum GAUGE 07.:m»0030000
on “gammy—mu tusn ,v:

ADJUSTMENT

N0"

V The No l camuvrlov cannot be adgusled, H1
m. but unburuoc

Inna“ \he vicwm gauge edema; and connect the

vmuum mug!‘

Sun lhl cnwnn Ind Idiusl the idle speed.

IDLE SPEED‘ LOW-1,100 rpm

Chuck "III I" urbuvoluu are within 60 mm (2 4 .n)
HI

Syncnmmu to [he Ioecnhcauon 13v mmmg "w
idimhnq mum mm the spec-3i too?

Rachcck ma «dln med Ind wnchvomzauon
Removo m. gang. Minute” and Install the plugs

 

ADJUS'HNG SCRE‘IA CARBbRE YOR ADJUSTING WRENCH
07908—477020)

CARBURETOR IDLE SPED

NOTE

r. Imam and Bdlufl .dle speed after all 0mm
Ungino odiunmonu are with specflicauom,
0Tb. mam: mun be warm lot accurate adjust
mum. Ten m-nulu ()4 nonvandgo riqu n
wmcunl

 

lem up mu tngmu, mm Io NEUTRAL, and place
Iht molmcvclo on M cemu stand

Tum ma "Home nap screw as required m can n
(N mocn'md Idl! weed

tDLE SPEED 1.000-[10079m

 

THROT‘H E STU? SCRE .‘n‘

3-11

MAINTENANCE

4

RADIATOR COOLANT

Romuv- m. rum ugh! I do emu

 

0190. m. rnerve uni coolant level mth the 213m:
runmnq or normal operanng lemperatue.

Yha Incl mould bu buwnn the "FULL" and
“LOW" lovvl lmu

I! necessary, remuve (he reserve tank can and “II to
the “FULL" lcvol hm with I 50/50 mlxmre of
dlilllllfl wulor and nnli freeze.

Rmnsnll [M can Ind rum: vde cover.

RADIAWR CORE

Lumen the ram-tor ude cover anad’h’lg balls 3m:
remove the min corms and gull:

Chuck KM our ounces '01 crown-‘9 or damage
Strnlqman hem Mn and collapsed core tubes
Human much. mud or any obsrructrcn mm com
pruud alr or low wner prnmra

Rnphcn rhu rodiolar .l m an haw li ramlcud over
morn than 20% or m- rndmlvng surface.

Relnsllll [ht arlllc and rhe HOE covers

COMING SYSTEM HOSES &
CDNNECTIDNS

Inwocr rhu hon: lot cracks or oeterro'ulon, n6
veplaco xi nocnuvy
Check In. rlghlmn of all has: climns

RESER»

'I-‘.‘( (L119

 

 

3-12

MAINTENANCE

 

CYLINDER COMPRESSION

Wam- up we angvnr

Slop 01:- mg ne ‘I'ven d worms; tru- spark plug
caps and remove :M 5031 qua

Instr! the compressmn gauge

Open {he throttle all the way and crank (he engine
with {he staner momr

NOTE-

Cvank the engme Will the gauge leadlng
stops r smg The maximum readlng :5 usually
reached w (hu- 4 7 seconds.

 

 

 

 

, , _l
COMPRESSION PRESSURE:
I3 ‘ 2 kg/cm: I134 : 28 pH)
u .‘ I h H .m f ;| ,. COMPRE$ION GAUGE
— 73272?3,°J;.LL‘2?Z;3:§. n E a a“ ”9 ATTACHMENT 07510—M500100
‘ " ’ " [Commercially avaiIabIe in USA.)
A Leaky valvus
— Leak ng cylanu- head gasket V
A er. DISIDr‘r'nngv'Ich‘ndel , ‘ , AIFI VENT CONTROL
II compresswn Is mgh, n vndmaxes that carbon »_.f VALVE

chambev andxm me p «or crown

doom-Is haw.- accumulated an the combusuon -‘ W,” 3 ./

   
 
 

EVAPORATIVE EMISSION CONTROL
SYSTEM (California model only)

Check We hows between the lureame' separawr,
iuel yank. rharroa: car-5W, nurgn comm) valve and
an vent comm: val-as- Inv drum. or Iucsc noun-3D ,
xiom. Clmec: as necessary ‘

. ,» I _ r,
'I” f PURGE
.Wcomnm

, Y VALVE

Chock thi- charcoal camstev m, cracks or damage CANISTER

 

 

 

CARBUF-ETOP VACUUM HOSE ROUTING
VACUUM HOSE IIIJUIIIG UIIGRAI

IIIIII 3IIlI IRIOIIMII
IIIIGI'I'I HIU I!“
“will IIIILI

NOTE

 

 

- Be Cir-”U ‘ band was? or k n}. m»

 

SI “1!—
Wily and sMu-J

I was

   

1,1117. :3 mun-g

  

A lum' LMMM
' C'mck mat mu "JZL; 1-» mn' cm'acfna
sham 9:198: m cowl-Ms

 

 

 

 

 

 

3-13

MAINTENANCE

 

(CHASSIS)
BATTERY

Rrwuvt‘ 2h? iefi ‘rggmr mlr mum 5rd “gen 'hr
nauew I ma Iéhi:

‘uvnor We 'iu-d "nu m: vowel ‘eael rarrune In:
utle'v and add dumled wale' In the harm \em
Ima as Inflow:

Remova [he balle'v holder DUI! DISCOHHEFI m»
nuanvF cable an [hr [mm-w IP'MIr‘a“ mm III‘
connect Ihe posmve rnhle

Rum-we xbc fMe' «am Ind ado um-Ited mm”! w
M: upuev 92ml Ime Homxlal‘ "m hanery

N01!

 

Arid arm (:5? ‘ec wuz' 7517 art w
movu'u me Sl'wce J: n‘ m- nay-9y,

 

Mr bane/y (learn/Hr ronmms sulphum

and Proleu vow (In 1AM. and (In/hm):
If rIrrlm/ylr gt]! In war (In flmh Ihrm
Ihamughb wuh Mir! and gel pmmpl

 

 

mnhral alltnlwn

 

BRAKE FLUID

Chuck the brake ‘lmL! wwrvuu luvgl

II me Ilmd nears Me |owvv luv-II mark. ml {he new-
mu wuh DOT4 Bun Fund IO xhe quPv Iwu-I
mall,

Check 1hr ("11¢ wutm 90' uh ' 2"! um I; my.

CAUYIOM

 

0" "iv: rtmw: 1hr .‘mr' u'rru' {hr Mil-[Jr
Mr ha: hem rumrd w 1th Ihe resenwur n
Incl

Aron! opmmng Iln' mu Imer wllh Iln'
rap ”mam! Muir ,fluul mil squirt uul 1]
[hr [rt-er n pal/rd

Dw nu! ma Jim-rm! firm u; {Fun} .2: :Im
an m v! Comguuhlr

 

 

 

“0‘" Ir: secl‘cn 17 ‘c- built I Ind‘"; p'oczcu'n

3-14

NEGATIVF CARI E

 

FRONT

PUSI Tl VE CARI l'

_‘;t /

r_PF’EFI LEV

””7

UPPER Li’VH MARK

/

HOLDER 801 I

 

UPPE R LEVEL MARK

 

LOWER I FVE. MARK

MAINTENANCE

BRAKE PADS

       

BRAKE PAD WEAR BRAKE PADS BRAKE DISC

Check the brake pads (or weer by looking through
the slot indicated by the arrow cast on the caliper
assembly»

Replace me brake pads l' the wear line on lhe pads
reaches the edge 04 the brake disc (page 17-5l‘

CAUTION

 

Alwarr «plan the hmkt pm]; in pair: in
055“]! IV!" dllf‘ pruxurr.

 

 

BRAKE SYSTEM

Inspect the brake hoses and {mines for deterio»
ration. cracks and signs 0' leakage, Y-ghien any BRAKE DISC
loose fmlnqs

Replace hoses and linings as required

 

AND! ‘84
After '34 ADJUSTER ARROW

BRAKE LEVER FREE PLAY

Measure [he distance (he hon! brake lever moves
belore lhe "om brake sums to engage,

Lever free play should be 20—30 mm l’A—lV‘ in)
as the lip of thfi lever ll adjustmenl is necessary,
turn the edlusrer

CAUTION:

 

 

Ahgn 1h! (71de mar/r on lira adjust” with the

arrow on fire Inwl INDEX MARK

 

 

 

 

Apply the brake several times and chedr for lree
front wheel rotation.

 

BRAKE PEDAL HElGHT LOCK NUT

Adiusl brake pedal heighl so me pedal is 15 mm
(0 59 ml below the [op ol the loot peg‘

CAUTION

 

Int-mun hmkr prda! hrrghl ran musr [wake
drag

 

 

 

To Adjusl

Loosen the slopper boll lock nut and turn the
stopper boll

Reuqhten the lock nut

NOTE.

 

After ijusllng Ihe brake pedal height, check
the rear brake light swnch and brake pedal
free play and adjust il necessary. STOPPER BOLT

 

 

 

 

 

3-15

MAINTENANCE

 

 

BRAKE LIGHT SWITCH 55?:le m,

NOV!

 

Perlorm .\ but: hth which adgusxmen'. am"
adlunmg [he bake pedal play and neughl

 

 

 

Adnm m- bun lam much so mm the mak-
llghl wull coma on when me make engagement
begim

Adluu by holdmg the sw-(cr‘ body and luvmng
(he adlumno nul 00 no! mm mr switch body

NO"

 

Tho hom nuke lught Much dots not rang-re
ndluumonx

 

 

 

 

ADJUST WC: NJ 7

EDALKEY ‘JC‘JNTIHQ BOL'

IEADlICHT AIM

Adm“ homor'ullv by ‘oosenmg Dom neaawgn
case moummq bum

Adpun vulhcally by luosemng born hEadUghl "
buckel mouulmg (sons 1

NOTE

 

Adm" the Munich! beam as “mama by
luul lnvn mu veoulnhom

m—

An Impmprtly adj-um! hmdbglu may bland
cumming dmvn m u may {all In lighl M: l
road [or 1 IO]! dulanrv l

   

 

, l' Why/I

 
    

 

 

 

‘JOUNT LNG SOL Y

:JPPEP l EVEL VAR-f.

CLUTCH

Check "In clulch Vluvd mnwow quel

H [M 'luuu nun lh! Iowa-v level mark_ hll the user
you mm DOT 4 Brain.- Flmd ID the upper level
mm

Chock "m min- lysum lov leaks, I' the level n low

CAUYION

 

' [)0 mu "mm-r 1hr mm mm! {he hm}
Irbar ha! brrn Iunml 34v Iha! the fame»
H [mm]

‘ Ann! vpmlm: M! dun-I: [on MM the
mp rrmmnl Huh! .1!" xqmrl nu: 1/ Ih!
Inn 1: wild
Do mu mu «ll/farm Urn H! {but as
(My arr m: r-rmpanbh

 

 

 

 

3-16

MAINTENANCE

 

After '84 A
CLUTCH LEVER FREE PLAY l

 

Measure the distance the clutch lever moves
belore lhe clutch starts to disengage Lever "ea
play should be 20—30 mm lM—‘IVA In) at the up
ol the lever ll adjustmenl IS necessary, turn the r
adruster

CAUTION.

 

Allgn the mdrv mark on the admire-r n-lrh [he
arrow on ”I? [FPIL

 

 

Start the engine. pull in the clutch lever and shift
the transrmssnon into first gearr Check that me
engine does not stall and that the motorwcle does
not creep Gradually release the clutch lever and
open the throltle, The motorcycle should start
smoothlv and accelerate gradually

SIDE STAND

Check the rubber pad for deterioration or wear
Replace it any wear euends to the wear line as
shown Check the Side slend sprung lor damage l
and loss ol tension. and the side stand assembly l
lor freedom of movement, Make sure the sude
stand is not bent

 

ADJUSTER

 

 

GOOD NO GOOD

NOTE

 

When replacrng a pad, use one wnh the
mark "Over 260 lbs ONLY"

Spring tension is correct ll 3 force ol
2—3 kg (4 4»—66 lb) rs required to pull
the Side Stand into its lowered posruon

 

 

 

l

 

 

SUSPENSION

 
   
  

Do not ride a vehirlc with faulty Iuspam‘onl
Loon, worn or damaged “spatula" pens
impair vehicle rlnbr'fily and mnnol.

FRONT

Check the action of the hunt lorlls lw compressing
them several times

Check the entire lork assembly (or leaks or damage
Replace damaged components which cannot be
repaired

Tlghten all nuts and bolts

 

MAINTENANCE

Check the Iront Iork arr pressure when the Iorks

are cold
Place the vehicle on Its center stand
Remove the left Iork arr valve cap and measure the

an pressure

AIR PRESSURE:
0‘6 psi (0#40 kPn. 0-0,4 kg/cm')

NOTE

‘I The rtgm Iork air valve cap should not be
removed unless the nght Iork I5 overhauled

I

 

AIR VALVE CAP

ANTI-DIVE SYSTEM INSPECTION

 

Selrcl a safe plow (may from (rd/it m prr- I
[arm lhii' insprdion. I

Check the Operatron of the antrdlve system bv
ndmg the motorcycle and firmly applying the

brakes

 

 

 

Pasntion Ann-dive damper Iorce
I LIGHT ANTI-DIVE
II MEDIUM
III HARD
IV MAXIMUM ANTIleVE

 

 

 

 

Inspect and If necessary. tepalr the system [refer
to section 15)
DAMPING ADJUSTER

AItar adtusnng preload BI' pressure‘ set the Iron!
Iork rebound dampmg adjuster

 

 

 

 

 

 

 

 

    

REBOUND
DAMPING RIDING CONDITIONS
ADJUSTER
I General or around town ndmg
2 Highwav or winding road ridmg
3 Rough road riding
CAMPING ADJUSTER

 

3-18

REAR

Place the mmurcvcm Im :15 comer stand

Move {he reav whm' svdaway: w-zh 9mm- tn sun
.0 me Sw‘ngavww beaungs ma wum

Rewace the Deanna; ‘9 1H9“;- 5 an mm.- m...
lmge 16 15>

Check the shock absorb-5:5 My leaks :v dar‘mgn
Tugmen all year suwcnaum ".st and twin

Ran—ave [h5- ugm and m“ We covers

Remnve 1’18 568?

Remove the valve can and weasuve me Veav >hou
:msn'he' a" piessmu

NOTE

 

Chuck [he an macaw! when ma veal s'iuttk
nbsormr is rnlr!

lg, ,,7,, A

REAR SHOCK ABSORBER AIR PRESSURE
O~57 psi [0 7‘00 kPI. 0 4 0 kg cm’)

Amusz the ’Pbou'\d nnmnm; azca'g-ng 'w "n
Mllnwmg cha't

Rocumvrended Final Sumonszon Adjustmun'.
I * A—Y—
REBOUND RIDING
CAMPING CON
ADJUSYER DITIONS

Rear An R-duv

\
pressuve [ Load

 

 

D psr Om- General 0:

<0 lpa ‘. alumna town.
0 kg Cm“, namg

l i 2 Hanna” or
UD '0 mndmu road

57 um ‘ yumm- .

I400 kPa. lmummy 3 Rmuy‘ mud
.4 0 kg cm” man J ndmg
l A l A ,7 A

 

MAINTENANCE

AIR VALVE AIR VALVE CAP

REBOUND DAMPING ADJUSYER

 

 

3-19

MAINTENANCE

 

 

WHEELS

NOT!

 

Tue pressure should be checked when tires
are COLD

 

 

 

Check the was tor cuts. umbedded nails or other
sharp objects

RECOMMENDED TIRES AND PRESSURES:

 

 

 

 

 

 

 

 

Front Rear
Tyre sue MUG/9018 M130/‘90~‘7
I Up to
J 90 kg 32 36
Cold me? (2?0 lbs) 1225, 2 25) 1250, 2 50)
pressurel “‘1 ‘ 7
psl (ItPa. 90 k9
kg/crn’) (200 lbs) 1
load to 32 40
vehicle (225. 2 25) (275. 2.75)
capacvty
load
7'"? DUNLOP r11 K627
brand

 

 

 

 

Check the lront and rear wheels lor trueness
(Sechcn 15 and 16)

Measure the tread depth at the center of the was
Replace the lures :1 the tread depth reaches the
lollowtng llmlls.

ertlrnum tread depth:
Front: 15 mm (1/18 in)
flour: 2.0 mm (3/32 ln)

STEERING HEAD BEARING

MOTE‘

 

Check that the control cables do not mten
Vere wuth handlebar rotatron

 

 

 

Fletse the tram wheel of! the ground and check
that the handlebar rotates freely

II the handlebar moves unevenlvt binds, or has
Vel’llCaI movement. adjust the steenng head
beannq by turnan the steering head adtustrng
nut {page 15-33)

 

 

 

3-20

MAINTENANCE

 

NUTS.BOLTS,FASTENEBS

Chocll mu MI chasms nuts and ham Ill flamenco
lo than curved ‘orque valun {Shanon H at me
muwaiu Ihuwn m the Maintenance Sch-dun
{mu 3-3)

Chock all oancr pms. "(my chat. hon clamps
Ind cable stays

 

3-21

FUEL SYSTEM

 

California type onw

 

 

 

 

 

4-o

4. FUEL SYSTEM

 

 

SERVICE INFORMATION 4—1 CARBURETOR INSTALLATION 4-16
TROUBLESHOOTING 4—2 PILOT SCREW ADJUSTMENT t—17
CAHBURETOR REMOVAL 4—3 FUEL TANK G—‘IB
VACUUM CHAMBER 4-5 AIR CLEANER 4.19
FLOAT CHAMBER 4—7 FUEL PUMP 4—19 I
PILOT SCREW 4—9 HIGH ALTITUDE ADJUSTMENT 4—20
CARBURETOR SEPARATION 4—10 (USA only)
CARBURETOR ASSEMBLY 4—13 PURGE CONTOL/AIR VENT 4—21
CONTROL VALVES INSPEcTION
(CALIFORNIA TYPE)

 

 

 

SERVICE INFORMATION

GENERAL

 
  
 

Gasoline is extremely flammahle and is cxplasI‘vr under cumin conditions. Work In a well nullbled om. Do no! make
In allow flamex or spark: in the work Im-a.

 

 

 

I Tho from cylmders use down duh auburetors.

C When dassssemblmg Iue‘ system cans. note the locations of the OairIgs. Replica (htm with am on“ on rumblv.

I The "cm howls have dram scram that can be loosenod to d'ain rasidunl gasoline.

I Full pump :nspemion Is In sactmn 21‘

o The NBA and No.3 caIbuIetofs use dIflerenI needle let holders and shoner vacuum piston spring "an the N02 and No.4
cavburetozsA Do not Interchanga these pans.

TOOLS

Spud-I

Pressure pump ST—AH—Z‘SS—MC7 (USA. only)

Vacuum pump ST-AH-"SO—MC7 (USA. only)

Common

Float gauge 07401—0010000

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

_ , Primnry 12.2 mm (6.43 "H
Venlun dIameIm ‘ Secondary 34 mm ”'34 inI ‘
IdemvacalIon NO. VD7IA. VD74A (CaIanmi. type) i
FIoaI level 7.5 mm (0.29 in]
Mam let ‘ Front 4' 120. Rear #123
Jet needle I Frontiflear: IHA/IHA, ‘IHG/THG (California Type]
L ldEI: speed I woo—moomm
L anome gzip Ivee may ‘ i 2—6 mm I1/B—1/4 In]
L_ PIIOI swew mf‘fal openIng 7 _ I iiiiiii ¥ _:See page 4'17

 

 

FUEL SYSTEM

 

TWINS

Elli:- uh Inn um“ um

.No MI in tank

No luol Io ammo:

Emin- floodofl with M

No wall: It plug (Imam syn-m bully!
All clumr clan-d

. Inukc Alr duh

Improper than opomlon

. Impvopor thronlo accretion

wwaprpp.

M min. at nailing lhl mm.
Imp": nor chok- operation
Iormion mliunclbn

Cubumov hum

Fu-l tannin-tad

mm. m but

ldh loud incur.“

PP‘PPf-‘r‘

M II.
lmbn man may
. Idh mud 5mm
. locum! ammo: Ivndvonimion
‘ Carbuntov huny
. Fun! contaminant!

Wham?-

thmno mum Mention
I. lonillon mum flultv

Wiring
1. human svmm flully
2. Cadmium “any

be! m may) Ind poor Ind my
1. Fun! wit-m down!
2. Initial Imam lanky

 

I... m
Gmdmmu
Vacuum pmou mack cloud
“0'" "M VIM
Float incl low
Fuol up mu bloated
Fuol minor scum clung-d
lectld Ouol Hm
. Alr um tuba don-d
i. Int-kl .1: Iain
10. Human a: bum Ind pump

nsppywvr

Rldulllnun

I. Claw-dim.“

2. Faunyllouvdn
1me“:th

A MMUM
5. Dinvlirm

CARBIIRETHR REMOVAL

Remove the seat.
Remove the (us! tank {page 4'18“).
Remove the two screws and remove the arr cleaner

035E.

Remove the bolt attachmg the thermostat housmg
to me arr chamber and the ground cable.

Remove the srx screws and the air chamber top
cover.

 

FUEL SYSTEM

 

4-3

FUEL SYSTEM

 

 

Dvscnmwc'. the cvankcase breatnm lube and the my
win my Inosumng tut): chp

Homovo thn carburetor choke clump Ind dnconnect
the choko and throttle cabin,

Roman the thevmostiuc swutch wt" and war.
plug vme: hom the damp; on the nu chumbgv hul
wild

Loam" the carburuor bands and roman 1h! Cir
bur-tor unmblv 1mm the 1m side.

(AFR

THER‘JOSTA H

 

FEVFP E-X‘.

 

\x‘.‘ 1| H N‘HHE

 

 

4-4

 

VACUUM CHAMBER

REMOVAL

Roman me hoax quavd horn me an chamber

anovo mu low "mum chambe! cove! sans Ind
the cover

CAUYION

[)0 no! mmchanp mam»! dumb" cove".
xpnngx. pumm or fa "((dld between my»
burtmn

 

Removo mo comortumn sonny, dnapmagm and
vacuum omon

Impocl the vacuum pnslon Vor wear, mdu, scratches
or om" damag-

Makn wry (ha pmon man: up and down huly In
(M dumber

Noll thll lha No, 1 Ind No 3 uvburemn use
mHevem nuedlc 1e! lwldnu and shorter Lpllngs xhan
Ihe N03 and N043 urhurnlors

FUEL SYSTEM

HEA! GUARD

 

VACUUM CHA‘JBE" 52L, ‘. f»?

DIAPHRAQ‘: ~. JUNK“ PtSTON
\

COMPRESSION SPRING

  

 

FUE L SYSTEM

 

Pub "10 needl- holdu in 0nd turn it 60 down:
mm on 8 mm soduL Than remove m nudlo
hold". spring and nndII "cm the piston.

lmoocl nu noodle fa "com" wnv n [M up Ind
in: landing. at rah-r «moot

M the diaphngu lot Mot-ovum and lun‘

INSTALLATION

Imallnion Is manly mu mum of removal
mun m. chemo" nova no that In may shen-
with th- hole In tho datum-om.

3. mm the shoruv spnnm or! "mailed m me No. I
Ind No. 3 carbureton.

 

NEEDLE HOLDER

DIAPHRAGM SPRING

 

 

CAVIYV

 

 

4-6

FUEL SYSTEM

 

FLOAT CHAMBER

REMOVAL

FLOAT CHAMBER

    
    

Remove the four float chamber screws and mo float
chamber.

FLOAT LEVEL

MBasure the float level with the carburetor mclmed
16°—45° hum vurxical and the final tang just
contact‘ng the float valve,

NOTE

Measure the float level nearest [he float valve.

SPECIFICATION: 7.6 mm (0.29 in’

Adjust the 1103! lave! by carefully bending me float
Kang
FLOAT LEVEL GAUGE
07401—0010000

F LOAT AND JETS

Remove the float pin, float and float valve.

 

FUEL SYSTEM

VALVE SEAT

lnwocx the "on ”In lm grooves and nicks
lnwoct the operation of the "on valve.

 

FLOAT VALVE
MAIN JET FLOAT VALVE SEAT

anovo [ht slam: ju, mum m and slow 1:!
Human (he ‘loal ulu ml Ina Mu!

      

STARTER JET SLOW JET
FILTER VALVE SEAT
Imam! the float vulve In! am hue! Gov grooves, /

mdu or deposm‘ (,

l

ASSEMBLY

Aucmbln (he "on chunbu componenu m th-
uvuu artist of d-usumblv.

I

 

4-8

FUEL SYSTEM

 

PILIIT SCIEVI

REMOVAL

N011

' The pilot screw: It: “now run and
should nozbnmnowdumoulmm
ton If! mm.

' Tho pilot mummlm Inn-III!
to flaunt Dam W nil-film Do
not mm m M union on pflol
man being rum.

~ Cow oil opening with no. to hop mud
mlclu out when [M plop In drilled.

 

 

 

memmmmwwpmlomwm
anl palm.

Dvlll (Mum an plug mm o l m (W h) drill
M. m awful not to drill mm m pilot m.

 

CAUTION ‘

hurtful mtmdflflinmmpflolm.
Allpl'lar m rim! beWmL’only
one "quire: it for papa pilot mafia!!-
mem (page 4-] 7}.

 

 

 

 

 

 

Fowl a all-hoping 4 mm mm (HIC 069390.
PIN 33903—35410) into an druid plug Ind
continu- turning on WNW! unlll IN M
mum with m- m.

Ml on mum-whamm- uhntovomm-
nm- ‘
Unmammmmmwuww l
um mliuvings.

 

 

 

 

 

FUEL SYSTEM

 

 

Tum “ch n-Io! mew m and cau'ullv count me
numb-v o! lurns adore ll um llflhllv

Mala I not: a! lhus m an n a ruhnncn whon
nlmullmo the pion sctewx.

CAUYION
[ [Wt to Ihe pilot um- Ian! ‘01” occur if

[hr min! mrw u nghmmi mm: the war, ‘

 

Romow the one! Icrews ind MW! mom Root-cc
man 1! [M are now or damagnd "'

PILOT SCREW

INSTALLATION

Imull "It DIIOI scram and "(um mom [0 men
onqmnl pohlmn as noted dunnq vmmu

Pqurm pilol screw adjunmenl II m DIIOI sum
am muallm (page a 17!

N0"

 

' Do nor Install new plug: on nnw pIIol
Icmw holes umil any adiuumm has been
made

I ' l4 you woke: me print “:10!!! In em cal

buv'lov. you must vepucr IN pcIoI tan"

m the othev carbumon Io: atom: palm

scion liguslmenx.

CARBURETIIR SEPARATION Am cuwaen

Remove Ihc screw: amcmng nu nu Chlmblv lo the
cubumou and iepatlll the thumb" Ind urbur
'IIOH

SCREWS

 

4-10

FUEL SYSTEM

 

CHOKE RODS AND LEVE RS

Remove the run and rzmove me choke levers and

vodl
Remove mt com! Dm‘ and washers, and lemon

the choke mm

   
  

 

CHOKE ROD
No 4 CAREURETOR
No 3 CARBuREYOR AIR JOINT PIPES No.2 CARBURETOR

fl]

SYNCHR-DNIZAYION HRUST SPRINGS No ICARBURETOR
5"““65 FUEL JOINT

    

0-vaqu noun: Me No 3 carburrlor "am 1h.
“2me Then upturn me No 4 carburnov

CAUVION

Srpamlr Ihr rurfvurrmrs hnnzunmlly In pr:
mu Ilanmlr In the mm! pipes.

D‘sconn-c'. "up "Home Imb horn the No. I and No‘
7 ravhuvuon by vemovmq the conev mm.

 

THROTTLE L INK

 

4-11

FUEL SYSTEM

 

No. 2 CARBUFIETOR FUEL JOINT PIPE
Corequv nonm- m. Na. 1 Ind No‘ 2 urburalon‘

 

No VCARBURETOR

CHOKE AHM SPRING COLLAR
Remove the shah arm collar and nmovu m: choku

um and saving.
Ramon the choke vllvn mu. sprung 0nd "I"

 

CHOKE VALVE

Cheat tho dick. ulva Ind gonna '0' man, grooves.
0! other damp,

    
   

Of

."\

SPRING

4-12

FUEL SYSTEM

 

CARBURETOR ASSEMBLY ARM VALVE SPMNG

Install the choke valve, valve soring and nut end
tighten the nutt

Instell the choke arm and spring while hooking the
arm to the groove in the choke velvet Install the
choke arm COI'Mt

 

COLLAh

O-RINGS

Coat the new O-rings with oil and install them on
the fuel joint pipe for No. l and No. 2 carburetor;
lnmll the fuel joint pipe to the No. l and No. 2
carburetors.

 

FUEL JOINT PIPE

Nc, 2CARBURETOR COTTER PINS No. 1 CARBURETOR

Reconnect the throttle linkage between the No, I
and No. 2 carburetors, using new cotter pins.

THROTTLE LINK

 

4-13

FUEL SYSTEM

Con now O-rlnp whh DII and install lhem on m.
fuel Ind air joint pip-t,

Pm tM No. 3 and No l arbor-tors month-v mm
[M Iolm pipes.

Looun an synd‘romnllon adhming scum unm
{Mn 5 no "mien.

Inn." 1M zynchromtmon swings.

Imull the thrust mung mam the lhvoulo valv-
Whl‘

Make turn [M foul pain! Ind air jmm pcpes III
handy-mailed

4-14

 

 

FUEL JOINT PIPE AIR JOINT PIPES

No.1CIARBURETOR THRUST SPRING N0 3 CARBUHETOH

 

' .5

  

No 3 SYNCHRONIZATION si‘RING

No 2 CARBUREYOH N07 2 SYNCHRONIZAYION SPRING

 

   

‘2

THRUST SPRING No 4 SYNCHHONIZATI
SPRING

 

 

ON No 4 CARBURE YOR

FUEL SYSTEM

 

CHOKE ROD AND LEVERS

Insrall the choku rods and levers, using the nurs and
new cotter pms‘

    

CHOKE ROD

FUNNELS

Make sure the air chamber lunnels and dowel pins
are In place.

DOWEL PINS

SCREWS
Plane (ha lrr chamber over the carburetor; aligning

xhe dowel pins wnh lhe carburetor holes.
Anach the air chamber to the carburetors wilh me
aighr scram.

 

FUEL SYSTEM

 

Tum the throttle nap Icrnw to Illgn the No‘ l
(hvonln vulva with 1h: idol oi me bv-pau hola‘

Align nth lhmnlo vulv- wnh (he bv-pass hole edu-
bv turning the svnduomullon .djustmq screw:

Impecl throttle over-non n dumbed below

Com m: that!!! shamly by nressmg the lmoulo
Imluon. Thin rams. IN "Home.

- Make sure that n ruurru mommy.

- Make sura [Ml than u no drag when openmg
and closing the lhmull

Man turn that chok- volvu operuion it imoolh by
movlng mu choke linkag-

Clou the woke 10le by luymm me make lmluoo
Bolus. the chain lining. Ind make suvl "In :I
Mum: smolhlv

CARBURETUR INSTALLATION

Imulluvon :1 annually m. twene oi remmll

~07!
_ — #—W
[ Home the "vault Ind choke ables pvoperly

(page 1—9 l01~13L

Por'om‘ (N lollowmg lnlotchom and adiunmenn

- Throme opeunon {one 3 51

‘ Cumvelov nhoke (new 3 6)

- Cuburemr ldla spud (page 3 H).

- Cltbunelor synchvomuhon (page 3 IOI

 

NO I CAHBURETOR

 
   

mNMMmiJ
llllll‘l‘ll
4

O

BYPASS HOLE THROYTLE STOP SCREW

No 3 ADJUSTING SCREW

   
     

No, 4 ADJUSTING stEw

No.2 ADJUSTING SCREW

 

 

4-16

FUEL SYSTEM

 

PllIlT SCREW ADJUSTMENT

IDLE DROP PROCEDURE (USA. ONLY)

NOTE

- The pilot screws are lactory prrsn and no
adiustmnnt is necessary unless the pilot
screws are replaced (page 4 9)‘

- Use I tadlometer wrth graduations 0t 50
rpm or smaller that will accuratelv indium
I 50 rpm change

 

1. Turn each pilot screw clockwise until It seats
lightly and back it out to the specification
given, This IS an initial setting prior to the final
pilot screw adjustment,

INITIAL OPENING: 3 3/8 turn: out

2 turns out (Californil onlvl
CAUTION

 

Damage {0 Ike prior screw seat will occur
if [ht pilnr screw is lightened against the
sear,

 

2. Warm up the englne to operating temperature
Stop and no driving for 10 minutes is sufficient

3 Attach a tachometer accord mg to Its manutac-
turer’s instructions

4’ Adjust the idle speed With the throttle stop
SCIEW.

IDLE SPEED: 1.000-1‘100 rpm

5, Turn each pilot screw 1!? turn out Item the
initial setting.

67 H the engine speed Increases by 50 rpm or
more, turn each pilot screw out by successive
1/? turns until engine speed drops by 50 mm or
less

7 Adjust the idle speed with the throttle stop
screw.

8, Turn the No. 1 carburetor pilot screw in until
the engine speed drops 50 rpm

9 Turn the No l carburetor pilot scrawl turn
out Irom Ine pusitiun obtained in step 8.

H1 Adjust the idle speed with the throttle stop
screw.

11 Perform steps 8. 9 and 10 for the No. 2. 3 and
fl carburetor pilot screws.

12 Drive new Dl‘al screw plugs MID the pilot scrlw
bores With a 7 mm valve guide driver (P/N 07942
v8230000i Whm tullv seated the plug surfaces
wil: be recessed 1 mm mm the pilot screw bore.

  

 

 

THROTTLE STOP SCREW

 

  

PILOT SCREW PLUG

 

FUEL SYSTEM

 

FIEL TANK
m

[)0 not allow flame: or (path nan 5:me
Wipe up willed mount at our

REMOVAL
Rama we the seat

Tum the luel valv: “OFF" and dlswnnecx (he lunl
undncum wira coupler and "H: mm lme,

Human me fuel tank mounnnq bolls and tank

Chock (M van! halo 0! ma filler cap for blockage
Chuck Hm fual il flowing um 01 the luol vllv!
Gully, U {ml Now I: vunncud, cloan [he lual
Ilvllrm

INSTALLATION
lnlull me Ouel unk In mu mvprie order 0' rlmnval

Man sure that (have are no luul Inks.

     

/.

  

J,

   

/

a g /
a ‘5

FU EL VALVE

Q

FUEL TANK
MOUNTING sous

 

8
I
c; _ t
t 7 z;
‘2‘»
2,.) ‘\r
\
l
l
FLVH VMVE

$UE L SENSOR
/

FUEL SYSTEM

AIR CLEANER

CASERCHAMBER
Check the air cleaner case for deteriorarion.
CRANKCASE VENTILATION SYSTEM

Check that the breathei tube is not restricted.

 

SPARK UNIT
WI RE COUPLERS

FUEL PUMP

Remun- Um side: counts and seal

Disconnect the spark uni! and fuel pump wire
coun’ers,

Remove the spark unit from the hoidevr

 

' SPAR UNIT FUEL PUMP
me COUPLER

 

 

FUEL SYSTEM

 

Dnconnpn mo luel mm mm cnunlev Remove the
(ill flop hqh‘. unto! ‘mm the hold-v.

Tum the lucl illva a" und clmp the fuel lines to
pram! the 'qu lvom (lowing om

Disconnect mu lual lmn lrom me puma and
remove the furl pump

HIGH AUITUII ADJUSTMENT (USA oily)

When the «ma: u to be Operated cominuouxlv
than 2.000 m (6 500 '32” me carburetor mun be
readnmod u lolloM m lmp'ove dnveaba‘lutv and
dean—I "hum omvu‘om

Warm no m. «10an to opermnq temperature. 5100
and 90 drivma lor 10 mmulu is sufficient.

Rumove um pllor tcnw plug (0:90 4-9).

Tum “ch nlm mu-w clockle I tum,

Adlun the Idll umd 10 1,000 x 100 rpm wnh the
lhrouln flap ICMW

Driva rmw leDl mow plug! into the pilot screw
bores (Olga 4 17L

NOTE

Thu “gunmen! mun be made a! high Illi
mm In «Muir pram hugh almude 00:1!!an

 

Attach a chclo Emmon Control lnformahon
qulu lflrl onto the lrrne 3 shown Refer to
Serve! Sum-rm =SL137 lo: mmmzuun on abuln
mg the lflxl

NOTE

Do not lunch ma label to any part am can
be gully mmovnd from me vehicle

Oprmu‘un a! an almudt Iahrr than [.500 m
(5,000 for!) will: line mrhuremr adjusted [at
high altitudes may may the mglne m Idle
raunly and will

when the which I: m b: 0mm! man'-
nuously below I F00 m (5,000 feet}. turn
and! pl‘lol wmr munlmlnrkwbr I run In In
orm'nd podlion all" "mm-1n: (Id: pflal
mr-v plug Md lad/am III! Mk speed In [.000
1 lot) rpm Drnr nn- pflnl wren- PM! uuo
[hr palm yaw bum (me 4‘! 7! B: m In
do [but odiuumrnn a! low altitude

4-20

TAIL/5T0? LIGHT SENSOR

FUEL UNIT WIRE COUPLER

FUEL PUMP

/
// VEHICLE EMIwON CONTROL

7 INFORMATION UPDATE LABEL

 

 

FUEL SYSTEM

 

PURSE COITIOl/AIR VENT CUIIIGL
VALVESIISPECUUI
(Elllfllllll IllflEl)

Chock ll M Ink, Plum Comm. Viv: (PCV).
A" Von! Control VIM (AVCV) and damn!
emu-r hammbomthcyuenotkinmmd
m neurolv comm. Ravine! any has. mm
mm “gm of dun-g: ot dateriomlon.

PURGE CONTROL VALVE (PCV)

OW in PCV boas 1mm 'uir m-
“mmmmnmmmmamm
WromMIab-Ionn- hadnbiaindm-nulov
incumbent.

Comm vacuum pump to the 3 mm ID. hon um
90. to m No. 2 urbumor body. Apply (in
lmlflcd vuwm to th- PCV.

WCIPIED VACUUM: 80mm (9.8 in) W

Th. WM "mum mould be mainuimd. Rt
plan tho PCV H "mm in not mint-ind.

ammovmmm-flmhmm
mummwmoNo.3a¢umho¢v.Am
mwM-mwmncv.

mcmm VW: 30M :01 h) "I

The mum noun tank! In Mind Ro-
mmlmltmbmmm.

Comm-mun mammoflml.o.hou
mu con to the charcoal min-r. Whig away In
wacmod vacuum to ma PCV hose um pen to m.
No. :l cut-humor been Wmv air mmuoh an
clfllfll' hm. Air should flow throng. 1m PCV Ind
out th- hon um goo: to on No. 2 arbumor body.
Roone- Ihu PCV H Ilr don nmflowom.

“U1“:

Ta Pmlmlo (hewrzzmnnulvdu. ‘
do muuhkhdprmnma Una

Nomad-(Imam.

 

nmmmimdeu/mmmm.
twoummmmmmmm
rank-aw.

 

  
  

’ mace ooumm
VALVE

 

 

TO ORARCOAL
CANISTER

‘-

 
  
 
 
     

PURGE
I CONTROL

VALVE
TO Na. 3
CARIURETOR ”DY

VWW PU"
STAN-m7 (USA. My)

VAOUW m
SY-AH-MW'I MIA. 000v)

 

 

 

 

 

\
l

 
 
  

PRESSJRE PUMP
‘ -AH~255MC7
(USA. MM

 

 

4-21

FUEL 3V8TEM

 

AIR VENT CONTROL VALVE (AVCV)

mmwcvmmmarm
“mm-Avcvmmmma-wmm
70mm lab-i mmakmmmwfum
nominal.

Cam I pvmnnumptomnsmm Lukas-um
you n: m Mn lolm md pump Iir "WW" tho
3mm LO. hon. Air would flow mmunh the Avcv
and out me but that can to m No.1. Sur-
buntor lll’ mm mm. Roam thc AVCV it air do"
not flow ouL

Mammpbmml.b.hm
Mummioummtmhmmemdf-d
mntoIMAVCV

I'ECIFIE D "EBURE: 15 mm I059 In) A.

Th- uocfliod mun should he nulmaimd. Rt
910:. m- AVCV, it puma u not malnuimd.

anmmmm-mmnmw
IN No.1inhl mnflold. MY W WM
vnuumtomlAVCV.

SPEC'FIED VACUW: 30mm It! In) ”I

The woel'hd vacuum would b- mlimllnod. fir
DIIOI Ch: AVCV of vacuum Ii not moiuuimd.

 

4-22

 

     

AIR VENT

CARBU RETOH
AI R VENT TUBE

  

 

     
 

  

 

 

 

  

T0 OUTER

VENT TUBE PRESSURE PUMP
STAN-m7
(USA. onM
VACUUM PUMP
ST-AH-MMCT

 
   

 

(U.S.A. only)

 

 

FUEL SYSTEM

 

Com-cl a new!” m to the M has
Mmmmflod Inhmvu'fold-ndcom
Amman mwmmm mugs-comm
loinl.

Whill Wimlholpodflodvmmm
AVCV lo m- ncuum hon one: to me No.1 ink!
mllold, M In: milieu pressure through th-
3-way loin! m.

SPECIFIED VACUUM: 55 mm [2.1 in! ”I
SPECIFIED 'REIIURE: 15 mm (M In) A.

