Introductlon Contents This service manual describes the service procedures for ’ _ and technical feature or the VFR400R. . General Information This Model Specific Manual includes every service pro- 7 cedure that is of a specific nature to this particular : Frame/Body Panels/Exhaust System a ,imogel. Easll service procedures that are coeronito T - other Honda Motorcycles/Motor Scooters/ATVs are PART OF THIS PUBLICATION MAY BE REPRDJ . DUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACQUIRED BASIC KNOWLEDGE OF MAIN- TENANCE 0N HONDA MOTORCYCLES, MOTOR '7 SCOOTERS OR ATVS. Technical Feature covered in the Common Service Manual. This Model " ma'menance ,3.”ch SeTvice’ManuaI should be used together with 7 . . the Common Service Manual in order to provide com- LUbr'ca‘lon System , . plete service information on all aspects of this motor cVCle> Cooling System WW 7 i 7 . .7 i = Performing the first scheduled maintenance is very im~ 3 W portant. It compensates for the initial wear that occurs ‘- Fuel System during the break—in period. g’ . _ ’: Engine Removal/Installation Section 1 and 3 apply to the whole motorcycle. Section 3 2 illustrates procedures for removalnnstallation of com- : Cylinder Head/Valves patient; (hit may:be rgwired to fliprrrl §‘L1i§§.¢3:5* ,2 scribed in the following sections. .5 CI tch While Search 4 through 19 describe parts of the motor» g1 " ' cycle, groufed aficfiding to locations. Lu Gearshift Linkage 5; Find the section you want on this page, then turn to the table of contents on the first page of the section. 7 Orankshalt/Piston/Transmission Most sections describe the service procedure through . . ,, aster" “lui‘la‘l'irh Refer E° the next ”9810,7011!an 7” Front Wheel/Suspensron/Steerlng how to use this manual. '5 3 Rear Wheel/Suspension If you are not familiar with this motorcycle, read Techni- 5 cal Feature in section 20. Brake System .7." you don’t know the source of the trouble, go to section 21 TROUBLESHOOTING' Charging System/Alternator ALL INFORMATION. ILLUSTRATIONS, DIRECTIONS To Ignition System 7 AND SPECIFICATIONS INCLUDED IN THIS PUBLI- lg CATION ARE BASED ON THE LATEST PRODUCT #3 Electric Starter/Starter Clutch 7, INFORMATION AVAILABLE AT THE TIME OF AP- I 2 FROVAL FOR PRINTING. HONDA MOTOR (20., LTD. ' “-l . . RESERVES THE RIGHT To MAKE CHANGES AT L'ghtS/MEte'S/Sw‘mms '7 ANV TIME WITHOUT NOTICE AND WITHOUT . _ INCURHING ANY OBLIGATION WHATEVER. N0 1 Winne Dlagram l Troubleshooting Index 7 7 '7 HONDA MOTOR 60.. LTDI SERVICE PUBLICATION OFFICE Date of Issue: February, 1990 © HONDA MOTOR C0,, LTD. 7 ~ Important Safety Notice ”—1 Indicates a strong poss Indicates a possibility oi equipment damage ir instructions are not followed. ility of severe personal injury or death if instructions are not followed, Gives helpful information Detailed descriptions of standard workshop procedures, safety principles and service operations are not included. It is important to note that this manual contains some warnings and cautions against some specific service methods which could cause PERSONAL INJURY to service personnel urrcould damage a vehicle or render it unsafe. Please understand ‘ that those warnings could not cover all conceivable ways in which service, whether or not recommended bv Honda, might be done or of the possibly hazardous consequences of each conceivable way, nor could Honda investigate all such ways. Anyone using service procedures or tools, whether or not recommended by Honda, must satisfy himself thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected. Type Codes ; ; - Throuéhout this manual, the following abbreviations are used to identify individual model Code Area Type U,K. Austrie E AR F {M Model only) G (M Model only} France Germany How to Use This Manual l Finding Information You Need ‘ ' This manual is divided into sections which cover each of the major components of the motorcycle. To quickly find the section you are interested in, the first page of each section is marked with a black tainhatlines up with one of the thumb index tabs heiore this page. The first page of each section lists the table of contents, ,4 within the section. i Read the service information and troubleshooting related to the section before you begin working. - An index of the entire book is provided in the last chapter to directly locate the information you need, Note on the Explanation Method of This Manual ‘ The removal and installation of parts are for the most part illustrated by large and clear illustrations that should provide the reader with visual ald in understanding the major point for servicing. ' The system illustrations are augmented by callouts wlfise numbers or letters indicate the order in which the pans should be removed or installed ~ The sequence of steps represented numerically are differentiated from the ones represented alphabetically to notify the reader that they must perform these steps separately. For example, if the steps prior and up to camshaft removal are performed with the engine installed, but the subsequent steps like cylinder head removal require engine removal, the callouts are grouped in numerical and alphabetical orders. - The’illustrations may contain symbol marks to indicate necessary service procedures and precautions that need to be taken. REfer to the next page for the meaning of each symbol markt - Also in the illustration is a chart that lists information such as the order in which the part is removed/installed, the name of the part, and some extra notes that may be needed. . Step by step instructions are provided to supplement the illustrations when detailed explanation of the procedure is neces- sary or illustrations alone would not suffice - Service procedures required before or after the procedure described on that particular page, or inspection/adiustment proce dures required following the installation of pans are described under the title Requisite Service. a Standard workshop procedures and knowledge covered in the Common Service Manual are abbreviated in this manual, Detailed description of the procedure , i / Symbol mark System illustration Step seq uence (numerals muflLTrl-l or alphabets ”-w—n :131:2~"~ —. . . m 7 Part number Numb'er of T Extra not; or precaution pans related to the service procedure Symbols The symbols used throughout this manual show specific service procedures If supplementary information is required pertain- ing to these symbols, it would be explained specifically in the text without the use at the symbols. _ ‘ $5 Fleplace the pants) with new onels) betore assembly. Use special tool Use optional tool These tools are obtained as you order parts‘ 6 Torque specification. 10 N-m (1.0 kgrm. 7.2 fl-lb) 10 (l. , 7.2) I Use recommended engine oil, unless otherwise specified. 5‘ Use molybdenum all solution (mixture of the engine oil and molybdenum grease with the ratio 1 : 1i. .r-fii Use multirpurpose grease (Lithium based multl-purpase grease NLGl #2 or equivalent] Use molybdenum disulfide grease leontafing more than 3% molybdenum disuliide. NLGl #2 or (m equivalent) Example: Molykotee BHrZ plus manufactured by Dow Corning. U45.A. Multi-purpose M-2 manufactured by Mitsubishi Oil Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disullide. NLGI #2 or equivalent) , s 7 , ,, m Example: Molykotefi’ G—n Paste manufactured by Dow Corning, U.S.A. Honda Moly 45 (U.S.A. only) Hocol ASP manufactured by R6001 Limited, U.K, ROCOI Paste manufactured by Sumico Lubricant, Japan (El Use silicone grease % Apply a locking agents Use the agent of the middle strength, unless otherwise specified, Jams Apply sealant a Use brake fluid, DOT 3 Dr DOT 4. Use the recommended brake fluid, unless otherwise specified. fl Use Fork or Suspension Fluid, 1. General Information General Safety 1.1 Model Identification 1-3 Specifications 14 Torque ,Values 1.14 Tools 1-17 Lubrication & Seal Points 1-19 Cable 81 Harness Routing 1-21 General Safety Carbon Monoxide If the engine must be running to do some work, makessure the area is well ventilated Never run the en e in an en- closed area.