Roplm IM AVCV If pressure is not mdnuinod.

uunou:

To WM! dang: la the If! m! control
"Neda mluxhfihaimmml
Wlwwwmofly.

WhammmlImAVCVonMW,

you" and noon-cc! mo hon; continuum
"Minimal.

 

 

r
|

‘ ” 777' kuw M!

  

PRESSIHE PUMP
STAN-MT (USA. only)

 

 

4-23

ENGINE REMOVAL/INSTALLATION

 

H Nan
(3.5-4.5 M-
25—32 h-lb)

  
     
     
  
 
  
   
  
    
 
 

3-4! N4»
(3.6—6.5 IIW.
26-32 «dbl

18-3 Hm
(1 3-2] Ito-m.
18—20 tub)

(2.0-3.0 km.
14—22 Mb!

00—70 N m
(0.0-7.0 hm.
‘3—51 "40’

3.14 Nan ‘
01-1.. km.

5-10 mm ‘5 g,

(3.5-4.5 Item. 3.45 my.

75-32 "M (15—45 km.
13-2: N-m 25-32 mm
(Is-u kw,
13-20 «4:»
8-12 N-m
(0.0—1.2 hall.
5-9 out»

 

5 ENGINE REMOVAL/

INSTALLATION

 

 

SERVICE INFORMATION 5—1
ENGINE REMOVAL 5—2
ENGINE INSTALLATION 5—5

SERVICE INFORMATION

GENERAL

0 A Moor iad: or other adiustabla support is rewind to iuppon and maneuver 1m mine.
I The Iollawing mm or components can be mlced wlth the engine inflallod in me frlmo:

' Clutch ' Akunnor
' Gearshift Iinkngt - Snner motor
' Cylindu heads ' Carburetors

SPECIFICATIONS

Engine dry might 9&7 kg I2I3.2 IbI
Oil enmity 3.51m” (3.7 US. qt)

TORQUE VALUES

Engino hang-r Ink
8 mm boh 20—30 N'm (2.0—3.0 Ina-m. 14—22 R41!)
10 mm bah 36—45 Nvm (3.54.5 Ito-m. 25-32 ft-Ib)
Sub-frame bolls
Upper 60-70 N-m (6.0—7.0 Ira-m. 43—51 h—IbI
Lower 36-45 ern (3.5-4.6 kw“. 25—32 ft-IbI

 

5-1

ENGINE REMOVAL/INSTALLATION

 

PULSb GENERAHJF UH. PRESSuF

ENGINE REMOVIL me caume

Pllce the moxuvzvcle on H: center Hana

Remove he seat and (UN unk

Remove me Ieh and ngm "am: «we cove's

Dunn the engine cvl mm 2721 are me Loolan'.
(one 6'31

Remove the mat Mum! (mow 16 3|

Remove the radmlm (page 6 6|

Remove me cachurewr (pan: 4 3|

m

Duconnccx the WM: mum-u flow the Duke gmauxo:
cul pvusure, geav poslnon swflch Ir‘d alxemalor

I

    

GEAR POSITtoN ALTERNATOR WIRE-
SWITCH COUF’I EH COUPLER

Disconnecl [he Haney moun cnhlr

 

_ smmERMOTon
MUVFLER CM“:

"‘04?le EL)! TS
Loom-1 the exhauu woe Llama Dow
Remove the elhaun mut'w Wow-2 mm and me
mum“

Remove the exhaust pupa |um7 nuts

 

\ Q

|
CLAMP BOLTS JOINT NUYS

 

5-2

ENGINE REMOVALJ INSTALLATION

 

Rewow- the (mum: chambe' 'mmv" {)0‘1 and 1h:
exhaust Lune mamm"

   
      

EXHAUST CHAMBER MOUNT BOLT
, STARTER CABLE CLUTCH SIM/E CHANKCASE
Rumuve m slnr‘w' Lable ‘rcmn 1hr leumm CLAMPS CVLI‘JDER EREAYHER FUBE

Remove "II! chm." «law, cvlnndm

NOTE

 

DC to: uu<“a'e 3h: curt" ‘euer mm renmmg
we (huh Hm! (whey M m; w m can:
‘ anew” m vocrnall‘ng me hug ‘ ylmuvr

 

Remove me wound! arm me flu: mm 5pmdla‘
Loosen the want DMVD Hose LIG'H! and Inmuvt— ma
walt‘ Dum- hm:

Remove me no" at'awmg we grown] mb‘e to t":
crankcase and u'HL'UNrHJL'I the ground th-e

Dmconnec! the Ivunkcase breather mlm

Remove 1m Wan hon :hu wur (lamm
Remnw: {'19 um [vale L-tdal SUB FRAME WATER HOSE

(}“OUND CABLE
WIRE CLA'M’ SPARK PLUG CAVS

Watt. 3 Hum ad: or any ammuble wagon under
the ergmu

NOTE

 

The ”Ex laugh! rm.“ be cormnuoux‘y I’jufl
r: so 1"]? mm“ mg 501" car [2- vcmo-efl.
am so 5mm 4 queued ham orb" mm wt

Me aren-mn :11
I 7 V ' *1

 

 

 

Remove x'nc engine mountmg boll!
Remove the Mr nub Name balu and mu xubf'ame
gamma! me chnmr ‘vom the \e1‘. 3qu-

 

REAR BRAKE PEDAL

5-3

ENGINE REMOVAL/INSTALLATION

 

 

ENGINE INSTALLATION -

Innall the engine mount rubbers.

Engine inmllatipn is essentially the reverse of
removal.

Use a floor ieck or other edlusteble support to
ur-Iully manuever the engine into place.

CAUTION-

 

i Carefully allgn mounting pplnts with the luck
to prevent damage to mounting bolt thread:
and wire bunnies and cablui

 

Tighten ell fasteners to the torque values given on
page 5-2.

- rFloute the wires Ind cables properly (Peg-
1—9].

- Fill the crankcase lo the proper level with
the recommended on (Page 2-1),

 

- Fill the cooling system (P399 6-3)- TORQUE' 18-28 N-m
' Perform the following inspection and ad- a (LB-2.8 kgm, Ill-20 tub)
iultmenui Ga

Throttle operetlon (Page 3-5).
’ Clutch (Page 3-161‘

 

 

Install the exhaust ryetem:

Inst-ll new exheust pipe joint gasket;

Assemble the left and right exhaust pipes.

Tighten the cxheutt pipe band loosely Ind instill
the exhaust pipes.

Hand twitch all born Ind nuts, then torque them
in the order given below:

   
  

1. Tighten me exhaust pipe Ioint nuts, TORQUE: 8-12 N-m

TORQUE: 3-“ N-m TORQUE: 3-14 N-m (ore-1.2 kg-m.
toe—u III-m. 6—10 run) (0.34 .4 Ito-m, 6-10 ft-lb) 5-9 mm

   

2. Timten the exhaust chamber mounting bolt‘

' TORQUE: 8-12 N-m
(0.8—1.2 kg-m, 8—9 INN

37 Tighten the rear muffler hanger setting bolts.

TORQUE: 18—29 N-fll
(1.8—2.8 Ito-m. 13—20 It-lbl

4, Tighten the exhlust pipe joint bend bolts»

TORQUE: 18—28 N-rn
Its-2.8 Ito-m. 13—20 ft-lbl

 

®
%\TOROUE: 18-28 N-m
11 3-23 mm. 13-20 mm

 

5-4

MEMO

COOLING SYSTEM

 

6-0

6. COOLING SYSTEM

 

 

 

 

 

SERVICE INFORMATION 6—1 THERMOSI’AT 0—4
TROUBLESHOOTING 8—1 RADIATOR/COOLING FAN 6—6
SYSTEM TESTING 6—2 WATER PUMP o—To
OOOLANT REPLACEMENT s4

SERVICE IIFORIITION

GENERAL

 

Do In! PEI-cum: Mineral when thalficixluu. ”(meant “rpm-inundagmum.

 

1k mun mm b: cool Minn antral; the cooling om.

Un only distilled wam and mwlom glycol In "In coolin «yum. A 60—50 mixture i; "command-d lot maximum mo
Non ovonclion. Do no! on alooholhmd summon.

Add cool-m at the Ins-M tank 00 not "mow the radially up mam to Mill or drain I». mum.

All cooling syn-m mu:- can b. mm with "I! maln- in III. lama.

Avoid milling coolant on peanut! Indus-R.

Ah" gun-ring the wm. duck lov lulu mm a cooling mum tutor.

mm In Sumo" 21ml." motor movmnicnitm Ind turnout-mm mm

SPECIFICATIONS

 

 

 

 

Radlator cup renal pmnuro 0.75—1.03 Ina/cm' (10.1-14.9 psi)
sss nmum mm + 45x nhybm glycol: — 'c I—zs‘FI
F mung poinl 505 OIIIIIM wnot ¢ m flhvlono glycol: -37'c l-zu’Fl
45s DinlIl-d mm . 551s mum glycol: are (-u'Fl
Coolant wacky:
Rub-lot ma mom: 23 Hun (2.9 US all
Ream unk 0.6 liter: ”.6 US all
Toul "nun 3.4 liters (3.5 U5 cl)
T mmmzoo'mu'cmo‘mm‘rr
T"""°"“ ‘ vumm: Mmmmsmna‘c «ms Mum‘s)

 

Unpnuuvllld: Ion'c I226‘FI

Bonllng pom! (wnh 50—50 mutual: Cap on. pruwrlud: 125.6": (268."

 

 

 

 

TOOLS

lucid

Cool-no mum Tenet Commercially wallow
[WING

lulu. lump-rm"! too high Em l-nmm no low

1. Fully Tamper-tun 9:09. or gluon mum 1, Fully lomunmn pugs or M mum
2, Thurman“ stuck closed 2‘ Thormwu Ruck oven

3. Flulty udinov cap

4‘ lawn-mm cool-m Cool-n lot:

5. PM” blocked m ram-(OI. hon. OI wnuv helm 1‘ Fully pump mead sul
a PM blues hem 2‘ Donna-Ind Owing:

7. Fully 0m mom:

 

!

COOLING SYSTEM

SYSTEM TESTING

COOLANT

Test the molanr m=xtule w m an unhhevzu mm."
For maxlmum COI'OSVO'l M Khan, a 50—50%
solution cl nhylene glyrol imrl dgsrwed wam vs
recommended

 

RADIATOR CAP lNSPECTlON

Pvexsure lesl the rad-aw mu Ruuare vhe 'admm
cap ll n does not hold DTEuL~v Hr vu‘ pzuswra
is [00 Mg?! 0! too low 1' 12m. hold 53ec:flad
wessuve luv at Inst svx secmcs

 

NOTE,

Belare Installmg the rap nn I‘m taut-x {DUN
walm l0 saalmg surlacsa

RADIATOR CAP RELIEF PRESSURE:
0‘9 1 0.15 kg/em’ (12.8 . 2.1m

Pressume me radium, ez-gm: .1W"\nwfi,d"d check
for Inks.

CAUTION

 

 

    

132:" ”w m .... .
‘.'.,4 .4 [all

Excessive pressure ran ,
D4) m)! acted 1‘05 kg“

 

 

Repair or replace con-vacuum; lvhp nut-3m w w 01,-!

hold SDGCI'IM pressuve lor a,“ t: w wmnm

 

ANTI FREEZE TESTER
[Cnmmercxally available)

    

RESERVE TANK

COOLING SYSTEM TESTER
COMMERCIALLY AVAILABLE

    

RADIATOR CAP ‘

 

COOLING SYSTEM TESTER
(C(mmermally available)

 

COOLING SYSTEM

 

COOLANT REPLACEMENT

CAUYION

 

77:! mnnr mzur M rnm' mm: sen arm; ”I:
mull" n'llrm‘ .1, mar yaflmg mm- result

 

Remove mu mdmcv can screw. and 1m- :adtfitov can

Dan the coolan! bum me 'ad‘azor by ’emowr‘q the
drum ohm \ocamu 4' l"! ‘uwe' ‘5” sub "ame

 

DRAIN Pl LAG

WATE R PUMP COVER

Drawn m. comm! ‘vsm In: «name by vlmmng the

cum boln u rm wan: pump cover and tvI-ndl'

heads

italics "10 (Sum plug and Dom,

Full ma gym-m mm . 50—50 'mxture o! rimmed

mum and alhylunr glycol

Blood III ham 1%: vadsarov

0 Sun my engine and um um»? (here are no air
buoblu m m. coolanL and the lave. stabilizes

0 Stop the “gym: Inn sod :ooia"! UD :0 the DropII
"we 1‘ necnun

O Roam-II 1th name! can

0 Cmck me new 0' coolnm m X”! veurvn link and
MI m mo noun? :nol -' the ‘ue’ 1 10w

    

DRA‘INHULT Drum BOL“

 

6-3

COOLING SYSTEM

 

 

GROJND

THERflOS‘flT 1mm RATURE SENSOR ma: aou
REMOVAL

Remove the coolom Gum plug and drain {he team!
(page 6-3),

Ramon (M Icnws that attach the water woe to
Iho mammal housing

Duconnrct m wu- irom (he (emporamm tumor.
Rumovl (M boll mu atuchu the thumbs!“
hounnq lo the nu chlmber, and remove (he around
was

Loos-n m. hon blndl.

Ramon lhn thumoult housing‘

    

THERMOSYAT HOSE BAND SCREWS
HOUSING THERMOSTA7
HOUSING COVE R

  

Rummy the "utmost" ham-n9 cover.

THERMOSTAT

Ramona ma mavmosul hom the nous-n97

 

HOUSING

 

6-4

COOLING SYSTEM

 

INSPECTION

Inloocl ml xhcnnoml vimllly (o: dunno.

Suwund [he merino-nu m hand wan to check us
opotulon.

Do nol In tho marmonn ov lhumomnm mum
{ha pm or lulu wading: will vuulL

chlocn me mammal a me My: IUV‘ open at
mom umpmiture‘ m i! it respond; I! lempenluves
emu than men wecn‘ued.

THERMOSTAT

TochmcoID-u
1' Sun zoomI BO'toBI'nge‘i—‘BJ'FI 7

m I 8mm mnnumum710‘31 m)
V-Ivc Ml ‘ when hand to 96°C (203°F)

'0: five minmu.

 

 

INSTALLATION THERMOSTAT o m~G

lnuu the thymus"! mm me houlmo

«mun . m Dung on me mmnmm houung
COVOY

Inna” m: thermosux housmn cow" and human
[71! balu

 

Cannon m: hum m m houunp and Ilqhfln the
hon bum“ Inna” the want mm to lhl housmg
wslh mum and hymen ma sate-M socuvalv HOUSING COVER
TEMPERATURE

SENSOR WIRE

 

GROUND WIRE BOLT

        

Socuva the mermcmn homing lo lhl air chamber
mm the bolt, attaching the ground who minim!
n the some uma.

Connoci the temperature sumo: mm to (M mnmr.

Fm (he tool-n9 syslzm (DIP 5‘3)

HOSE BAND SCREWS

 

COOLING SYSTEM

 

RADIATOR COOLING FAN

REMOVAI

 

Ramon-1hr seat am: V' 2- Me I

 

Ramon We 'J’ax" w"; m3 G'J " Mr C5021! Mag!
67]»
Lomwv me vadlarm ”(11‘ ran: uftnr‘hIr-g holy; and

rcr’mu- me His N‘wrn

 

Ddzovwrv 11 1’ "mm: ccuaie'
Loosen m:- upue: mm'or has: mm
Remove Ihr vadmo: Hum moum Doll

DFKOHHQC! The OVEH'ON 1ND! 37 I"! VI: 310' “VI!”
neck

Duconnocl xha mmmonnnc swath wtrei "am the
swnch

Locum :he laws! w! “3- nose and

Remove mu 'admov ‘cH mom: bo-‘I
Hemow the mdlarov whfle Du“|l\u {he UDD!" mu]
cwe' hm»; UN

  

 

BOLTS
UPPE R RADIAYOR

5:04 MOTOR COUPLEP HOS-F BAND

   

  

RADIATOR RIGHT
MOUNT BOLT RAlNATOR LEFY
UVERFLOW TUBE MOUNT BOLT

 

LDWERRADM'IW “494 0623ch
HOSE HAND SWITLHWIRE

 

6-6

COOLING SYSTEM

 

DISASSEMBLY FAf-J SHROUD

Remove the Mo nuts attaching the fan shroud (o , ‘ \
tho radmmr and remove the shroud,

    

RAD‘ATUR

NUT

Remove the fan machmg nm and null the I'm 0"
m. (an motor,

 

FAN

Remove the screws auachmg the fan motor to the
fan shroud.

 

6-7

COOLING SYSTEM

 

RADIATOR INSPECTION

Impact the radiator wide-ca 501m: and sum: 40:
Iulu.

Blow dun WI "om human can has mm com-
mu-d m. If Inm1.fl:..lndming mo rue-nor.
I'M mom a” with low gum" wnu‘

ASSEMBLY

Inn." [he Ian mom: onto [he 'an shroud and
“film the flute scrow‘

lmull [he kn over on mom: mm

Awtv a locking mm [0 the hn moxoc mm
mmbdx. mmll Ind mmue the plum washev, lock
wnh-r Ind nuL

Install the kn smoud onm (he rudluov and human
010 two nun

6-8

 

NUT

 

FAN
FAN SHROUD

 

COOLING SYSTEM

 

 

 

FAN MOTOR UPPER RADIATOR
INSTALLATION COUPLER HOSE BAND
[mall the upper and lower hoses onto the radiator. ‘ // -

\.

Install the radiamv mm the frame and (igman the
mounling bolu.

Connecx the upper and Iower hoses and tighten (he
hose bands.

    

RADIATOR RIGHT

MOUNT BOLT RADIATOR LEFT
MOUNT BOLT

Connect The waves In the Ihetmoslanc swuch.
Connec: the overflow tube to the fillev neck.
Connem the Ian motor couplen

 

LOWER RADIATOR THERMOSTATIC
HOSE BAND SWITCH WIRE

RADIATOR SIDE COVERS
lnsml the radiamr gun: and side covers.

Fill the cooling system Ipage 63).
Install the fuel tank and sea

 

COOLING SYSTEM

WATER PUMP Mm PU“?

MECHANICAL SEAL INSPECTION

Ramon ll" cunkcue rear conv.

lnwlcl "In ullule hols lo: mm 0' rmclunical
ml coolant Iuhge

Rnploa thu walev pump I: an ummbly H the
mom-meal uol us leak-n9

REMOVAL

Rmovo the dam plug 0mm m. loam um hm
Md Gum thc cool-m,

Roman tho dram bolt 3! 1M wnm pump Ind dam
"to coolant 9mm [he cvlindnu.

Ramon lhe stutter motor cob“ Ind Illemuer cable
lvom lhc clamps.

 

DRAIN BOLT DRAIN BOLT
{WATER PUMP) (CYLINDER l

WATER PUMP COVER

Ducocmlcl the water hose lvom the wane: pump
CDVI'.
Roman th- wnev pump can! bolu And COVEI‘.

 

 

6-10

COOLING SVSTEM

—— r _ I 4—

WATER PUMP

Loosen the water hose bands.
Remove the dowel pins.
Rumovc the waler pump from {he crankcase.

 

Check lha war-r pump for mochanlcll ml linkage
and bearing duariornion.

I— 7 7 ,
INSPECTION ‘ O-RING WATER PUMP ASSEMBLY o RING 4‘
Replace the water pump u an assembly if necessary.

 

WATE FI PUMP COVER

GROOVE

INSTALLATION

Apply I can of clean engine oil to a new O-rinq
and innall it in the water pump groove.

Alrgn lha water pump shlh groove with (M oil
pump shaft Ind Insert the wntar pump into the
crankcam,

    

OIL PUMP SHAFT O~H|NG

 

6-11

COOLING SYSTEM

WAYER HOSE WATERPUMP COVER

Connect th! mm "05!: :0 me .I...-.~ L'uHID and
Ughte" the hon tun.)

Inurt the (Iowa! mm. mm the mm, mm; inn
min“ a new 0 unq m m: groove :19 {he watt! Dump

covet

   

ORING

WATER PUMP COVER
lnnall thu waxm munn cover and 1h:- cahla clamps
Ind Ughten the bar”

 

Cor-web me mum-r " r,» 'c T‘: mum m'nv CC-E' CLAMFS SVARYEFI MOTOR CABLE
and mgr-men m. hm" [mu-1

Home and damp m. 5mm motor cnhlu and menu
luv cabie

lniull the c'unkcm rear covuv

hwmr mu uum piug a‘. Pu: MI. huh hr“!

Fvll (ht svslcm win a 50—50 vmnuvp a1 amt-med
wnm and ethylene glyro' mag: E 3)

 

HOSE BAND

6-12

WATEH WPE REMOVAL

[)le' 1W LVL-"JU? lPagi‘ E- IN

Ram-3v“- "w navtm mum mph; hum rim.- [:lamu
Loosew the muse band we -emuve Um mm hos-J
"om ‘nr: wawr nun-p Cavev

l w me “use baflfl and “Emma? me dei“ haw
‘mmi 3U up

Remcva m: ~me {ND-E mum mlv

 

 

"' Wat"

 

Deur'lert me wale‘ [DD-3 wuh 'he 01mg, hu'vr

Th? Impala-u:

 

WATER PIPE ENSTALL ATION

Irma” a new 0'1er on the wars! nut? and comment

|‘ m xhu swarafn'
\m’dl‘ 1h- mnur‘l !;rxl'

117214“ the hoses and ngnmr mu firm! hands
Secure 11‘: 3mm rrotuz cm a m the damp
’r‘ 1 in: ccuhvgsgazo-r- image F: Jr

WATEH PIPE

 

HOUNT

BOLT

  

COOLING SYSTEM

SEPARATOR

 

WATER PIPE

C LUTCH

 

'84

 
 
     
 
  
    

AM '34

  

1—2 N-m 1—1 PM!
(01.02 kg-m. o,7_1.5 mm (on—0,2 Ila-m. 0.7—1.5 mm
10—14 N-m
n 0—1.4 Ila-m. 7—10 n-n»
10—14 N-m 0%
25_35 N-m (LO—1,4 kg—m,7--10 lt-Ib)
(2.5—3.5 kgm,
19-25 mu) 5 ’
\ 53‘
6’8
/\.
Cf

4-7 N'm ‘\‘

“I
@ [DA-0‘7 Kg‘m. 3—5 mm
,/

25-35 N-m
(IS—3.5 kgm,
13-25 'l-lb)

 

 

7-0

7. CLUTCH

 

 

SERVICE INFORMATION 7—2 CLUTCH COVER REMOVAL 7-11
TROUBLESHOOTING 7—3 STARTER CLUTCH DISA§EM8LY 7—11
CLUTCH FLUID REPLACEMENT/ CLUTCH DISASSEMBLY 7—13
A'“ “550'“ 7“ CLUTCH macaw 7—19
CLUTCH MASTER CYLINDER 7-6 STARTER CLUTCH ASSEMBLY 7_21
CLUTCH SLAVE CVUNDE“ 7-3 CLUTCH COVER INSTALLATION 7—23

 

 

 

 
 
 
  

53—37 N'm
(6.3—6.7 kQ-m,
45—48 h-lb)

30—100 N-m I
(Sb-10.0 kg-m. a
:9

26-30 N-m
(ZS—3.0 kgAm,
19-22 ft’Ib)

 

 

CLUTCH

 

SERVICE IIIFMIMATIIII

GENERAL

I mumbnemnvmlwwmmmmnwicmmmmumm.
I mdmnuiahummummwmmumauuthu-umoomumm

“Mummmwm
I mmmummeMhm-(m.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Clutch m wlim Cyfindu LO. 15370-15113 mm (03248—0326 in) 15.93 mm (0.621!”
Pinon 0.0. ISM-15.5! m Iona-one in) “Mm (0.522 in)
(3mm Illncvlilflu Cylhdn ID. Slim-Slum (um-15024 in) 3.10m (1503M)
Pinon 0.0. 38.034075 mm nan—1.4m in) mm m (1.407 In)
Clutch Out" Quid! LD. “SH—30.012 mm (mm-1.13m In) 30.“ mm (1.18. In}
Spring (m mm 1.6 mm “1.18 In) 3.0 mm (0.14 In)
Sara-3mm ns-Iaswzmlzu-zamm MI —
DIG mun-1 172-3." m (0.1‘7-0J” In) 3.1 M (0.12 in)
M m - on m (0.012 #1)
SW do” brim W 0.0. Inna—5:200 mm (mm—2.12m 'III “.18 mm (2.132 In)
TORQUE VALUES
CW has oil non: M N-m [25—35 km 10—” hi»)
Clutch Mid ml! m 2—3.5 N-m (0.2-0.5 firm. 1.5—2.5 N—II)
SW duld’l 1:01! ”-1W "‘1‘ 13.0-10.0 RIM. 50-72)
emu elm- led: nut ”—67 um (83-6.? Ian. “-48 (Mb)
Smut damn com 26—!) N-m {2.6—3.0 km, 10-22 (Nb)
Mum: cvlindfl ho“!!! be" 10-14 N-m (1.0—1.‘ M. 7-10 11-11))
TOOLS
Ind!
Snap 1m. alias OHIO-m1
Lodz mu m 010154220000
COMM
UnIvoruI holder onus—0000000
Din. once-0010000
Mada-nun. 42 I 41 m 017M102!!!
HI“. 5 mm ova—com

 

CLUTCH

 

IMMUNE

um bur MI or m

i. All bubble: in hydraulic mm
2. Low fluid Inc!

3. Hydraulic mum inking

Om lonr too had
I. sucking cutouts)
2. Cloud hydraulic man

and ib‘

i. Hydnulie WM sticking
2. Dim mm

3. Savings uni

cum will m cm.-

. All mbbln in hydraulic synum
‘ Low fluid I'll!

r ”yarn“: lystun locking

. Hydraulic syn-n stidtino

. Hm am

“.9”.-

W m with cum limp-II
I. Air MW in hydrulh mum

2. Low fluid Inc!

3. Hydraulic Iymm letting

I. Hydmlic Iva-m sticking

5. Hum wood

mutant—U
I. NWWmnidin'
2. Liv-mm

anu- oration MI and!
1. 00m drum skin may:
2. Budd". DMMII)

 

7-3

CLUTCH

 

CLUTCH FLUID REPLACEMENTJ‘
AIR BLEEDING

Crack the mm law war. the Elma :nuvon DIFJIIII
lo the ground

CAUYION

 

 

- Install the duphugm on the res-"mu whln I
oneratmg lhl dutch tevev FMIuve to do so
mu allow clutch Imd to sown out o! the
mummy aunnq clutm uncut-on

Avoad ivaImg mud on DimlEd turf)“;
Plac- I rnq mm the tum tank whmever
the system It wvwced

 

CLUTCH FLUID DRAINING

Connect a blend hon ID the bleed um

Loos" the Hive cvhnder bleed valve ma pump tha
dutch (we!

Stoo ooeratmg tm Inn when no ‘Imd Ilowt out 0'
the hind valve

CLUTCH FLUID FILLING

NOTE

I Do not rm: dIHL-vant types oI “ma mace may
mu not be comp-hm: ‘

 

 

Clou the bleed "In III! the vague", and mun
IN! amphrm

To prevent putnn OvcrlraveI and clutch "ma sea
pugs. keep I 20 mm (3M In) SDICEI butwun the
handlebar cup and lever when blumnq tho clutch
Ivttam Pump up MO tystm menu” wuth the lever
unnl there He no A v bubbles m the Ilurd Haw-19
Oul 0' the reserve" tmII' hoie ind I've' 'u‘stince I!
Inlt Then bleed the tvtttm

 

lOWER LEVEL

BLEED HOSE

 

 

CLUTCH

 

 

AIR BLEEDING

 

NDYE
' Check the lluld level ollen while bleedung
the chIch lo prevent Elf from being

pumped mm the system

' Use only DOT 3 or 4 brake llu:d ham a
sealed comamer

‘ Do not mix brake llmd YVDES and never
reuse the lluxd whsch has been pumped out
during bleedmg_ or the EHICLEUCV r)! the
clutch system erI be Impalred,

 

 

 

Remove the mastev cylinder cap and hll xhu ruser
you in near lull

Connect the anva: Brake Bleedm or equwalenl la
the bleeder valve

 

BLEEDER VALVE PLASTlC HOSE I
A

     

', MITYVAC BRAKE'BLEEDER #6860
Commercmlly avaliable ln LaS.A

 

Pump the Mllwac Bleeoe' and loosen me clutch
bleudur valve

Add lluld when the Mud Ievc' m We master cvlmdel
reservoir vs low

'84 Shown

Repeal above procedures unnl air bubbles do not
appear 1n the plastlc hose.

NOTE:

 

If an ls enternng the b‘aeder lrorn amund the
bleeder valve threads, seal the threads wilh
xeflon tape

 

 

 

I' a Mvrvvac Brake Bleedev 0’ equ valem not avail

able, bleed {he system as follows

1) Connect a bladder lube lo the bleeder valve

2) Saueeze (he clulch level, open lhr bleeder valve
1J2 [um and then close we valve

NOTE

Dc; um release the Elulch lever
bleeder new; has been closed

 

unb the

 

 

 

3l Release the clutch levev slowly and wan seve’sl
seconds me. it reaches the end of Its travel

Repeat steps l and 2 unnl bubbles cease to appear
\n the fluid 3! [he and 99 we host

Fl” the 2mm reserve" to me uppev level mark

 

 

BLEEDER VALVE

7-5

CLUTCH

 

CLUTCH MASTER CYLINDER '84 Shown OILBOLT

DISASSEMBLY

Dram clutch fluid from the hydraulic system
Remove the left rear view mirror and clutch lever.
Disconnect the clutch twitch wires Ind remove
the clutch hose.

CAUTION;

A mid spilling clulrh flufl on painted surfaces.
Plea a rug ova the fuel tank whenever the
‘ cluvth system I: serviced.

 

 

NOTE

When removing the oil bolt. cover the end 0' '

the hose to prevent contaminltlon and secure
the hon.

 

Remove the master cylinder. CIRCLIP

Remove the push rod boot‘ then remove the ctrchp
from the master cylmder body.

 

PUSH “00 300T SNAP awe wens

 

 

079143230001
‘84 Shawn
Remove the piston end secondary cup. I i ’ ' i
Remove the prim-1v cup end sprmg.
Remove the clutch switch, it necessary.
3 CLUTCH MASTER
{raj CYLINDER

    

31" ,‘

'PRIMARY CUP

   

 

 

[f *3», SPRING
*7 J. PISTON
4:: rs:
‘ NI?) ';
:5; ~‘ ”miles“.
‘x ’ -7!
d \
CLUTCH SECONDARY CUP

l SWITCH

7-6

CLUTCH

 

MASTER CYLINDER LDI INSPECTION

Muwm IN mun: cyhndcr ID.
Chuck the rumor cvlmdu Io: mom. mum
a: men.

SERVICE LIMIT: 16.93 mm (0.627 in)

MASTER PISTON 0.0. INSPECTION

Mom" mu mmov mnon OD.
SERVICE LIMIT: 15.” mm (0322“!)

Check IN onmnvy and sltondlrv cups Inf damp
bnfuu unmblv.

ASSEMBLY

CAUTION

[lard]: III: "mm plnan, xprbu. prbnlry
cuparu umudary turn" m.

 

 

 

 

Con all mm mm clun DOT-4 brake fluid bcIon
Ilumbly.
Inn-II (h. .prmo, bum-rv cup and custom

CAUTION

fl“!!! Manning the cups, do ml allow III: lip:

L (0 mm MM! out.

 

 

lmull (M cucluc Minn. sum it in mud hunky III
the gloom

InmII the boot and push rod

Inlull [M dutch mulch, I' II nu nmcwod

 

 

'34 Shawn

RESERVOIR COVE R
DIAPHRAGM
HOLDER

    
   
  
 
 

CLUTCH LEVER
PIVOT BOLT
SPRING PRIMARY "57°" AND

SECONDARY

cup
3001
\tx ’J
cm~oen
ms» noo
CLUTCH
PUSH noo
swn'cn mo msce

 

7-7

CLUTCH

'8‘ Shown CLUTCH HOSE

Place the mastev cylinder on me handlebav and
mstail the holds! and the Ywu mounnng bolls
Alygn ma and o! the holder wuh me punch mark
on {he handlebar

Tighten1hexop ball “15!, men the bottom boll

TORQUE:
10—14 N-m (1‘0—1.‘ kg-m. 7—10 h-lb)

Install :he clutch hose with the bolt and us two
sealing washers

Install the push rod end mace Into the clutch lever
hole and xnsxall ma clutch lever

Connect Ihe clutch swuxch wues m the swuch
lermmals

FHI the reservoir and bleed the clutch system
(page 7 4)

Aftev '84:
Adtus: clutch ‘ever Oree play (page 3 173

 

PUNCH MARK

CRANKCASE REAR COVER

CLUTCH SLAVE CYLINDER

DISASSEMBLY

Remove Me Ieh crankcasa rear cover

 

Piece a comama! under me slave cylinder remove
me all be): and dxsconnsct the clutch hose

NOTE

 

{BCBS

 

Avovd spilling clutch Hum on painted sur- j

 

Remove me slave cyhnde:

    

OIL BOLT

 

7-8

Remove the piston from the cylinder.

H the piston removal is hard, place a shop towel
over the piston to cushion the piston when it is
expelled. and position the cylinder with the piston
down.

Apply compressed air to the fluid inlet to remove
the piston. Use the all in short spurts.

Remove the spring Irom the slave cylinder.
Remove the oil and piston seals.
Clean the piston groove with clutch Iiurd.

Check the piston spring lot weakness or damage.

PISTON 0.0. INSPECTION

Check the piston Ior scoring or scl‘llchss.
Measure the outside diameter 0' the piston with e
micrometer.

SERVICE LIMIT: 38.02 mm (1.497 in)

OIL SEAL

   

SPRING

PISTON SEAL

 

CLUTCH

 

CLUTCH

 

CYLINDER I.D. INSPECTION

Chock the [Ian cylinder '01 Icovmg or scrum“
Mum" m. unmi- diamnlr 0' mo cylinder ban,

SERVICE LIMIT: 38.13 mm [1.503 In)

 

ASSEMBLY OIL SEAL
FISTON SEAL

Amman th- um cylindfl us me man! 0:6" 0'
dummbly TN oal suls mun D. none-d mth

now mm ermm "my hm boon «moved SLAVE

CYLINDER BODY

Lubricuu KM pmon Ind pmon ml mm a rhodium
and: a! Hu-Tcmpcrlturl u'IIcom gum or brlk'
IIuid Infor- nmblv.

 
   

Bo curt-n mu non ml u and In I" ‘non
' 7" °' suucou

groan 7" it
Pm. mo pinon m m. cylmau wvlh mu on ml GREASE ‘t
Ind Inc-n. aux. INSU LATOR ‘-§

SLAVE CY LINDEH CLUTCH HOSE
Inn-ll mo Imuluor md slave cylmdn

Connocl (ho clutch hon wnh ma on Don and the
Mo ulhna wuhem

lmull lh- Io" crankcase rut cowl

Fm m cImch fluId reserve-r mm 00'“ Duh
mud, Ind blood me clutch mum Ip-ot 74)

 

OIL BOLT

CLUTCH COVER REMOVAL

Dvlm [he 0119!!" cu"
Remove (M bull. pedal
Romovu m: clutch COVE!

Remavn tho onion-1d dowel om:

STARTER CLUTCH DISASSEMBLY

Rtmov- thn "um vdllv our man and gut

 

CLUTCH

1

CLUTCH COVE q

    

BRAKE PEDAL

GASKET

 

DOWEL PiNS

STARTER IDLE GEAR

GEAR SHIFT

7-11

CLUTCH

STARTER CLUTCH

Remove mo mmnnov covet 1w 9—2b
Hold mi Hymnal mm a unuverui holder

Ramon mo "um chum ban.
Rmon mo Imm clutch lulmbly and son-v,

   

 

UNIVERSAL HOLDER STARYER CLUTCH
077250030000 PRIMARY BOLT
DRIVEN GEAR SUB GEAR

  
  

SM! n. unruly dnnn mbrlr with l unw-
dlim to ma unload on on primary dvin gnu
And «may. on primary dun gar.

PRIMARY DRIVE GEAR

Ramon the 1mm drum gar Ind needle bunng

"0me “In" cluld‘. STARTER DRIVEN GEAR
Impact KM toll-u 'ov mouth owmon. NEEDLE BEARING \
Ramon tho runny dutch cowr by rImov-ng -

TER CLUTCH _
mo ""00 bolu. STAR R Q
Ramon mu dutch rollers, plunge“ and springs. spams I
Chick lhl vollau Vor umu‘ve wur. \l I

 

PLUNGER\

ROLLER
STARTER CLUTCN COVER

 

7-12

CLUTCH

 

STARTER DRIVEN GEAR INSPECTION

Inspocl [ht driven gear for damag- or uccsslvu
wear.
Moasura the driven gear OD.

SERVICE LIMIT: 54.18 mm (2.132 in)

CLUTCH DISASSEMBLY

NOTE

 

Do nol operate the clutch lever Ihor "moving
the clutch. To do so will uuse dlmculty in
reusembllng mo clutch,

 

 

Ramon ma snap rrng, Ilftur plate. lifter guide
ralem bearing and lifter rod.

Install the rear brake pedal.

Shift the lransmisslon into hlgh gear and apply the
rear brake.

NOTE

 

When the engine is nor in the frame, shill me
transmission lmo gear and use the Main-
shafl Holder, PIN 07923—8890101. to hold
the final shaft.

 

 

Remove the lock nut and lock washer.

Remove {ha cluich spring so! plate. clutch spring
and washer.

  

 

SNAP RING

LIFTER PLATE

   

    
  

 

LIFTER GUIDE RELEASE BEARING
CLUTCH SPRING SPRING SET PLATE

 

LOCK NUT WRENCH
D7915—422W00

 

7-13

CLUTCH

DISCS AND PLATES

Remove :he clutch preuura nun:

Human me clutch Dine; And thus

 

CL U TCH PRESSURE PLATE

CLUTCH CENTER 8

.-—.

Homove clutch cemev 8 Ind Ih- one-way clutch u
an mmblv

    
    

ONEWAY CLUTCH

CLUTCH CENTER A
Roman clutch canny A and mr war-er

WASHE q

 

7-14

CLUTCH

CLUTCH OLIVER

Rmnuve Yhe mulch mum and uumv gmdu

Hen-Irma thé rlmcr “"1"er

 

CLUTCH LIFTER CLUYCH OUTER GUIDE
ROD
SLOT NEEDLE BEARING

  

INSPECTION

CJJTCH OUTER

Check the you " 'hr dutch nutty (or mail cu“ o!
rVder-tznsns mam: m 1"! H Chan d’iCS

(‘hmtk Im- dutch nulm numllu 083'an luv Gammon
nr uxcesswa pway

" :‘vr net-(11E {Ira-n“; ‘ mN‘cult to remove 9mm "w
(“410’ hous‘ng nu ('w 'szer fig took

rev 07.75970010000
AHmh-‘nev! 42 n 47 mm 07746—0010300
DMD! 35mm 07746 0040800

CLUTCh OUTER GUIDE

“um": I' c ! D u' 'M- o 110‘ Duty gu-de

SERVICE LIMIT‘ 3008 mm (1 13450)

 

 

7-15

CLUTCH

CLUTCH SPRING

Mumve the hva c' {M clutch sovng n shown
SERVICE LIMIT: 3.6 mm (0.1‘ in)

Rnpacu In: mrmg y! .u he-ght :5 less than the
uw.caInH

CLUTCH DISC

Roplkr. Inc mum uucs ‘ my show fly: 0‘ ICO"

mg 0v awcmouhon Meuurl the (ruckness a! each
0 st:

SERVICE LIMIT. 3.1mm(0.12inl

Ruplncn nnv dvm {hut m vhinnar thin the vaCI
Itmu

CLUTCH PLATE

Cnech me an: wuoago on a turface plate using
a mm mug»:

SERVICE LIMIT 0.30 mm (0.012 In)

7-16

 

 

CLUTCH

 

ONE WAY CLUTCH INSPECTION

Inspect the one way clutch Ior smooth operation

Check the vollers fo' excesswe wuar

Measuve the ID of clutch center 8.
SERVICE LIMIT: 74.50 mm (2.933 in)

Measure me O D. of the one way cluxcn Inner
SERVICE LIMIT: 57.7 mm (2.27 in)

 

CLUTCH

CLUTCH ASSEMBLY

Imull mo clulcn uulor guide into the 0:4 uump
dun “not“: over me mmmhfit

lMuH Ihn nndm burmg mm rho clutch omev
lmull mu cluum Mm vod

Ahqn ma nmm m m: clutch outer with ma pm:
on m- ml pump dme “flock" and mull (he clutch
outer over me guide.

 

CLUTCH CUTE CLUTCH LIFTER CLUTCH OUTER GUIDE
ROD

CLUTCH CENTERA WASHER
lmull clulch (in!!! A Ind me wuhu

 

FLANGE!) CAGE

   
   

lmutl «he Dnewly clutch mm c'ulch mm 3 mm
m flanged cm ham] «1

/ \
CLUTCH CENTERS ONE “cu (Lufmi

 

7-18

CLUTCH

 

CLUTCH INNER

lnstai‘ the clu‘cfi Inner mt!) Vhs one way dutch by
twnmg it dockwtse

lnsfa. n a one-way cimrhw amt!“ came! 8 assfimbly
OVEI the mamshah

NOTE

Make sue the on: may clutch assembly :5
.nsxailed CUVVECU', kw mmmg clutch center
8 wh.» 'mldmg me mamsham Th? uluxch
center Mould turn courterniockwme healv and
should no: tum caockvnse

 

Coax the dues and Dlates mm dean ehgme oil, ' V _ 7
Inna“ the clutch d-scs and views as shown,

CAUTION ‘

 

 

 

Du Hm ruff A luh'h rev”?! 8 Nu! after [mm/ling 1

(hr fun and piglev or 5 phi: ml! 12le bc1~ ‘

wa'n L‘Iun‘h "mum .-l and B, i ‘

Tiny will pm-en: {by clulz'll [mm ul'xengaging. ‘ \
, , ‘4

 

. PLATE (7D
DISC [8)

 

7-19

CLUTCH

Imul‘ ma dutch pressuv: put:

Inlull the clutch spnng sel Dine, Hum» mung Ind '

wish-n

N07!

Inlull (h. ciumh mung wuh (he duhed he!
\ towardnhelnsnde.
lmull ihe lock washe' mm m OUTSIDE mark
(Acme om

Inulll "u lock nut

Plum "1' transmission in 6th you
App|y me make Ind tighten me lock nu!

~0Y!

WM" wrvncmg me clutch mm m- engme Du!

0| Ihc home, shun [he :vammmhon min 92;:

and hold the output mm mm the “older
L 07923—689010]

TORQUE. 83-67 N'm (8.3%] ko-m, 56-48 9ND)

  

CLUTCH PRESSURE PLATE

 

‘ c TAM 59mm; WASHER
LU ‘
LOCK
WASHER SET PLATE

 

LOCK NUT WRENCH
079‘6 4220000

CLUTCH

 

lnsuil 1he clumh M331 plate, Mm guxde and bear~
ing.

 

Install the snap ring.

    

SNAP RING

STARTER CLUTCH ASSEMBLY "MW” ”WE“ SUBGEA“

Install The primary drive gear onto the crankshaft

while muvmg the plimary driven suboear wnh a
screwdvlvar.

 

SCREWDRIVER

CLUTCH

lnunll lh- Mum wither on (he cunlurm‘t THRUST WASHER IDLE“ GEAR SHAFT

    

lmu|l (he surly >dler gait and shah

SYARTER IDLER GEAR

DOWEL PIN

Inlull 1h. :pvirqs, p:ungeu Ana rollcn unto the
mm: cluld‘.

Imull (h: down pm,

InIuH the guru! duxm cont shaman the dowel
um hol- wnh the down pun mu ham-n mu boln‘

TORQUE: 26—30 N~m (2.8—3.0 ko—m.19—Z2 beI

Mon
r Apply a lodnng agent to m. bolt [mud]. j

 

ROLLER PLUNGER CLUTCH COVER

STARTER DRIVEN GEA R

Inlllll lha nmer driven guy by turning It counlsv-
clockwmn

 

 

Anan m: punch marks on xhe "or!" clutch and
cvanklhlh and msxail \ho starter (lurch.

Hold the flywhucl wxlh mu Unlvunal Holden
(07725 0030000) and hghten the nmm clutch
[mu m the mac-had xorque.

TORQUE 80100 N-m (8.04100 kq-m.
58—72 ft-lh)

1""0‘ ”W idem—110' cum New 94|

CLUTCH CUVER INSTALLATIIIN

lnum 1M down! p m sue a new gun:

Imml lnu clutch cover‘
lmmll nu- brake pedal
Fm mo cvankcasa wnh w (W3! 13]

CLUTCH

PUNCHMARKS S’AF’LHLLUTCNBOLT

 

 

DOWEL PINS

CLUTCH COVE H

 

BRAKE FEDAL

 

7-23

GEARSHIFT LINKAGE

 

 

 

8. GEARSHIFT LINKAGE

 

 

SERVICE INFORMATION
TROUBLESHOOTING

GEARSHIFT LINKAGE REMOVAL
GEARSHIFT LINKAGE INSTALLATION

 

13—1
8—1
3—2
3-4

 

SERVICE INFORMATION
GENERAL

0 The gearshift spindle and stopper arm can be summed wixh the engine In the 1mm.

0 If the shift forks, drum and transmission require servicing. remove the engine and separate the crankcase.

TRIIIBLESIIOIITING

led to shih
1. Air bubbles In the clumh hydraulic system
2‘ Shift forks bent
3. Shin daw bent
4. Shift drum mm groom damaged

Trlmmktinn jumpi out of gm
1. Gear dogs worn
2. Shift shaft Inn!
3. Shift drum flapper broken
4. Shih forks ban!

 

GEARSHIFT LINKAGE

BEARSHIFT LINKAGE REMOVAL

Dram mo mgme onl
Ramon (M 1m crankm- ruv cover,

Remove the gear sh“ um Irom the gem smh
spmdle
Remove lhe clutch :ovnv

Ind clulch Innmhly
(sechan 7)

Remov- mo oil pump duven lprodtet boIL

Ramon m. cul pump dnvu chum, drxve And dviven
mrocken

   
   

LEFY CRANKCASE REAR COVER

 

OIL PUMP DRIVE CHAIN OIL PUMP DRIVE SPROCKET

-,
OIL PUMP DRIVEN SPROCKET 300

r

GEARSHIFT LINKAGE

 

WASRER DISTAhCE COLLAR

“B"‘um Nu m qup am“: \Luurhu- .muhm and
‘JIHJHLC IZLIllm

 

Rtmow the drum sionoe' a'r" nut um and sown;

Pun m» Inc-arm”: socnu‘e ancmhly mu 0! the crank
cana

 

GEARSHIFT SPNDLE

 

 

GEARSHIFT LINKAGE

 

SHIFT DRUM

NEUTRAL STOP R ARM CAM PLATE

Remove the manual nopper arm boll. arm and ’ .

           
   
   

PE
spring.

Remove me mm drum cam péaxe hon and cam
plne.

ARM BOLT

HOLE

GEARSNIFT LINKAGE INSTALLATION

lnstafl ma dowel pm in the ho|e oi the ma drum.
Insert the live pins ‘In me holes of the cam plate.
Align the cam plaw hale with ma dowel pin on me
shift drum and install the cam plats.

Tighun (he bah securely,

 

CAM PLATE

NEUTRAL STOPPER ARM
lrmall the washer, nouml noppu arm, spring and

arm boll.
Tighten the arm ban “curds/L

ARM BOLT SPRING

Alwlnbla (he geavshlfi Iplndlc and return spring,
Ind install as shown.

Imull the marsh"! splndln holder aligning in cut-
out with xhe proiecuon on the 5""ka

Insull me drum new! um, coll-l. spun; WIN
Ind nul ovev the urn bolt.

7.9mm (he run wwvcly,
Rot-II the warm"! wmdll Ind chad: 1M lmkm

101 month opumion,

lnmll the dlstancn collar and wuhu

GEARSHIFT
SPINDLE HULDEH

 

GEARSHIFT LINKAGE

 

GEARSHlll SVWDLE

SPRING

  

ARM
DISTANCE COLLAR

WASHER

 

COLLAR RUM STOPPEN

 

8-5

GEARSHIFT LINKAGE

OIL PUMP OUlEH DRlVl
DRIVE CHAIN sump sPaL’uixi ‘

    

lnsull [ha ouuv guxde over the mam shall

Imull mu ml pump dnvo ma dmran Iploduu
with the drlvn chain and hohlun me dnven IDrocket
boll securely

NOYE

Tho dr-vtn wrodu" nu an "IN" mat that
mun flu m cur-ken:

 

Install mo clutch ussembly Ind cuvar (section 7)

DRIVEN SPROCKET 1N MARK

GEAHSHIH ARM
Align 1M punch marks on ma geaunm um
and gearshm ‘pmdle and mmll ma quash-H Arm‘

ll the oeunhih pedal ue‘vod w-s disassembled ad-
jun 1h: lock nul-to-locl: nul distance by looming
he lock mm and turning ma he rod.
STANDARD DISTANCE 26 5 mm H 0‘ m)
MAXIMUM DISTANCE: 300 mm H 13 l")

CAUTION

Do not exceedTlle mulmum flange: mo 1
‘ lie-cod mlv work loose um! loll all ‘

lnsull mo loll cronkcm rur cover and (III (M
cunkcau woth oul (m9! 2-3).

 

LOCK NUT TlErFlOD [OCKNLJT

 

MEMO

ALTERNATOR

 

(SD—10.0 Item. 58—72 ft-lb)

9. ALTERNATOR

 

 

 

SERVICE INFORMATION 9—1
FLYWHEEL REMOVAL 9—2
STATOR REMOVAL 9—3
STATOR INSTALLATION 9—3
FLYWHEEL INSTALLATION 9—4

 

 

 

SERVICE INFORMATION
GENERAL

0 This semen covers res-naval and installation of [he alumna.
. Refer to union 18 for inspecfing and Iroubleshooting.

TORQUE VALUE

Alternator rotor/Flywheel hon 80—700 N-m 18.0—10.0 kg-m. 58-72 h-lb)
TOO LS
Common
Universal holder 077254030000
Rotor puIIer 077334020001 of 07933—3290001 (U.S.A. only)

 

ALTERNATOR

FLYWHEEL REMOVAL

Pllc! a comamer under lhe olumalov cover [0 cuch
ongm! 0|!

Ramon: the It“ cnnkcnc cow."
Remove the altemalu: (may

Hold me flywheel mm a unwevsli habder and m-
movo lhe flywheel bull

 

ROTOR PULLER 017250030000
079337329000! (U S A l m 07 7337 M20001

Rcmovc {he flywheel w-lh 1m- rotov 9006!
Roman the woodnm in ham the canksmh

    

UNIVERSAL HOLDER
07725 0033000

9-2

ALTERNATOR

ALTERNATOR COUPLER

STATOR REMOVAL

Remove (he seal and lrame left snde cover.
Disconnecr the alternator coupler.
Remove the alternator leads from the clamps.

    

CLAMPS

Remove the stator by removing the bolts and wire STATOR W'RE CLAMP

clamp.

STATOR INSTALLATION

Install the stator and wire clamp.

Raul! [he alluvnalor leads according lo the diagram
In Secnon l and connect mu alternator wua coupler
to he wire harness.

Secure the ailemamr leads mm (he clamps.

Install \he sea: and frame lelt syde cover

 

CLAMPS

 

ALTERNATOR

r

FLYWHEEL INSTALLATION

Inn-ll m. woodvufl kw mm the crankshaft

lnlull IN flywheel by Ihqmnq n; kwwny wuh flu
in m me cranksh-h

Hon the flywheel mm a unnmul holdov and
town. the flywheai boll

TORQUE 80—100 N-m
(SD—10.0 ku-m, 53—72 h-lbl

Innlll the allemllor covu

lnsu‘l {he 1!". cvankcasc cove:

Chock lngme oTI Ian! and Ad on d necessary 1mg-
2 3)

9-4

 

UNIVERSAL HOLDER
WOODRUFF KEY 077250030000

 

ALTERNATOR COVER

  

MEMO

 

CYLINDER READ/VALVE

8—" Nan
(OJ-1.2 "on, 0-. fun)

10-1. N~m
{LO-Ll Item. 7—10 Mb)

‘ . l . as—so N-m
» _ ‘ (4.5—5.0 mm. 32—33 mm
’ n K

$22 «
M. 6% 1:
(24-15 an 15-15 mm / ‘ ?

«~52 N-m \g
«3—52 In». 35—33 mm % \

 

     
 

n—zo N-m
(1.3-2.0 km, 13-14 mm

(4.3-5.2 km. 3—3! hi!)

10. CYLINDER HEAD/ VALVE

 

 

 

SERVICE INFORMATION 10-! VALVE GUIDE REPLACEMENT 10—13
TROUBLESHOOTING 10-2 VALVE SEAT INS’ECTIW

REFACING 10-14
CAMSHAFT REWVAL 10—3 CYLINDER HEAD ASEMBLY 10-15
CYLINDER HEAD REMOVAL 10-7 CYLINDER HEAD INSTALLATION 10—16
CYLINDER HEAD DISASSEMBLY 10-8 CAMSHAFT INSTALLATION 10-19

 

 

SERVICE INFORMATION

GENERAL

TM cvlindor hud can b. "moved vim nu main. In IN I'm)

II on um mocha of rim-r from o: manna-run M. IM vulva min d but cyIIna-n most In duck-d Guru-I9
"installation,

Comm-VI manning oil I; he HIM an oil IIM. Be I"! m hoh in th- oél Inn. is nu dog-d.

0mm. mm, M Mm dimme- no mo earn“ ho“. was Io provida initinl Intention

The wllndu numb-vino is gin:- below:

EEC
G) G

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD senvuct LIMIT
Cum-men mum 13:2kglcm' (184:an —
Cum" Cum Mich! IN 36.4504qu mm (mean-1.4023 in) 35; mm [1.39 In)
ex Jam-sum mm (Lasso-1.4023 id 351 mm (1.39 W
RunouI - 0.10 m (0.” ml
EM WW 013—025 mm (mm—now in) an m (0.012 In)
01' chm Conn-r 0.0304100) mm (anon—am in) nus mm mm in)
am mm now—om) mm moon—come In) mm mm (0.003? inI
Roch! um Roan um LD. Inna—Ian“ mm (nun-0.4731 in) was mm (0.47. In)
sum on Ina—Ina mm (nun-0.47m In) 11.0: mm (0.00 In)
VIIVI VIM mm 0.0. IN 6175—5190 mm (01156—021 81 in) 6.47 mm (0.215 In)
EX “Isa—5.470 mm (01143—02154 In) 6.46 mm (0.2“ "II
VII" Md. l-D- 6500—5515 mm (02185-02171 I!“ 5.55 mm I01" lnI
Sum 4°10“. char-ne- IN now—0.040 mm tum—0.0016 In) 0.08 mm (0.003 In)
EX limo-0.000 mm town—0.01m in) 0.") mm (0.00: In)
I Valve mm runom - on: mm «mm In)
' Volv- mm IN _ am mm (3.44: In) 05.96 mm was In)
2x nus mm (1am in) 35.15 mm Iaaoo In)
vuv. um mm 13 nun Icon in) )5 mn «mo In)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10-1

CYLINDER HEAD/VALVE

 

 

 

 

 

 

 

 

 

 

 

 

 

VIM spun. Fm! I‘nnh Inn-r 39,49 mm (1.556 in) 3!." mm (1.50 In)
Own 44.81 mm H .756 In) 43,“ mm (1 .10 in)
mum/Imam Inn-v 5.23—6.03 W342 mm (11.53-13.30 50 W342 M
lb/I.38 IN (1 1m Ila/1.36 inl
01m! 14.04-16.2‘ fits/37.7 mm (30.96 - 35.90 133 “37.7 mm
Ibl‘l.“ in! (29.32 III/1.48 in)
Cylindor Mud Wm - 0.“ mm (a... in]
TORQUE VALUES
mum had m1 8-11 N-m (0.5—1.2 Ito-m, 6-9 h-lbl
Comic-fl hold-v.6 mm 10-14Nm(1.o—\.4uw.7-1on.mu
Cam Mn with A 21-25 N-m (11-25 kl-m. 16-18 h-Ib)
Cylindar Mud. 10 mm “-62 N-m (4.8-5.2 ka-m. 35-38 Mb)
Cylindur had. 8 mm 21—25 N-m (2.1-2.5 kw. 16-10 mm
Roch! mm M 45-50 Nm (ls-4.0 lug-m. 32-30 mu)
Can m 13-20 N-m (1.8—2.0 kw. 13—14 mm
TOOLS
inc-U
Viv. undo nan-Ir. 5.5 mm emu-2000000
Volv- ouldo driver (mu-3200100 or ova—0010100
VIIVI cum drim 01 7£3~0020000
Gannon
VIM suing mm 07757431”

Enolm mow prom-1m manly Mm «who ”damn“. TM. an In Gianna-d by n comm m1. at by tracing
noun wlm I worming rod or momma".

Low mar-m Cantu-Ion No Min
LVM I. hmmuwupwmu
- Imam um adiunnwm comb-mien m
- w o! hm vim
- Imam: vdvo mum Em not.
- lmmm I. lwmvmmm
2. Sfidlhnvdnuhvohnnhwin'
2. Cylindor had 3. Dun-pd av mom MM!
- “imam-pawn“ 4.Loonotwnmdnin
— Wupcd or crud-d cylinder ma 5. Worn or damn-d can chain mm
6. Worn cam mocha "In
3. Cylinder und piston (Rom to SIcIIon 12! 7. Wow roam arm and/or shaft

 

10-2

BAMSHAFT REMOVAL

Dram the coolant [page 63! And “01”. 0“ "am
the horn nlunder head by remowng lhe Dolls and
with!”

Remove the udmov (page 6-6).

Remove (he um um: mags a VB)

Remove the mnrk qu9 caps
Remove [he Igmnun coils Wllh (hen buckets and
remove (he mmlaxov com

Remove KM cylmder hem covet And cover one
horn the rear cylinder head.

Remove the cvlmder head cover from the (torn
cylinder hand

Remove the otl pup- and cam cum ounde mounnng
ham and remove the cam chem mild.

Remove the Alllvnetor cove! ma rout- lhe crank-
sha'l clockwm unll! the cam chem h“ hee play

Remore me ovl p-pe «Me mumg up on the rmddie
o' the chem

Remove (he "haul! mp“ (Manon 5]

Remove m celburnor lucuan 4)

Remove the engine mounting boll on rear cylmdev
heid‘

 

    

CYLINDER HEAD/VALVE

CC-OLANY DRAIN BOLTS

OIL DRAIN BOLT
INSULATOR IGNITION FRONT CVLINDER
COVER COIL BRACKETS HEADCOVER

COVER mum cvumom
BASE HEAD COVER

CAM CHAIN GUIDE

 

Oll PIPE

CYLINDER HEAD/VALVE

Tum mo crankshaft clockwrn unhl mu TI 3 mark ' ' Ia
chem wnh ‘he rur crankcase murng wrung. '~‘ ‘-

Plocu rags or shop towel: over the tour cylinder hud .
lo pravom pm: horn being dropped Into lhn crank
cnw

Ramon the roar chtnder vnlaha and uhnusl cam
sprocket bolts

 

Turn mo cronkshafl coockwrsu one turn (380') and
rumova "w olhar cam sprocket balls .

  

Tl 3MAHK MATING SURFACE

Yum [he crankshah dochwrse unhl me Y2 4 mark
lugnl With lhe rear crankcase mumg wince INDEX MARKS

Clean the camshaft sorcclets wuh conmcr cleaner
Index (he iron! cvhnder camsmm sporokels Mlh ”W \ ‘
/
A © 9‘ "
J m L . m;
M
sprockolbolts

the lap of tho cyhnder head U50 3 water 0100'

maker

Yum mo crankshaft counterclockwrso one turn FRONT CYLINDER
4.360“ and remove me olhar cam sprocket bous CAMSHAFT SPROCKEYS

   
  
     

N0“

Some camshah sprockels may hnvu perms
nam 1ndox (1015 as shown and erI not require
marking

Ramon Ihe Vrom cyivndar make and a-hnusv cum

  
   

Shdu Ihc cum sprockeKs with the cum Chlln o" the
cumin” inrocku flanges.

Remove the com Chi!" from (he unlock": Ind
"move me camrhlh hoiden erk rm cum-H
ho|d¢u no that they can be mmullod m (he-r
orrgvnh' IOCDNOM

CAMSHAFT HOLDERS

 

10-4

CYLINDER HEAD/VALVE

 

INTAKE CAMSHAFT

     

Remove the camshaft hmder dowel was and the

DOWEL PINS
masks and exhaust camshaft; ‘

A

Remove the cam sprockets from the :amshafis.

DOWEL PINS EXHAUST CAMSHAFT

CAMSHAFTYCAM HOLDER CAMSHAFTHOLDE“
INSPECTWON

Inspecx the canfishah and home: yournal surfaces
lor scoring scratches or ewdence of insufficeent
lubncmlon.

 

CAMSHAFT RUNOUT

Chuck camshafi vunoul With a dial If‘dlcalo',
SuDDorl both ends at me camshaft wvlh V-blocks

SERVICE LIMIT: 0,10 mm(0.0041n)

 

 

10-5

CYLINDER HEAD/VALVE

CAM INSPECTION

Uunq I micron-nu, muwve each cam lobe
SERVICE LIMITS, IN, 9035! mm (1.39m)

Chock Oar war or dim-qt.

Wipe my o‘l 'Iom ("I Journal:
Lav I "up 0' pun-gauge lenglhwme on top of uch
camxhnfl .00va

xmull mu cmuha't hold"! and hymen m I
C'Iucvuu pumn

NOYE

 

Do no! value ma camshnh when uhng
plutloaual

 

TORQUE:
A: I mm BOLY' 10—14 N‘m
n.0—u kgm, 7-10 mm
B: I mm BOLT‘ 21—25 Nan
Ill—2.5 krm,15—18 fl-lbl
C: 10mm BOLT: “-52 N-m
(“~51 Ram, 3—38 (Nb)

 

 

Romm- "u umman holdus and musuro m-
wmh 01 «ch alumna! The man! Undue“
dunmmes "1. ad clcuanc:

SERVICE LIMIT'

CENTER: 0.0“ mm (0.0037 in)
BOT" ENDS: 0.0“ mm (0.0031 la!

thn m. umcu hmm are exceededl upm-
mu cumin“ and rucmck me ml clearanco,

Rnplul lhn cylindu Mud and comm-h holdm
I' m. chm-not mll “midi antic! limits,

CYLINIER HEAD REMOVAL

Loom IM wam no” clamp
Roman mo wmv papa: and has:
leovc m. wllnr mp: 041719;,

Ramon Ihl oll pupe Ind suhnq wamars.

Ramon IN "on! and um um cham "nuance
Dlfl moummu on!"

Pull the cum chnm lInl‘Oan bu: up.

    

CYLINDER HEAD/VALVE

 

WATE Fl HOSE

 

10-7

CYLINDER HEAD/VALVE

 

 

TENS‘O'V'EE SLWFER PW
Ramon IN slipper :le‘ wnhev and um and remove \ 9

"1| tvnuomv wager bu \ /

 

n'vaf -°

Ruman rho cylmdov Mad bolls

Remov- tho cvlmdov Mud] mmq I scvewamer
ll (hi my pom"

‘

      

 

FRY POINT
:yASKET
Roman [M "on! and ram wimder head gaskets \
and down! pm: u
DO‘I\[L D‘NS

 

10-8

CYLINDER HEAD/VALVE

lirfi

FRONT HEAR
CAM CHAIN GUIDE CAM CHAIN GUIDE
I 0

Remove the rum Lylmduv cum cham uuudu holu
and Quin?

NU'E

 

When ’Q'fiUI‘WE} We 'vuml (vnnder cam chum
gurdL [he cranium mus! bt seaflazed

, I

 

 

 

TENSIONER GUIDE TENSIONER SUPPER
CAM CHAIN GUIDE AND CAM
CHAIN TENSIONER INSPECTION

Inner: me ca'“ Hun and: and tensor» '0'

  

 

damme 0! “new” war
Inwect 1h! cam C'Hllf‘ Suvwonel 9| pour Iov darn-on ‘ \
m nxcesswe weal ' F"
Inwccl the mung In! good Iensmn, mpllcc II \
nf‘CESIary \
\
\
'\
\
\
\
\
TENSIONEFI SPRING
ROCKER ARM
ROCKER ARM SHAFT BOLT
Re m.» me '.'::n' Am. 1",]?! mn rociw an“! .
Rvmove the vockuv .mr mung and 0 hm; hum
me shah buH
\ ;
ROCKER ARM SPR NG O~RING

SHAF Y BOL T

 

 

10-9

CYLINDER HEAD/VALVE

Remove the valve 597mg conevs‘ runners, springs
and valves,

CAUYCON

— ~ v

: ' To prevent loss of Huston, Jn um ("um-
presx the naive springs more than neces-
ml) to remove the barren

' Posinan the large retainer on [he cum-
prenar anachmem. so (ht mmpnflmr will
not touch the cylinder head,

NOYE

 

Mark all duassembéed pans to ensu": correct
reassembly. \

 

Remov: m: valve 5721'“ 549315

 

STEM SEAL
0775770010000

Remove carbon deposxts Pom the combusnon
chamber and clean off the head gasket surfaces.

NOTE'

- Avoid dimngmg mt gaskex “Mace;

- Gaskets wIII come 0H easxev I! soaked 1n
‘ iolvem.

 

 

CYLINDER HEAD INSPECTION

Check the spark plug no): and va've areas fm
cracks

Check xha cvhnde! head 90: walpage with a
shexght edge and 'ealu gauge,

SERVICE LIMIT: 0.05 mm (0.002 in]

 

 

10-10

CYLINDER HEAD/VALVE

 

ROCK ER ARM INSPECTION

Impoct m. rocker arms Ior won or dunno! to
tho «munch contact sud-en or In! I mom oil
hols.

Muwm the LD. 01 ad: rocket um.
SERVICE LIMIT: 12.“ mm I01" In)

 

ROCKER ARM SHAFT AND SPRING
INSPECTION

Mun". nah lock" um um: OD.
SERVICE LIMIT: 11.83 mm (0.470 In)

Impact me shaft for war at dump and calculus
lho 5M1! lo rock-r Inn cIur-nco.

SERVICE LIMIT: 0.12 mm (0.003 U"

Imp-cl the rocker arm shah gonna I0! war 0'
dam-o-

Mauuru the In: length M the Inner Ind cum v-Ivl
mums.
SERVICE LIMIT:

INNER (IN, EX): 38.14 mm (1.50 IIII
OUTER IIN. EX): ‘3.“ m ".70 MI

 

 

10-11

CYLINDER HEAD/VALVE

 

VALVE STEM‘TO‘GUIDE
CLEARANCE

Inspect such valve for bonding. burning, scratch"
or ubnormul stem wur.

Check vulvu movement in [he guide und measure
and record and: vulve “cm 0.0.

SERVICE LIMITS: IN: 5." mm I0.215ini
EX: 6.46 mm (0.21! In)

 

NOTE

 

Ream the guides to remove my carbon build-
up before checking cleurunces.

 

 

 

Manure and record each vulvu guide I.D. using u
bull gauge or inside micrometer.

SERVICE LIMIT: 555 mm (0.219 MI

Subtract ouch valve mm 0.0. from the corres-
ponding guide ID. to obtain the sienna—guide
durum.

SERVICE LIMIT: IN: 0.08 mm (0.003 in]
EX: 0.10 mm [0.004 ml

 

VALVE GUIDE REAMER
07984-200000!)
N075:

 

II the stummguida clearance exceeds the
service limits, determine H u new guide with
stand-rd dimensions would bring the clear-
unea within lolerunoe, II so. replace any
guides as necessary and rum to m,

 

 

II the “unto-guide clearnnca exceeds me service
limiu with new guides. replace the vulvus also.

NOTE'

 

Roi-cc the valve suu whenever the vulva
guidenru replaced (page lO—ld).

 

 

 

10-12

CYLINDER HEAD/VALVE

 

 

VALVE GUIDE DRIVER
07942—3290100 on 07742 00‘0300

VALVE GUIDE REPLACEMENT

Hul m. cylmdu hua m voo‘c (212%; mm -
hm plate 0' ovln

  

CAUYION

 

Do not use a torch to hen! the tyll'ndrr.
II may raun- warping,

To avnu bum. wear heavy gloves when
handling 1hr heated ryh‘ndtr had.

 

 

Support 1h. cyllnd'r hand and drive on! m- old
uuldu lvom the combun-on chamber min a! 1M
cylmdu Mud.

 

Adm“ the lool mum; depth by I pair of verniev
alnpan

DEPTH: 11.5 mm (045 in)

 

 

VALVE GUIDE DRIVER
07743—002001!)

Dhu now wudu .n horn the '06“! inn ya! a!
mo cylmdov "no ‘ A ,4

NOYE

l Cylmdov hud hm would suit be an 100°C

 

(21235:) Em muallal‘on 0' me new 9nd“.

 

Lu the cylinder head cool lo room Iempemture
and Hum me new vllve guide:

NOV!

Uw curving 01 on {he ("met during mi;
optic-hon

Rom. mc name: m the same direction
when mumng and remavmq vL

 

 

Re'uv rm um an! (0399 'VCHM and clean the
cyhnd" hood thoroughly to 72mm: any metal
put-cw:

 

VALVE GUIDE DRIVER VALVE GUIDE REAMER, 55mm
07743 0020000 079344000000

 

10-13

CYLINDER HEAD/VALVE

VALVE SEAT INSPECTION
REFACING

Clan on mult- and "hum "Ms {MYDUQMV [O
"move carbon dams-u

Apply I luv“ ch‘ng o! ulvu «apcmg compound
In uch ulvo he: Lap escr- an: and sea: usmg
I mbbor how or om" MndAlapp-ng toal

NOT!

 

Tllu mu no! to allow the compound H) mm
bemoan thc vllvl mm and guide. Aha! lap
ping, wash on! ma compound compiemy
nnd now I call a! gnome on! :0 the am
no. ong‘nn,

 

Ramon 1M ulu AM rum-fl ”he ‘52:

CAUYION

 

Th: valve: mrmnl be pH If 1):: mt»:
fat! I: rough. warn unevenly wr autumn the
sat! Improperly, 1hr mlr: mm x: M replarai

 

 

Imam m. vulva mu

I! [M nu II mo wldn‘ [on navruw nv has vow mots,
th- Ill! mull b- wound

NOTE

Follow me "has! mum-mum‘s opemmg
mfl'IJCDOHL

 

 

Mm ammo m. m: lpp‘. Assam; compound
to [no ule ne- and ‘a: '*- dive us'ng l-gm
prawn

Ahoy Innomq wan any vewj 1a Lgmmund ofl rm
cyhmv find and “In

 

   
 
 

SEAT WIDTH:
\ 039—1 27 mm
\ \( (0039—0060 an)
/\
ssavuca umr

15mm (OWN!)

IN CUTTER (30 mmd) IN, EX CUTIER (30 mmO) IN: CUTTER (79 mm)
ex: cunen us mm: Ex;cu1’TER ms mmo)
; ‘ >
,I 7" , \ AGED—127 mm
OLD syn mom \ 03° SEAT WIDTH -’ (o one—0.050 on»
\ ~-\\ ,
32L V \
50f

 

CYLINDER HEAD/VALVE

CYLINDER HEAD ASSEMBLY VALVE VALVE SPRINGS RETAINER
NOTE:

lnslall new valve stem seals when assembling. 3

U52 valve guide duvero7742~00101011
Lubncala each valve sum wuh molybdenum
dISUHVGI grease and Insect lhl valve mm the valve
guide, To avod damage to the stem seal, turn zhe
valve slowly whm unsenmg,
Install the valve springs and (enamels. The springs' V
tlgmly wound coils should face loward lhe head.

3

f

SYEM SEAL VALVE CUTTERS

 

 

 

 

Install the valve comm,

CAUTION

 

‘ ..
~ To We)?!” loss 01' tension. drl my! mm-

pmss Ike mire rpring more than nerexmry
ro hum/l (he vulvc keeper:

- I’bsin‘on the large remlner an the comprey
snr anachmenl, so the compressor will not
touch Ihe cylindrr head. l

 

Tap "19 valve stem; gently WI"! 3 sch hammer [O
firmly seal the canals

NOYE

 

Suppon the cylmdar head above the work
bench surface lo orevem possible valve
damage‘

 

 

 

 

10-15

CYLINDER HEAD/VALVE

1

ROCKER ARM

SHAFT BOLT
Inn-ll the 04mg md mung onlo ma rocket aim
shah bull,

ADva

LOCTITE E“m 1m- voc'zer arm shah Don
Ihvuds

Apoly enqu‘e o1: to [he mum rm shaft ma mull
(M rocks! arm

Inqu no tughun tm vockav arm shah Dal:
TORQUE: 45—50 "In!
Its—6.0 ko-m, 32—36 h-lbI

    

ROCKERARM SPRING ORING

CYLINIER HEAD INSTALLATION

Clean the cvimdcr Mad luv'm a! any gun!
mutual

 

GASKET
Insult (he dowel DIM lv-(j new head gaskcu

 

DOEL PINS

10-16

CYLINDER HEAD/VALVE

 

CYLINDER HEAD BOLTS
'\

/

 
   

Install the cylinder head and wmpovaniv Install the
cyhnder head Dons.
NOTE:

Do r101 ugmen [he cylmdm head balls at m:
hme.

 

REAR CYLVNDER
CAM CHAIN GUSDE
' » ' »»,

Install (he rear (.vhndor cam cham guide‘

 

HOLE LOCK PLATE
With the lock pfiate pushed down. and the cam chain
tensionar arm raésed in the direction of the. arrow,
insert a pin 0: piece of wire thchh the hole in
me tensioner base and tensioner ENTL

 

\
TENSIONER ARM TENSIONER BASE

 

10-17

CYLINDER HEAD/VALVE

TENSIONER ARM TENSIONER SLIPPER
Pm the cam chum lhvough lhe cur chom lemuone'
um and imml 0‘! mm oner slvppnv n mown

NOTE

Check um lho tower and 0' m. mun... M1
In the slipper hm canectlv.

 

Inna-1m: 0m and (‘4, as shown

 

CLIP PAN

Oll PIPE
Install (m "who: all mp»: wan wnhuri onto the
cylmdlr and cylinder head.

WATER HOSE
Imull the wllv Doe! and hose and hghlen the hose

bands seem-Hy

 

—\
WATER PIPES OILPIPE

10-18 ’

CYLINDER HEAD/VALVE

CAMSHAFT INSTALLATION “MSWWAR‘ ‘0 A "' ‘5

ND”

‘ - Follow this procedure Imm hmmnmg In

and, even II you are only urwcmg one
cvlmdar head

~ Chock the camshah Iommlvunnn muck: ‘
w mil you umulb each c-mthnh m u
conocl lac-hon

' The mark: on the cumin" mun
EX RR (ERIV Rea! cyImder unnuu
IN RR IIRI Rut cyxmder mulu
EX FR IEFI anI cyhndev uh-uu
IN FR (IF). From cyI-ndov mulu

- Thu camshaft sprockan I'll mmchange
lull

 

Lubncmc ma ham and Real rwndm head can--
mmmg sauces wuh Wm dwim (amuse

 

REAR C YLINDER CAMSHAFTS

Y! 3 MARK

Turn the cunkshah clockwue mm! "m TI 3 mark '
on the flywheel rmor aligns wim me your crankcase

mumo wvhcu ‘ ‘

CAUYION

 

 

when rummg (he cmnkxhaft make curt (he
can rhauu Jon‘l pen: a! 1hr mm - Mm len-
nmrn w .11 1h: rmnkshafl

 

    

REAR CRANKCASE MATING SURFACE

10719

CYLINDER HEAD/VALVE

INTAKE CAMSHAFT

Install the intake and exhaust camshalt and sort:-
ckctt through the rear cvltnder cam chain as shown.
Turn the camshaltt so the camshalt marks face not

I! the hunt cylinder camshalts were not re-
moved, check that the hunt camshaft marks
face up, ll not. turn 1h: crankshaft clockwise
360 degrees (one turn),

_ i 7,, W .l

  
  
  

II a valve clearance adiugter keeps the camshaft
lrom seating lully in the cylmder head back the
adiustet out all the way,

CAUTION

If you [am a valve open while inslalling the
camthaft holders. you may damage the
‘ holder: or the camshaft bearing surface:

 

y ,
EXHAUST CAMSHAFT

 

 

CAM HAFT HOLDERS PIN BOLTS

       
    

 

Place the umshalt holders rn the same locat-ons
noted dunng removal The groove In the bottom
01 the holder must sign with the camshaft locating
ndga

Install the camshaft holder bolts, but do not tighten
them yet.

NOTE

The 6mm pm bolts should be installed at
each corner Do not (solace them wtth any
other bolts

ll the cvlmders wore not removed, lock the cam —— 7
cham llnSloner lcr mtmmum tensron: push the lock
plate down wh-le pulling or prying the tensron arm
up, hold the arm up whrle you lnsert a pm or wrre

througl the lock holes. LOCK

PULL UP
*\

wmg—.‘

 

10-20

Check that the camshaft marks are strll tactng up,
then align the sprocket Index Ilnes wrth the top 0!
the rear cylinder head Place the cam chem on the
sprockets lvtewed Irom the let! srde ol angmel

SIIUE the sprockets onto the camshaft flanges, and
Install the sprocket bolts m the exposed holes
Check that the sprocket Index III'IES altgn at T1~3
Unlock the cam chat" torment-1r.

FRONT CYLINDER CAMSHAFTS
NOTE:

When assemolmg only from cvlmder head
remove the rear cylinder head cover to make
sure the camshaft marks lace up It not, turn
the crankshalt clackmse 360 degrees lone
mm;

It the front cylinder camshak sprockets were nm
Indexed durvng remuvul and are not marked as
shown renew the procedure below

Clean the sprockets wam curttact cleaner and WIDE
My

On a grace of paper draw two Lnas perpendicular
to each other IQO'I Use a protractor and draw two
diagonal mes at 345' tangle Center the sprocket
on the Imcs wrtlw the ongmal punch marks altgned
ur'. the hortzontal lune

Make r‘ew Index mark: on the sprocket where the
45' magonal lines moss the sprocket

NDTi

l'. ts not necessary to make new mac: marks
for the rear cylinder 5 uamshafts sprockets

 

CYLINDER HEAD/VALVE

CAMSHAFT MARKS

INDEX LINES
CAM SPROCKET BOLTS

 

#WT

DRAW INDEX MARKS

 

ORIGINAL INDEX
MARKS

DRAW INDEX MARKS

 

CVLIND ER HEAD/VALVE

 

T 4 MARK
Roma the cvanhhalt caunmclockmn 90 degrees 2 ,

(Ill turn). unhl lha T21 mark awnl mm ma may ‘
cranium mam-g Inna. ‘

   

CAUTION:

 

When running the crankshaft. mat: nm {he
cam chain doan‘l [am a! 1hr mm chain
tension” or a! (he cmnkxhdfl.

 

REAR CRANKCASE MATING SURFACE

 

 
  
 

lnnall lha inlalu and exhaust camahafu and 5pm-

clan. Ihroum Ina lroni cvlinda: cam chain as
shown.

lNTAKE CAMSHAFT

Tum me lamina": w the can-shah mad: he: no.

Rome Each Iron! camshah coumamlockwige ‘6

degrees (1/8 mm) [0 mt (he cam fully m (ha
cylinder haad.

IV a valve adpum loops the mm" "om wanna
ful'y m ma cylindat head, back out IN adhmav all
the way

Install [he lrom cvlmdar cammah holdars and i . ‘ 7“, E ‘
balls, as dncribad '0! the mar cvlindar head. I Kiwi ‘\ l I
Do not right-n al lhll tuna. ’ "
Lock [he cam mam lananotm ior m-mrnum wnuun.

 

EXHAUST CAMSHAFT

Allan mo pmmananl Index den or flaw Index malt 7 fl
on me from cylundor cam smockala wnh the lap
at (he cylmdar head (Viewed from tha la" snde n!
the angina)

 

       

meuw

K
F__ I \.
sun. on mock-u onto ma mm." "anon. ma /;§‘\ f?
Install ma Invockal bulls m (M "pow-d mm x
(7mm 1M cunluhalt clockwua a mm :0 neon

my).

    

 
 

Chadx ma! Ina wreck“ Index don align n T24.

Unlodt the can chain Imam.

PERMANENT INDEX DOTSOR
NEW INDEX MAflK

 

 

10-22

CYLINDER HEAD/VALVE

 

FronuRw Cylinders

Cnerh my franrtwreav ryhmier rzarvuhu'l wlhng
u 'unnws

NO”.

Wt-rn Yhu T1 3 mavk swam wm» mo "2.!-
rumkuau mdl‘ng smVace, "we H1001 I'm;
or a“ Law sprockeu would nl‘gr mm me
two a! ("e C\ ‘muev Reid:

Al‘ ramthr: Mavis «w other lace up 0'

rim/n

Yum the manks'wafz as thlu rev! (-3 mu“ Me
n-uwr: ng wrrvclve! ha rs at MI Mm camshahs

Mum-m me camshaft spranH bulls in ma specified
mmuw

TORQUE: 18—20 N-m (1.8«20 ko-m, 13—14H-lbl

Lumen the tens one base Donn acutelv

Tum lhu crankshan unul than: n. maximum cam
chum 1w: may; then Inuall the on unpox undal the
cam chain

Irvun‘l 1m cam aha-n guide on the ow 01m bit!
DUI!

Turner the :wmaer head 10 mm Dunn m n :ns}
(Von ultlern In 2—3 new

TORQUE “—52 N-m (43—5.? Ila-m, 36-38 h-lb)

ngfllmv the cylinder head 8 mm [mm m .I cmsctoss
pane!" m 2 , 3 swps,

TORQUE: 21—25 N-m (2.1—2.6 k9m.16—18 fl-IM

hunten the cam 3’1an holder 6 mm bum
TOROUE:10—14 N-m(1.0—1.‘ kW“. 740le)

 

 

INDEX LINES
A1

INDEX LINES

TENSIONER EASE

CAM CHAIN GUIDE

OIL PIPE

10-23

Lubncate the cam lobes With all,

Adjust the valve clearance (page 3r9l.

Apply soalmt of the head cover gasket.
Install a new cylinder head cover gasket,
Install the front cylinder head cover.

NOTE

 

Be sure the table of the from cylinder head
L cover face the rear {page 340].

—1

Install the reav cvllnum head cover base, cover and
gasketv

ums

F Be sure the cast mark inside the rear cylindev
head cover, and this tab of the cover base
face the "em.