‘ 7 V 7 7 _ The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death. \ Run the engine in an open area or with an exhaust evacuar tion system In an enclosed area Gasoline Work in a well ventilated area. Keep cigarettes, llames or sparks away from the work area or where gasoline is stored, - Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Hot Components - Engine and exhaust system pans become very hot and remain hot lor some time after the engine is runi Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. Used Engine/Transmission Oil AWARNING - Used engine oil lor transmission oil in twostmkes) may cause skin cancer it repeatedly left in contact wi h the skin for prolonged periods. Although thi unlikely unless you handle used oil on a daily basis still advisable to thoroughly wash your hands wnh soap and water assay as possible after handling used all. KEEP OUT OF REACH OF CHILDREN. Brake Dust never use an air hose or dry brush to clean brake , assemblies. Inhaled asbestos fibers have been iound to cause respiratory disease and cancer. Brake Fluid CAUTION l - Spinning fluid on painted, plastic or mbber parts will E —‘ damage them. Place a clean shop towel over these parts whenever the system is serviced. KEEP out or REACH OF CHILDREN l I] General Information Coolant Under some conditions. the ethylene glycol in engine coolant is combustible and its flame is not visible. II the ethylene glycol does ignite. you will not see any name, but you can be burned. AWARNlNG . Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a v ble flame. - Coolant (ethylene glycol) can cause some skin irrita— tion and is poisonous i1 swallowed. KEEP OUT OF REACH OF CHILDREN. - Do not remove the radiator cap when the engine is hot. . Th3 coolant is under pressure and could scald you. . Keep hands and clothing away from the cooling ran. as it starts automatically. If it contacts your skin, wash the affected areasjmmedl- ately with soap and water. If it contacts your eyes, flush thern thoroughly with fresh water and get immediate medi- cal attention. I is swallowed, the victim must be forced to vent the rinse mouth and throat with fresh water before 0 tai rig medical attention. Because of these dangers, always store coolant in a safe place. away from the reach of children. , . Nitrogen Pressure For shock absorbers with a gas-filled reservoir: AWARNING - Use only nitrogen to pressurize the shock absorber. The use of an unstable gas can cause a lire or explo~ ,._ sion resulting in serious injury. ~ The shock absorber contains nitrogen under high pressure. Allowing lire or heat near the shock ab- sorber could lead to an explosion that could result in serious injury. ~ Failure to release the pressure from a shock absorber before disposing of it may lead to a possible explosion , I and serious injury I it is heated or pierced. J To prevent the possibility of an explosion, release the nitrogen by pressing the valve core. Then remove the valve stem from the shock absorber reservoir. Before disposal of the shock absorber, release the nltrogen by pressing the valve core. Then remove the valve stem lrom the shock absorber. Battery Hydrogen Gas 8: Electrolyte AWARNVNG ° The battery gives off explosive gases; keep sparks. flames and olgarettes away. Provide adequate venti- lation when charging. - The battery cantalns sulfuric acid (electrolyte). Con- tact with skin or eyes may cause severe burns. Wear protective clathlrlg and a face shield. — It electrolyte gets on your skin. flush wlth water. — If electrolyte gets in your eyes. flush with water for at least 15 minutes and call a physician. ‘ Electrolyte is poisonous. — If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. General Information Model Identification (1) FRAME SERIAL NUMBER The frame serial number is stamped on the right side of the steering head. 1 l , l (2) ENGINE SERIAL NUMBER The engine serial number is stamped on the (up of the crank- case right side. (4D COLOR CODE LABEL The color code label is attached to the rear fender below the rear seat. When ordering color-coded part, alway specify its designared color. [3) CARBURETUH‘IDENTIHCATION NUMBER The carburetor identification number is stamped on the carburetor body intake side. 1-3 —r_.1 General Informations Specifications Unit: mm (inl — General Item r Dimensions Overall length 1,985 (78in Overall length (M Model onlyl 2,035 (80.1), G: 2,070 (81.5) Overall width 705 (27.8) Overall height 1,075 (42.3) Wheelbase ' 1,345 (53.0) Ground clearance ' 7 125 (4.9) Dry weight 175 kg (385.3 lb) Dry weight (M Model only) 176 kg (353.1 lb) Curb weight 132 kg (4233 lb) Maximum weight capacity Maximum weight capacity (M Model only) 347 kb (765.0 lb) 342 kg (754.0 lb) Displacement Compression ratio , : Valve train Intake valve opens at 1 mm lift Frame Frame type Backbone