7 if 7,;

Install the insulator cover and the lgnmon coil
brackets. Tighten the bracket mount bolts with
the ground cable.

Install the radiator (page 6-9].
Install the fuel tank, seat and Slde cover.

 

IGNITION COIL INSULATOFI
BRACKETS COVE R

    

COVER BASE REAR CYLINDER
HEAD COVER

 

10-24

 

MEMO

GRAN KCASE

8 mm
2i-25 N-m
(2.1—2.5 kg-m. 15-18 ft-Ib)

 

E)
“M /& $1 $5

10 mm
43—47 N-m
(4.34.7 krm. 31-34 ft-lb]

11-0

I I. CRANKCASE

 

 

SERVICE INFORMATION 11—1
CRANKCASE DISASSEMBLY 11—2
CRANKCASE ASSEMBLY 11—3

 

 

 

SERVICE INFORMATION
GENE RA L
I To mice the piston, crlnkshlft. conmminq rod and aluminium mu crankusu halves mun bu upland.

0 II 3 new cunkcasu is intuilod. perfotm counterlhafl shim selection procedum (Page 13-18),
I Th: following pm; must b: removed before disassembflng m crankcase.

- Oil pm Refer x0 sect-on 2
- Oil pump Refer to section 2
- Waflf pump Rah! to fiction 6
- CIuIch/mim dutch Refer In section 7
- Gui shift Iinkaou Ruler to section 8
‘ Aliematoi Rate: to section 9
- Cylindev Mods Ruhr to section 10
- Snner mom: Refs: to section 20
- Gear change much ReIer to section 21

TORQUE VALUES

10 mm be": 43—47 N-m (ma—4.7 kg-m, 31—34 fl-Ib)
8 mm bolt: 21-25 N‘m (2.1—2.6 kg‘m. 15—18 fl-Ibl
8mm bolt: 10—14N-m (1.0-1.4kg—m, 7—10h-IbI
T00 LS

Spocid

Driver 07949—371000: or 07949—3710000
Anachmam (”MB—3710200

11-1

CRANKCASE

 

CRANKCASE DISASSEMBLY

Remove me upper crarkuasa bolts

Refer to General lnformauon (page 11-1] for (he
list of pans to be removed below the crankcase
can be disasinmbled.

Ramon tha malnsha't uearmg holdnr by vemovnng
[he scvaw and Dom.

 

Remove the output gear case mounnng baits

 

OUTPUT GEAR CASE

 

11-2

CRAN KCASE

———_—

Tum m. engin- (war and remove m. lower crank-

case bolu.

NOTE:

 

Remove me bolts In two or more sup: and
m n crisscrcm pamm m pvmnt dam-9e to
th- crankcast

 

 

 

Super-ta the atrium.

Remove mo following 9am:

Piston and contacting rod: (Semen 12).
Crankshaft (Section 12).

Shift 'ork and sum drum (Section 13!.
Transmlssion [Section 13).

Drivo m. oounurshoh bearing am 0' the use.

CRANKCASE ASSEMBLY

Drive the munlershan baring into the aankcau.

 

 

 

COUNTERSHAFT BEARING

 

 

ATTACHMENT
mew—3710200

 
   
    
 

DRIVER
07949—371000] or
07949—3710000

 

 

 

11-3

CRANKCASE

Inlml the ful|owing pant

Sh." iork and shit! drum (Socllon 13).
Tunvmmon (Sect-on 13)

Cunkshlh (Scchon 12)

Pmon and connectmq tom (Socuon I?!

Apply mn|ybdenum ammo. guns: in [he mm
lork grooves 01 the M2‘ CS And (:8 gears.

11-4

C6 GEAR

HONDA

V65 SABRE

 

C5 GE AR

 

Clean ma crankcase manng surfacns.
Apply liquid sealant to the mating surhoe of lhl
lowcr and upper aankcue‘

CAUTION

[ Do not apply mutant :0 Ike area near the
main bearings.

 

DO NOT COAT THIS
‘ AREA.

 

l

Install the dowel pm

Assemble the crankcase halves. il-gning the shih
fork claws will the gears.

Tighten m. bolts to ma specified torque valun In
lhl “quorum shown

TORQUE VALVES:
10 mm bolt: 43—‘7 N-m
(4.3—4.7 ku-m, 31-34 h-Ib)
8 mm boll: 21—25 N-m
(2.1—2.5 Iurm. 15—18 "411)
8 mm boll:10—14 NVm
l1.o—1.4 kg-m, 7-10 fl-lb)

Tigmen the bolt: in a crissctoss pattern and in 2
or 3 maps.

CRANKCASE

 

 

DOWEL PIN

 

 

 

11-5

CRAN KC ASE

 

H mm HOL T
Tlohun tho upper cnnkcun holu to m. wow-ad
town. In I crisscvou pllum nnd In 2—3 3109:

TORQUE: B M: 21—25 Nrm

(11—15 km, 15—18 "42”
6 nun: 10-" NJ"

(LO—1.! firm, 1-10 h-ib!

 

8mm BOLYS 6mm BOLT

MAINSHAFW HEARING HOLDER
Inuoll [ha mmnshah bunno hold" ".5 “WW" m. . , >
mu Ind bolu‘

Imuu me oumux our can mount Dam and than
human to the woof-ea (ovum
TORQUE:

I mm Iodm baht:

21—25 N-m (2.1—2.5 kg-m, 14—18 mu)

 

6 m FLANGE BOLTS

B "m SOC-(ET BOLTS

 

11-6

 

MEMO

cRANKSHAFT/PISTON

 

N—34 N-m
(3.0-3! hum. 22—25 “M

_ FRONT

12-0

080%? 12. CRANKSHAFT/ PISTON

 

 

 

SERVICE INFORMATION 12—1 BEARING INSPECTION 12—8
TROUBLESHOOTING 12—2 BEARING SELECTION 12—10
CONNECTING ROD REMOVAL 12—3 CRANKSHAFT INSTALLATION 12-12
PISTON REMOVAL 12-4 PISTON AND ROD INSTALLATION 12-12
CRANKSHAFT REMOVAL 12-7

 

 

 

SERVICE INFORMATION

GENERAL

I Ali bearing inserts are select (it and are idantified by colo' coda. Select replacement bearings from the code tables. After
installing new bearings, rechaok them with piastigauge to verify clearance.

0 Apply molybdenum disulfida areas- to the main iournals and crankpina during ammblv.

I adore removing the piston and connecting rod assemblies. clean the top of the cvlindnr 01 any carbon deposits.

0 For servicing the piston, connecting rod and crankshaft, the crankcase assembly must be saparatad (Section 11).

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ITEM _ STANDARD SERVICE LIMIT
Crankmal‘t Connect-n9 rod big and side clearance 0.10—0.30 mm (0004—0012 in) 0.40 mm (0.016 inI
Runout — 0.03 mm (0.001 in)
Crankpin orl clearance 01328—0062 mm (00011—00020 in) 0.07 mm (0.003 in)
Main journal oil clearance 0028—0062 mm (00011-00020 In) 0.07 mm (0.003 in)
Cylinder TB? 10500—70516 mm (11290—11305 inI 70.50 mm (3.13400
Wamago ‘ — 015 mm (0.002 in)
Piston Ring-tc-groove Top 0915—0045 mm moons—0.0018 In) 0.10 mm (0.004 in)
"""m 50mm! 0015—0045 mm moons-0.0010 in) 0.10 mm (0.004 in)
Ring end gap Top 0.20-0.35 mm (0008-0014 in) 0.50 mm (0.02 in)
Second 0.20-0.35 mm (nous—0.014 in) 0.50 mm (0.02 in)
on (Side "W‘Tfiififim (once-0.023 in) 0.90 mm (0.035 in)
PistonBD. 79480-79490 mm (11283-11205 in) 79.35 mm (3.124 in)
Llfifton‘tofvllndar clnrance 0.01-0.055 mm (0004—0002 In) 0.!0 mm (0.004 in)
LPiston pin bore 211002-20“!!! mrn (07876—01877 in) 20.x mm (0.7” in)
I Pinon pin 0.0.- 19394—20.“ mm (0.7872—O.7874 In) 19.98 mm (0.787 in)
{Pistunmooiston pin clearance 0002—0014 mm (00001—00006 in) 004 mm (0.002 in)
i Connacting rod small and ID. ”DIG-20.034 mm (07880—01887 In) 20.00 mm (0.701 in)
Piston oin-toconnectino rod clearance 0018-0040 mm (0.1!)08- 0.0016 In) 0.000 mm (0.0024 in)
Cm chain 1 Length at 13 kg (29 IN tension 36L0§—362.40 mm (14250-14209 in) ”449 mm (14.37 in)

 

TORQUE:
Crankoin: 30—34 N-m (3.0—3.4 kg-m. 22-25 ft-Ibi

TOO L

Specral

Piston ring comprosror Commarciaily availabll compramr (Automotive atylc)
Spring scala Commercially available in U.S.A.

——_———_

12-1

CRANKSHAFT/PIST ON

 

TWINS

Em m

I, Civilian
O Wom main buying
0 Wom rod buv‘mg

2, Pinon and Connecting Rod
0 Worn gluon or candu
O Worn pmon pin 0' pin hole
0 Worn rod small Ind

Low compo-Mon M mun-n companion
1. Wow cyhndlt a: Dillon ting

Em not.

I. Worn cylmdor. onion 0! Dino's tings
2. Improperly mull” vino" ling!

3. Danna! omen ov cvl‘moov

0mm

l. Exam" whoa bunldw on aim bud
2. Block-d or mmcud ”ow cl coolant

3. Shutting Mormon"

Knock!“ av abnonni nah-
l. Worn pmonl and :yhndnn
2. Euro-um. curbon butId-un on aim-m hand.

 

12-2

CRANKSHAFT/PISTON

 

CONNECTING ROD REMOVAL

Supavate [he cranium! Mumbw QSeCIwm Ht

Check the :o'vteu "9104,11 as {err-:2

SERVICE LIMIT: 010 mm (0.016 ‘ml

Remove the comm-mum um Dea'mg cam um: umo
"w v mahons

 

Pug-1 the cannecemg uxh and astom oc' 1"»wa
we '0: o‘ 7“! (4 Hip two-n

CAUYION

(M Pngmts with laud: ”Him“, ””me Mr
I rrlmde‘rx [In .J rulgr m1! :1!va (lu- Ingmar]
1mm: nf rmg Irurrl «In; nJ/zi mm! b:- n-
murnl with an dub-munw :‘s'pe mfg: Immr'
brflwn rsmn'rmg Hm {VIL’V'U Iv allrm :ht
{'le my 1rd rings ,' 13471 Hz! mgr-#16 ’I-Urr

I—_—__
I ‘x
\
\\ ,

 

 

 

 

 

CVLINDER
“km-1 RIC-CF I

 

 

 

12

3

CRANKSHAFT/PISTON

 

Mark the rods, pistons, bearings on! cam as you
remove them to Indicate the correct cylinder and
position on the cronkpim.

PISTON REMOVAL

Remove the piston pin dips. Push the piston pin
out Ind remove the piston.

Mark the piston pin: to indiutl their correct
piston position

PISTON/PISTON RING INSPECTION

Measure the piston ring-to-woove cIunnca.

SERVICE LIMIT: 0.10 mm (INN). in)
(TOP/SECOND)

Remove the prslon rings and mark thorn to indicate
the correct cylinder Ind piston positron.

Clean the pitton crown. removing Ml carbon do
posits.

Inspect the piston for crooks or othsr damage and
the ring grooves [or excessive wear and carbon
build-up.

  

 

PISTON PIN CLIP

 

 

12-4

Usmg a prslon, push m. 1mg mm (ho cyIInmn
mulrulv Ind measure lhl md glpl

SERVICE LIMITS:

TOP: 0.5 mm (0.02 in)
SECOND: 0.5 mm (0.02 in!
OIL (5'39 "I”: 0.9 mm (0.035 In)

Mniuvc me plsmn O D

 

~01:

, 7; _‘ *1
You measu'tmenh YO mm IDA m} "om Iho
bottom, and 90' to mu much am note

, , , 7777 774

I A

 

SERVICE LIMIT: 70.35 mm (3.124 in)

Inwefi me cvhncov Down Io: war 0' tum-go
Musme the cvmdu I D II mm Vevfls m X and V
“a

SERVICE LIMIT: 79.60 mm (3.134 MI

Culculnu :he pbton-Iorcvlmdu cleannm
SERVICE LIMIT: 0.10 mm (0.004 in)

Orewu custom Ml lullabll In {he Iollomnq mm

0.25, 0.50, 0.75 Ind 1.00 mm

CRANKSHAFTJ'PISTON

 

 

 

 

12-5

CRANKSHAFT/PISTON

 

Muwn loch pnton pm hon I‘D,
SERVICE LIMIT: 20‘“ mm (0.7” h)

Muwn uch nmon pm 0 D
SERVICE LIMIT: II.“ mm (0."? in)

Calculus lhl pnuon lam-moisten cieuince
SERVICE LIMIT: 004 mm (0302 MD

Mount. mo oonrmmng rod small end I‘D, H the
vudmg "neat nu umce hmit, mono: the vod‘

SERVICE LIMIT: 20.“ mm (0.731 in)

 

 

12-6

 

CRANKSHAFT/PISTON

 

 

CRANKSHAFT REMOVAL

Remove the cvnuhoh and rrmon the cam chem

CRANKSHAFT INSPECTION

Set Me crankuuh on a uanc or Var muck.

SH 3 dz; :nmcuo' on the emu-v mm bear-n9
[ou'naI Romp me c'ankshefi mo 'uo uhons and
read the lunouI

SERVICE LIMITV 0.03 mm (0.001 in)

CAM CHAIN LENGTH MEASUREMENT

Place the cam chain on In: Gamma" ‘pvockels
With the punch math posnioncd as indncalud.
Secuve one urmhm smock” mu apply 13 kg
I29 lbs) 0! Iens-nh 10 me othe'

Then measuv: 3h. dvstam Dclwun the punch
marks as show"

SERVICE LIMIT. 34.9 mm ("‘37 In)

NOTE

 

 

 

, , I
Ihe DUN?! mull. would be par-Hal [0 each

othey

 

Prolaca the cam chum H -I Is Iongm mm the se'vice
mm:

CAM CHAIN
[REAR CVLINDEBJ

_. an SHAF‘I

CAM CHAIN
(FRONT CYLINDER!

 

 

 

 

‘ I

ung’

791m ,

r: f
. (I

/

 

.3“
/
/" ‘— SFRING SCALE
(Commvcially
avadablc)

VUNCH MARKS

 

 

 

12-7

CRANKSHAFT/PISTON

 

BEARING INSPECTION

CONNECTING RODS

FLASTIGAUGE

    

Insotct me bearmg Inszns for damage 0' sepavahon‘
Clean an Oil Ivom the buarmg Inse'xs and crankpms.
Put a piece of plasugauge an aacn crankpm avmdmg
the oil hole.

CAUTION,

 

The bearing lab: shuuld face (award the
cxhaust pom Remember the from and real
cylinder exhauxl parts fact opposite dilec»
(fun: I

 

Install the beam; caps and rod; on m: cmrec!
cvankoms, and hgmen mam evemy,

TORQUE: 30—34 N-m (3.0—3.4 kgm, 22-25 h-lb)

NOTE‘

 

DD not rotam the nrankshah durmg mspec T
x-on‘

 

 

Remove the caps and measure I've compressed
plashgauge on each cuankpm

OIL CLEARANCE SERVICE LIMIT:
0.07 mm (0.003 in)

 

 

12-8

MAIN BEARINGS

Impact [ha bear‘ng muuu 4o! damaga or stpluhon
Chan :14 od Horn me belnng mum and mum.“
Put a 9-9:: 09 phmqauqe on each joumui‘ avoudvng
the 0.1 Notes

lnnul the mum bunnqu an the correcl younult
on (he lowev cranium Ind :ughren mam manly
.n 2 0' 3 steps m we xequcnce xhown‘

TORQUE VALUES:

6 mm bolt: 10—" N-m
(1.0—1.4 MAM, 7-10 I“!!!
3 mm bok: 2\—26 N-m
(2.1—2.5 kg-m, 15-18 't-Ibl
10 mm hon: 43-41 N-m
(4.3—4.7 Rom. 31—34 h-lh)

'40"

Do not route the cvlnkwah dunno «1509c
“0'1

Rmme {he lowev cunkuw Ind measuvc the com
v'nnd plashgauo: on “Ch murnal
OIL CLEARANCE SERVICE LIMIT.

0.07 mm (0003 in)

CRANKSHAFT/PISTON

1i

 

 

 

 

12-9

CRANKSHAFT/PISTON

BEARING SELECTION

I! rod bearing clearance is beyond rolerancel SEIect
amusement bearings 35 foIIDws:

CONNECTING FIOD BEARING
INSERTS

Determine Ind record the corresponding rod |.Dt
code number.

NOTE.

 

The number 1 or 2 on each conneéfing rod is

 

 

the code Ior each connecting rod l.D.

 

Determine and record the corresponding crankpin
0.0. code number (or measure the crankpin OD.)

NOTE:

 

The letters A or B on oath crank weight is the
code for such crankpin ODA

 

 

 

Cross reference the cmnkpin and rod codes to deter
mine the repIac-rmnnl bearing color.

CRANKPIN 0.0. CODE NO.

 

 

 

 

 

 

A a
39.992— 39934--
40000mm 39.992mm

‘0 ~ i 43.000-
5° 3 I “1008"“ C(VIIIowI BlGrunI
$393 1
- £3,003—
‘83 8 2 1‘3916nm1 BIGmI I Alarm)

 

 

 

BEARING INSERT THICKNESS:

A (Brown): 1194—1198 mm (03583—00590 in)
B IGmn): 1190-1494 mm “10587—00588 In)
C IYeIIaw): 1‘486—1A90 mm I0.0585-0.0687 in)

 

1 2-“I()

0.0V CODE

COLOR CODE

 

|,D. CODE

 

CRANKSHAFT/PISTON

 

 

MAlN BEARING
Duumml and recon! crankcm 1 D, code numben

~OYE

Th. Hutu (1 m 2) an the uDOE! rear crank
can Ihown an m. coda 'or the mam jomnal
1.0 Mom I.“ la my".

Ollummn Ind vrcovd KM conespondmo mam
)ou'nll O D cod. numheu (or menu" the Mann
gou'nal O D D

No"

A numb-r 1 cc 2 on end! Clank wengm :5

ma cod- Ia: the Adjacent mam iouvnal O D ‘

Clo“ VO'I'OV‘C! in. can and iournai codes lo Gem
mm the Ino‘aclmm! bear ng

MAIN JOURNAL 0.0

 

‘ coo: NO \
7 2 1
1* as 992- 39.984—
‘4 no 000 mm 39.992 mm
i - 1 if 4
41000—
:30 I ‘3 H” mm ‘ C (VcHow) B {Gum} ‘
33“” ' "7 ‘
< ‘1 w" ‘ a [5mm A lewnl

 

U l) 016 mm

MAIN BEARING INSERT THICKNESS‘

A lewn). I ‘98v1,502 mm (09590—00591 m)
3 (Gm!!! IAN—1198 mm (oases—010590 In)
C (Yellowl- 1490-1194 mm (00587—00588 in)

O DACODE

 

COLOR CODE

12-11

CRANKSHAFT/PISTON

 

CRANKSHAFT INSTALLATIUN

Install the main Dealings mm [he uppev crankcase
Apply molybdenum dxsulfide grease lo the upper
and lower mam bearings.

lnslall ma crankshaft with th: cam chain

 

PISTON AND ROD INSTALLATION

Clean the ulston domes, ring lands, and Skins
Carefully install the pislon ungs onto (he piston,
Sugger the ring and gaps as shown.

NOTE:

 

l

B- careful not to damage the pislon and 1‘
l piston rings durlng assembly, ‘
I - All ring: should be lnslalled WITH rha
: markmgs lacing up‘

- Ahar msulllng the rmgs lhey should lolale
L healy.wi1hnm sticking

  
  
  
   

SECOND

SIDE RAIL

SPACER
SIDE HAIL

 

 

 

12-12

 

CRANKSHAFT/PISTON

 

FRONT CYLINDER "MBLF" MARK
Call the rod mull and with molybdmum diIuIIidc

all.“
Animal: 1h! muons and connocnng rod: wnh [he
pmom and piston clips Is Iollowl

From cyIInd-r calming rod and plum: may

Non mu the Iron! cylmau connonmq rod! are
mull-d MBA-F

lruull (M muons on (M Ivonl conmctmq mm 10
mu m- :nqu "IN" mark vs Inc-nu oooomu "II on!
holu m rho rod

 

"IN"MARK OIL HOLE

REAR CYLINDER "M47R“MARK

     
    

chwhm'mxfingmdlndphmw

Non that [he may cvlindu conmcnng vods In
mukod MBtR

Inn-ll IM muons on the rail rod: I0 mu me mull:
"IN" mark is being the uma dtrmlon at IN on
holu In "I. 70d.

no?!
r 7 ‘ V
- Do not Inlevchnngl m- DIIIOI“, mnon
cum 0: cannecnng rod:
' Mal. sun mat [M nulon pm chm In
L D'DD'vIv mm!

 

OIL HOLE "IN" MARK

Alton "u hole m the connect-n9 vod bunnfi mart
wuh the hole m the connaclmo rod Ind mnnll (h!
mu"

OIL HOLES

12-13

CRANKSHAFT/PISTON

 

 

Install the connecting (06 can bnanng insert
Apoty molybdenum disuHide grease to the connect
mg rod bearings

Coat the cylindeu, piston rings/grooves and pistons
with oil.

Install the cod and puston assamblles Into the
cylinder: 1mm the top of the crankcase. Be sure
each assembiy is returntd to Its oriqmal posntion as
noted dunnq removal.

NOTE:

The pitch iriake "I—Nr matks should be
tacmg each other Ii shownt

 

 

Compvuss the puston tings with a nng compvcssor
and Insert the ptston and rod Into the cvilnder.

NOTE

 

‘ ' Be caraful not to damage the DISIOHS or
rings dullflg assembly

\ ' To mevcnt damage to the crankpin iour~

nais, slip short actions at Iubtm hose over

[ the rod bolts before Installation.

       
 

 

CONNECTIN ROD BEARING

"IN" MARKS

PISTON RING COMPRESSOR
(Commerczally avatlablu)

Install and tovqua [he connacxmg rod caps.

TOROUE' 30-34 N~m (3.0—3.4 kg-m, 22—25 ftJb)

NOTi
[ - Ba sure me bear-n; caps aw mulled m
‘ [hell currem Incation as mavkod during
VEmOVBl
- Tlgmen the nuts m two or more steps
Aher ngmen‘ng the bolts, check lhaz the
rods move Yreelv without binding,

L”

;,

Assnmblo the crankcase (See page “~31.

CRANKSHAFT/PISTON

 

 

12-15

TRANSMISION

30—40 N°m
(3.0—4.0 Ito-m,
22—29 h-Ial

Q M ‘53
2% <53

(10.0-12.0 kq-m.
72-87 h-Ibl
”—90 N-m

' a 7040 N-m
(an—on mu. 55-65 mm a \ (1.0-3.0 hum.
s \a \s: .53 mm

   

13-0

I3. TRANSMISSION

 

 

 

SERVICE INFORMATION 13-1 COUNTERSHAFT INSPECTION 13—10
TROUBLESHOOTING 13—2 SHIFT FORK AND SHIFT DRUM 13-17
TRANSMISION DISASSEMBLY 13—3 TRANSMISSION ASEMBLY 13-20
OUTPUT DHIVEN GEAR COUNTERSHAFT 13—22
REMOVAL 13—9

GEAR TOOTH CONTACT

PATTERN CHECK 13—14

 

 

SERVICE INFORMATION

GENERAL

mewmmw Wldfi’vefl’lulifl.

Th- '“l'l link”! an b0 untied mm Ibo anom- m "I I'm (Sect-on 8)
F0! ant-mu hummus-on noon, the animal mm 00 mum [Sou-on HI.

Whoa mm. m 10d: nut wnnch. um ldo'hctingbum w Imam wand! 14-20 menu Iong. Th0 lad! nu! m m

m (Micron. munch‘l m, mflwtmmnfinfilmwfllhummtmmmwumom-Ina
out. The meihufion ohm: Is tho mum locum undid In KM lock nut. no! the reading on an Iowa. munch mm um
wnh I» lock nut munch. The [Drum mm gale rudmg In W with the «null torque swim-ton.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD sanT/Ica LIMIT ‘
TrInIquIon emu-m low 0.0094170 mm (00035-00070 in) cm mm (0.000 In)
M. 3m, 4m. 50.. em ' 0000-0130 mm mow—0.0054 m 0.10m (0.007 MI
, 4. ‘‘‘‘‘ _. . , 1 ,.
t691:”). us,m,cz.ca.C4 I31.000-:n.0usmm(12205—132211an) nuamumh)
'gfgmw" us.m.c2.c3.c4 ‘30350-30.015mmn.2105-L2195an1 Jonamuuw In)
Eff Mi" 155.0 21.005.20.010mmn,1022—uoaom mesa-n11.1uw
1 mm on. i at us I 2Tflfi:27_.MnIm mars-1.1020 5.031.130 mum In)
v I —- "H T
3%"“""" 0104 27971—27soomm mars-1.1020 my 0 21.92 mm ".000 In)
sou-mums”. M5. M0, c2. (3. u ' .
a mu wam‘mm 0025—0000 mm memo—00020 m 0,0 mm (0.000 in)
dunno. ‘
if"? “WW” onus-0.030 mm mom—0.00m") 0.05 mm (0.00200
sum lurk em thickncu d 0.63—0.00 mm (07263—0250 in] 6.1mm (0.2. In)
|.D. Lck .na mm 04900—14010 mm “15511—0561“!!! 14.05 mm (0.553 In)
Fort mm 0.0. 7 13300—11004 mm «0540-0550 in) 13.00 mm (0.541 N

 

 

 

 

 

 

 

13-1

TRANSMISION

 

TORQUE VALUES:

31—34 NM (3.0-1! ko-m. 22-25 h—bl
33-40 N'm (3.0—4.0 I‘M, 22-29 h—Ibl
90-110 Mm (lo—11.0 Ito-m. H IND!

Omnp-mbuvhgm
Dummy-reu- lmwdmhou
Output cur buying lock nu! (Gum)

Hnnorb 70-80 Nun (7.0—8.0 kw. 51—58 VHb)
Count-um" our During lock nu!
(Ouw) non—120 N'm (10.0-12.0 lam. 72-87 «45)
(Inna! 30-90 N'm (80—90 Rim. 58—85 h-Ibl
TOD LS:
Social
Lad: mu mm. NIH mm omn—uaooooo
Lock mum. ‘ZMM OHIO—Mm
M hold-v men-mom:
Buying mm, W mm 0793-37103!)

Rumour Pundit
Rumour wulgh!

0mm

Dam

HIM, 3) mm

Pilot. 35 mm
Mud-mom. 62 x 88 mm
Amchmm. 52 x 66 mm
Amdmnm, ‘2 x 47 mm
Pum, 17' mm

Duvet

Amchmem. 1) mm

TROUBIISIIOOTING

Man! In am

I. Clutch It." cvllnon sticking
2. Shih fed: ham

3. shih shah ban

4. Shih claw bout

5. Shin dmm com grooves dunno“!

0193-3710100}, 0! Boating "my ”10793-371!!!”
0793—3710200

OHIO-Wm ov DIM ("m—611w
071mm
077%
onu—omosoo
WHO—M10441)
WHO—0010“
077W
ownz-ocamoo
mus—comm

Tun-allia- in. m a! '-
1. 60¢ do. worn

2. Shut duh ban

3. sum drum stoop-v brolun
‘. Sm" 'orks bum

 

1 3-2

TRANSMISSION

NOV!

For aqua-n9 l'w gunk-4h Imkeg. see Secnon 8

TRANSMISSION DISASSEMBLY

Saoarue Inn c'ankcaw (Sutton 11)
Remove nu.- dowel pln hum the crankcase
Imp-CI mu lmckmh 01 “ch qur

SERVICE LIMIT.
Law 0.24 mm (0.009 in)

2nd, 3m, 4th. 51h, 80!: 0.18 mm (0.007 in!

 

MAINSHAFT

Heme" lhe mammal!

Remove the mumunmn wuh the C1, C5. C2 and
C3 gnu, m0 [he mime washen. clam washen and
bum-lug: 1mm the cvanhcase. Pull the coumershah
on! u! we cmnkcw: mm m remaining 9mm.

 

C3 GEAR C5 GEAR

Remove rm: counwu'uh hum the oulpu! gear
cue

Index the cwnmuhln belting holdar lo the outpu!
9n: cue, lm My: 0! reassembly.

 

C2 GEAR C1 GEAR

TRANSMISSION

 

TRANSMISSION INSPECTION

Chock gut dogs. dog hoI-s Ind lmh Io! axe-sun
or Ibuormnl won, at awdcncc o! Imumcicm
Iubrncmon.

Muwu the ID. of each our.

SERVICE LIMITS:
'5. m. CZ. Cl, CO on". 31.1. M (1.2” HII

Menu" me I D and 0.0: a! 1M gm hummus:

SERVICE LIMITS:
II. us. ca. (nu—Mb. 0.0.:
M Inn (1.21! in)

“. OI [I- m l.D.:
nos Inn (1.10! h)

Manure (II. 0.0. o! the mammlfl Ind «mm»
mm

SERVICE LIMITS:
A In“ Min): 21.92 mm (1.0“ "II
B (II C‘ balm): 17.92 "In [1.0“ IIII

Calculuc (M dunno! Damon IN on! ma out
mm at bum-no.

‘ERVICE LIMITS:

I“. I“. C). C3. (:4 "In-India:
OJO mm (0.004 III)

M5, 03 out Mlnfmm:
0.05 mm (0.002 MI

 

 

 

 

 

 

13-4

TRANSMISSION

DRIVE GEAR REMOVAL DOWEL PIN

Remove :hz nowel pm and Ornngs,

 

0 RINGS

DRIVE GEA\H SHAFT OUIPU? GEAR CASE

Nam: me oulpul yea: case In a visa wnh so" iaws,
being careful no! to diston the case.

Place the shaft holder Kool on the oumut driven gear
shaft wedgmg it auainn the vase (o lock the shaft.

Unstake (he ‘nr‘e! bearing race vock nut wuh adn'l
or 9mm?! 3? cavehu that I'm-[3| parhclcs do not
enter the Dearlng and that the threads on the man
are not damaged.

SHAFT HOLDER
07 32376890101

 

 

Remuve the ‘nner bearmg race lock nut.
Discard the nuts SHAFT HOLDER LOCK NUT WRENCK 42/56 mm
07923 , 6890101 07916—M840000

/

    

 

 

 

 

 

CCUNTERSHAFT‘

 

 

13-5

TRANSMISSION

 

 

Ramon mo cmnmwm bunng holds: no!" mo
holder hom 1h. can.

Remove the output drivu our .nd uhim.

 

Place lhu counurihamholdm m a ores;

Prns [he countershlh out 09 the Deanna holde'

 

COUNTERSHAFT BEARING _ W , 7 r ,
REPLACEMENT ( 1

’» LOCK NUT WRENCH' 4756 mm
~07: \, 079167 uaaoooo

 

Th! counxavmall must be vernoved odor:
mpllcmg bur-n9.

Pllce 1h: bur-n9 holder «1 n ma wllh son mm
at shop low'l

 

 

NOTE

Do not damn: nae—bunng holder. upocully ‘
lho cunkcm mating Iurixc‘ BEARING HOLDE R

   

 

 

 

Unnike m. oulev use lod- nu! wah a punch

Remove the bunng cum rl¢l lock nu: wvlh I
Ipecial tool‘ Ducard {he lock nu!

 

— — — — — — r ~— -

13-6

TRANSMISSION

 

Place the bnanng holder In a pm“ and remove the
bearlno.

Press m a new bear-n9.

Plac- the bearing holder in a win with sch iaws
and Install and lighlan a nvw outer (not lock nm
to [he :pocilied torque valuo‘

TORQUE: 100—120 N‘m
(10.0—32.0 Ito-m. 72-87 fubl
Tomo- wnnch seal. nadlnu:

92-110 N-m I93-11.0 kg-m, 66-79 ft-IIII

Stake rm nM lock nuL

COUNTE RSHAFT INSTALLATION

NOTE:

 

The ooumomuft and drlven gear must be
repllud I: I set if they or the our use at
the boating rlquire replacement.

 

 

Plan "1! countershlh tnd ooumushlft baring
holds: Into I press. Press me acumen-shah imo the
bearing.

NOTE:

Place the minded and of the pllo: IMO the
onunuuhm.

 

I

 

 

Place the Idiusunent shim over the burlnu holder.

NOTE:

II (he counterlhnft/driven gut, having or
year case are replaced, I new adjustment shim
must be saluted (W 13-15. Buckllsh
Inmctlonl.

 

 

 

 

 

ATTACHMENT, 62 x 68 mm
INNS-0010500

DRIVER
077494010000

 

 

BEARING HOLDER

 

  

PILOT, 36 mm
MFG-W

 

 

\\

LOCK NUT WRENCH,
42/56 mm
owe—mum

 

 

 

 

 

BEARING HOLDER—

 

 

 

 

 

 

 

 

 

 

 

 

    

PILOT, 35 mm
07748-004080!)

BEARING HOLDER

 

 

 

13-7

TRANSMISSION

Plies me coumenmmbeanng holdul Ind curred
adjunmg sh'm mm the oulDul gen cue

Imul' {he be!“ and Inlmg «amen mm we cover
bracket

hymen the Dom m a erase-mu pan-m untvl m:
dme goal bunng holder sans loam“ the can
Tm" hghIen lo we modified torque,

TORQUE: 304” Mm (3.0—3.4 kvm, 22~25 fl-lb)

 

Face the case mm a use win so" HW‘ SHAFT HOLDER LOCK NUT WRENCHW
42/56 mm

Inn“ and harm-u a m-w Counlru'u‘l run to the 07923 6890101 p—r-Q‘, 07916—MB40000

‘09; has to'uut ‘ J“ \

  

I
YOROUE: 80—90 N~m (8.0-1!) hm, SO-GSHJD)

Tavque wrench sun vudmg:
73—82 N‘m (7.3—8.2 Ito-m, 53—69 9141:)

 

 

\ COUNTER SHAFT

L i i _ ‘4

Sun the [on flu! [ — *

 

13-8

TRANSMISSION

DUTPUT DRIVEN GEAR REMOVAL OIL SEAL

Remove the outpu! duven gea! ml seal 1mm xhe
output gear case

Place the output gear case mm a V524 clamping H a!
the shah shah smndle boss

 

l

LOCK NUT WRENCH, 30/64 mm DRIVEN GEAR

07915~MBOOOOO BEARING HOLDER
Unslaka and loosen the output driven gear bear-n9
Inner race Iock nu! using a special lock nut wrénch
and shaft holder.

  
    

SHAFT HOLDER BEARING INNER RACE
07923—889010] LOCK NUT

Remove the driven geav bearing homer mounting
bolls and remove me gear and bolder Vrom the case.

.I
BEARING OUTER RACE

HOLDER

13-9

TRANSMISION

 

O‘RDNG BEARING "OLDER

     
 
  

Rome" the sham and O-nng lrom (he bunnq
hold-I.

 

T? T V I
(RJlEJPLkJCEaflREINgN GEAR BEAR NG LOCK NUT WRENCl-L ‘

30/84 mm

Plot! the outpux any-n out bunny holdm mu: 5
ma mm so" im Umuh And remve lM ouxoul
onvm guy bunng nun! rm lock nu! 0mm ml
hold"

Fun the output dmon 9m hem (h: hoIdnr

 

Flu: the hey-n9 how" m a mess and pun (M v _]
bunny out DRIVER

07749—0010m0
”on

 

Bo careful 00! m dunno. the bunng holder
DIM can mating “Mm

 

 

ATTACHMENTA 52 x 55 mm FILOT, 30 mm
WEB—0010400 DUMB-0040700

 

13-10

Press In a new bearing Ind make sure il routes
freely.

Place the blaring ho|dar mm a me wirh soft jaws.
Install and tighten a new bearing ouxer race lock
nut to the specified torque value.

TORQUE: 90—110 N-m
(ED—“.0 kwm. 65—80 INbI

Torque wrench ml. reading:
82-100 N-m IGZ-‘IOD ko‘m. 59-72 I‘Hb)

OUTPUT DRIVEN GEAR
INSTALLATION

NOTE,

 

,

‘ When the gear set, driven gear bearing and]

or gear case has been replaced, use a shim
0.30 mm (0.012 inl thick for initial re-
feronee.

 

 

Place (he output driven gear bearing holder into I
press.

Then press in the output driven gear.

lnstall the O-ring and some! shim. See page 13-14
for thim Ieieclion procedure.

TRANSMISSION

 

 

 

 

 

DRIVE R

07749—0010000
ATTACHMENT 52 x 56 mm PILOT, 30 mm
07746—001040!) 0774649040700

——_J

 

 

LOCK NUT WRENCH

30/64 mm
07916- MBOOOOO

    

BEARING HOLDER

 

 

 

13-11

TRANSMISSION

Much the Dunno holdev to the gear case mm
[he (our he: non; Tugmen ma bum m a ammo“
pumn m mo 01 mole "em

TORQUE: 30—34 Nvm «3.0—3.4 kqm, 22-25 h-lb)

 

 

  
  
  

-‘
l v hr n” bk 1 ohm. .
.3125: °‘ “ “ 9 " \
‘ LOCK NUT HOLDER
TORQUE: 70 40M m l7.0~8.0 Ito—m, 51—58 'Hbl ‘ \ 07923—68901!”
\
Torquu wnnch male vudmg.
64—73 N-m (GA—7,3 ligands—53'1“!)
;‘;\ fl
LOCK NUT WRENCH,
306-! mm

07916-—M800m0

Sun bow new lock mm and Irma” a new ml Les! 7

 

STAKE OIL SEAL

 

13-12

OUTPUT DRIVEN GEAR CASE
BEARING REPLACEMENT

Hui the onion: quv can mound ma bunnq m
80°C (178"H

caunou

,— , fiifi — _
Aft-my! wan (film when handbag a ham!
(car an:

Remove m- bunng *4" me Durnq Vernon!

Dku a new Dunno mto the output gear case

TRANSMISSION

    

BEARING

BEARING REMOVER 17 mn-
07936—97103“)

HANDLE WEIGHT
079364110100 0793G—3Il0200
DRIVER 077“.) 0010000

 

  

ATTACHMENT_42147 «rm PILOT U rm
077‘670310300 mus—0040400

13-13

TRANSMISSION

 

GEAR TOOTH CONTACT PATTERN
CHECK

Home" "1- 11m. and dnven nun (papal TIT-5‘
13-8).

Apply Prussian Blul lo m- dnvln out tum

Inn-H m dun and duven gun wnlh [M sundard .
than:
Rum- !" arm 9er mm hm“ m the normal
duuchon ol rob-hon, : - '
Remove [he drivn gear and truck the our zoom I!!!
contact pumn,
-

  
  

A. .d

 

 

fl
Oonucl II nonml I! Pruw‘un Blue n "mum DRIVEN
to m. Doro-vi“!!! comer 0' nah room ma H-ghlly GEAR' AFT
lo lhl ma .S)\‘l\ I %
\\
\
AA \
SHIMS j ‘
‘j‘~cou~TER5HAF1
NE
f} I TOE “ NEEL
FACE, ‘
’ CAET‘
. ,, DRWE
"-“N'd SIDE sms
A —.‘
H m. oluom II not correct. remove Ind taping the r—’ —' ’ 5 fl
duvnn on: ndpunmenl Shlm 1—“
_/'J . \
Realm mo mum mm a lhmnal on. .1 [M conuc! , m\ 7
Mum: u too high \‘L—v K
x
.3‘ 7“ r
\ , , <3 I \\
‘4;th ——‘ ‘
K r

TOO HIGH 5_[

‘ACE FACE
‘ 1 Ci 7% T
DRIVE SIDE COAST SIDE

 

13-14

Replace the drxven gear adjustmen! 5mm wuh a
thicker one If the contact IS (00 low.

The pauerrr ml! shin aboul 1.5—2.0 mm (0.06—
0.08 In) when (he U‘Hckenss DI [ha shlm (5 Changed
by 0.1 CI mm (0.004 m)

OUTPUT DRIVEN GEAR ADJUSTMENT SHIM:
0.40 mm (0.016 In)
0.45 mm (0.018 In)
0.50 mm (0.020 in)
0.55 mm (0.022 In)
0.80 mm (0.024 In)

BACK LASH INSPECTION

Place the output gear :35: In a vrse with son jaws or
a shop mwel.

Set a horizontal type dral Indrcalor on the counter-
shaII as shown.

Hold (be driven gear wrth the shaft holder and
rotate the countershaft by hand uanl gear slack Is
taken up.

Turn [ha couruershah back and I13th 10 read
backlash

STAN DAHD: 0.08-0.23 mm
(0003—0009 in)
SERVICE LIMIT: 0.40 mm (0.016 InI

Remove [he dIaI Indicator. Turn the counlershan
120° and measure backlash. Repear this procedure
one: more.

Compare the diIIerence of the three measuremems.

DIFFERENCE OF MEASUREMENT
SERVICE LIMIT: 0.10 mm (0.004 InI

DRIVEN

GEAR/SHAFT

TOO LOW:

I
FLANK

ff)

"DRIVE
SIDE

    

COAST
SIDE

TRANSMISSION

 

COUNTERSHAFT

I

FLANK

 

 

 

 

13-15

TRWI$ION

 

II (M difllrtnm in manual-mints 9:1de "I.
"ma, N indicates um "I. bunny Is no! inn-"Id
mun-ow Impact nu bunny and run-mall i( man-
my,

(0 Indian :5 um”, "ulna nu cont-mm"
on: adjunrmm shim with 3 Wm m.

I! mo backing: is no mall, mm me count»
duh mm with I New om.

Backluh is char-old lav About 0.06—0.07 mm
(am—om: m) Mm- miclmcu of IN min (I
w by 0.10mm to,” in)

OOUNTE RSHAFT I001?!" DRIVE GEM
WENT SHIMS:

0.30 m (0.012 in)

0.35 mm (0.014 In)

0.40 mm (0.018 in]

0A6 mm (0.018 in!

0.50 lllll (mm In)

0.56 m (0.022 in)

0.00 mun (0.024 in)

BOUNTERSHAFT INSPECTION

”0'1

IMMWMIonmmb-w-
, (and w you uni-u my oi m-
foliomnonm.
‘ ' CrmkcudSIcflonH)
- Coumcrshnft hurinHSoctlon H)
' Countershah

 

 

 

Inn-lim- Wmmmfilvmmm
omo IN lover an
Ammo tho tut-mm mm mu 0'th W.

Mun": 1h: dunno. buwun the bum-o and
Ion-r with a (vol-r gluon.

CLEARANCE: 01—0.. nun (0.010405 in)

H m charm um um mm. m u w to
eon-n m- m dunner

”AC‘R/T‘ucxum:
0.“ m (0.033 (0'
0.” mm (0.03 In)
0.06 mm (0.037 in)
1.00 mm (0.0” In)
1.05 mm (0.0“ In,

 

13-16

 

 

MI"

 

 

 

 

 

 

 

    

FEE LEN GAUGE

 

 

 

 

 

 

SHIFT FORK AND SHIFT DRUM

REMOVAL

8.06 the lock wash" uh down and rmovt the
ClnIIr Vovk mourn-n9 bolt.
Roman mm mm Iork uhah and 5M! Iorks

Remove the bay-n9 nope-e1 planes and {M mm
dlum

GEAR SHIFT DRUM AND SHIFT
FORK INSPECTION

Impecv m: cm drum and Io: scormg, scratches,
o: undone: a! unwmcuenl Iubncahon
Chuck 1M mm mum grooves Ior damage.

CENTER FORK RIGHT FORK

LEFT FORK LOCK WASHER

SHIFT DRUM

BEARING STOPPEfl PLATES

TRANSMISSION

FORK
SHAFT

 

 

 

13-17

TRANSMISSION

 

Imp-c1 m: mm dvum halo mm! mm Iork shall holu
Iov wormg ov scramhu‘

Mum's [he mm Invk mm 0 D a! nun: and um
um Io'k furious
Check '0! scratch”. Kenna 0v evtdenc! 0' mw'
hcmnl lubncatmn

SERVICE LIMIT: 13.” mm [0.547 in)

Menuu the ugh! ind m: In.” Oovk I70
Mum's the 5me fort on Imcknms

SERVICE LIMITS:
ID. ("am And loft IorkI 140‘ mm (0.553 MI
CLAW YHICKNESS: 0.1 mm (0.24 in)

 

13-18

 

 

 

TRANSMISSION

 

 

INSTALLATION

Inn-II (he mm drum

Apoly l lockmg arm m me screw [mum and
mu.“ IM Dunno nova" plates

Inn-II "w mm mm and $313".

CAUTION
I [ruin]! the sin/I fork My 10 mm m: mum]7
1 end :1 Inward "I! left tide. J

 

Inn-ll m- Iock wnhu Ind Ughmn the an"! Iovk
boll,

TOR OUE: 16-20 N-m (1.5—2.0 kn-m, 12-14 beI

Send an Iock wuhev tabs up.

 

SHIFT DRUM

BEARING ST

CENTER SHIFT FORK

FLUGG DEND LEFT FORK

 

 

OPPER PLATES

RIGHT FORK FORK SHAFT

LOCK WASHER

  

13-19

TRANSMISION

 

DRIVER

TRANSMISSION ASSEMBLY omo—ooamoo
MAINSHAFT

mm" m mumshnh bearing wlm ml spacial look
II Ihown

 

ATTACHMENT. 30 mm ID.
07745—003030!)

Mmemlovhmo'mxovmu
“ocean-cm

and: Min-wrinuunmdmlhuwm

MAINSHAFT

  

 

13-20

TRANSMISSION

CDUN TERSHAFT

Before placing the coumershall in (he crankcale,
install me (:4 and C6 gears, washers and collar

 

C4

C3 GEAR SPLINED COLLAR

Install the C3 gear and spluned collar.

Install the stoppcr washer whrle aligning the tab of
the swap" washev with groove in the splmud
collar.

Assemble the CI C5 and Cl gears. washer: and
collars‘

 

TRANSMISSION

1M1.“ mo xowu cr-"hcau 19:12: to Semen HI

NOTE

 

7 Wiin
Chnnln the ad nnhce Iov coggmg, b10019

mnalllnq lhd low-v crankcase

 

OIL ORIFICE

13-22

 

MEMO

DRIVE TRAIN

8mm 223—28 N-m

[2.3- 2.8 kg—m, ”—20 11-")!
10 mm :45—50 N'm

(4.5-50 kgm. 32—36 fl-Ib)

 

100-420 N-m
(10.0—12.0 kg-m, ‘3
72—87 Mb» 0 ®

    

14-0

(6.0—7‘0 Rpm,
43—61 hvlbfi

I4. DRIVE TRAIN

 

 

SERVICE INFORMATION ‘M-I
TROUBLESHOOTING 14-2
FINAL DRIVE REMOVAL 14—3
DRIVE SHAFT 16-3
FINAL DRIVE GEAR 14-.
FINAL DRIVE INSTALLATIW 14-18

 

 

SERVICE INFORMATION

GENERAL

0 Thohulom-wnnmblv «want-moved mmlhdfinm.
o Realm 3" oil nals nd O-nngs Manon: 1M find diivl 9.. mm It GWV
o M toomconmp-mmndo-uhxkhm immunimwmuworw numb-mm.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Final gm oil Cnpnclly 150 cc (5.1 015) um dilunmbly —
Hammond-d all vaok! our oIl: SAE m —
Guy backlash 0.08—0.18 mm mom-onm In) 0.30 mm (0.012 in]
GI. may weioad 0.2—0.3 h-m (2—3 Ito-m. 1.7—2.8 mu) —
Dunn can oil swanky 60 cc (1.7 all —
Draw can spring m. length 5 mm I10 In) C! m I15 in)
TORQUE VALUES
Pumon bunng unit-er 100-120 Nm (10—12 Ito-m, 72-07 h-IbI
Pinion nu! 100-120 N-m (10-12 kn-m, 72—87 fl-Ibl
G"! cue cover boll IO mm 45—50 N-m (4.5—6.0 Ila-m, 32-80 n-lb)
3 mm 23—28 N-m (2.3-2.8 uo-m, 17-20 (Nb)
Final cur can “15qu run 60—70 N-m (GD-7.0 krm, 43—51 h-Ib)

 

14-1

 

 

DRIVE TRAIN

——

TOOLS

Susi-i
Attachment C
Retainer wrendi
Pinion holder
Shift puller

Driwr
Amer-mom
Annehmom

Barring nee inert machrnenr

Atuchmnm
Amdimenl A

Common

Driver

Armament, 42 x 47 mm
Attachment. 52 x 55 mm
Amchmom. 32 x 35 mm
Film. 30 mm

Driver C

Atuchmem. 25 mm 1.0.
Shock «mm: comprise:

TRDUBLESHOOTING

Exuuin noiu

owed—M30030!)

07910—40301“)

own—memos

07931 —ME40000 0r Pinion pull" at 07935-M500000
or Pinion puller 07931—46302!” and
Pinion puller Inachrnml kit

0793i ~M30m
079494110001 or 07969-47101!)
079474340201
079454330100

07931—46303!” or Fork In! driwr 07847—371010! Ind
Attachment 37x40mm 0774841010200

07945-33303“)

07964-MBW100

07749—001“)!!!
07746—0010“
ands—0010400
07746-001011”
077484040700
gzzzgjggggggj or Driver 07945—3710200

07969-390001

1, Worn or scored rlng gear mm and driven flange

Worn pinion and ring gear:

ampugu

. Oil level too low

Oil Ink

1‘ Clogged breather
2. Oil incl loo high
3. Seal: dun-pd

Scored drivan "once Ind wheel hub
. Worn or scam! drive pinion and splines

. Euoossiv- blcklash bctwecn pinion and ring gear

 

14-2

FINAL DRIVE REMOVAL

Pug. we mOYD'cycw! on A man." “and D's-n mo
IlnaI gem a" lnloe 7-IOI and Vemou the rev wheel
(on! 16 3'

Place an ad dam on undnv the gear case and mono
lrm mnmo lumen to cuch any dampev am on
that may leak out dunnq removal of the geav use.

Remove the Imol gur case attaching nuts and
remove: 1m.- wan! cm ‘vom Ihe swingarmv

DRIVE SHAFT

REMOVAL

II ma mwauhm came out of the swingarm lfllch
ad lo (ho hum! new Gav “mm :1 W5; removadl do than
foilowmn

Inw! the "In :hmugh the gear case and secure [he
can In I mu wuh ml! lawn or shop vags Dy ciamn
mg "w a-Iu PI-cu me mock mounx between lha
iawx Io: nabvlu

Pvncu m o» dun-n nan unoev the damper cm 10
cucn [he dumpw on that M‘ EDI“ om

Scum-u ml damper .m‘x Ivor“ I’ve gear use by
germy Inch-no the drum-1 In I c'cuIav Mohon
wmln mm Hg mum»,

Aha "mun no l’\¢ ‘unwe' u“-I "om me gem case
remove Ind d-suru me outer “on r‘ng um hn m
the groove on me [Mr-ed end 09 mt Carnot-v T511
I-nq sewn m .u~ m In Mm omduchonr and should
no! he munl'et! when the Ina‘ mwe u reassembed

DISASSEMBLY

Own the gem mI Ivnm xhe damper case

Remnva Ihl' lam! whna cl‘p Irom the damper Cam
la in”! unnaunu 1.

Common :hc awe mm w-th xhe veav shock an
sorbet anpvcnov Ind alfachment mok

DRIVE TRAIN

 

FINAL GEAR CASE

 

Pull «hula
mvo vmq.
I .—

I“:

  

CUTE? STD? RING'
Dvhcud -l

I Aluzflmonl A
07964 MBUOIOO

 

 

<- 7 7 , as” suocx
' ‘ , _ '- ABSORBER
.1; , cownesson
. ‘ 07959 7329000‘
~ 7, Anachmam C

07969 14500309 I

 

14-3

DRIVE THAIN

 

A HONDA

\fl ' V65 SABRE

 

Ramon Inc mung “or; H»; 3"" an: shah "arr
m. comprouov

Homo" (he mum) no: danger {am 5‘1!) damp!"
Mn: "om [M an" mav-

Check lh. dlmoev MT-J 3N1 car.— mv wer 0'
durum

CAUYIOM

Duran! Ihr xlup ~ng and {rum/I a Iu'u' um-
upon rmnrmhlv

anovo m: u‘ um and m we: guV’JV‘ born the
damn! tau
NOT!

Regina "11! ml seal with a new one .' u s
removed

 

14-4

SPRING STOP RING

    

DAMPER LIFTER DAMPER CAM

/"
SPRING $70? 570? RING

OIL SEAL GUIDE

 

(,1
/

DAMPERCASE OIL SEAL

DRIVE TRAIN

 

Remove the damper cam sprung.

Measure the damper cam wrmg free lengm
SERVICE LIMIT: 83 mm (2.5 in)

Remove the damper case and O-nng 1mm the Grave
Shlh‘

lnspec! the O-nng and replace -1 if necessary.

Replace the damuev case on me dnve shall.

ASSEM BLY

Install the damper cam SD’IHQ mm the damper case,

Drive the oil seal gunde and oil seal in with the driver
Attachment and driven

Assemble the ramalmng aarls m the ravevse order
0! disassemblv.

NOTE.

 

 

Replace (he 04mg, 0:! seal and slap ring with

 

‘ new ones when (assembling the draw shah.

 

DAMPER CAM SPRING

 

ATTACHMENT, 52 x 55 mm
0774643010400

O-RING

F REE LENGTH

DAMPER CASE

 

DRIVE SHAFT

DRIVER
077490010000

   

DIS/ASSEMBLY TOOL

D7964—M340100

14-5

DRIVE TRAIN

 

FINAL DRIVE EAR DISTANCE COLLAR

RING GEAR REMOVAL

Rumovo me distance collu‘

Romovo 1m dun guard plu- bolu‘ Home" the dust
gum! all“ by mmmg ix clockwiu

    

DUST GUARD PLATE

CASE COVER

Roman IN ugh! can con! Dam and cove: H the
lung out luv; :0 (he conn do my 1ollawmq

Plan tho com m I pass mm m vmg p. down
Man an. m can: is null mpponnd

Pun mu rung our out a! th- <ovor vmh drivev
07749-00100“) and lunch-mum 07746—001010!)

 

O’RING GUIDE
Roman m ring gear 1mm the “ml draw as:

Roman IM Dung @de by uppmq :1 ham the
oppomo undo

 

RING GEAR

 

14-6

DRIVE TRAIN

 

RING GEAR BEARING REMOVAL

Ramon "w nag guv button and our Idhmmg
mm:

CASE COVER OIL SEAL REPLACEMENT

Rm the oil too! from mammalian-as
m I "W onl Hal,

PINION GEAR REMOVAL

[mull mo pinion hold" onto the pinion IoIm
and "move [he onmon inf! nu!

Roi-now mo tool and pimon jaunt

ATTACHIIENT, 32 I 3 mm OWN—WWI”
PILOT. 30 mm onu-oounoo

 

 
   

RING GEAR BEARING

 

BEARING FULLER
ICOMMERCIALLY
AVAILABLE)

 

 

OIL SEAL

 

 

PINION HOLDER
OWN—Mm

 

 

 

 

14-7

DRIVE TRAIN

 

LOCK TAB

    
    
 

Ramon IN mu ner lock uh

m

RETAINE‘! WRENCH

07910 MEBOOOO
RIMOVI ma pmlon ran-rm M"! the Iock nut
wrench

PINION HOLDER D7926~ME90W0 OR PINION WITH SHAFT FULLER

07931 MEMXDO 07931—MBOOOOO W‘TH PINION
PULLER 0793l74630200
PINION FULLER

Pul| of! ma DII’UOI" Mummy with {he mmnn puller 079354;,1300000

\

14-8

Q HONDA

V65SABR

 

PINION BEARING REMOVAL

Ramon (he Owing from the Din-on shaft.

PINION RETAINER OIL SEAL
REPLACEMENT

Remove [ha O‘rmg and all seal fmm (he pxnuon
ratainnr.

Dnve a new owl seal mm the velamen

Coat a new O-nng wilh on and Install I! come the
mainu

 

 

DRIVE TRAIN

O~R|NG

 

DRIVER

OIL SEAL 07749700I0000

     

r.

PINION RETAINER O-RING ATTACHMENT

DRIVER 07945—3330300
077497 OOIOOOO

ATTACH M E NT
07945 -3330100

 

14-9

DRIVE TRAIN

CASE BEARING AND OIL SEAL ams GEAR BEARWG HNION BEAPHNG
REPLACEMENT

Heal Ihe out case to 80°C (178"F) Tap the new
cast wnh a plague hummer and remove the mm
9:: no pumon bunnq

HEEML ,

‘ Alwyn war glow; when handllnl the (m1
my ajm i! ha: been healed.

 

 

 

NOV!

Use bnnng ramionr, 35 m:07939~3710400
to «move ring our case bunny

 

 

DRIVER
OIL SEAL 07149701010000
Ramon the nng guy mm on all

Drwu I new onl sul mm m: can, using lhe spam-I
tools shown.

 

DRIVER ATTACHMENY
07749-0010000 or 07945—3330300
07949—37 10001

Dwe new Dmtc" ma nng 9cm bnnngs me I"!
can

.

      

AWACHMENY 37 t 3‘1 m-r- AWACHMENT 52 x 55 mm
0’745700‘0100 07746 41010400

 

14-10

BREATHER HOLE CLEANING

Remow me manner hole can and blow Ihmugh the
mum" hole wsth compresud IH

PINION GEAR ASSEMBLY
lmu‘n In: Ongma- pmon gca' mica

No"

When the geav set, pm on b0ann9 AndWm on!
case has been rcplacsd, uu I 10 mm thick
103C"

Press me bunny onto (he mmon gulf 0h." wdh ma
mean! look Ihown

Imull I new 0an over the pmuon mm

 

DRIVE TRAIN

CASE COVER

PINION BEARING PINION VACER

 

 

DRIVER

omv an
on 07945—3710200

D77d&0030100

   

ATTACHMENT 2!: mm I D
07746~m30200

 

14-11

DRIVE TRAIN

 

Flue. the pimon numbly mlo Im on: houxmg
Dun me pumon crumbly into IM on: cue unm

ma pinion mam "wood; can on” mm mg I:-
threads.

Apply our oil to IM O-ring and thvuds on 01.
pinion renlnu. lmull an O-ring gust!- tool

Scruw m m. plmon uuinu (0 pm; on pinion

baa-no in plan. than (mun II l0 mo who
locum.

TORQJE:
Im—‘IZO "1'! "0-12 krill. 72—07 h-lb)

RING GEAR ASSEMBLY
Install the odylnol W onto the rmg out.

”011

 

II the gut Ill. plmon bunng‘ vmg can buy.
lng Ind/0v gut use ls upload. lmull a 10
mm thlck wlcu,

 

Plan: a m rung my hearing on an no. out mm
Place [I'll old bur-n9 on top 0' u Thin, drive the
am bnrmu onto lho shill with m old boring and
alt-durum, Than roman mo old buvlng‘

      
 

ATTACHMENT RETAINER WRENCH
079I0~46ZKJIOD

07931 —4630300

 

RING GEAR BEARING

 

ATTACHMENT

07947—634020!

 
  

OLD BEARING

DRIVER
’\ 07749- 0010000

:1”)
1/

  

 

 

 

 

14-12

lmull 1 new Owing on m! 0 "no uuvao
Apply grease lo the 04mg and arm nu: 04mg

guide emu ml [inn gear shift.

Imull Ihc ling our unto the gem an to":
Muwm lhc (Jeanna Inlwnn mo mug an: 3nd
the “no you stop pm mm - lulu our

CLEARANCE: 0.30—0.60 M (0012—0024 III)

II m. cluuncu "and: m- nrv-co limit. "move
ma "no our. Hut the near an aunt I0 approx-
muovly 80°C “76°F! and "move Iha “on pm by
[memo [ha covor

Hwy: mu! glow: when ihudlIu‘ Ilk- gm
an: .110 ll ha been halal

 

lmuH a now am mum to com-on mo count ctur
Inca

SHIM THICKNESS: A 0.10m «0.004 In)
B 0.15 mm (0.006 In)

Inlull nu 1mm and dnvc me flag pm mm 1M can
COVHV

 

 

DRIVE TRAIN

 

Dawn
0 mus GUIDE came '61 owe—0010000

 

AT‘IACHMENT, 42 n 47 mm
mus—0010300

 

GEAR CASE COVER STOP PIN FEELER

GAUGE
Sm? pm
awe GEAR
'; 0 30—0 so mm
I IOD‘2-0024 ml

 

 

 

 

 

snw PIN SHIM

 

 

14-13

DRIVE TRAIN

 

Clun III snlmg mum! 0" ma “1.le NH” 01
the our can and cover

NOTE.

 

{ - Kup dun Ind d-rl cm 0.1;. geér ml 1
80 cunlul ml to damage ma mumg I
surf-m l

 

Apply [laud lullm m (M mmng surhco a! ma
our cuu can!

 

WAVE WASHER PRUSSlAN BLUE
GEAR TOOTH CONTACT PATTERN
CHECK

Apply 3 mm con 01 Pruwm Blue to [M omion
9mm lamps meme-3mm mnunchodz.
Plot: tho um um 0nd "no gar unto me our
cut.

Apply on! all to ma Up 3! 1h. ml seal on me gear
cm OM! and nun-ll 1h: guy can om",

 

8mm BOLTS 10 mm BOLTS

Tigluan 1M cover bolu in 2 or 3 sum umll (ha
cover evenly mums [hi on: cut. then light-n m
8 mm bolts to "I will“! “you: in a cmlcrou
mum in no a: mom new.

TORQUE: 23-23 N‘m (2.3—2! harm, 17-20 fl-lbl

    

\

Tlghun KM 10 mm bolu.
TORQUE: HN-m (4.5—6.0 ku-m. 32—36 91-6)

 

14-14

IHKDEIEHK
V65 SABRE

 

DRIVE TRAIN

 

Remove (he oil filler cap from the (mal gear cm.

Rotate the ring gear several time: in the normal
dimmion of roution. Check me gear tooth com-ct
plnern lhrougi the oil (iller hole. The pattern I:
indicated by the Prussian Blue applled to (he
pinion balm assembly.

Contact is normal i! the Prussian Blue is transient!
to the approximate mm of each tooth rid slightly
to the flank side.

If the patterns are nol correct. remove and replace
the pinion spacer, Replace the pinion smcor with a
thicker one i! the contacts are we high. toward rhe
face.

Replace the pinion water with l thinner one If the
contacts are too low, to the flank side. The panems
will shift about 1.5—2.0 mm (QM—0.08 in) when
the micknesl ol the spacer is changed by 0.10 mm
(0.004 in).

PINION SPACER:
A 1.82 rnrn(0.071ln)
B 1.80 mm (0.0" IIII
C 1.94 mm (0.070 IIII
D 2.00 nun (0.079 In) Shaded
E 2.08 mm (0.“1 lnl
F 2‘12mm (0.084 ml
8 2.10am (0.000 In)

 

 

 

 

 

 

 

 

NORMAL
__I- - M’ h
A. TOE \

use? ‘ HEEL
FACE l FACE
:umu FLANK

COAST SIDE

DRIVE SIDE

 

 

TOO HIGH

 

 

 

FACE FACE

ififfi?

DRIVE SIDE COAST SIDE

l

 

 

 

PINION SPACER T00 LOW

 

 

DfilVE SIDE

com SIDE

 

 

 

 

14-15

DRIVE TRAIN

 

BACKLASH INSPECTION

Rumovi (he on! (Me! cap.

SM ma Iiml gear assembly into a No or “and (a
mud n nudv. Se! a honmmnl type dial Indicator
on thv "no any, throuyl the ml MI" hol-

HoId (h. pInIDfI out mime by hand Roma me 1mg
you by hand unlil gel flack u ulun up Tum the
1mg gm back and form (a read backlnh

STANDARD: any—0.13 mm (ems-0.007 inI
SERVICE LIMIT: 0.30 mm (0.02 In)

Remove the dual mdicnov Yum In nnq 93v 120’
and mum" backlash Rzpea! mu procedure one:
mono

Comm" m dMorence of m- muo mauummenu

DIFFERENCE 0F MEASUREMENT
SERVICE LIMIT: 0.10 mm (0.004 In)

II (he diHarunce m measur-menu "cum thl! lumll,
I: IndICIIII mm the bearing is not umullad mum-Iv.
hum! (he Danny; and mmul! II mcnuvy

II backlnh u too small. veal-ca (he "no gut spacer
wah a mum" one

Backluh a changed by mm 006—0 07 mm
(0 032-0 N3 ml when (harm; a! the want I:
chm by 010 mm (0.004 «(I

RING GEAR SPACER:

A 1.02 m10.072in!

B 1.08 mm (0.074 in)
C 1.04 mm (0.076 inI
D 2.00 mm (0.079 in) swm
E 200 mm (0W1 In]
F 2.12 mm (0.004 in)
G 110 mm (QM in)
H 2.20 mm (am in)
I 230 m (0091 it"

 

 

 

 

 

 

 

 

 

 

 

RING GEAR SPACER

 

 

14-16

 

.' ‘HONDA
\/ V65 SABRE

DRIVE TRAIN

 

PINION JOINT INSTALLATION

Inslall ma approprmts pvmm retamev lock lab‘

NOTE
fmare are two types of lock tabs as shown. J

Apolv new on! to the all seal ilD COHIaCY $uL’aCc
of (he Damon gem: and Install the DIV‘IO" mml

Install the pinion holder lool and fighter! the pinion
nul,

LOCK TABS

 

 

PINION HOLDER
07926751590000

 

' 'r
\
TORQUE: 100—120 N-m (10—12 kg‘m,
72—87 h—Ib)
Remove the pinion holder moi.
Make suve that me gen! assembly rotates smocmlv
wxmout bindxng by turnmg the punch ioinl.

 

DRIVE TRAIN

 

lnslw the dun 9.11m pm: and m’nm‘ H1! boll.
Inmu the munc. (CHI!

FINAL DRIVE INSTALLATION

F H me dampe' an a L! we recommendbfl {vDE
5nd amount of Iubucar‘:

RECOMMENDED OIL HVPOID GEAR OIL
SAE K80

OI L CAPACITY: 60 cc (1.7 o!)

Knmnq me darV‘Dm cue vertical‘ mac: me damper
mung onto the dumpev cam and rnuall me [man
dnve neat can own We damper cam

 

NOTE

Be cut-‘u: we! to damage we dampe' cue
cw seal Gunny numb!»

Du no! In :hl guy case way-h: ham ('1:
dampev can: at 04: ml wu'l mm mm

 

 

DUST GUIDE PLATE

\J
“

DLSTANCE COLLAR

 

FINAL GE

AR CASE

 

 

14-18

Mu: mu: 2-" .umng yum: s 1‘ me «19 me
as wannh Thu—- r‘u-t'. in: cmersran «no me
xw-nqav'r‘ alvqmnq In wines wzrf‘ IN uulev shah
xphnu Keen 1hr goav cam and damofl case together
01 campw o» w‘ll :uh (ml

Saturn the my use [0 the swmgarm wnh Me (hm:
anachmp nun To cau- axle nstal-atvon, do no!
“9N3" "‘9 0N" C4541 nun unm aher the axlu u
unnnllud

Imth the mar whom (page 168]

Lyman mp axlc rm!

YOROU E
85'105 N-m (9,5—10‘5 Ito-m, 61—76 h-Ib)

7.9hlefi the "we: 1mm 9“: rise éttachmg Hun
TOROU E‘ 50— 70 N 'm [6.0—7.0 kw, 43—51 ll-lb)

leltn m: ule v-flch boH
TORQUE 20—30 N-m (2.0—3.0 kgm, "-22 OHM

Make surc mu the drain Dan A (igmened
Remove the all Mlev can and pour ‘n ma spec-had
amount 0' mcommendud Ull.

RECOMMENDED OIL: Hyooid Gnu oil
SAE 4‘80

OIL CAPACITY
‘50 “(6.100011
1!) u (4.1 or! mun mu draining

j

FINAL GEAR CASE
ATTACHING NUYS

ovL DRAIN sou

DRIVE YRAIN

OIL FILLER CAP

 

 

14-19

FRONT WEEMENSION

 

30—40 N-m
(3.0-4.0 Ram. 22—19%")!

  
   
   
 
 
     
    

(2.54.0 hum. 18-22 “4!»

”—120 N-m
W/ (9.04m Ram. “—07 mm

943 N0"!
W con—12 tom. 7-0 mm

18—28 N-m
(LB-2.8 Ito-m. 13-20 h-Ibl

‘5—55 N'm

Its-55 kgm,

32-40 h-Ib
20—30 N-m
(ID-3.0 kg-m,
“-22 fun)

‘4-il OI-lb)

 

SERVICE INFORMATION
TROUBLESHOOTING
HANDLEBARS

I5. FIIONT WHEEL/SUSPENSIII!

15-1 FRONT WHEEL 15— 8
15-2 FRONT FORKS 15—16
15—3 STEERING STEM 15-30

 

SERVICE INFORMATION

GENERAL

I A iack or other support IS required to support the motorcych.

SPECIFICATIONS

 

 

 

 

 

 

 

STANDARD SERVICE LIMIT
Axle shaftprunool — 0.2 mm (0.01 in)
Front wheel rim runour» Radial 0.3 mm (0.01 in) max, 2.0 mm (0.08 in)
Axial 0.3 mm (0.01 In) max. 2.0 mm (0.08 (n)

When) bearing play - — 0.03 mm (Ii-om in)
Fork springirfe length 534 mm (21.02 in) 523 mm (20.6 in)

 

Fork tuba runout

- 0,2 mm (0.0) in)

 

Front fork Iluid capamv

Right 470 :4: (153 02). Left 495 cc (16.7 or) -

 

FIB"! fork 3" Drain"!

0—40 kPa (0—0.4 kg/cm2 , o—a psi] —

 

 

 

TOROUE VALUES

Handlebar upper holder
Handlebar pinch boll

Calioor mounting bolt

Front axle

Axle Dmch boll

Front Iork socket boll

Fork tube can

Steering hearing adiuument nul
Steering stern nut

Brako disc

Front lurk lop prnch bolt

Front for): bottom pinch bolt
Front Iork stabilizer bolts

Front brake master cylinder holder bolt
Clutch muster cylinder holdar boll
Anti-dive piston pin boll

 

 

30—40 N-rn (3.0-4.0 kg-m. 22—29 It-lbl
25-30 N-n‘ (2.5—3.0 Ila-m. 18—22 h-Ib)
30—40 N-m (3.0—4.0 kg-m, 22—29 ft-lbl
55—65 N-m (5.5-8.5 kg—m, 40—47 h‘lb)
20—30 N‘m (ID—3.0 kgm, 14-22 Il-IbI
15—25 Mm (III-2.5 Ram. "—18 It'IbI
15-30 Mar (1.5—3.0 Ila-m, 1 1—22 It-lb)
20—22 N-m (2.0—2.2 kgm. 14—16 It-lb) (Sta panes 15- 34]
90—120 N~1t (ED—12.0 Ito-m. 65—87 ft-ibI
25—30 NArr (2.5—3.0 kg-m. I8—22 't-Ib)
9—13 N'm IDS—1.3 kg-m. 7—9 h-lb)
45-55 "41‘ (4.5—5.5 kg—m. 32—40 h-Ib)
18~28 N-n' (1.3—2.8 kg-m. 13—20 h~IbI
10—14 N‘m (1.0—1.0 Ito-m, 7—10It-IbI
10-14 NAM (1.0—1.4 kg-m, 7—10 beI
20-25 N'r‘l (2.0—2.5 kgm, 14—18 ft-Ibl

15-1

 

 

 

FRONT WHEEL/SUSPENSION

 

TOOLS

lucid

Hex. munch. 6 mm

Snap lln' Dlilrl

Fork unl drivu

Fork lul drivm madman!
Sta-duo mm sock-t

Ball nu rumour

fin- mom Inch-mm
Stilt-nu mm drum

0mm

Cam

DIM:

Armament. 42 I ‘7 mm
Pilot, ls mm

Lock 0m wnnch. 30 x 32 mm
Exumion bur

Burma "mover Ihlh
Baum rumour had, ‘5 mm
Amman, 31 x ‘0 mm
Alt-amt. 52 x 55 mm

WU“

Mud nun-In.

I, Staring boning adjustment nu! we fly"
2. Funny «mm. mm bearing:

3. Dorms-d glaring mm boating:

4. Inwflicum tin pmsuu

lmtomwnovdoanmuuk mm

I. Unmly Ahmad mm and In" mock awn-n
2. Bum horn mm

1 Dan! hem ale

I. Who-l mull-d WV

From and Win.

1. Born rim

2. Worn hon! wheel During:

3. Fully turn

4. Axlo nu! light-Md impropuly

M amnion

L With M urinal

2. Imflicnm fluid in from for!“
3. From loci air mum- incur-ct

Had um

I. Inc-mot! fluid new“ m hum lulu
2. From mu: my arm" men-mm

3. lam 001k tubes

4. Claw-d "uki Image

5. Clog-d arm-dive onl‘m

From :0qu noi-

1. Wu": war or with bush‘mm

2. Inmflbcmn fluid in ion“

3. Leon mm out human

I. Lad our... m Wu who:

15-2

 

man—3230000 » n ma. In us».
079144230001 }°' ”mum V m.

GNU-WW

07047—KFWIOO

07916-37101”

MUG-3710600

07953-MJIMA (USLA. only)
(”W—Mm

OWSTIMI ov om—anoom

onto-comma
urns-0010300
07746-00C0300
077134320400
07715-002060!)
07746—413501“)
OWN—m
mus—0010200
mus—0010400 or 07946-37101W

1» or commucluuv mil-bk In USA.

FRONT WHEEL/SUSPENSION

 

HANDLEBARS CLUTCH MASTEH CYLlNDER
REMOVAL

Discunnact the clutch switch wnres.

Rumova the clutch master cvlindev.

 

Remove the left handlebar swxlch.

 

SCREWS

040 K E CAB LE
Désconnecl the choke cable from the choke lever.

 

CHOKE LEVER

15-3

FRONT WHE E L/SUSPENSION

 

BRAKE nusvzu CY; was;

Dvsconnecl (Pu- honr make march «we;

Rtmovo tn! huh mum cylmdev

 

BRAKE SITT‘C“ mni

Homo" 1m ngm hlndllbu mach

Ddconnecl Pm fh'mzle cabin horr the mmme
gnu

 

 

15-4

FRONT WHEEL/SUSPENSION

 

 

HANDLE BAR COVE R

Remove the bolt up: and the handlebar cover.
Remove the handlebar upper holder bolts.

Remove the handlebar upper holder and the hand
lebar.

 

HANDLEBAR UPPER HOLDER
BOLTS PUNCH

INSTALLATION

Place the handlebar onto the lower holder, aligning
its punch mark with the upper surface of the
lower holder.

Place the right upper holder onto the lower holder
with its punch mark lacing lurward.
lmtell the bolts. but do not tighten them yet.

 

RIGHT UPPE R

HOLDER MARK
HANDLEBAR COVER

Inxtall the handlebar cover on the handlebar, ' ~ V ‘”

aligning its lug with the recess ot the lower holders

 

 

 

15-5

FRONT WHEEL SUSPENSION

lnunll me lefi uppm huldm unln me lowvr hold-n
whh m Bunch mark lacmq forward, rakmg care
not in dnplac: hindlnbm cave! lugs Oro'n (ha low-v
Wolda'x,

Inn.“ we left upon homo: mm

fight!“ the iorwavd holu (my men ngmen me
rur balls

TORQUE: 30—40 N-m
(an—4.0 Ilwn. 22—29 11-")!

Apolv grease to the mmule qnp sluqu wrhce and
mmll the [Name gup own the handlebar

Sumner? the "Home any». :0 the Invmw uvrl‘z
[mauqh lhe ugh! Handlebar “we?!

Inna” [he ugh: haludlebav "Mich by ihgnmg m:
mummy pm mm ma holr r m:- hafidleba'

Ylghleh ‘hu 'orwa'c 5cm“ "'5‘. then hymen
Me real “'9“

 

PUNCH MAM
{a

LEFT UPPER
HOLDER
H01 E

PIN

Si. NE WS

,6.

  

  

HOLDER BOLTS

RDITLE CABLES

THROTTLE G‘RIF’

 

 

15-6

 

FRONT WHEEL “SUSPENSION

 

Install 'he "on! brake master cvlmdev with "UP"
mark facmg up‘

Align the end of the holuar wrrh {he handlebar
punch mak.

Trghren rhe upper bolt fll’SL than me lower bolt

TORQUE: 10—14 N-m (1.0—1.4 ky—m. 7—10 h-lb)

Connect the brake light switch wires

Connecl the choke cablz :0 the choke lever :hrough
rhe lei! handlebar switch,

Install {he left handmoar swncn by alugmng me
wanna nm vmh the how. \n the Handlebar

Tighten the forward screw first, man lighten the
rear screw.

InstaH the clutch master cvlSrvdev with the "UP"
mark facing ur).

Ahgn (he and 0! (ha: holder With the punclw mark
on the handlebar,

Tighxen [he upper bun fivsr, lhen tighten the lower
bah

TORQUE: 10—14 N~m (1.0—1.4 kg-m, 7-10 {1-11)}

Connect the clurch rcrew wnes.

PUNCH MARK

BRAKE LIGHT
SW! YCH WI RE

SCREWS

 

"UP” MARK

CHOKE LEVER CHOKE CABLE

 

PUNCH MARK

"UP" MARK

    

 

15-7

FRONT WHE EL/SUSPENSION

HONDA
‘L V65 suns

 

FRONT WHEEL

REMOVAL

germ: 19 "'2 SL‘ "5 w 514'. “5% M d ,rHSu'

     

Humove thu ugh! brake (:ahne: hunk": mummng
[nuns and :muuw I'W! tanner

NOTF

 

Do no: open“ the horn nuke mm any

vemcvng me tampon To do so wnl cause

dnfllculxy -n hnmq the brake dust between ‘
L the brake path

Loosen me We [MWL‘P‘ m‘:
Loosen and Vernon» me hon: ave
Remove the ham what-L

15-8

BRAKE Cl“ 195?

 

SE 7 SCREW

    
    
  

SPF E (J SENSOR

AXLE PINCH 8011

A
mom AXLF

FRONT WHEEL/SUSPENSION

 

WHEEL BEARING INSPECTION

Check wheel bearing play by p|acmg the M1001 In
a truing mud and spinning tbs whnI by hand.
Replace Ihe bearings wIth new ones if they are noisy
or Inn excessive pIov.

WHEEL INSPECTION

Chuck the rim runom by placing me thcI in i
(ruins stand. Turn the wheel slowly and read me
runout using a dIaI Indicatov.

SERVICE LIMITS:

Rm Hanan: 2.0 mm (0.08inI
Axid Human: 2.0 mm (0.08 in)

NOTE:

 

The wheel cal-mo: be rapaived and must b:
replaced wuh a new one II the servica hqu
are axondad.

 

 

 

AXLE INSPECTION

Set the axle in V blocks and manure ma runout.
SERVICE LIMIT: 0.2 mm (0.01 in!

 

 

PLAY

 

 

 

 

 

 

 

 

 

15-9

FRONT WHEEL/SUSPENSION

WHEEL BALANCE

CAUTION

ll'lml [Iaiaurt «Jlm'llv alfalx m: smhillr},
hundlm; and metal! ”I!" u/ (ht munwwlr
Alan}: duck halamr uhm [I]: m: hm Nru
rrmmrd from Ihr nm

NOTE

' Fm nphmum bnlnnnu, the we balance malk
, (I mm! dol on "up |lda wall] must he locum"
nm to the valve um Remounl lhe the .1

l
npcusavy l

 

Remove the dust ml and sandal-hue: gen lvnm
lhe whet!

Mount the wheat we and bull! disc Immbly m In
Inweclnon “and

Sam (he wheel. allow I! lo “00. and mull the
low"! lhcavnut) Davl 01 (h! wheel mm dulh
00 ”m {we or three Irma to Villa“ me Manon
llll IV the wheel :1 hillncvd, ll wull not “on can.
mlenllv I" (he same pcnllon

Yo blllnc! the wheel, mu-ll wheel weigh“ on the
h-uhcn side 04 Ihe um, Ilu mic 0000541: the dull
mun Add lull annoy! Wayll so me wheel null
no longer uoo ll'l me umr pouuon when It's spun
Do not add mow "um 80 vurru lo the from wheel
lvnv wheel: 70 gun")

15-10

    

A? HONDA
$, vos sun:

YIRE BALANCF MARK SPEEDOMETER GEAR

«Iva-m .u va

fawn—V“

 

I»

WHEE L WEIGHT

 

FRONT WHEEL/SUSPENSION

DISASSEMBLY

Remuv! me speedomrm 993!
Remove the brake Ulic mounnng bolts. and cum

 

Remove me side com" and ugh! seal SIDE COLL ER SEAL
Remove the leh sun! And weedamelev gear veulnor

 

SEAL SPEEDOMF TEH
GEAR RETAINEH

WHEFt Bl AHVNG REVOVER HEAD 15mm

Romove the wheel bum-v91 and the (“lance coll-I ‘ ‘ . . ..
OI/éu OUSFJuOC LfifimeV‘ar. -“u|\‘1l3bv€ n u :,A

"om the hub

  

NOTE

IV me beamla; nra ramoved. they should be
replaced With new onus

     

BEARING REVOVFP SHAF’
37’“ UCEOW‘H} 1'T"‘"v. . i‘

 

..'..| ,uHu 11 USA

15-11

 

FRONT WH EEL/SUSPENSION

 

ASSEMBLY

 

The can wheel needs no rim band‘

The Iron! wheel uses 3 warns: me For
lubeluss me renew, ride! In xha HONDA
TUBELESS TIRE MANUAL

Pack 3"] heanng caure; wuh grvase
Drwe m tn: v‘gn: u-Ja‘mg Mn and mess the d‘sranCP
collar mm place

 

NOYE

,_ , ——
Bu cenam the dlsxance coliav s ‘n pos'hun
before ‘nstalhng the vi: nearing

an I” we [eh bearing secuarely. making sure

that :I is fully scaled and that me sealed Side is
facing ouL

 

 

 

00 no! ‘2! (mm on the brake disc or slap-

\ ping pom" will be reduced.

    

 

    

DRIVER
07749—0010000

ATTACHMENT. 42 x 47 mm 07746-0010300
ATTACHMENT, 15 mm M746—0040300

 

15-12

 

Install the spmdomeuv gear retainer in me wheel
hub, aligning me Lungs wnh the glow

Install the Ieh seal.

Install the ngm seal Apply ureasa to ma inner seal
hp and Insert the sude collan

Attach new gaskets to each brake disc

RETAINER

FRONT WHEEL/SUSPENSION

 

 

 

 

FRONT WHEEL/SUSPENSION

Inlm: ma brake dust mm mo "H" mm on aha
“th Ind IN a»: With the "L" mark on m: Iufi.

TORQUE; 25—30 N»m (2.5—3.0 ko-m‘ 18—22 MIN

lmull IM Woman gen In [M wheel hub.
nhgnmg IN ling: ml'h the you

Chan me but:- mm: mm a mgh qull w dtgleismg
mm

INSTALLATION

Pox-(Ion the wheel between mu Iovk lag while
hum; Ihe Ieh celipev om 1h: dnc, ukmg care
not lo dunno: the brake Duos

lmull the "9m Cll|D€f bucket mourn-n9 bolu

TORQUE 35—45 N‘m (3.0—4.5 him. 22—32 "J?”

Ahgn mv spudometev gear wuh m. lug on lhe
Id! 107k leg as shown

Tlfithfl me lea lo (he specr'nod lovquc
TORQUE: 55—65 N-m 15,545 kg-m, 40—47 h-lb)

15-14

 

 

SPEEDOMETER GEAR

  

F RONT WHEE L/SUS?ENSION

 

Manure bemeen ma outnde suvlace ul the nah:
bmke dxsc and thn nm‘do of ma ngm cal-om holder
w m a 0.7 mm {0,028 In) Voo‘m gauge

IV "1! gauga :annol be Huerta! mu! [he M3711 ‘rnx
nu! .m'. : (he gaur Cln N ””1390

Tmhlen the axle pmch bolt to me specdled xmuua
TORQUE 20—30N~m12.0—3.0kg—m, 16—22 H-lb)

Thu: mould ml! ha :1 man 07 mm (0 028 m)
clearance Demetn m. uhpqv homet and (MC

CAUTION

After installing Ihr whwl. apply (but bmkes ‘
several Irma um] rx‘rhcck {he cleamm'c un
bnlh 1121:: Fall“?! In pmrid: :lcamnrr will
dame the bmAr Jnrr and affeu braking
(Warm).

Iv will :He sfn’éfl :P'uu' .Iuh H19 35: scvew

 

TRONT AXLE

SE1 SCREW

 

 

AXLE PINCH BOLT

 

 

15-15

FRONT WHEE L/SUSPENSION

 

FRONT FORKS
REMOVAL

Remove the hon! whea‘ .939! '54!

Ramon the 1m hrake cahper bracket mountmg
bolls, “can, 01mm pmon calm and Ian brain
ulbpev

Ramovu th: from lundm

Rm" ma ind: but:

Ruuu lam an pressura
Loown the knit upon 1nd lmr pinch bolts

15-16

SLEF .k C 9 NES

  
    

"
P35} )N BRACKET \ROU‘JWNGBOK TS

COL ,AR
FORK BRACE

WU

 

Puv' each fork tube down and out 0* the fork top
bridge and an joxm Rotate the fork tube whxle
pu|'mg,

Remove (no .’ork slop rzngs‘

Purl each Vork lube cm of mu bouom bridge.

If air ioml needs service, remove the handlebar
(Dag: 153,

Remove the two scvews attxhxng the fork a3r joints
to the fork (on bridge.

Remova- zhe mr lnln'.

FRONT WHEEL/SUSPENSION

AIR JOINT

AIR JOINY

 

 

15-17

FRONT WHEEL/SUSPENSION

 

DISASSEMBLY FORK TUBE CAP

    

Hold me lori mm In a mm, mm 501mm Or a shop 5-
mm! and umon ma 'ovk’lube can

CAUIION
- Du no! Jamar Ihr xii/mg rurface‘

~ Do In .( n-Imm' Mr strewn" the right/13M Iubc - ‘

cap, m (In- damping mtrhanlxm pans could be
spar/rm] whvn Ihr m,- i: removal

 

 

Remove me Ion: mung, lower and Viewer
Futcu oul ml 10d lluld by pumping the (ark up
and down maul nmu

 

MEX WRENCH (6 mm) 07917-3230000

OR COMMERCIALLY AVAILABLE
Hold mo 'ovk Hud'f m a us: wnh soft [m or I

won tow-I
Rmovn mu lock-l boll mm I hex wrench

N07!

Tompourily Inlllll 1h- spring and fork who
cap H dlmcully II cncounurad in rumovung
(hl b0”
Thu (mum and ubwnd swing can now be remand
ham m. ugh! (ark

 

15-18

FRONT WHEEL/SUSPENSION

 

'84

Remove the duel seal loam seal and plastic wash-
el Discard the loam seal and plasnc washer. they
wrll nol be reinstalled.

After '84
Remove the dust seal

Remove the snap rung

Pull the lorl lube oul until resrsmnce from the
slloer bushing rs lell‘ Then move n In Ind out,
lepprng the bushing lightly Until the fork lube
separates lrom me illder The slider bushing will
be Forced out by me lurk lube bushlnu.

Remove (he all look piece from Inside (he slider

SNAP RING

DUST SEAL PLAS IC WASHER

   
 

 
 

spon‘c‘s SEAL
SNAP mus mans men—3230001
on COMMERVCIALLY AVAILABLE IN U.$.A.

 

 

 

FORK TUBE FORK SLIDER

 

 

 

15-19

FRONT WHEEL/SUSPENSION

 

Remove m- a «3' back 4:: ' "c and 0rd?! bum-mg
hon the Pork mug

NOTE

 

Do N3! vomme if“: Mr: mh- bush‘nq anlou
q ,5 ntcnu'v :u 'PD’DCP ‘t w 1" a "M one

 

 

 

From m. run ‘ork remou me curcI-p, onl Ioct
valve, spring. Ind spring 58-11mm the Milan
Remove "w v‘slnr‘ and whom!) sormg hm me
(ark tube

INSPECTION

FORK SPRVNG FREE LENGTH

Measure the lad: spur-.9 9v» mam
SERVICE LIMIT‘ 523 mm (20.6 in)

15-20

SLIDER BUSHING BACK PRING OIL SEAL

   

   

FORK TUBE BUSHING
PISTON §RING SEAT

CMCLIP OIL LOCK SPRING
VALVE

 

 

FRONT WHEEL/SUSPENSION

 

FORK TUBE/FORK SLIDE R/PISTON

Check the Iovk Iuba, fovk shder and piston for
more marks, scmchcs. ov extensive or abnormai
wear. Replace anv components which are worn at
damn-d.

Chock lhI Iork piston ring for wur or damagn.
Chuck the abound spnng for Inigo: 0r damage.

FORK TUBE

Set lho Iork tube in V Hacks and read the runoul.
SERVICE LIMIT: 0.20 mm (0.0081nI

BUSHING/BACKUP RING

Visually inspccl ma ‘Iidcr and Iotk lube bushings,
Raolaco rm bushings if more i! excessive scoring or
mulching, or if (he [often is worn so that thc
cooper surf»: leOa'! on more than 3/4 ol the
3min mrfm.

Check the backup ring; replace it i! (here is anv
dinonion at me points shown.

 

PISTON RING ,
FORK TUBE
PISTON
he

RE OUND
SPRING

Li

 

 

 

 

 

 

BUSHING

 

 

BACK-UP RING

CHECK POINTS

COVER
SUR FACES

 

 

15-21

 

FRONT WHEEL/SUSPENSION

 

ANTIleVE CASE ANTI-DIVE CASE

Rmove mt 'our node: Dom ind remove the 3'"-
deve cut

 

PISTON RUBBER STOPPER

v

Ramuve the pmon and spring
Remove the hooL O rung and vubhm uoppev

 

 

.
r» .
.A
I V
a Q ’
\5—
PACKING O RING PISTON CASE 800T
Check the spring and pnlon 'ov war or damage.

 

15-22

FRONT WHEEL/SUSPENSION

 

CHECK BALL

Remove me check valve selling screw, valve sprung
and check ball

 

VALVE SPRING

Assemble 1hr aml dive case ‘l' the reverse side! a!
dwassemblv.

NOTE

 

Realace the O tings With new ones‘
Apply lock-n9 agtnr to the lhwads 0' 1h:
screws and socket bolts Defon: assemnlv,

 

 

 

  

PISTON O‘RING PISTON CASE
BOOT

ChEc‘K me operation or me Dmon.

 

15-2-3-

FRONT WHEEL/SUSPENSION

 

ASSEMBLY

Boiou unmbly, wash a" pan: wnlh I Pugh Huh
palm or non~flammable solvent Ind mm "mm 9”
complaloly

   
 

msnc FOAM DUST
WASHER s 35‘“-
Ahov '84 \\ A". ‘u
roux ruse
.1 _J CAP gym“;
‘1: ' FORK (on. SEAL
. 5:2? was \ 9:3“ UP mm;
, ‘ SPAC n

“f H E r7\suoen

; BUSHING I

/ \fi ‘ P romance ‘5'
‘ A“ ,9 f1, , . Ab SLIDER , \m . §
,«7 "W ” '” \f? \gg ‘

c ;‘\:3::

Am JOINT ,

I; v
[1' (j? ,I/ a ausums
. ”STD” , s mum son
on LOCK macs 1‘ 59.0%
REBOUND smmc 9,:
SOCKET sou ‘ ' “
\1 ANTI-ONE CASE

SPRING SEAT

Innn mu abound spring Ind gluon mm 1». km:
tub.

0n Iho Id! lork mSIaII me toting an. “In sprung
ml Iock vulva Ind cwclnp on m: palm

Pinc- Iho onl loci place on tho and d m. pawn

 

CIRCLIV OlL LOCK VALVE SFRING

 

15-24

FRONT WHEEL/SUSPENSION

 

PLAYSIDES

I'null [he m4 lock rue-Ce on m: ugh! 'mh‘ ahgnmq
[he ”an mm n9 me on! locl- pneu- dnd mt DMD"
end

 

RIGHT FORK PISTON OIL LOCK PIECE

DRAIN BOL'
lnurv in mm lob! mm the xlvrin

N01!

 

Ahqn we culoul 51 the ml luci- one w-lh mu-
mum bnll In me man

 

 

 

 

CUYOUT

Plane mu 'ork under N a van mm w" {.M‘ uv a
9105:0er

Apply ,1 locking agent :0 1h! wclu bolt and Thil’dd
vV mo '71! a “on T‘ghrm w!" a 6 mm nu wvench

hulk

 

Tcmpoqmy ama‘l 7H5 ‘o-n mum; And 'orh
lube Cap In figure“ ma sock“ boll

 

 

 

 

TORQUE 15-25 N-m(1.5—Z,5 him, 11— IE 'Hb)

    

HEX WRENCH 079174230000
0! Commemiallv awn-labia ‘m USA

15-25

 

FRONT WHEEL/SUSPENSION

 

Place (ha :I-dcr bushing our the Ian: tub: and VIII
it on lho Illdel Pm m. bachua nnq and an old
bushing at oun'mhnl lool on Ion

Dnvo 1M bush-fig Inlanlmwnh tho uudrmv Ind
mm Ibo oId bush-n9 at annuals!“ IooI

Com I m ml ml wnh ATP and man" u MIN
"1: ml marking: hang up Drive m. uul m wilh
who all driver

Install IN snap nng mm in manna was Inc-no
down

'84

Discard Iha loam loll Ind plum: wnhu. Do not
mInnIII [hue pom

lnsllll IM dun “II

A“. '04
Install [he dust seal

Pom mo wfiod Imoum oIA‘rF Into "It Iorkluho

CAPACITY:
Right Iork: ‘70 on (‘53 all
L." M: C96 be (10.7 cl)

SPECIFIED LEVEL-
mum but: 235 mm (0.25 In)
uh I“: 220 mm (8.90 In)

SNAP RING PLIERS
07014—32”!

FORK SEAL DRIVER
07947—050109

     
 
 
     

o7947-xroo1m

 

 

 

 

 

 

 

 

 

 

 

"‘ oust SEAL ”I" '9 oust SEAL
‘ FOAM 3
SEAL
PLASTIC
WASHER l
‘ ‘ SNAP RING SNAP RING
on. SEAL OIL SEAL
' new)? ‘ ‘ I Mex-up
“ / mm: L\ nme
‘ ; ( SUDER ‘ ( SUDER
‘ wsmuc ausmuc

 

 

 

 

,fiV

1!th

235 mm (925 In)
L.“

225 mm (a 90 In)

 

_ L

 

 

 

 

 

15-26

FRONT WHEE L/SUSPENSION

Inn.” Im 'uvl what wing slat ahd spacer .n the
mm mm

'40"

Now Im- mung dam-on, me closer wound

ISO!“ mun 00 Inward me bottom,
A; 7 fi,

BOTTOM TOP

<———-

 

—-——>

WWWMMIWWWVWWW

On me my“ 'olk, lhqn the cavrlv on me
damping .d'unev you mm me “a! xidc m ma
omon

lnnall and Iorqua me Vovk lube cap

TORQUE: 15—30 N-m (LS—3.0 kgm. 11—22 H-lb)

   

 

/
PISTON FLAY S'DE

GROOVES [ABS
0n "1! non! ‘ork ngn me ‘ovk can my mm m:

punch mm on the darnme adiuslev Then Install
me dumpmg mguuu cap, ahgnéng me adiuster mm
with the cap oroovn su mu "No‘ "‘ us Iowan! the
lug on thy: Vovk can,

 

No 2’ DUNCH VlAFi'( LUG

15-27

F RONT WHEEL/SUSPENSION

 

INSTALLATION

l‘ m: an 1m”! IS d-mwuulph'u, mstall new 04mm
.0 the I4 mm: gloom-

 

mun“ rm.- 'rom 'ovh um) ‘vmpomnly hgmun the “JP MN MW“

lowzl lurk pmch Dom

l'uu' {he a r mm! qu mag; 1-. the groovrs n the
(ovk (L05

'V‘HJ” {he hurt av mm" 0er me fork {noes

SHWHING

 

Locum he Iowev km 94".?" Don and 3mm: 2":
huh mm lave! so PM! H r on mmx :ingi mum me
unduwoe of the iork mu bncqr,

179M211 the a" juxru mourmnq $cvews

    

A'W JUVNT MCHJNTIRU SEVERE“.

 

15-28

Tighten the upper and lower lork punch bollsl

TORQUE:
Upper: 9—13 N-m (0.9—1.3 ltq—m, 7—9 ft~lhl
Lower: 45—55 N-m (4.5-5.6 kg-m, 32—60lt‘lbl

Loosely- mstall the lront fork stablliler

Install the removed parts in the reverse order of
removal

— handlebar [page 153:

- lront lender,

Install the leltérontcallper bracket wrth the sleeve,
O‘riltgs and piston collar

Tighten the anti»dive pivot boltl
TORQUE: 20—25N-m (2.0—2.5 kg-m, 14—18fl-lh)

Tlghten the cahper mount bolt.
TORQUE: 30—40 N-m (3.0—4.0 Ito-m, 22—29 ft-lbl

Inttall the front wheel (page l5720l_

Wnth the front brake applied, pump the from forks
up and down several timet
Tighten the iron! lork stabllizer mounting bolts.

TORQUE: 18—28 N-m (1.8—2.8 kg—m, 14-21 ft~lbl
Install the bolt caps,

Full the lork tubes with arr to 0—40 kPa (O—OA
Itgl/cmI , 0—8 psi), and check lor leak;

CAUTIONV

 

Use only a hund upcmled air pump to fill
the fork tube; 00 no! use mmprctmi all
- Maximum pressure it 300 era (3 kg/cm‘,

41' psi). Do no! exceed rim or fork tube

mmponlnl' damage may occur, A
With the lronl brake applied, pump the front
lorks un and down several times Place the motor
cycle on nts center stand. Chock (h! an pressure-
and adlust if necessary.

LCWER PINCH §0LTS

CALIPER MOUNT BOLT

   

ANTI-DIVE PIVOT BOLT

FRONT WHEEL/SUSPENSION

 

    
 

O-RINGS

PISTON COL LER

 

15-29

FHONT WHEEL/SUSPENSION

 

STEERING STEM

REMOVAL

Rtmove the tollowmq compontr-u
7 'me COHEN home! mm 2' i
, Heatihght ar‘d use (Dogs 2' 3‘ ma buckets
mltmmenis {page .1 .1
anmon swdch (page 27 '7
handlebars (page 15 1‘
V from wheel {page 1': B»
Removl- xhe bvakn {hvurwuy po-m by remuvmu
lhr- mm

Remnvt- the angle sensor uuxmn

Home" (’1: angle ”fill" unpou‘imwav blues and
«um wnal cancel um

Damnnccw the counter

Looun he “mung (3cm amch bou

Remove me sleermq um ML fork nudge mm:
mm l"‘d 'mk air {omh Vol?! 't 15 ‘7

HEADL :(MT

   
      

NUTS

1URN SIGNAL CANCEL UNIT

STE“! SUV

CUUPLERS

‘

ANG| E SENSOR

ANGLE SENSOR SUPPUFH

EX VENS'ON BAR IUCK NUr WRENCH 30X37mm 077160020400

0 I 7! 60020500
\

u' Cum—”yr. . (“‘3me rv 1.! SA

SH’N' pWCH BUM

 

FORK BRIDGE

BRAKE THREE WAY JOINT

UPOER‘LUWER PLATES

 

15-30

FRONT WHE E L/SUSPENSION

 

LOCK NUT

Strlvghlm thu lock washu um and remove the /
lock nu! Ind lock wash"

IOCK WASHER TAB
D77160020$CDm STEERING SYEM SOCKET
Commevcully gullible In USA, 07916 3710100

EXTENSION BAR

 

  

I

   
  

Loonn {N beams; aclunmom nu!
Remnw- IM mm seal

BEARING ADJUSTMENT NUT DUST SEAL

INNER RACE UPPER HEARING
Remow the Deanna Inner use and umm boating,
Remove lhe steering slam, grease raumn IN} Iowa:

boaunq
Check lhe matings, and Dun! and mum vote; '01

went at dummy and rephce d mounrv

LOWER BEARING STEERING STEM

 

15-31

FRONT WHEEL/SUSPENSION

BEARING REPLACEMENT

NOTE

1 Always replace the bearings, rnnurv and outer
races together as a set

 

Remove the upper bearing race: place the dnver.
wrth rts prlot‘s large OD and tacrng up‘ into the
steerrng neck trom the bottom

Place the attachment with the "A" stde up on the
drrver‘ by trlting I: through the upper race

Hold the drrvor's prlot against the lower race and
duve the upper race out of the steenng neck

Drrve the lower bearrng inner race from the stee-
rrng head neck‘ wnh the touts shown

NOTE t

Attachment 077460010200 rs placed In the
steerrng neck to grve a better drrVIng surface
agarnst the removor attachment and to pre
vent damage to the drrver

 

 

Remove the lower bearing inner race and dust seal
tram the steering stem.

 

 

 

UPPER nAcE REMOVAL LOWER RACE uncut.
ATTACHMENT 07953. DflNEfl 07949.37er
MJTOOOA (USA oum
UPPER
me n
1’ 1 ATTACHMENT.
rafffixk 37 x ‘0 mm
" .r r 7 «s-oorozoo
'Ffi’w‘o 7

 

DRIVER
0794647 ‘ 0400

 

 

REMOVER ATTACHMENT
07945-37lm

 

 

 

BEARING INNER RACE

 

 

DUST SEAL
‘V ‘— LOCK NUT
‘L <— LOCK WASHER
_ ' ~— STEERING ADJUSTMENT ~ur
' Q) —— DUST SEAL
'3 INNER RACE
@4— BEAHING
Q OUTER RACE

 

 

 

 

GREASE HOLDER

OUTER RACE

BEARING
INNER RACE

DUST SEAL

 

 

15-32

FRONT WHEEL/SUSPENSION

suemm,‘ .- 0:1»in
{mus xxaoogm
\

 
  
  

IMuII .- nrw dun wa' ovt' We Heennq mam
lmllll a nrw lnwov lwl'mq -nne.' use mm! the
"mung nun uung a ems

     
  

,
—-— ,I" ,
my“ SEAL LO‘.\ER BEA'R‘N‘l-
- Whit»: P
9*“th AYYACH‘. .' u.‘ - h: ~v

   

M ‘H‘Mh 3JTOVUX
‘

‘

0/ HQ OOSOOOO 0 7748413104“)
lmlal) new lawn: and unpev bearing cute! races mm u
me new mp:

A1 ummgm 47 . 47 mm
071440010300
INSTALLATION INNER “cg upper gamma '6!-

.
Pack (Put buunq cumm wnh gvease

Inn-ll the 119mm; “um and lawn hearing

huh” I“! gumse return", "pp!!! beavvng‘ bearing
Inn" In” am! mm "M

LOWER BEARING ‘WTEFW‘N‘L "

 

15-33

FRONT WHEEL/SUSPENSION

 

57E ERR“) STE-V SOCKE‘V
D791!) 'HmlOn

IMuH Ihn hearing SdIUFmEV‘Y nu! And than H J

to "I. Immmd tnrryue’ /

TORQUE: 20—22 N~m
[2.0-2.2 krm. N-‘IB ll-Ib)

STEY RING MJJUSTMEN’ NUY

Tuvn xhr unnng men all the may nqm no 4m 1w!
um" m an IM bunny)

thghlth "w adnunmenl ml In [no mm (mm!
Yum m nemmg stem [0 seal me bear-hm

 

l OLIK NUT
Innnl! 3 mm Inck washer by alugumq uh uh wnh ma
moon 0' lh! adjuumcn! nu!
Finn" upmrn [hr loch nu! I“ tru- way
Hold MI hu'mg odwnmem um and hgtunn 1h!
loci mu wnhm 90 (Sugar; 1:: r qn m muow: w-n.
mo uh o' the lock washer
Bend up the lock wsshev xab .mo lht qnme of me
|och nu!

 

Er‘a ' "'C A117“ H {USHER
'Y TAB

15-34

Tempazanty Install the hunt forksl
Install the lork bridge and tighten (he smaring
stem nut,

TORQUE:
90—120 N-m (SD—12.0 kg-m, 65-87 h—lb)

Tighten the sleenng stem pinch boll.
T0fl0UE:1B—30 N‘m (1.8—3.0 ku-m.13—22 f‘Hb)

STEERING HEAD BEARlNG PRELOAD

Install lho lrom forks (Page WE- 2E

lnsxal! the lrum wheel «page 15 *4“

Place a sand unduv me 9ng|ne and misc xhe Hon:
wheel all the ground.

Posmon the SIeEllng stem at me snalgm ahead
pnmion

Hack A SDHN] Seal? m the lovk tube and measmu
the steering head bearing pmload

NOTE

(Make sure max "me as no cab-e or wwe

 

l

harness mlerlerence‘
The preload should be wthm 1071.6 kg 0.21
353 lbl lor ugh: and lull wins
I? the readings do no! ‘a'l wozhm ms! llmll‘ lOWel ms
llonl wheel on the ground and adjusl {lac hearing
adjuslmenl mu.
After establlshmg lhu bearing COH’ECI prelnac, rnslall
the removed parts m the VEVFI’SF. nvdgv of mmoual

FRONT WHEEL/SUSPENSION

EX'ENSlON BAH 077160020500 OR

     
   

STEM PINCH BOLT

 

Carr‘merclalw auallable m U SA

SEEM NUT

LOCK NUT WRENCH, 30 x 32 mm OR
Commereiallv available In U S A

 

15-35

In): in” OCOVMZQOZ

 

                            

313 2.3
:blnb .33.
delve—1w.

:obl . 0.0 :03.
vulc- 3.5.

sol. Pa .63.

3.3 2.
a 2T3 .1!

:blnbga. \
3-1.2... .

:blub g.
SIX. .2!

313 2.3
sauna .33. 3:8 2....
a-.. .2! .272. x. 5.
tr..." :3.
6-8 2.3 8:33....
Song .63. a «lab x
8-8 .22 . .3
2:22;...
. - r 818 z
818 z. .a
thumb—“.3 <3?uhnofi
8:8 2.5. 1 =3.

A3:0

16. REAR WHEEL/ SUSPENSION

 

 

 

 

ssnvwEiNFORMAnou 13—1

TROUBLESHOOTING 13—2

REAR WHEEL 16-3

SHOCK ABSORBER 16—9

swmc ARM 16—18
SERVICE INFORMATION

GENERAL

e The rear wheel um I tubules: tire. For tubeless tire repairs. refer to the TUBELESS TIR E MANUAL,

0 For wheel balancing. reler to Page 15-10.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

 

STANDARD 7 seRyrcs LIMIT
Axle runout — 0.2 mm (0.01 In)
Rear wheel rim runout Radial — 20 mm (0.08 lnl
Axial — 2.0 mm (0.08 in)
Shock absorber air pressure 0—400 kPa (0—4.0 uglcma , 0—57 psi) —
TORQUE VALUES
Shock arrnvlo-lrame bolts 40—50 N-m (4.0—6.0 kgm. ”~36 lt-lhl
Shock link-tomcat arm bolt 40—50 N-rn (4.0—5.0 Ram, 29-36 fl-lb)
Rear shock absorber mounl bolts 40-60 N-rn (4.0—5.0 lawn, 29—36 OHh)
Swing arm lett pivot bolt 90—120 N-m (QB—12.0 Ito-m. 65—87 h-Ibl
Swing arm right pivot bolt 16—20 N-rn (LG-2,0 kgm, 12—14 h-lb)
Swing arm pivot lock nut lib—130 Nrm (role—13.0 kgrn. 72-94 ft-lb)
Rear brake torque rod 3 mm 15-25 N'm ”3—15 kg-m. 13—18 lt—Ibl
10 mm 30—40 N~m 110-40 kwm, 22-29 ft-lb)

Flnal gear case attaching nut

Rear brake disc
Rear axle nut

TOO LS

59”“ Attachment

Oil seal driver

Swing arm pivot lock nut wrench
Socket bit, 17 mm

Bearing remover, 30 mm
Remover handle

Seal remover pump

Remover weigh!

Driver

Attachment, 42 x 47 mm
Pilot. 20 mm
Attachment, 37 x 40 mm
Attachment, 52 x 55 mm
Bearing remover shaft
Bearing remover head

45—70 N~m (4.5—7‘0 kg-m, 32—51 ft-lb)
35—40 N-m (3.5—4.0 kg-m. 25—29 h-lb)
35—105 Nan 13.5—10.5 kg-m, 51-76 (Mb)

07986—MA10100
07965—M3001 on
once—4590001

07703—0020600 Commercially available in U.S.A.

07936-889030!)
07936—3710100
079714401000».
07936—37102“)

mug—0010000
07746-0010300
07746—0040500
onus—0010200
07 7413-0010400
07745—0050100 —
07146—0050600 A

— Commercially available ln U.S.A.

or KS—HBA-08—469 (U.S.A. ON LYl

16-1

REAR WHEELISUSPENSION

 

'flflflflflflflflfi

Dull-flan

. Worn 16m

. Tln pnuur- incorrect
. Fuulrv rim

30M rim

Loon uh

wfiwpwn—

I. M WW
2. Imufllci-M fluid in shock Interim
3. Shoat Mb" air prism" lncovrm

Mud aqua-Ion

L Incorrect fluid weigh! in mock absorber
2, 80m thud: Ibsorbev
1 Shock absorb-v Jr pruuuro IW'IC!

Munch
I. meéndlng
2, Loon-9m

 

16-2

HEAR WHEEL/SUSPENSION

REAR WHEEL

REMOVAL

Piece [he motorcyoe un st canny stand and remove
me 3:02 nun

 

AXLE NUT

AXLE PINCH BOLT REAR BRAKE CALIPER

     
   

Loosen the axle pmcn bolt and remove me rear
axle.

Remove the rear brake :31.qu k1()>ta‘ldfl\u ualvm-r
(page I? 10;

A

CALIPE R BOLT

Move the wheal 10 [I'm right to saturate “1'0!" me
fmal dnvc gear case
Remove the rear whee:

 

 

16-3

REAR WHEEL/SUSPENSION

 

INSPECT|ON
AXLE

SCI manilm Vuoduandmadlrnaxlumnout
with a dub moimov.

SERVICE leT: 02 mm (0.01 in)

WHEEL BEARINGS

MIMMIhnvuwnmeVf-I
when buying ally by rowing 1m MI by hand.
Rnnlm IhI bouillon vim m can 51 [My an noisy
at N". «mm phv,

WHEEL HIM RUNOUT

emu m. vlm In! mnout by m Ihn anal In
I wing "and. Turn th- whul slowly. and mad an
mnoul min. a dial Indluwr‘

lEflVIcE LlMlfl:

Hull-I lumm: 2.0 mm (0.00 in)
Axln Rum: 2.0 mm {0.0. in!

mmalmmbutmodndmunbnmflm
N m abov- llmln m nun-dud.

 

16-4

 

 

 

 

PLAV

 

 

 

 

 

 

REAR WHEEL SUSPENSION

 

D‘SASSEN'ELY

4M, m m

 

av

Rmmwm "w n,- ,1 5: Dow. 1an "V“ :9er

 

 

Hm”. . 'n ' -.1‘ 1- .9 ‘7 u ‘ “‘3 ”rd "

 

're 3' u." ‘ J’JEC.‘

mew- " '1Hmml'wlmlA

   

«mm.» ,.,_ ue‘ bra-u!» u m :m‘ Mu. up mHa’

u‘. ' ‘1

 

CHI SEAL

 

HEARING REMOVE-H EXP/VH1}: I" D77AC~DUSDYDO

m Lmrmvwmal‘,‘ autlulilr H H N A

V

M Wm} “5.3:. Ly: yt-n ;'*'-E 33535-00

 

 

16-5

REAR WHEEL/SUSPENSQON

ASSEMBLY
non

Tm wheel usns a tubal!" me For lubeless;
(in repairs. refer to [ha Tubal!“ The Manual

 

~07!

Use Inhiumbased multipuvpow gnu! wuh

Most’oddiuve an 'ONOWI

' Molykm! BR? PLUS manu'ncnued by

Dow Corning US A

Multnnurpose M~2 mmuincruved by Mum-

high: Oil. Japan

Su-iube NLGI 82‘

Olher lubvicnnu o1 “plum“ quality |

 

  
  
  
  

,6

UYNIUM BASED
MULTIPURPOSE
NLGI No 2 GREASE
[MOSI-add-hv!)

 

DRIVER
07749—0010000
Pick Ill bunny cavmes wxlh grouse
Pveu 1h. duunce collar finlo pllce Horn the lush
uda Dnvl the right ball Dunno m hm, men "w
I.“ bull bunny.

CAUTION

 

Dm-¢ Ihe bcmngx m uuarrl), mkuu INF
Mn :27: fully Jenni

 

‘ .-v . J2x47mm
077467WI0GN mus—0010300
PILOT 70 mm 077la~00405W PILOY 20 mm (VHS-Wm

 

16-6

REAR WHEEL/SUSPENSION

 

lnmll I raw OII seal mm m. hub

Imml the ‘ma\ duven flange omo ma war wheel
Ind lighten the Don;

TORQUE
50—80 N‘m (5.0—6.0 kgm‘ 38—43 h-Ib)

Inunll a new Ovring in the groove M the final duvun
flange

Imull the rear disc and harm" ma bolu

TORQUE.
36—60 N-m (3.5—4.0 lug-m, 5—29 fI-Ib)

lmull (hr nde collar

OIL SEAL

FINAL DRIVEN (LANCE

 

 

 

16-7

REAR WHEEL/SUSPENSION

INSTALLATION

App'v Mull-Durban NLGI No 2 Grease (M052
addmul lo the lmll dnven Mange 501mg: of me
in! wheel :nd I-nq on:

Enema rho vnr whnl mm [M hnal dnvc new,
making bull Im mlmos are correctly ahgned

Inn" m. In! all! lmouw mo mm; I'm. With."
amp-r buck-L udn calm, huh and Mn! duve- gear
Tigrmn me Ill! nu!

TORQUE:
86—1“ N-m (8.5—‘05 liq-m, 61—78 ft-lb)

hymen lhl nle pmdw boll
TORQUE:
20-30 N-m (2.0—10 ku‘m, 14—22 h-lb)

lnan m:- m: nuke calipet§pa9¢1713h,

 

 

 

AXLE NU?

AXLE PINCH BOLT

 

16-8

  

SHOCK ABSORBER

REMOVAL

P‘s-:2 Xhfi mn‘al‘r‘yaln on ‘15 sentry “.‘nml
Remove [hf wal‘ ugru and Eat: 'mmn «Ida coverv.‘
and Mel tank
D-sconnecx mo wm- noummc .mu vmmw-J [he
'0 mmr-g pain
nartew Jun;- ‘8 3
- mark Ink“
7 “OD and (mlhqm sense!
Duconnact mu veqularndrenmm and Mlevnamr
muulms
vauve [I'm luqulaun “vrcnhcv
Remove the met mm‘u ‘uage 4719:
Remove tin: sum-v mangehc much

Remove me mumv ’ mnl box 'mm tho- (name by
vrmuvlng [he bun

Lonsen the lad ‘Vul add 'e'nmr the '93: Emma:-
dafiwmg amuuu "om m: b-acnw'.

OASCUI'VHECI (m,- «urrumu aduslcr caulr by remuumq
:hr cup and Inowumu 1m- lock rm!

Remove ma Ihnrk slumber Onwm mnummu boll
Remove! 1h! mock nbmvbm upon mnunlmg bolt
nu (he shock wwvbet veavwmd um remove u
"am In: fume bv DUII‘N; I! up

REAR WHEEL/SUSPENSION

REGLII AYORNRECTIFIFR
FJEL PUMP COUPLER

     

REGULATOR

ALTERNAIOR SYARTER
RECTsflER COUPLER MAGNETIC SWITCH
LOCK NUY

 

HATTERYHOOI BOX

 

LOCK NUT LOCK PIN

 

UPPER MOUNTING BOLT LOWER MOUNTING
BOLT

 

16-9

REAR WHEEL SUSPENSION

 

OIL SE AL REPLACEMENT

Release air lrom the shock absorber by dearessing
the valve core.

Remove the valve core from the valve stern

Remove the boot from the shock by removmg the
boot clip

Press the back-up ring m I'D—2.0 mm (0.04-008
in) with the oil seal driver 07985—M800I00 and at
tachment O7965—MAIOIOO.

CAUTION.

 

‘ Do not prm the backup rlng in qu far ur (h:-
guide bathing will (am mm {he shock can,
l making guide bushing removal diffimll,

 

Remove the stop ring.
Clean the shock outer case.

Place a think plastic bag mound the bottom ol the
shock and duct tape it securely to the shock's outer
case The bag will catch the ATP when the seal is
forced out.

CAUTION-

 

r 77w seal will he remm'ed with h‘l’lIMlllr' prev»
sure- to II: form: can he xignificanl. Wear pm-
m‘rivc clothing and face guard to protect

l min.“ potable A TF spillage. J

Clamp the shodt upright in a vise With soft jaws

NOYE:

The shock must be kept upright orevenl ATF l
from leaking out of the damper and into the
shock outer can. 1

 

 

 

Fill the see! remover pump with ATF and connect
the attachment hose to the shock‘s air valve stem.

Pump ATF into the shock absorber to hydraulically
force the oil seal and guide bushing out

NOTE

It takes an average of 2 to 3 minutes ol pumpr
mg to lorce the 0-: seal out

 

 

     
 
   
  

 

OIL SEAL DRIVER
079657MA$0100

SHOCK CASE BOOT

BOOT CLIP

STOP RING

ACK»UP
RING

    
   
   

OlL SEAL

GUIDE BUSHING

 

 

PLASTIC
BFG

OlI. SEAL

GUIDE BUSHlNG

 
  
   
  

SEAL REMbVER PUMP
07971—M01000A

 

16-10;

REAR WHEEL SUSPENSION

 

Leave the mod! Imam! m the use for [en mmuu:
m In any ram-hang ATF drain ham [he cum use.

Know; I! naught. vemove the shock horn the van.

Sfill kqnpmg the shock upright, remove In: plastic
bag, oil ml and guide tummy.

In om Imoolh mmion, tum the shock upside down.
Thcn "clamp (ha shock in 1b: vile.

PM "I. vulva com back into the air vulva.

Full ma mock body mm the specifiod Imounl DI
ATFV

SPECIFIED AMOUNT:
1200: (4.06 US 01. 1le oz)

ASSEMBLY

 
  
  
 
 
  

DUST SEAL

GUIDE BUSHING
OIL SEAL

BACK-UP RING

 

DAMPER OIL (ATV OR EOUIVALENTI

AIR VALVE STEM

.64

UPPER MOUNT BUSHING

800T

STOP RING

8007 CUP

 

16-11

REAR WHEEL SUSPENSION

Inn-II Ihn guide buathg mm 3? . dump-v can:

To woven! damage in ruw nu! mm: e {um oi
uny! up! around the grcuu- .vt :"- e'ui 0' ma Mod
ammo

DID KM ml seaI In AT; aw: nun H. mm me
damper.

CAW‘ION‘

[It vary/u] m»! (4.4 Jnmagr 1hr MI, mu' .Jurtw
[mm/[anon

flemuve we may hum Um no”

Renove the mock (mm the 1 w

PUB“ the all 5934 mm 1h» shnch ahwvbrv with .7 hvr
drum: was mm! H“: anachmwv'. now In me edge
a! Ihv cum case, Remove the mac“! MIDI!

lnnall me back up ring In Me nan-l ,mwvhm and
vunemble the $063.“ “30>;

Pun m the back-4: n' g moto- muw‘y 1 (r 4
mm 10 nm the 5300 L115; mm hr annm m m. gran-m
in "‘0 0mm can

CAUTION

U.\‘r carr m 1111' all ml] nun hr [mun-J (/1 law
fur whlr'h will [rim {In gun/1 Nulunr l'lu'rL
[hf rlwmvu'z' aft" ? ":va ‘

 

GUIDE BUSHING

SEAL

 

T APE

AT YACHMENT
07985 MBODIOO

 

/
OILSEAL

DRIVEN 07965-MAV0100

 

16-12

 

 

 

 

ATTACHMENT
07985‘MA10100

OIL SEAL

GUIDE
BUSHING

   

 

 

REAR WHEEL SUSPENSION

 

“own“ thu .rm m'uwf

Dc m; we 7 s Lam seated Ir

I'vr run-1' mas-3

[mum 'r- ”up

 

l"-‘ r w; 111’ my.

 

fiwumuu
I)” (1in (mm: 1.. null)” m: «(up rmyflhv
and mu rum! upmt mlhuul lln‘s rmu

mg, ‘m fink! cm") ”W mm—v,

INSYALLAYION

Avply pour wuu- ‘(fiun'ammg more than 45%. 0'
mulyb-lnvvumr m we upmr and lawn moummq
hmhqu

NO"

U10 mun- uvrnw Icnmam‘mq mom man 45%
n1 nmlyl-niwuun} ;. mum-n
'Mm writ!» (1n PIAS‘IE mawummmu
by (MW rimwuu U 5 I.
'lw'n‘ Pavr manufacwsed by Sum-cu
luhvurn Jamw
'r)lhr1 M1!"'ffl"!lU' P'Iuw a’enl Qualmr

mm. (n. w ‘1 ,3 ._‘.: ,u ., m, ‘ym’u an". r Q'prn

”u uprw 3' '1 \ ;.-.—' v- ‘1." ' 'vq t’n "
TORQUE 40 50 N m (4 0 >5 0 qum
79 16 H lhi

GROOVE

BOOTCLIF’

 

UF’FE R MOUNTCNG BOLT

Q

 

/

STOP RING

BACK UP RING

 

 

LOWER MOUNTING
HOLY

 

16-13

REAR WHEEL SUSPENSION

 

Connem the damping adlusxev cable to the shock
absorber‘

TTghmn lhclock nut and ms‘ail the lock pm secuuety
Install me dampxng adjuster on the brackm and
tighten the lock nu! securely

Install the battPrv mn‘ hm mu :he heme
Install the mgulalorn‘xecnher.

lnslafl mt Starter magnutic swuch

Install me iucl pump (page 4 19}.

Connect mu mgulatov/rectxfmv and alternator
couplers,

Install the inflowwg rfimoved parts.
snalk unns,

— stop and taillighl strum

‘ battery lpage 1873‘-

Connect the wve couulers securely

NOTE'

Rome the wures, hoses and tubes properlv‘
luages I 9 mm 13!

 

lnsvau me fuew xank‘ seat right and left frame side
COVEFS
Adjust the an pressure [page 319).

   
 
   

LOCK NUT

 

   

BAT THIY‘ TOOL BOX

RHJULATUR RH‘IHHHI

REGULATOR-‘RFCTIFIER
F—UEL PUMP COUPLER

     
 

ALTERNATOR STARTER
COUPLER MAGNETIC SWITCH

 

16-14

REAR WHEEL/SUSPENSION

SHOCK ABSORBER
SHOCK ABSORBER L'NKAGE SHOCK ARM MOUNTING BOLT LOWER MOUNTING son
REMOVAL

Remove we left and ugm mquleys Inage 5~2I

Remove the shock arm by removing Ihe shock
absorber lower mounting bolt, shack arm-mAvud
boll, and the arm moummg boll.

Remove the shock connecung rad Irom the frame

SHOCK ARM ARM TO ROD
BOT

 

LINKAGE BUSHING INSTALLARION '

Check Ihe linkage bushings 10! wow or damage
Inspect the dust seals Ior damage
Replace parts as necessary

SHOCK LINKAGE INSTALLATION ‘

AppIy paste.- gums: Iconlatning more than 40%
molybdenum) m the bushing; and dun seals, See

now un Dag! 16’ I 3

 

SHOCK ARM SHOCK LOWER
MOUNTING BOLT MOUNT BOLT
Install the shock connectmg rod and shock arm and ‘
ngmun uach be" In the order listed.
TORQUE:
SHOCK CONNECTING ROD-TO—FRAME
40—50 N'rn (mo—5.0 kg-m, 29—36 h-IbI
SHOCK ARM MOUTING BOLT
40—50 N'm [4.0—5.0 ka-m, 29—36 Il-lb).
SHOCK ARM-TO-CONNECTING ROD
40—50 N°m14.D-5.0 mm, 29—36 h-lbI
SHOCK ABSORBER LOWER MOUNT BOLT
40—50 N-m (4.0—5.0 kq-m, 29—36Itvlbl.

ImmII 1m.- ugm and left mufflers {page 54L

SHOCK ARM-TO- SHOCK CONNECTING
CONNECTING ROD BOLT ROD TO‘FRAM

16-15

 

REAR WHEEL SUSPENSION

 

SWING ARM

REMOVAL

Remove the 193' wheel 1:139: 1673

Remove [be final dnva gear case (039214 3'.
Rumove the mock absorbev lower moummg Do"
me mock urn mnunhng boll

Ramow [he In" muHM'

Rumom the may brake hose ‘rom the clamps or
the bulk! mvaue -od

“move [he lock pm ham the may brake torque rod
boll and vcmovu mu lomue rod boll

meu [M swmq am‘ ptvot caps and lawn ma
“gm p-vol hon lock nul

Remuw the nth own: no”, using a 17mm socket
bl!

16-16

SHOCK AR'J '.'OUNTING HOLY

K
7L

{N '-'Ul""' \NG
T

    

       
 

L'h’.
TOROLJE QOC- 9m.
BOLT

RE :5? BRAKE
HOSE CLAMPS

 

LOCK 9m TORQLE HUI;
SWING ARI} PIVOT LOCK NU" WRENCH (1)008 469M0'
OR KS H8A708—469 (U S A ONLY!

PIVOT CAP

Remove the swing arm pivot cap.

Rarmm the left pivot bolt and remove the swing-
arm.
Remove lhe boot Irom the swungarm

PIVOT BEARING REPLACEMENT

Remove me dun seals and bearings from both
sides 0' the swing arm 5 follows:

Remove (he swmg arm bearing races usmg the
bearing remover and weight. Insrall the remuvrr
and expand It as much as possible behind the
bearing race. Strike the walgm Ingmly several
times to move the race out enough so mm the
remover can be expanded completely, Expand the
remover completely. Slide the weth again wirh
enough force to remove the race.

INSTALLATION

NOTE:

Replace ma Inner and 6U!!! beefing races as
I an. Replace the grease retainer plate when
ever it is removed.

 

Install new grease relainar plates. Drive new outer
bearing races into (he swing arm,

     

PIVOTCAF‘

REAR WHEEL SUSPENSION

SOCKET BET, 17 mm 07703—0020500

LEFT PIVOT BOLT

Crm‘mrrlalv d‘-rIIEAL'IU m U SA

 

  
    
 

REMOVER
HANDLE
07926 377

GREASE
RETAINER

~bruér SEAL

.7,

0100

/

 

OLJIER BEARING
RACE

   

 

RE‘vIOVER WEIGHT
fl7ldl‘0010201 OR
07936 37I0’200

/

flunuh‘

3.;1
‘I\\

 

\
‘ HEARING RE‘x'IOVERSOmm
5 07935 8890300

 

DRIVER
07749 0010000

  

ATTACHMENT, 37 x 40 mm
07746 0010200

16-17

REAR WHEE L/SUSPENSION

 

DUST

BEARINGS

Apply guise [a [he nwot bunny: dust sells Ind
ofvo! boll um.
Inlull (he bearings and dun unis

 

DUSI SEAL

"up" MARK
Ivmall (he swmg mm mm mm the "UP“ mark up

 

SOCKET BIT, 17 mm 0770] 0020500
Cammerclulw unmahle m U S A

LEFT PIVOY BOLT

     

Inn-II (he swmg arm and own! hem
Tuomen me let: p.10! bolt [0 [he soccmm lovqu!

TONGUE ”—120 N m
(9.0-12‘0 kgm, 65-87 OHM

 

16-18

REAR WHEEL SUSPENSION

 

 

Tyv :‘r‘y",‘.;"hrw-‘-I."‘.m40h;n
'19 v x ‘ ' ar‘d 'e‘mHvr‘ 'u Hm XDV‘C hm:
mum-

TOHOUE 16 20 N»m 11.6- 2.0 kg-m, 12 M h lb)

Mvw- l’w \wmg u‘wv up and dmvv' v‘wm‘ “mu
"quh'm' m- mg": 1,01: w rm morphed

   

rm 1w

T am 2—.— var: nu Ar e “o J zm- '5": n w“
:1“ ~
TORQUE “134130 N rn

110 0713 0 kgrm. 7279.: n m)

Inna“ Hu- mung mm cwm mm

H w '1' 07133 0070500
Lr b t.

SOCKET 817
Ccmwnev ; u‘ .

mu‘rd
DW'J' qu?

1mm: u- u

 

S‘MNh ARM LOCK NUT WRENCH
07938 46900010R KsiHSAAOBAMS‘J IU S A!

  
  

 

SOCKET BIT 17 mm 0770370020500
[M "NH" “My nvmlnl’llie m U S A

 

9! MOT CAPS

 

16-19

REAR WHEEL SUSPENSION

 

IORQUE HEAR HRAKQ—
ROD BCMY HOSE CLAVFS

lnua’ :he uwu‘. MW." m we 5w n“ um o‘vox

CuHfiect Me In. 3.3-” ‘D'Qué ,0” L7 mg ”mg
I'm inc 1-9hh‘n nm nu"

TORQUE: 18—25 N-m (1.8—2.5 kwm, 13—18 fHM

Secure {he nul mm a new caller pw

Clamp me bviku unu- securely

 

LOCKPMN 'UROUE ROD

SHOCK ARM MOUNHNG BOLY
Connect thz- mnck mm m 1hr: swmu mm and

shock absovbo-
install and Ughll‘f‘ me shock arm and shock
abosrbe' mounlflq 1’0“}

TORQUES
40—50 N'm l4 0—5.0 kg-m. 29-36 'HbL

Ivmail the IN! ”MINI!" {page 541)

 

Inuall the hm: d1.” 9am case ”my: 14 19‘
Irma“ the neat Whl‘P' (page 1681

 

16-20

MEMO

HYDRAULIC BRAKES

 

‘-2 N'm
[DJ—0.2 Isa-m4 10—14 N-rn

~ .I f -lbl (1.0-1.4 lgm‘
07 I 1 \ 7-!01‘Hb) .

    
   

‘- 30-40 N-m
' ' (an-an um,
2249 mm

25-30 N 'm
, (2.5—3.0 Ito-m,
-. 718—22 «4!»!

22—32 mm

20—15N-m

(2.04.5 km,
1‘-I 3 "-lb)

    

23-30 N‘m
(2.5-3.0 Ram.
“-22 ft-Ib)

  

\_20-25 N-m

FLO-2.5 km,
‘44 E R-fli)

“’3’

5
\

    

 

17-0

I7. HYDRAULIC BRAKE

 

 

SERvaINFORMAflON 17—1 FRONTMASTERcYuNDER 17—3
TROUBLESHOOTING 17—2 BRAKE CALIPERS 17—10
BRAKE FLUID REPLACEMENT/ REAR MASTER CYLINDER 17—13
Am “550"“ ”—3 BRAKE PEDAL SHAFT 17—18
BRAKE PAD/DISC 17—5

 

 

SERVICE IIIFIIRMATIIIII

GENERAL

The front end reer brakeS can be removed without disconnecting the hydraulic system.

Once the hydraulic systems have been opened. or II the brakes feel spongy. the system must be bled.
Do not allow ioreign material to enter the system when filling the reservoirs.

Avoid spilling brake fluid on minted surreoes or instrument lenses, A: severe damage can result.
Always check breke operation before riding the motorcycle.

SPECIFICATIONS

 

 

STANDARD SERVICE LIMIT

 

Front disc thickness

4.8--5.2 mm (0.19—0.20 in)

‘.0 mm (0.18 In)

 

Front disc runout

0.30 mm (0.012 In)

 

Front master cylinder LD.

1§:870~15.913 mm (oozes—0.6265 inI

15.93 mm (0.621 in)

 

Front master piston CD.

15.82 mm (0.022 in)

 

Front caliper piston 0.D.

31348-31898 mm (13578—12598 in)

31.94 mm I1.253in)

 

Front caliper cylinder I.D.

32030-32000 mm (12610—12830 in)

32.09 mm (1.263 in)

 

Fleur rnnter cylinder ID.

14.0m—14.043_mm (05512—05629 in)

14.06 mm [0.553 in)

 

Rear mester piston 0.0.

11967—13384 mm (05495—05506 in)

13.95 mm (0.549 ml

 

Rear caliper cylinder I.D.

30230-30280 mm (1.1902—1.1921 inI

30.29 mm (1.193 in)

 

Rear caliper piston OD.

30148—30198 mm (LIES-1.1889 in)

30.14 mm (1.187 In)

 

Rear disc thickness

6.9—7.1 mm (0272-0280 in)

6.0 mm (0.24 ini

 

 

Ree: disc runout

 

 

 

0.30 mm (0.012 inl

 

 

TORQUE VALUES

Front brake caliper bracket mount bolt IRIghtI
Front brake caliper bracket mount bolt lLeft~upperi

Piston pm bolt ILEitI
Brake caliper mount bolt
Brake caliper prOI bull
Brake hose ml bolt

T00 L

Special
Shep ring pliers

07914—3230001

30—45 N‘m (3.0—4.6 kg‘m, 22—321t-Ihl
3C-40 N m {3.0—4.0 kg-m. 22—29 ft-lbI
10-14 N-m (1.0—1.4 Itg~m, 7-10 ft-IbI

20—25 N'm (2.0-2.5 kg-m. 11—18 lt-IbI
25—30 N-rn (2.5—3.0 kg~rn. 18—22 it>lbI
25'40 N-m (2.54.0 kg-m. 18—29 It-lbI

 

17-1

HYDRAULIC BRAKES

 

TROUBLESMIITINB

Duh burly-dd to?! at loom

1 Ah mm m hydvluhc Wncrn
2. Low llu'd Ind
3 HydrauIic syn-m looking

Into Ina/nodal too had

I. sucking pinion“)
2. Clogged hydnullc wmm
3. PM: glared 0! wow "naively

Batu drug

I. Hydrlulic mum making
2‘ Sliding piston“)
3. Incorrect rev huh DIM odiunm

 

17-2

Brak- nub

l. Pads contaminant!
2. Dig o: who-l miuli'ud

Bit-dame!“

I. has contaminant

2. Ens-um GM mnout

3. Gallon mull-d incornnly
4‘ Div: 01 Mm! minligmd

BRAKE FLUID REPLACEMENT
AIR BLEEDING

Check me lluld level wnh the flu-.11 veserm‘r pavallel
to the ground

CAUHON

 

- Ilmux'l Ihr diaphragm :m "lf fawn-(w when
operallng lhy brain: Icn'r “‘ur pedal). Fallurz‘
(0 do w wu'la/lrm‘ bmkt fluid In squirt an!
of the ressrl‘oil during brake operation.

‘ Arm-l milling fluui nn painted ur plamr
Eur/21w: Plum a rag (we: thy fuel tank
whelm‘yr [hr sysmn is Svn'iued.

BRAKE FLUlD DRAINING

Connect a bleed hose to the bleedar valve.

Loosen the caluper bleeder valve and name {he
brake lever lor pedal].

Stop opevatmg lhe leuev [or pedal! when no flund
llows om ol me bleeder valve‘

‘ A umlamirlalrd Ilmkr dis." ur pad reduces
flopping puwfl' Discard mnlarm'naled pads
and clam a ("alumina/Pd disc will: a high
qua/Hy bralu- dz'grmxing up!"

 

BRAKE FLUID FILLING

N016
Do no! rmx dilleram types 09 brake flUld
smce may are "a! companbfie
Do I‘m allow loreng-l materval lo emu :lw sys

tem when {wlmg me reserwn

 

 

 

Close ”’26 bleed valve, {EEK [hp reservoi' w‘vh Dot-4
make llmdA and Install the d‘aphragm

Pump up the sysxem pressur: with [he lever until
[here are no air bubblas in (he lluid "owing aux ol
the veservolr small hole and lever resistance is *EIL
Bleed the system as descnbed on the next page.

 

HYDRAULIC BRAKES

UPPER LEVEL
4". 1
‘ , LOWER LEV L

    

BLEFDER VALVES

 

 

17-3

HYDRAULIC BRAKE

 

AIR BLEEDING

NOTE

Chuck IN: ' um .va ”Hun wm; file-rd m;
me brakes m [urn-n1 aw horn bém;pumx>
00 nm the fin?”

when usflq In: Mm”: 8'3-‘6 Blrfldl'
Ml'nw 1'1: mar‘u’xlum ‘ rsfwct om

CAUYION

lfsc nnly DDT 4 hralur fluid fmm J it‘d/1'41
A'unlwnar

{)4} no! mu fwh Hun] {\ pm 1nd urn-r u
am (1'2: CD'IIJ'VHILHM Hun: wim"
ramped ‘ >11! Jumw flukv' Man.“
.4 :I:. huh

 
 

' hm by. L
51.11.!"
(hi; null (”3,"le (In . "3‘ :(W '.
Y. slim.

Pump 'he make ewe: .u meI
mm m contact Mm 1m- mu.
Remove
wwnw tn near fu‘

Carmen the Mm": Bun Blr-odc'
the b45962: van-.-

Pump the bra-2e b-cede‘ .mu mowr V'w‘: [feeder u it
Add Mm! when lhe 'Ium: my m 1h: mane :y mow
vrwvvn-r :5 ‘cm

Rope-l above procemum mm an bunnies nu um
appear m the plashc hum

m In n; Im- LJHHV'I
‘J‘e mam-r Lylmlvv rap and 1m {lw

momma M,

NO“

I‘ a 1 :5 mm: ng 1m: blender ham avmnd "I:
b‘n-de' :a'w- mvum “a the "wean w m
Vr’ on {we

H a M :vvac B'aho Elk-mm r71>‘qu>‘-ah~='7' "ml 4‘.“

nblu. bend the synum a, lnllnw‘

1) Cnnnecl a hlrme lulm 7:: We thedev vdhu

'1) Smut-
unm, er 1H
chow the (EV?

lrw huh . \wm

 

n' deress Hw 1min-

.J‘v‘e‘f vn‘w 1271‘” um! 'hun

 

N0?!

Du no! 1123:: (hr [3’06 'ewr or peoat ur‘fn
the bleed valvu Nu new rlmal

i 1

3| Release me braiu' lavas: m noun! slowly am! wml
seve'al seconds ai'rv ll wachm the end n‘ m
PMPI.

Room Ham 1 and " mh hmmes case In .mpmv

‘n We 'm u a! Eh: mJ m rvz- haw

 

F ‘\ me "u r} 'rszv.i'1wl\‘!‘7r Jnm' ‘51? ma-n

m.

‘4 brake fluid mnmmmuml hruAr Jim 1:! pad
mime: Hopping [)uk’l‘! Duran] containm-
nlrd pad: and rlmn a runlumlnuud dist wuh
a lug): qua/in hraLr Jan-nun; up":

 

PLASVI

FRGNG 'HOSE'

    
    

M‘TYVAC H'RAFL BLEEDEH

36860 Cmnmvw Valli Avaslable m U 5 A
REAP \

Pl ASY |(Z HOSE

F RON—

 

 

HI EEDER ‘vl‘d

 

17-4

HYDRAULIC BRAKES

CAMPER CALI°ERPWOT

BRAKE PAD DISC 85W eons

FRONT PAD REPLACEMENT

N01!

 

 

Alwnvl replace the brnke mm m pairs to
. uwvc wwdrsc pressme,

Ramon me and pun veumcr boll
Ramon the shoe! boll and awn: ml!
Ramon ah! calmer;

 

PAD PIN CALIFER
RETAINER 80L? BOLT
PAD DIN RETAINER
Ramon "is pm pm mama and pull 1m pad puns
oul 0' the calm"
Roman IM tank: was

 

PAD FIN

PAD SPRING
Pomlon lhe pad spnng In the caliper n Ihown,

Push Ihe uhpu plslons m an the way

 

 

17-5

HYDRAULIC BRAKES

PAD PiN

Install (h:- new pads In me cal-(per

Install the pad puns, one pad pm “751, than unslall
the mhev pin by pushing the pads against {he cannot
to depress me pad spung.

Flam me pad pm ratamer over me pad pm; Push
1h: retainer down 10 secure mp pms

 

RETAINER

RETAINER CLIP

Check to be sure the! the renamer (1le Is In place /
on {he calupev hrackm

 

17

I
O)

HYDRAULIC BRAKES

 

Ms" ”w vru WW 1; w “my”

 

ADD. v rnw ‘y-mv v» “a :19? pm' 30'
03429 .,\e n u' :m ' bow: id or 20' from and
roma-

‘mmv tho ”Mm-x am my macke‘ so me :1 5c 5 Des
'mmu turwurv 'hn pads haw; 73mm no! to
damaqn mu mm

ImmH and Mahler "w cahov- bolt and pun? hnll

TORQUE:
Plum Boh‘ 25 -30 N-m
(2 5-3 0 kn~m,1B—22 h-lb)
Cahpn BolL 20_25 N m
(2 0—2 5 kg m 14—189Hb)

Y‘IT‘TP" 1"" rW‘ "tau-w Lm‘t

TORQUE 8—13 N m
IO 8—! 3 kwm. 6—9 bel

REAR BRAKE PAD REPLACEMENT

Loosen rm ca um: Dal! and vemms It Mom lhe
cal [m mocha

PM)! rm who-H up mm 49 {he way

Replace mm mm bvakc pads usmg the same memod
as uwtl Im hon" brake pan Veplmemenl,

DISC THlCK-NESS

Mnauuu the dnr w .Jmni w "I a mmometev

SERVICE LIMIT'
Hum. 40 mm [0.161n)
Rm: 6.0 mm (024 In)

BRAKE DISC WARPAGE

MI-asmc x'u- tnabc ’J 5( wavnage or a S‘H‘BEF max:

WM .1 full“ :nuue

SERVUCE LIMIT 0 3 mm (0012 in)

.1

  

_ fiEYAI‘JE—R .
r r - ' ‘
'6‘ 5‘L"O'[ BOL7S ’61 51 L "E

PAD 9m RETAWER ESL?

CAMPER 80L?

 

    

 

17-7

HYDRAULIC BRAKES

FRONT MASTER CYLINDER on HOSE sou

DISASSEMBLY

Dram Duke Huud "om me hydrau'ic mum
Remove 1M Mike In" an may new mmov from
[M mam: cvlmdov Duconnecl me brake hose

cumon

F Amid Iplllmg brake fluid on paimrd orj
plum surfaces, Plan a rug aver Ihe fuel tank
whenever lin- brake xyxlcm u united.

N07!

W'Mn vamowng the all hose hon, wear me
Inn 04 me how lo eleven! mnlamrnahon
Secuu [ho no“ lo plevenl Huud horn leaiung
out

Remove me many cyhnon

Ramon the onion boo! mo me Clrchp hom the
main! cvlmdu body

 

SNAP RING PLIERS
079144230001

Removl mo “condo" cup and piston Then remove , «
lho pmmry cup and wrung

      

PI Y{.W

  

Roman "10 Duk- lrghl Iw:tch from (he muter
cylmdav body, H uncanny

Chan lha lnudu a! mu masts: cylinder and reserve"
wnlh brake fluid

 

 

17-8

INSPECTION

ann "w mun chundr ID,
and! tho mam! cvhndu '0! moles, watches 0'
mdu.

SERVICE LIMIT: 1583 mm (0627 in)

Minute tho mama pmon OD.
SERVICE LIMIT: 15.82 mm (0.622 In)

0nd: lho pmmrv and monduv wpl 90¢ damag-
boiom ammble

ASSEMBLY

CAU'ION

,_._._._—..¥,A i
I Rephre ”I! master cylt'ndn piston. ryll‘nda
and spin; a: a m‘

Anon-ml. In. muur cylundlv. Coat all pom wilh
clun bun 'IuId before ammbly Insull the sprIng
and pclmuv cun lengthy.

DID lho much can In bukl fluid before assembly.

CAUHON

Mun tIuIaIIm; (h: mm. do not «How the (up?
to mm mud: n-ul Br «ruin the drrhp u

I "W Mb 11'l'2't2377,

 

Innall mo pmon and char
[mull (he bool

 

HYDRAUUC BRAKES

BRAKE FLUID '
DOT-4

PISTON %

 

 

 

 

‘mom BRAKE
LIGHT swncu

 

17-9

HYDRAUUCBRAKES

 

Place Mr mastar rvlfldFr 0'! the handlebaf and
Inswll the holder and 1h? Iwn mauntng bolts
Align we end 00 the hnider wsm we punch mark
on the handeaI, and tighter“ the upper bolt M15!
men hghten the Inwer no!

TORQUE: 10—14 N~m (LO-IA kgml 7—10 h-Ib)

lnstaiI he a}! hose w-th xm- bm: and st two 5231an
washevs
InsIaH the brake ieveu

PM :he veservonr xo the upper level and bleed me
brake system accordvng {0 page 17—4

BRAKE CALIPERS

REMOVAL

Maze 1 claan cumaim’ under 1hr: calmer arm (1-;-
cormecl Hm brake hose from the caliper

CAUTION’

 

4 ma! xplllmg brake fluid an painted mlfiatex. 1

Remove the cahper bol: and pwot boll
c‘emcwe the caliper

OIL HOSE BOLT

F RON?

REfiH

 

PUNCH MARK

    
     

BRAKE HOSE

CALIF’ER E01 T

PIVOT BCLT

,V, a

CALIPER BOl T

PNUT 801 T

  

BRAKE HOSE

 

17-10

HYDRAULIC BRAKES

 

DISASSEMBLY

 

Remnw .M- "Hun: mg
"11* um :M: mu N."

7 mn mm and mm mung

7 «he (alum nwm an“: and been

Rnr'mvu Wu (xv-"mu (mm W? Lara?!

1‘ decflu'v IDD‘V commnseo an to me 1:474)!”
Hmd mm to 9‘". .M maven nu: Place a shop var)
under the uhm' to rushncn the omen when ‘1 ‘1
expelled U}! the an m mm: spuvu

 

[)0 no! (may (hr mum mo (lost In the mini

 

Exammn [ha pistuu'. and cylinders for swung.
ScViIChIN m utre' damage and repiace J necessary

Pznh :rw {mum mm H w‘f Men DuY and dncam
lhn-m
Clean lhn (nl ua‘ qvumes w‘m bran “mo

CAUYION

8v awful nu! In almnufl’ rile pmun xlnlmg
.\Ilflllt‘r\

 

BOG‘S C’W‘D7CCM L 5“

 

17-11

HYDRAULIC BRAKES

PISTON INSPECTION

Check the pistons for scoring. scratches or other
faults. Measure the piston diameter with a micro
meter.

SERVICE LIMIT:

Front: 31,94 mm (1.258 in)
Rear: 30.14 mm (1.187 in)

CYLI NDEH INSPECTION

Check the caliper Cyllndll’ for scoring, scratches or
other faults. Measure the caliper cylinder bore.

SERVICE LIMIT:

FRONT: 32.09 mm (1.263 in)
REAR: 30.29 mm (1.193 in)

ASSEMBLY

II the piston boots are hardened or deteriorated,
replace them with new ones. The piston seals must
be replaced with new one: when-var they are
removed. Cont the seal; with silicon: atom or brake
fluid beIore assembly.

Install the pistons with the dished ends toward the
Dads

Install the collar boats and collar making sure that
the boots are seated in the collar and caliper grooves
properly.

Install the pad spring and pods.

 

 

COLLAR BOOTS COLLAR OIL SEALS

‘ I
0

~ 0%:

PAD SPRING PISTONS

 

 

17-12

HYDRAULIC BRAKES

 

INSTALLAT|ON

Be sure max lhe vexumm cm I; m Doslhon an "we
caltpm bfitkl'.

Ivsoecl U‘E cond Hon '1' we cal-per D110? boll tmu'.
Amw l-izcone yen: w om. m»; :n ma mNp—x
nwot Do't

Mnyl in! cahoev ant-Wm y on" me b'ahr mu; w
"13th 6.34:1: 005m m-d (man: (he puts

CAUYION

 

 

[fr rareful m ‘l 11‘ JJmux'r 1hr pm}:

Imuil the cahpel plum Dc. r and tallpe' hoi!
Cannes: the Drake hou- ma hg‘fir" we brake how
30!!

YOROUE' 25—35 MM (2 5—3 5 km, 18-25 't-lbl

H! the brake mm muwovr anc bleed {he brake
system Ipagc 17-4)

REAR MASTER CYLINDER

REMOVAL

Dram my brake Huh! hum the hydvaulic Lystnm
(“my 17-3),
Hrmeva me ugh! 1001 [mg markex

F RON}?

N

BRAKE HOSE CAMPER BOLT

RE
CL
HEAR

TAINER
IP

RETAINER
HIGH" FOOT
PEG BRACKET

Cm IPER PIVOT BOLT

80L T

CALIPER
BOLY

   

BRAKE HOSE BOLT

 

PIVOT HOL‘I

 

 

17-13

HVDRAUUC BRAKES

 

 

'[R 2‘1 'Jfl- h
“‘H

 
 

9114an HOSE
Fix: a urnn dram pa" pay: 2” mas'm' Ly‘fl‘d!’
am d-Ko
cylmae'

31L: WI, brake N. ‘ron‘ (”we Magic“

   

CAU'ION

 

Judd srtllmx P-Nkr flua.’ .vn patina! ur pimm
mrjm‘c‘s I“I”T.I"1IIIUI’IILIUVVTIXK"
Remove the mum Lyhnucr auachmg Doll; and
vemuvu lhn mulm uylulum

 

Uil FUSE 80L? SCREW

Rtmove (M ma)‘ 1 cyl-nur‘ 41:36th mm: and
.emoue I'm "mu-r cwwm‘ hum” (rs "emu

Hemuvr1h:Hymn-hm,"mum-3v mag-:- 51‘

 

M TACHINu am ='S
BRAKE
STU? C‘ UNDER
Loomrw inn mrk n-x'. and rerrow the Drake mutt! .
:vhnce' hnrv' m:- lyah-I rod lam? by turning cm
me man rod

 

LUCYHL' HEARS
mm mm"

 

17-14

 

DISASSEMBLY

Rumova [In “1er cove!

Remove ml map nng with snap vino plum I07914—
323000” and Iemove the pum vod "om ma master
cylmdev

Romm- me mnlev amon‘ pnmuy mo and sonny.

II may bu Mmurv to apply I small mount a! an
nmwm (a me "qu 0mm [0 roman mu mannr
oqun and pnmry cup

Clnn III am: With braka "Uld.

REAR MASTER CYLINDER LD‘
INSPECTION

Manure lhv Inside dmmetor a! mu miner cylmdu
hon

SERVICE LIMIT: "DO mm (0.553 Inl

Chock Ior icons, scratches ov mclu

HVDRAULIC BRAKES

 

 

SNAP RING

    

SNAP RING PLIERS

079143230001
SNQP RING PISTON MASTE“ CVLINDER HODV
n ‘
9““ K"
RUBBER PUSH PRIMARY CUP
COVER ROD AND SPRING

 

HYDRAULIC BRAKES

 

REAR MASTER PISTON O.D.
INSPECTION

Measure lhl muster piston OD,
SERVICE LIMIT: 13.95 mm (0.549 In)

Chuck the primary cup and secondarv cup to:
damage before Issembly,

 

 

ASSEMBLY PUSH ROI) PISTON MASTER CYLINDER BODY
CAUTION: /
fiREplaL‘? the master cylinder thton. cylinder !
and spring as a m. J
Assemble the master cylinder “‘0

Coat all parts with clean brake fluid‘

 

Dip the piston cup In DOT 4 brake fluid before
assembly.

CAUYION'

’ When installing lhe cups, tln nor allot: the lips

Io mm t’mtde oul Be cumin the map ring I:
stated firmly in line groove,

 

Install the pnmary cup and piston, RUBBER SNAP PR IMAW V CUP
CAP RING AND SPRING

lnstalI the push rod and snap 7mg LOCK NUT BRAKE ROD JOINT

INSTALLATION

Install the master cylinder on the brake rod joint by
turning in the push rod and tighten the lock nut

 

BRAKE MASTER PUSH ROI)
CYLINDER

17-16

Secum [he maste- cvhndm m the harm and human
"w mounhng bolts

Connect the Mann cvhndm hose to ma rvmu.‘v
cvlmoe' wmh | new 0 nag

mum the ngm exhauu nmmer wage 54‘

Ilghzer the screw anarhmg we train) mun.“
rv nrkr Hose cor-man!

Connef‘. IRE brake how to me master cylmdrr WIN
the ox! boil and {mu m; .ng washers

Lower» me but: husr non

TORQUE:
25-40 N'm (2.5—4.0 kqu, 18-29 h-lbl

Inn-II the ngm '00: we lunch!

Fm me Drake "we Von-won ind mead m: I"!
make tynem (Dag: ‘7 4|

 

S C R F 'u'.’

:Z'JU' "EC: EPACKE ‘

HYDRAULIC BRAKES

 

OWNG

(”4,34be HOSE

  

SK ALIN!» WAQHFPS

 

 

17-17

HYDRAULIC BRAKES

 

BRAKE PEDAL SHAFT
REMOVAL

Unhoui the brake uqH swm": 5m “9 and vcvnuw
the rear brake medal

Remove the brake master cvlmdar Iran: the brake
vodiomt Inage17-14I

Unhcnk the bunks ‘eu/r sp-mg and remove the
rear brake pedal the“

Remove the cutter pm and jam pm, and men
disconnect tn? brake 'od yo=nt from the pedal
shah,

INSTALLATION

Connect thu brake ma Join: to the Drake fledm shaft
wrth Mu Iomt ow and d new cotter mn,

Apply grease to tha bake pedal shaft and innalI It
In the frame

Install ma htaka master c,‘ radar [939217 16!

 

Hook the brake return sprung correctly

lnsuIl the brake pedal alignmg the punch marks on
the man and pedal.

Trghten the braka pedal hurt.
TORQUE; 24—30 N-m (2.4—3.0 Ito-m, 17—22 ft-lb)
Hook the brake lught twitch spring

BRAKET LIGHT
SWITCH SPRING

BRAKE PEDAL

REAR BRAKE
LIGHT SWITCH

/
BRAKE PEDAL SHAFT

BRAKE HOD
JOINT

LOCK NUT

BRAKE ROD JOINT

 

   

PIN

RETURN SPRING

PUNCH MARKS

 

 

17-18

 

MEMO

BATTERY/CHARGING SVST EM

 

 

 

 

 

 

 

 

 

 

ALTERNATOR /
BATTERY
—— RED/WHITE —T_
RED
1r>
K
FUSE 30A :— E
g _ <
— Q
_I —
J _
u, _ _
" MAIN
VOLTAGE swncn
I SENSOR
ALTERNATOR I c 3“, cx _
GREEN REGULATOR/RECTIFIER
BATTERY/CHARGING SYSTEM '2'

 

18-0

18. BATTERY/CHARGING SYSTEM

 

 

SERVICE INFORMATION 18-1
TROUBLESHOOTING 18—2
BATTERY 18-3
L CHARGING SYSTEM 1H

 

 

SERVICE INFORMATION

GENERAL

0 Mary fluid 11ch should In Mod vow-Hy. Fill with diam-d mu! won my.

0 Quid: duru- a bunny only in In «new. Slower-crying is onion-d.

I Ramon m. balmy from m. motolcycll Io: charging. II the bunny mun be chm on th- mmomydo. discount: xho
battery ablu.

 

Dommh.-lkqfl-nawfiulmm. m-WbyIMIywmbbllfl-Ia
any-harming

 

 

o All Wmmmmmwkmdmflnmam.
O Murmur mum-l in In Smion 9.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

 

Clo-city 12V IMH
MW Sud": vanity LZBORO°C IQ'FI
W m: 1.3 M mumm-
Loon mm 5.” rpm
Alternator Cluck
v 10.2A min. (No loud) 25A mm (No loud)
Volt-9c muluov Trmlnorlud mnadiumblo rogumor m

 

 

18-1

BATTERY/CHARGING SYSTEM

TROUBLESHOOTING

 

No‘powu - key turned on: Intermittent power:
1. Main fuse burned out 1. Loose battery connection
2. Dead battery 2. Loose churning syn-m connection
~ Low fluid level 3. Loose tuning Iy-mm connection
— Low specific gravity 4. Loose connection or short circuit in ignition
— Chming system hiiure system
3. Disconnected battery cable 5. Loose connection or short circuit in lighting
4. Faulty Ignition switch system
Lora PM! - kw turned on: Chewing mum failure:
1. Week battery 1. Loan, broken or thomd wire or connection
— Low fluid levei 2. Fully voltage regulator/rectifier
— Low specific gravity 3. Fully Iiternllor

— Charging system hilure
2. Loose battery connection

Low mu —- engine running:
1‘ Battery underchargod
— Low fluid level
— One or more and cells
2. Charging system failure

 

18-2

BATTERY/CHARGING SYSTEM

 

BATTERY NEGATIVE CABLE HOLDER eon posmvs CABLE

   

REMOVAL

Ramon me wh o-dr covev

Remove me mmrv hnldm DOIL

Ducnnnocr mo ground cable at the banew xerrmnal
than diuconnacl the positive cabIc.

Disconnect "w battery hruarhm lube.

Ramon: lhn bllluvv

TESTING SPECIFIC GRAVITY

Tut each an Mn a hvdvomuev

SPECIFIC GRAVITY 1170—1290 1201,6371 “"5"" "“7““

 

 

 

TUBE
V2707 I 290 Fully charged ’
Botow I 280 Umeruharged
ET“, { ..
‘ Thu bun-1v must b! rucherged I! the spe- ,
cm: graww u below 1,230, 5 ‘
- .1 r‘ I n n - 5.
Th! ,9“; uc gllvfly va nu w l x a temp: ._ ‘
ruuuo u Ihown In me accompanyunq tablu‘ x‘a
‘ - Replace "w binary IV mlhuon IS :videnl g ,

‘ m n "u.- spaee below Ihe ceH plates :5 “Hod
\ wnh lad-mam ‘

 

The Murrv cmmms wlfunc acid ,4 mm!
mama mm dun an. or rlolhmg

lnnduu Hum unit “In and 3H pmmpl 7; imTr—r
mcdml utmmun

'5 2t- :5 x: 1: iv
as at v n u ‘
Dn‘i ”nuis-

25.;-

     

CHARGING -- 7 7 v T

Roman lhl buluy ct“ ups . .

Fnll mo bumy can: wnh dmnled water :0 [M § ‘
'4 \

uppm lav-I line, >' nlcusarv

Cannon tho chum" ommve In chI! to the bunny
pomwu H) lavmmnl.

Comma mo charger negative 1—) cable m m.
mum mum: (ml umwul

Chiming tun-M: Ll Imponl mnxv
Charge the Dulcw unhl mach: gtavnv :5 L270-
1790“ zoic (68°F!

 

BATTERY/CHARGING SYSTEM

 

t wAMING

~ Belarr damn; a banana runme (be can
flu!!! (nth all

- Kn; flamn and walks away from a (hair ‘
in; bunny
Tum pawn ()N,‘()FF All ”It Merger. not
all II“- bunny lamina]: to prevent xparlu.

- lfiuommur rimming if Illt ckrlrolylr
Irmpmnurr (find! 45 I”C(l I3EF).

CAUYION

' Quick-(hauling should only be done In an
tmrrunry. xluwvhalgmg ix preferred
Raul: {hr hmnhrr rub: 11: shown an 1hr
Murry muluzn labrl
Am. .mullmg the battery, con me terrmnzls with
dun gvuw

CHARGING SYSTEM

CURRENT TEST
nor:

at In" mu balury I; m good madman
bolon pedovrnmq thus (an

 

 

Warm up "w engml‘
Remove both harm sndo convers and me seat

Ducunmcl lhu buck wue n ma mgulalorfrocnhm
counlu

Dnmnnen [he hudngm

Dawovmect me tmmy poslme can): i! the Danny
lumunll Ina connect in imMflEI between [he
bonny (obit no "rm-rm

Allow "\un in die

luau” anqmr we“! xloww

Chuumg Amman! should be a mummum 09 1O 2 n
1,000 mm And should be a mm-mum 0125 ampere!
n 5,000 mm

Check m. smm [page 18 4) and {hen the regulalou‘
vecllhm (mm- 185), I! (he wavgmg spacaficnhum
nu nu! ma!

STATOR CONTINUITY TEST
Duconntcl 1h! Illevnllor and vegulalon‘uclmel
couplcv,

Check 10' connnully between the leads, urn m,
ann In: Ind! and gvound.

Replic- the uuov .' mere rs no commww between
an leads, 0: :' "we :1 commurly between "19:06;
am ground

18-4

 

BATTERY/CHARGING SYSTEM

 

 

VOLTAGE REGULATOR/RECTIFIER
TEST

Remove the light side covert
Diannect the regulatot/rectifiar couplers.

Check for continuity between the leads with an
ohmmeler.

”0th

 

The test results shown are for e posltlve
mound nhmmeter and tho opposite results
will be obtained when I negative ground ohm-
motu is used.

 

 

 

 

NORMAL DIRECTION: CONTINUITY

 

 

 

 

 

 

 

 

 

 

 

REDMHIYE
C2) ptobe G) probe 0 z
I YELLOW GREEN 2 E
u RED/WHITE YELLOW 9 S
a» 3‘ g
REVERSE DIRECTION: NO CONTINUITY g 3 g
r G) Mob- 9 probe 1 2”“ E
g I GREEN YELLOW g > n:
L n YELLOW RED/WHITE z x

 

VOLTAGE REGULATOR
PERFORMANCE TEST

Connect e voltmetev across the battery.

Check rewmov poriotmanoe with the engine
running. The tegulatm must divert current to
ground when buttery voltage reaches 131)"
Nov.

 

GREEN

 

 

 

BLACK

 

 

 

 

 

1 8-5

 

IGNITION SYSTEM

 

’1]
W ENGINE STOP SWITCH
I/fl

f I
\ Q3, IGNITION swszI 5"“ U" T5
”Q,

#2/ In IGNITION cOIL
III/#3
IGNITION con.
, . _, g

 
 
  
 
 

I, //
'\1:-
VII

    
  
 
 
   

 

 

BATTERY
PULSE GENER ATORS
TO
Tpcnoumn ENGINE 5“,, “WHO“
IGNITION COILS SWITCH SWITCH
or r
0 ON g
u
OFF OFF a
1% F use

 

 

 

 

 

 

MTTERV

 

 

 

 

«||——I|I|I|I|I|I

sun: nuns 5““ UNIT; PULSE ususnnons

 

19-0

19. IGNITIUN SYSTEM

 

 

SERVICE INFORMATION 19—1
TROUBLESHOOTING 19--2
IGNITION COIL 19—3
TRANSISTORIZED IGNITION SYSTEM 19-4

 

 

 

SERVICE INFORMATION

GENERAL

0 A Transxsxonzed Imition System is used and no adjus‘menls can be made.

SPECIFICATIONS

 

 

 

 

 

 

 

 

 

 

ND NGK
Spark plug Standard X24EPR-US DPREEA—Q
For cold chmm Blluw 5“c (41°F. xzzepnus DPR7EA-9
For exxended high speed driving x27EPR-U9 DPRQEA-Q
Spark plus up 03—09 mm (anal—0.035 in)
Ignition timing Atidlo 10' BTDC
Full advance 37° BTW/3,300 rpm
Pulse non-mo: air 939 0.4—0.6 mm (DING-0,024 in)

 

 

 

 

 

19-1

IGNITION system

 

flNfllfiflMflfli

TM ignition syn-m rm mo tub-walnut; on let
t»: No. 1 Ind No. 3 cylindort and on in: tho No, 2
m6 No. l cylinder; Determine which wbqvnom is
unity, lhlfl woe-Id to th- dcuim um alum.

lnflm cumin but val not turn

1. E090. slop twitch 0F?

2. No out n plugs

3. Faulty "Mail-d mari- unit
4. Funky DUI-I pier-w

No M a plug

1. Engin- map valid: OFF

2. Poollv com-cud. htoiun or would wun
- Buwom ignition switch and angin- ttoo witch
- lumen park unit we main. «no Mitch
-' 30mm sud: unit And ignimn coil
" 3mm ignition coil lid ping
- Emu apart unit and Du"! gum-tut

3i Faulty But-lion coil

4. Funky i'Iil-on wind!

5. Faulty tout unit

8. Fluitv will ”not

lulu m bu! nu- poorly
I. lntullun yummy drum

- Foulty ignition aml

- Loon or hit! wir-

- Int-mitten! Mn drum
2. Secondary circuit

— Faultv DWI

- Fully hi0: [union win

VIII-h. HIM m
I. letv pul: mm
2. Foulty work unit

 

19-2

IGNITION SYSTEM

IBNITION COIL :2, M IGNITEON COIL

REMOVAL

Remove; xhe seat and fuel tank Ipage 4-18]
Dnsconnecr (he IQHKIOH cod wire leads,

Ducoonec‘ the igninon wire leads.

Remove the coil bvackets by removing the attaching
DDItL

Remove the coil from the brackets.

 

3: I,#3 IGNITION COIL

CONTINUITY TEST
Measure the mummy coil resinance‘

RESISTANCE: 23 ohm!

Manure the secondary cod resistance wixh the
spark pIug caps In pluce‘

RESISTANCE: 21—23 It ohm!

 

19-3

Ramon (he spark plug up minor renlnau Ind
rumor] hum me am
Mnuur: the secondary COII vnuuncz

RESISTANCE: 13.6-15.6 Itohml

 

TRANSISTORIZED IGNITION SYSTEM PULSEGEVSWQKWLER
PULSEGENERATORTEST ' \\

Remove the sea and Incl unk (page 4715)
Dusconnect the palm emu-tor couple” and men
u"! [M GOII manna:

RESISTANCE: Approllmnnly «0 ohm

Bclwnn whilulvlllow nnd vlllow leads (1, 3 cvlm
don)
80mm Mam/bl” And qua Inds (2. 4 cvhnd-u)

 

I 3CYLINDER PULSE

PULSE GENERATOR REPLACEMENT GENERATOR

Roman me clutch emu (on! 7 111

Remove the nu!!! panama: mount-n9 Doll: and
out” Muritm‘i

lnnall new pulsl gomutort

    

7 4 CYLINDER PULSE
GENERATOR

r I

 

19-4

lGNiTlON SYSTEM

 

Check me air gap wrlh a Male! gauge

STANDARD AIR GAP:
GAO—0.60 mm “1016—0024 in)

Install the dutch cover [page 7~232
Recheck the xgmt an turning [P399 3-8)

SPARK UNIT

IF the pulse qrneralms, igmhan coils and wmng
are good, and (he cgnmon :mmg Is not wnmm
SDeCILCBIIOHI replace the spark urns mm new one:
and vechEck the lgnmon ummg

 

 

19-5

ELECTRIC STARTER

 

 
  
   
  

STARTER BUTTON

‘ STARTER RELAY
‘ - <7- SWITCH
J

STARTER

 

GEAR POSITION

SWITCH / BATTE RY
STARTER
RELAY SWITCH

  
   
 
  

STARTER MOTOR

ORE EDI/I ED

 
  

 
  
 
  
    
   

,—
_ _ g - CLUTCH
FUSE WA 5 WW
IGNITION 5mm: 5'.-
“E
U

  

SHIFT INDICATOR
GREEN GREEN

‘?
BATTERY

 

20-0

20. ELEIfl' RIO STARTER

 

 

 

SERVICE INFORMATION 20-1
TROUBLESHOOTING 20—1
STARTER MOTOR 20—2
STARTER RELAY SWITCH 20—5
CLUTCH DIODE 20—6

 

 

 

SERVICE INFORMATION
GENERAL

0 The starter motor can be removed with the engine in the frame.

SPECIFICATIONS

 

 

 

 

 

STANDARD SERVICE LIMIT
Starter motor ”Brush—sprung tension 530—920 9 (2411.315 MI 545 g (19.2 oz)
Brush length 110— I10 mm (017-051 In) 6.5 mm (0.26 in)

 

 

 

 

TROUBLESHOOTING

Surtur motor will not turn: Storm motor turns, but angina dons not turn:

1‘ Battery discharged 1. Faulty starter clutch

2. Faulty ignition switch 2. Faulty starter motor nears

3t Faulty starter switch 3. Faulty starter motor or idler gear

4. Faulty our change switch

5. Faulty starlet relav switch Stan-r motor 0rd engine turns. hul engin- do“
6‘ Lease or disconnected wire or cable not m

7. Clutch ledG open 1. Fultv ignition system

2. Engine problems
Stem! motor turns engine dowlv
1, Low specific gravity
2. Excessive resistance In Clrcmt
3‘ Binding in starter motor

 

20-1

ELECTRIC STARTER

 

 

STARTER MOTOR smmsn CABLE

REMOVAL

m

\ Wilh 1hr uni/Inn much 0H!" rrmmv (he
negariw cable a: Ihc‘ bunny hejmr printing
the Hal!!! "(aim

 

D‘wonnec! the ulnar mom: able :1 [he mowv
Ramove the HUTIV motor MOUM‘W Do‘u. and
the “any molar

 

STARTER MOTOR - BOLTS

CASE AND FIELD COIL

  

ARMATURE

BRUSH HOLDER

BRUSH SPRING
Q
a ‘

CABLE TERMINAL AND BRUSHES

REAR COVER SHIMS

 

FRONT COVER

20-2

 

ELECTRIC STARTER

 

BRUSH INSPECTION

Remove thu starter motor case straws.

Inspect the bvurhes and measure the brush length.
Measure brush sprung tension with I wring malt

SERVICE LIMITS:
Brunt length:
Brush spring tuition:

6.5 mm (0.26 in)
545g (19.2 ox)

COMMUTATOR INSPECTION

REMOVE the “3’18! motor CHM.

NOTE:

 

Record the “30300“ and number of thrust

 

 

washers.

 

Inspect the commutator bars ior dlsooloratlon.
Bars discolored in pairs indrcate grounded armature
calls.

NOTE:

 

Do not use emery or and paper on the com
mutator,

 

 

Check 'or continuity between palrs of commutator
barsv Also, make a resistance check between in
dividuai commutator bars and the armature shah.

There should be no continuity.

BRUSH SPRlNG

 

BRUSH LENGTH

 

COMM U TATO H

 

COMMUTATOR BAH PAIRS
CONTINUITY: NORMAL

 

COMMUTATOR BARS AND ARMATURE SHAFT
N0 CONTINUITY: NORMAL

 

20-3

ELECTRIC STARTER

 

 

 

CABLE TERMINAL MOTOR CASE
FIELD COIL INSPECTION NO communv NORMAL

Check for cont-Many lrorn (M cable uvmmal m
(M motor an no horn 1M cable "mum! 101M
bvuuh mm:

RIDIICI (h: run-v motor ll the hold coil u not
commuoug at I! 4' u shorud ID lhn motor cue.

  

CABLE TERMINAL BRUSH WIRE lGLACKl
CONYINUITY NORMAL

BRUSH HOLDER PIN
ASSEMBLY/INSTALLATION

Allyn the cm nelch with (M brush holder pm

  

 

NOTCH CASE

INDEX MARK PIN SLOT ‘NDEX ”ARK
Install the nu cover .I-wnng vu slot mm Ihe Drum

holder pin,

Make sure (h. vnr cover mdax mmk I: signed
mm the cuss lndu mnrk

 

BRUSH HOLDER MAR COVER

 

 

20-4

ELECTRIC STARTER

 

STARTER CABLE

Install the starter motorr
Connect the starter cable and gallery ground cable.

 

STARTE R MOTOR

 

STARIER RELAY SWITCH

INSPECTION

 

Depress the slirter swnch button Wllh the ignition
ON. The COII is normal if the starter ralay switch
clicks.

 

Connect [ha In ohrnrmtor to the “arm rally Mitch
terminals.

Connect I 12V battery to ma switch cable armi-
nals. Thu switch is normal if there is continuity. 1

 

 

 

 

20-5

ELECTRIC STARTER

CLUTCH DIODE

REMOVAL

Remove vhe seat and fuel tank.
Remove the clutch duode Irom me wire flatness.

INSPECTION

Check 70! comimmv wnh an ohmmelel‘

NORMAL DIRECTION: CONTINUITY
REVERSE DIRECTION: NO CONTINUITY

Repiace the diode iI it does noI meev wecihcalions.

20—6

 

IN ONE DIRECTION: CONTINUITY
IN THE REVERSE DIRECTION: NO CONTINUITV

 

I

21. SWITCHES

 

SERVICE INFORMATION 21—1 BRAKE LIGHT WITCH 21—12
FUSE/COUPLER HOLDER 21—2 CLUTCH SWITCH 21—13
HEADLIGHT 21-3 FUEL LEVEL SENSOR 21—13
INSTRUMENT 21-4 FUEL PUMP 21-14
SPEEDOMETER 21~7 FUEL PUMP RELAY 21—14
SPEED SENSOR 21—7 THERMOSTATIC SWITCH 21-15
TACHOMETER 21-7 TEMPERATURE SENSOR 21-15
HANDLEBAR SWITCHES 21—8 TEMPERATURE GAUGE 21-18
IGNITION SWITCH 21—9 BRAKE AND TAIL LIGHT SENSOR 21—18
GEAR POSITION SWITCH 21-11 TURN SIGNAL CANCEL SYSTEM 21—17
OIL PRESSURE WITCH 21—12

SERVICE INFORMATION

GENERAL

0 Some um“ hm o-Huml colored band; around mom nu! the comet, Than In an“ Io mm: mm midi cor

 

moond mm m bond colol

All plastic plug Mn locking lIbI that mm b. mound bola- diseonmctmg. Ind must be Ihpod who "coon-ulna,
ThI Inflow-nu color and!!! and III lfldICIIOd throughout! thi section Ind on (M wivinu diaguml

Eu -IIuI G -Grnn
ll '8lIek Gt '6!"
Rt '3” LI-Li'nfllm

Tu scum In electrical lulu". m the maximum of m- min! nth "mum th- out. A community and: an muIlly
b0 nude mthout vaovmg KM pm horn th- mlovcvch. Simply discount“ the aim Ind cum I continuity tum o:

volt-ohmnu tn the annual; 0t connocticm.

A cont-nutty mm is uselul when attacking to find out w'mhar or not than I: In electrlul connoctinn buwun the two
poinu. An onmmom I5 nndId to mIIer the ruinIncI ol I circuit. Iuch II when then It I mcllic coil rulmm Involv~

LG - ”in Gran R . Roll
0 - 0mm W - mm
P - M V - Vim

ed. at when euclung lo: high "mum tamed by curved“ comm.

21-1

LIGHTS SWITCHES

 

fUSE/CWPLER HOLDER
REMOVALNNSTALLATION

R'mon (h! fun maid-v cavev

 

HJSE HOLDER COVER

FUSE HULDEQ COVE; ”(mu .-, 545.5
Ramon etch ham mountmg bo'I and pull the \ 4
ham: "om ufldc' "I! covv D.xconr\ecr the horn
mm horn me lem’unl‘x

  

FUSE HOLDE R
Remove rm.- ’ust holner anachmq 5249M
Dnccnnecl me van counlou f'om me fuse fielder

I
COMP. Em

 

 

21-2

LIGHTS SWITCHES

 

.w'r 31""3 1“: :_r‘f“‘ff‘) ; H " "

‘u. rhr-r :y'L‘Q-r a: 93;; w‘ v.—

   

RF-wLmz 'Vw- UH” aflarr‘wq me ‘Liu 2rd rawnhr
n'; da- IV.“ in" 'n 'l

 

'Jv’P'WC 5?;er
Rcvv‘wr Haw twmzh‘r :v,‘ *ar'murg Thu "Ju d'VJVH
mu NW: [you vmm- wav yum

ltumll Hm hm: «minim 'mldw bracket In m9 7:-
valse min-v a! “"1va

HEADUGHT

REMOVAL

Ramon: vhu hemhgm mountmg xrrew
Ducunnnu Ih— w”: coumev and remove 'he heal
Ilgm

CASE REMOVAL INSTALLATION

Removr m- hnmugh: case mmmr-ng Dolls and the
mum-9m cuu

Imull me Mullah! case Irv mg reverse oruev ol
removal

RR-ifKE' gowns“

 

  

mum [ohm vowwwc
scam. HEADLIGHY CASE
MOUNMNG (10; Is

 

 

21-3

LIGHTS SWITCHES

 

 

HEADLIGHT BRACKFT
BRACKET REMOVAL/INSTALLATION MOUNTING BOLTS

, \

    

D-me! IM hon! tum ugru‘ mre connector!
Removu Ihn Mlfll-vm buck" mounting bolu ma
bucket/tum pen-l linmbliu.

lnsull m. hudlrghl bucket m the men: order
of ramoul

 

INSTRUMENTS 'couPLE as

REMOVAL/ INDICATOR BULB
REPLACEMENT

Remove lhn hudhqm and case (page 154!
Dnsconnnu w: couplers horn (he mmumenu.
Remnvo lhI Inmumsnl housing mounting nuts and
In: housma

 

MOUNMG mns

 

21-4

LIGHTS SWITCHES

LOWER COVER

Remove the lower cover by removing the screws‘

CAUTION
' Du rm! leave Ihe instrument; upxide down or 1
damping fluid will leak mm) (In: [nude of III:

‘ (an: }

g7, ,

 

NUTS, SPRING WASHERS AND
PLAIN WASHERS

Remove the unstrumem bracket mounting nuts.
SDHHQ washers and plan washers

 

INSTRUMENT
BRACKET

Replace any inopevaliva bulbs.
Aher unstafling I new bulb, check for conunuuy‘

IV The new bulb does not Ivghl, .nspect the wiving To:
an open or short cucuil, or loose connections.

 

LIGHTSJSWITCHES

 

DISASSEMBLY

Ramon the IMHWMK upon! com by nmving
the warm

ASSEMBLY/INSTALLATION

Asa-male Ind inmll m nnsmumnu m m mum
cm! a! dlommb‘y and "maul.

 

 

 

21-6

lIONTS/‘SWITCHEB

 

SPEED I TACHO
ClflCUlT COMP.

    

SPEEDOIETEI

l' the epeedomerer re maneretrve. It rs necesse'v
to check both the odometer and tachometer as
follows

e I! only the tachometer xs operating, check the
speed senior as described below

0 II the ebove check evidences that the speed

0 sensor re normel, then reolece the speoaolend
techometer clrcutt
IV ell the above checks fell to turn up the prob-
lem‘ the condition rs in the Wire harness In the
meters Drecerd the harness end Install a new
on.

e If only the odometer Is ooeraung, check the
speedometer for loose or leultv connector!
ll they ere normel replace the speedometer
thh a new one
Replece the weedoend tachometer cel’cull :1
YM condition “in oerysts WIRE CONNECTOR

0 ll both meter: do not operate properly, reor
lece the ioeedolend tachometer crrcm

SPEED SENSOR

Turn the Ignition twitch ON‘
Meeture the volteoe between the Brown/Sleek leed
lpoeltive] end the Green/Bleak lead [neg-live) It
the inttrument coupler.

VOLTAGE: IV mln.

 

 

 

 

 

 

 

 

 

 

Mature the volteoe between the Black/Yellow
leed (omltivel end the Green/Bled: teed (negetlve)
It the lnetrument ooupler while turning the "ant
wheel elowly

VOLTAGE: 0V .. 4V to IV min. AW

   

ll there it no volt-9e, check the wire connection.

TABIIIJMETER

Ir the techemeter done not Indicate properly, chad:
end repelr the Nail cylinder ignition system.

 

 

 

TACHOMETER

 

SPARK UNIT

 

 

 

Ir the orohlem ttlll enpeere, check continuity ‘
between the yellow wire terminel of the wire
hernm tachometer coupler end the yellow wire ‘
urmtnel el the No 1 cylinder ignition coil end
repair the circuit il nee-stew.

 

 

 

 

 

 

s

N there it cont-nutty, repleoe the tachometer with
0 new one

 

 

 

 

 

PULSE GE NE RATOR

 

 

 

21-7

LIGHTS SWITCHES

HANDLEBAR SWITCHES ‘ THERMOSTATIC SWITCH

The handlebar cluster swixchas (lights, mm signals.
horn, etc.) must be replaced as assemblies.

Cormnunv tests Iov the components of (he handle~
bar cluster switches follow:

Continuity should axis! between (he coIor coded
mm: in each chart.

 

 

 

 

 

 

 

JUMPER WIRE
HEADLIGHT Hl—LOW SWITCH Haidllchl Hi—an Switch
HI: Bu/W m an i mg I HI Lo
MIDDLE (N): HUN :0 w m Bu 1 r) '
LO: Bu/W to W ‘ H. O W.“
(m o ~19-43
Y Lu C) . _C‘ ‘
Color cod- Bu/W Bu W
“L _4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TURN SIGNAL SWITCH Turn Signll Switch
mam: G: m L8, Br/Bu m LBIW ‘ w R L ‘
G to P ,... ».
LEFT: Gr (0 o. Br/Bu to 0m “'6'" U Q
6 m P LEFT {3— Q
PUSH: c to LG/W ‘ I
PUSH
Comfode 6- 1 LB 0 Iar/au‘ 10/w G V P G LG/W
HORN BUTTON Hom Button
,, , ,_ _
LG to G with button depressed Ho BA? 3

 

Na continuity wnh button rel-axed

 

 

 

 

 

21-8

GHTS SWITCHES

 

STARTER BUTTOP. E‘JCI‘HF SYOF’SM‘CH

BINV (0 V!!! wnh human Dmhcd 111.
EUR :0 Bu/W wuh OUI

Start" Button

 

 

mes A
PUSH IR. 1 I

Colo: cod- Y/R HIM BIA/W 8| R

ENGINE STOP SWITCH

RUN‘ BIM m Bl/LG
OFF’ No continuity

 

STAPTER UYT
Enomo Slop Swuch 5 ON

 

 

   

 

an; 7 :G
iOFF ' V I j
7mm ‘ : 1 g
for; ‘ ' #
¥CoIovcoda ' BI/W - BULGfi
I_ v 7‘
IGNITION SWITCH
WET.” “45-. "“.(1Ix" ’ijef E’VI LSI)‘ IV‘F‘éZI
IFIB 19' ECU SWIIU' {Only r"
Check CCIHII'HMV a! [gunman on we Igmmn Much

.1qu! .v each smlch Damon

 

IGNITION SWITCH

SWITCH POSITION

LOCK: No :onlmunv

OFF No Conllnully

OH R (0 Bl, BI to Salt). Bu/O m Bv/w. 81M to By ~ Continuity
PARK' 8 m 8: - Communv

rrum... ' 7 ' ' ' ‘ fl

' — BAT! IGN FAN TLI 1’L2 PA

 

 

 

C°‘°' a aI BuO avw a: a,

 

21-9

LIGHTS SWITCHES

 

REMOVAL/INSTALLATION

Remove [he headlith and headI-gh! case.
Remove the msL-uments {page 21 ~43

Disconnect the Ignition swnch wire coupwr at :he
coupIer hoIdur

Remove the Igninon switch moumnnq bom, and
Ignmon switch,

Install ma IgnIlIOn switch In the reverse order 'of
removale

DISASSEMBLY/ASSEMB LY

Open the wwe clamp.

lnsen the Ignition key and turn I! I0 between me
ON and OFF detenl DOSIIIOI’IS,

Push the lugs mm the slots and pull the contact
base Irom me swnch,

Assemble xhe sgmtion swixch in the reverse order of
disassembly

IGNITION SWI TCH

  

mine COUPLETE

 

 

WIHECLAMI’ IGNITION KEY

SLOTS

 

LUGS

 

21-10

LIGHTS SWITCHES

 

EHR PHSITIUN 8mm“ POSITION SWITCH COUPLER

Remove the sea! and fuel tank,

DISCOnflECY (he posmon swnch couplev,

Check for continuny between each terminal and
ground in each gear posmon.

m 'v nvulnm 5.7-?7'7036 Yam/"70‘
‘Af

     

Lam ‘

   

 

 

REMOVAL

Remove me gear position swttch cover.

 

GEAR POSITION S“ 'chH
Remove the gear posmon swnch anachmg scvewsl
and the switch,

 

 

21-11

LIGHTS SWITCHES

OIL PRESSURE SWITCH

Dram the engine nilt
Dlsconnccl the an pressure swrtch lead and remove
lhe swvluh.

Check for contlnulty whlle BDDlvzng oressure to the
swutch‘

Replica the switch ll necessary.

Apply a liquid sealant to the swutm threads belora
Installing the swrtch.

Scrnw the switch into the crankcase and leave two
threads from the bottom. Than t-ghlan II to tha
specifrad torque

TORQUE11O—14 N»m(1tO—1.5 Inc-m. 7—10 h-IbI

NOTE:

Do not ovartighmn the switch, or the crank
‘ case may be damaged‘

BRAKE LIGHT SWITCH

Check the rear brake light twitch for continuity
with the 'ear brake applied.

 

Chack the Iron! brake light swntch Io: contmurty
wnh thc from brake applied.

Replace the swnches N necessary.

CONTINUITV BE LOW
0 3 ‘ 01 Itgr’crnJ [4 3:11: pSll

 

 

21-12

LIGHTS SWITCHES

 

CLUTCH SWITCH

Crudv curmnum a? me much eve' us‘uy. swam
wm‘ (he Clutch "~59an Inc 3:1le
Rau’acr H "Qtflfllvy

FUEL LEVEL SENSOR

REMOVAL

annu my hm- Huh rm (1'; n the hm
Rmmwo Hu- luw‘ Ian-I v-mm anacmng nus; mu]
hm Ievo: wmu'

No“

He carom! no! to hand me “on! aim

INSPECTION

Mnuu- mo hm! level serum IESISXBHCY wmn NH
and nmuw ”on pummns

RESISYANCE FULL 3.5—9.5 ohms
EMPTY 90—100 ohm

 

éTCH SMTCH

CLUTCH AWUED CONTINUITV
CLUYCN RELEASES NO CONTINUITY
FUEL LEVEL SENSOR

FULL

EMPTY

 

 

21‘13

 

h. DZDOEO

 

mwkw5h40>

 

><4wm n23; Jung
meEU #10: xU<4m

mwxqmm

m5; Emmi“...

><4mm $23.; JwDu

 

vruwu

mmuEw: 83> 2: 32%. 5:25:09 0: m. 8!:

2 >39. 95:. .9: 0:. 33¢». 555:5". w. 0.0.:
= .35, 2.3 .295". >22 95.5 .03 2t 93 25)
2.3 :5 {can 2: c9933 25253 .3 xuozu
5 F .v mama.

Scan .03 9: 9.5 53:3 Bnan. .8 5.9.8
aEaa .3 I: xowzu .3930 E: 38 aEaa w... :
20 a. 22.3“ coEco. a...

93 68.55 Eu quS 323 an. .623 Sign >59.
9: 2.5.5 3::qu nEan 32 or: .2: 33 9.32
,20 5:25 coin? 05 5:: 5550. 2305
33.9, Eaton or; “.595 >39 5 can 33> 50.5
Em; gum."- >39 9: cunts—an wanna: 9.: 0553.2
39532

can .323 suntan... 3. 53:3 >39 9: xumnu
63783 ESD m L3 ,3sz

.335 530E n5 Ea: >93 95.... 3 9b 99:01
5>0u 25 9:2. :2 2: u>oEom

>55. .52 E:

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$2.... 9.5.. .03

m5 9 .2038 2.: 52:3 .3? .095: vi 9550:
42.: .03 or: Ewccou

0—::_E\$a_. a to 3E. :6 .5 v.3 mud. Uu 8o
u>h_0<m<o 30.: gm JED“.

£55.:

an 2633 So: BE... 33 3: 05.52% 2 9
>2 .uxamn 9t 5 #595 St 32:32 .:o 55.3
cofcu, on. 53 :2: 46:83 m .2 3an 2t
2:. 25: .2: 5 use :0 53:3 5.5:! 9: 52h
.20 oz: .2: E: 5:.—'

‘u:__ .03 E: 3.2-: .333

33:35 a 20: 95 a: 33 2: 53.535
.3338 32:3. 2: .o miEEE. SE;

9.5 5.3m Em; £53 an. Evian 2:; 9t :95
V3328 >23 9:3 33 2: 59:50.5

.uuo

oz: .3; E: 53 US 9:95 at. nofi :3... .35
6:3: m2? .2... m5 55a «Em ucicm m5 taum
.53”. yr: 5.... US an...“ .2: 2;...on

 

 

Hy .aSEuu 3»: "E“ B 3.55 is; 3: an

E
5...: a...

.25 in: a 5:) 2 3232 .3)! ins: Qt EmBUE
5: “you 33m .2: u... : 60:86:. 83m 3:. on.
:85 as: >52» new :3 2 =0: 05 26$. .325:
3:; any 8 .2960 .023 .32 .02 ft 52:50

.20 18:3 5.5.9 on. $3...

mm:0h.>>m,,m._.10_._

THERMUSTATIC 'SWITCH

The cool ng (aw mornr s ar‘ruared by I'H.‘ :hrrmo
Hurt swtch Jonah-a w: hrwcr rm: 'ad‘aTDr

H the ‘an motor con 'mr mm, drscnnnear 'J‘r: b at
.5an green ‘eam ”arr rN- trvrrnstaz r, mad: n"r1
mart them 2096mm min .1 Jr'rpe' .w'r:

Yum the rgn rror' svmrrr m.

The cooling far moro' ”mum van runn 'rg.

IV ll does no! slan‘ rim-ck ’0' Danery volugr- lrarrr
rhu black iead (DOSIINL‘I m lrlockn‘blue cur-9.1mm; or
rho inn molar ccupIr-r

IV more I; no vo‘ugr r-r\.~(h Im a blown D' ‘au'w
law .0952 {emunu‘r m Lu'mecvrri ' a" upm-
C 'Ca‘r

I‘ r na’ts, nsmci 17w NH th-r'vrastaEI tfl-JC” .u

 

'm lows

Suspend In! much vrr H mm 01 coolanl 150 50
mrllwfl and check My lnmmralurus .41 mm rm,
much opens and clusu Mahm sure that “new «1 m
rwdch wnrmu-rv a! room temperature rmd
gradually verse we coo‘mr teth'a'rur? Ync swrrw
lhould have comrnuru (cImel :1 m- 102:C (208
NET)

N0"
1

 

' Malmain me 'rruh temperature for 3
minutes behin- roumg connnurw A run
den many:- 01 lemmramr! will cause on
«re! rn rm: umpeulme readmg belM-t-n
me Ihermomerer am the swnch

Do nu'. rex (he r'u-vmomemr or xwrcr
loud" the pan n u wrll grvc a false reach-IQ
Soak me much m Cooia'r: un m m
thraads

TEMPERATURE SENSOR

Duconnec! in: green Imp ww- ‘vam the tumDe'a
'0'! “(nor

Dram rho cooianr and remove {he rcmpcrurmc
rumor 'rom (he rhermosmr case.

 

LIGHTS SWITCHES

THERMOSTATIC SWITCH

     
 

TNEHTAOSM'AIC
SWYCN

 

 

21-15

LIGHTS SWITCHES

 

Suspend the um! m ml over a burner and measuw ‘ .
the rmslanca through the uni'. as the oil heats up, TEMPERATURE ”FMSOR

Y

 

60°C 85°C no"c 220%:
140°F Has“; 230"r 748‘F

 

Temperature

 

Resistance 104.032‘ 4195i idéii 16m

 

 

 

 

Wm! gloves and rye prolztllon

NOYE

 

Oil must be used as ['12 hened humd 7.)
check operalinn above mo”c 012%)

~ You‘ll 991 [also readmgs if either (ha

lhmmnmeiev 0! lemoeutme uni! touchas

the pan, ‘

TEMPERATURE GAUGE

Disconnecl ma wire hom 1h;- temperature sensor
and shon ii to ground‘

 

 

Tum the ignition swimh ON The mmDmalure
gauge segmenu should move all the wav to [he
right

CAUTION:

,__¥,, H,

 

, —1
Do not leave the temperature serum was
grounded for longer Ihan a Jew seconds at N1:-
remperarure gauge will be damaged {

 

BRAKE AND YAIL
LIGHT SENSOR

    

BRAKE AND TAILIIGHT SENSOR

Torn me ignmon swnch on‘

Check the source voltage at [he black/brown lead.

If there Is no voltage, check and repair me source
circuit.

If them is vollage, measure [he voltage at the
whliO/VBHDW (positive) and green/yellow "199::th
wlrES.

VOLTAGE: 5 V

H there ls no voluqe, replace the sensm unil,

 

21-16

LIGHTS SWITCHES

 

TIIIIII SIGIIIl CIRCIIIT

r' “““ W
: TURN SIGNAL R.RIGHT TURN

J INDICATORS SIGNAL

       
 
 
   
 
  

F, RIGHT TURN
SIGNAL

TL1

SPEED

a BAT

   

  
     
 
  
 

  

TACHO
CIRCUIT 'GN'T'O" BATTERY
cow. swn'cn

F. LEFT TURN

SIGNAL

FI LEFT TURN SIGNAL

 
   

POSITION
TURN SIGNAL “6,,” TURN SINGAL

swncu RELAY DONTROL neuv
UNIT

 

TURN SIGNAL INSPECTION

Disconnect the lam signal switch coupler.

Check for cominuitv between the switch mmlnals
in each posltion.

 

 

R: BrrBu to O/W and Gr to Lb
N: Brilu to O/W lo Lh/W
L: Br/Bu lo Lb/W and Gr lo 0

 

 

 

 

 

 

 

 

 

 

 

 

 

Hold the knob in left oi right: P to G
Puch (he knob: LW (0 G

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TURNSIGNAL
swrrcn COUPLER
IE": 7‘” J F!" ‘g "‘ PH ‘ PL 5 IG’NI (OvéFl
a 0+0 o——o I o—-o
N V“ o——o—‘-o
if C ' o o o o——o
PUSHH A O {J
coma} Gr Lb O ar/auILb/w 0M 6 P Lo/W

 

 

 

 

 

 

 

 

——

21-17

LIGHTS SWITCHES

 

CONTROL UNIT INSPECTION CONTROL UNIT

Tum [he hmdltbu raw" and leh‘
Check the And. some: support and control uni!
k" wur, anag- ov loos-nus.

 

ANGLE SENSOR SUPVORT

Ramon the hand light (now 213).
Tum m. mmnon swnch ONV

Chect mo won-on humor: the blue/black and
gum Mu InrmIn-lx o! the normal unit was
coupler.

VOLTAGE: IV min.

 

Turn Iha Ium u'qnal swixch lo [ha Iqu m 739!“
pmllion. Thu vollmalm roads should drop hom
8V R) IV.

Pum me Ium van-I mulch
Thu vohmmv land; should rm ham IV 10 8V

 

 

21-18

LIGHTS/SWITCHES

 

 

TURN SIGNAL RELAY INSPECTION
TURN SIGNAL

RELAY

   

 

Remove lhe headlight (page 21-3)

Connect a jumper wire between the blue/bladt
Mr: 09 ‘he turn signal relay and ground. Turn the
ignition swirdi ON.

The turn signal light should come on.

 

 

BLUE/BLACK
WIRE

 

 

 

If tho light dons not com: on, Sleek the source TURN SIGNAL RELAY

volt-ac at the grey wire terminal while pounding
ml blue/block wire oi the turn signal relay coupler.

II more is no voltage. replica the turn signIl rally.
BLUE/

BLACK 9
. GREY
m“ WM C)

 

 

 

 

 

 

 

 

 

POSITION LIGHT RELAY INSPECTION

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Remove the headlight (page 21-3).

Roman mo posifion light relay. @

Chad for continuity between A and B («mil-ills.

Connect the lully charged 12v bamry to the ® ®

mlav terminal! asshown. E

The position light relay ls normal ii there is no 1

continuity when the battery is connected. ’

_ .I a r ,
I—f
\——\._f—)
H {5-4:
POSITION LIG T 12V BATTERY

 

RELAY

 

 

 

 

21-19

 

MEMO

 

_22. WIRING _ DIAGRAM

um um ""_‘

   

L..V .0" 3“
gnu.

Irv-nu:

 
  
 
  
  
  
       
  

“MW”

 
  

SUEDE I'A'El.

 

 

 

“ ‘ ‘9" :1 $3532 cu'
an “1.7‘ \ ,_ n y'tzég. L ‘ sump u 1 sum-
: ( 1‘ » an" I': 1‘. i:
uww'u‘ ‘ 1 “\MUI)“ MI ~ g "L3" ~ r

   

    
    
 
      

   

 
 

m 9.00! IF!" ‘ - 1; - -
m ans-mm LE. 5 ' L] 4.631% turn in! m '5 ‘:‘
‘ ' lv nmuv

n.“ 3mm cucu uml / I M 3 4”... E:
I I I Mama I in

1 In." 1v - WEL [fiL 'um SXJNAL Mm

Dunn
\ I “JR ‘5'!” LXI-(V 5mm

up: i Ii“ '1"! “I‘ll .ml‘ "369‘"!

0.11:3":

_/

  
      

          

 

 

VIN NEW“

W A new:
‘@ #9!!!“

M[ Iva umv

    
  
  

   
     
   
    
  

WK. tU
hr n

 

mama cnw
nu. u:

 

 

{'{LZ‘IW‘ 11

 

In u: 1'!‘ .0" "I’VLWHAI

a Hum! mm mum mn' ,
Inn/3W1”.

 

r
nunmm mum. .: E
T ,

 

. IL.” l-¥;’.Dl

 

 

 

 

5 J

 

 

   
 

 

 

 

 
 

 

   
 

 

 

/
.7 4 4 n, \n/ —4
Mvg.‘ ;. -,~_,.. ‘ ' LYHM": azimnanmgcnnéi
, ., 7 ‘ u v I
‘ - um um .0:. 39m: m" .\ . 4'.
ww. um mm,” w .n my. :4, FEEESui£ awn‘cn “ 014an ll

GLILCK ”‘5 Run!-

   

B D' :a‘
v v. :1:- U (1111!
. 9!: L: . n- w .4
Q 61!" '4 A. 4'" I""
: a.- I- u a
' 0‘”! '2' 2' I:

 

00302-M83 '6700'

 

22-1

23. TECHNICAL FEATURES

NEW TRAC (Torque Reactive Anti-dive Control) FRONT SUSPENSION

 

GENERAL

Thns motarcvcle has an armdwe front suspensmn svstem vmh ‘ouv-wav adiustabiiiw m provide the desired ride under various
braking conditions. The system consuls of a pisl,on,ve1um sprung. ml conlrol orifice and bodv‘

BODY

     

RETURN SPRING

PISTON

ORIFICE

 

23-1

TECHNICAL FEATURES

 

OPERATION

Muhammad-is dMuuow-d.“
bake dis: is would by ma bun m, causing
an bak- wlw to pivot on in back“ mounting
bolt.

This mowmonl came: the given bolt to push mu
plan" in, unommlng the on control ormm.

5m m oriflu has but on W of diflemt
dim. mo Mind dumping can In W bv
turning it. ”my: adjust an '6'" m hi! to a:
mu Fashion.

 

NORMAL CONDH’ION

 

23-2

Fvom Winn Allin-mum 0m

 

v

PSTON

DAMPING EFFECT

 

 

30F?
STANDARD

 

FIRM

 

DUN

EXTRA FIRM

 

 

 

24. TROUBLESHOOTING

ENGINE DOES NOT START OR IS HARD TO START

L

 

Chock lull (Ian u: subtly-tor

REACHING CARBURETOR

Pevform a 31mm spark III!

GOOD SPARK

V

Tm cylindtr compression

COM PRESSION NORMAL

Sun hy (ollawlng norm-l macaw"

ENGINE DOES NOY FIRE

 

V
R'mow and (nut: wk nlug

NOT REACHING CARBUREYOR——> ( I )
(2)
(3)
(6|
(5)

WEAK OR NO SPARK—— H)
(2)
(3)
(t)

(5)
(6)
(7)
(B)

LOW COMPR ESSIOH —— (1)
(2)

(3)
(fi)
(5)
(6)
(7)

ENGINE sums au‘r STOPS—O (I)
(2)
(a)
(4)

(5)

ws‘r PLUG — u)
‘(2)
(a)
(4)

fiOSSIBLE CAUSE
Fuel um empty
Claw-d Ml tub. 0: (ml mm
Sticking (Inn um
Fluiw (not puma
Pinch“ Nu) m): V.“ hon

Funny work plugs

Fouled my)! plum

Faulty our): unit

Swim at marl-a high "mien
when

Flulw lurk unll

Broken at mama lgnhlon cu“
Faulty guano» much

Funky pull: Inn-Incl

Law mnm chug:

(mummr v-m durum (loo

mall)

Vl|vI Ruck com

Warn :yllmv Ind plunn ring-
Dumnd :vlindor bud utkn
8.))!!! vol"

Impmpor VIM timing

lmpmocr chok- cow-(ion
Water Imorr‘cflv adjust-d
lmlu nip. inking

lrnpmoa Ignition Ilmlng
(Spark unit 01 pulu mm!)
Funl cumin-Inna!

Cabumor (m
Chou clam
Thrumo VIM ow
Air clam mm

24-1

TROUBLESHOOTING

 

ENGINE LACKS POWER

H.

ll

‘3.

 

Hols- whuu on mud and win by hand

WHEEL 9|“ FIEILV

t

no: rh- m
MEWRE NORMAL
Ace-1m mainly "on low Io m

ENGINE SPEED INCREASE! PRO-
PORTIONALLY TO ACCELEIAY‘ON
MEI CW ‘8 HEEELEEO

WIN

ENGINE MED INCREASES

Duck with than.
WERECI'
minimum
CORRECT

Tm cvlln‘or Wm

NORMAL

Duel cum lo: M
NOT CLOGGEO

Rum M WI

NOT FOULED OH DIECOLORED

mod MwMIm
connect

Roman :7th Ball m an mun
lubthtion

VALV! TRAIN LUII ICATED
PROPER LV

anal m Wm
NOT OVERNEAYING

mm av mu .1 my: run
ENGINE DOES NOT KNOCK

24-2

WHEELS DO NOT SFIN FREELV—‘l‘l
12!
Ill
Ill

Mm! W——.Hl
(I)

ENGINE [FEED INCREASE! IUT MOTOR—DH)
CYCLE DOES NOT ANLEMTE WELL I!)
NNEN CLUYCH l5 RELEASED I!)

ENGINE WEED DOES N07 menus: —>ll)
(I)
(I)
I.)
III

INCORRECT—’Hl
(2)

INCOIIifl———. "I
(21

T00 LOW—> "I
(ll
13)
M)

CLOGGED '—-——. (II

FOULED OR DISCOLOHED—D "I
III
1:”

lmlECY —(ll

(1!
‘3’

VALVE YIAIN NOT LUIRICAI’ED—bfll
'fiO'EILY ‘1’

OVEINEATING—‘HI

m
I)!

ENG|NE KNOCKS ——>(ID
I?)
IN

14)

FOSBIILE CAUSE
WI MRI
Worn roan-l! “Mb-In.
W m m WM
Hall 0' having“

NM ll!
lulu WI m

CIU [an llwlno
We"! dutw dhclplm
w um finial-II

m M- don-d
cm mu :1"
RM MI um
00" WWI-r

mm Oval um: am has

Fun "I M
hum m m

IWWW
”fin-I

VIM II“. ”I"

Wm will“ M m HI.
“I" N “I!

IW m “nil.

would“
Imam-In.

Flu. not named h‘qumly
mu

lurk duo with mm km
W

N: m dim

oat-alumna.
Oil-numbn-
Won!

W 0“ all-l-
00-" a“ mum)! ovlfiu

lwmwo
hmm
Luciana-admin:
GNU“

Mm ”I”! III! glint:
Mm [van 0' Out!
Eng-M nut-on baud—«p m
mien era-mu
mum "mm too would
lF-ulw "In nah)

TROUBLESHOOYING

 

POOR PERFORMANCE AT LOW AND IDLE SPEEDS

1. C's-ck igrmion Ilmnn Ind valvu durum: INCORRECT——-—->( I)

(2)
wHRECT

2. (hack autumn» pilot acrew ndiumnem
CORRECT

3‘ Duck for l-‘thg innkl 959! LflKlNG_( 1)

(2)
NO LEAK
I. Perform mart mu WEAK OR INTEHMITTENT SPARK—h ( II
(2)
(.3000 SPARK (3)

POOR PERFORMANCE AT HIGH SPEED

1. Chock unmet! timIng and "IV. dunno- INCORRECT—(ll

POSIBLE CAUSE
IW VIM allow-nu
IW immon timing
«=1qu spark unit!

INCORRECT —> So. Fool Swan Mien

DUI-flout“ inmlmr 04in.
Lao- com-5mm

Fully or lull-d luck plug
Faulty wk unll
Faulty ignition coll

worm VIM clam"
Flully soul: unll
Funny Dulu Dinar-tor

LII: 0' Incl h mt

Cloud Owl llm

Claw-d Ola-I uni: lav-mu hol-
cuom foul um

FIIIW NJ WW

(2]
CORREC‘I’ I3)
2. 0mm 'uol who I! ammo! FUEL FLOW RESTRICTED —(1)
(2)
FUEL FLows FREELV (3)
(4)
(5)
3. Banana mama: and chick Gov CLOGGED——b Chin
do”!!! In
NO CLOGGED JETS

4. Chuck VIM liming

INCORRECY—fim Wk“ not im‘llll'd

Broocflv

CORRECT
5. cm "In can: nmlcn

NOT WEAKEN ED

POOR HANDLING _+Chmk tire pressua

 

>(1l
(2]

l ll stating n Mow

>(1 I
(2)
‘31
“I

1 ll ember whul I: wabblinq

 

‘6]
(63

> (1)
IZI
{3)
MI

 

1 I' "I. mama/ch ”III IO M. Ml

WEAK—b Fully mung

saving up mud nu! loo raw.
Dam-m llllfln' "II! ”In.

Emlyn M bolting plw

Bum rim

lww lmllu maul hub
suing-m glvm having
one-SM" won!

3'“ trawl

Mag-m pm dinning bolt too
Iii"

Faulty Ihock dumb.

From and I- who.“ m Illwd
lam "om lovk

lam Mlnwm

 

24-3