Front suspension Telescopic fork Front wheel travel 120 (4,7) Rear suspension Swingarrn Rear wheel travel 120 (4.7) \ Rear damper Gas-filled damper with reservoir Front tire size 120/60 VR17 ' Rear tire size 150/60 VR18 Tire brand (Bridgesnfile) FR/HR 7 7— 7 Tire brand (Dunlap) FRIRR 7 K510A RADIAL/K310 RADIAL Tire brand (Yokohama) FRIHR 7 — Tire brand (IRC) EBIRR —- Front brake Hydraulic double disc Rear brake Hydraulic single disc Caster angle 25°20’ Trail length 96 (3.8) Fuel tank capacity 15 liters (4.0 us gal, 3.5 imp gen Fuel tank reserve capacity 20 liters (0.5 US gal, 04 Imp gal} Engine Bore and stroke , 7 55.0 X 42.0 (2.16 x1155) 3953 cm3 (24.3 cu‘inl 1 1 .3 : 1 7 Gear driven DOHC, 4 valves per cylinder 15° BTDC Intake Valve closes at 1 mm lift 35° ABDC Exhaust valve opens at 1 mm lift 35" BBDC 7' Exhaust valve Closes at 1 mm lift 5° ATDC ’ Lubrication system ’ Forced pressure and wet sump Oil pump type Trockoid Cooling system Liquid cooled Air filtration Paper filter Crankshaft type Unit»type, 4 main journals Firing order 1 — 90° — 4 — 270° — 3 — 90° — 2 Cylinder arrangement Cylinder number 4 Cylinders 90°V General lnformation — General (Cont‘dl Unit: mm (in) Electrical item Specifications Carburetor Carburetor type Constant velocity, 4 carburetors Throttle bore 32 (13) Drive Train Clutch system Mum-plate, wet Clutch operation system Cable operated Transmission 6 speeds Primary reduction 2.117 (34/72) Secondary reduction 4— Third reduction i Final reduction 2.566 (15/40) Gear ratio 1st 2928 (14/41) Gear ratio 2nd 2.166 (18/39) Gear ratio 3rd 1.500 (20/36) Gear ratio 4th 1.591 (22/35) Gear ratio 5th 1.435 (23/33) Gear ratio 6th 1.318 (22/29) Gear ratio reverse ’ 7 Gearshift pattern Left foot operated return system 1—Na2—3—4—5—6 Ignition system Digitalized full transistor ignition Starting system Charging system Regulator/rectifier type Lighting system At: regulator type Electric starter motor Triple phase output alternator SCR Shorted/tripie’phase full-wave ramification Battery 1-5 General information Unit: mm (in) — Lubrication ) j Item ‘ Standard i Service Limit ) Engine oil capacity at draining 24 liters (2.54 US qt, 2,11 Imp qt) —- at disassembly 3.0 liters (3.17 us an 2.64 Imp qt) — at oil filter change 2.5 liters (2.64 US qt, 2.20 imp qt) ¥ Recommended engine oil Use Honda 4-stroke all or equivalent OIL VISCOSITIES , 7 Viscosity: SAE 10W—4O Other viscosity shown in the chart may be used when the average temperature in your W riding area is within the indicated range. Oil pressure at oil pressure switch 480—588 kPa (5_0_ 6.0 kg/sz, 71—85 psi) at 5,000 rpm(80“C/176"Fl — Oil pump rotor tip clearance ® 0.15 (01106) ¥ body clearance ® , 0.157022 (0006—07009) — end clearance (33 0.04—0.09 (00016—110035) — l , — Fuel System [ * ~é 4' Carburetor identification number VDE 3A (E), VDE 3C (AR) — Carburetor identification number (M Model only) VDE 3F (E, F) — VDE 36 (AR) VDE 3H (G) Maln jet ¥ , _ (High altitude) — — (2, 3) — — ('l, 4) ¥ — (From) #1 22 — (Rear) #120 a Slow let #35 _ Jet needle clip position — — Pilot screw initial opening 2 turns out — Pilot screw high altitude adjustment —- — Pilot screw final opening 1/4 turns out — Pilot screw final opening (M Model only) 1 turns out (E, F) — 1/2 turns out (AR, G) Air screw in 'al opening — — Air screw h h altitude adjustment ¥ —- Float level 6.5 (0.28) — Carburetor Vacuum difference \Nithin 40 mmHg (1.6 ian) ¥ Base carburetor (For carburetor synchronization) No, 2 carburetor — Idle Speed 1,300 1 100 min" (rpm) — Throttle grip free play 2—6 (0.03—0.24) — Accelerator pump clearance —— , — 1-6 —4 Cylinder Head General information Unit: mm (in) Item Standard Service Limit Cylinder compression Cylinder compression difference Valve clearance IN EX Cylinder head werpage Com lobe height® IN EX Camshaft runnut Camshaft oil clearance A Camshaft journal 0.0. A B Camshaft holder ID. A E Valve stem CD. IN EX Valve guide |.D. IN EX Stern-to-gulde clearance IN EX Valve guide projection above cylinder head IN in) Ethl / L . Beime guide installation: 1. Chill the valve guide in the freezer section of a refrigerator for about an hour. 2. Heat the cylinder head to 100715O°C (212—300"F) Q \ Valve seat width W EX Valve spring free length IN EX Inner IN lnner EX Outer IN Outer EX Rocker arm |.D. IN EX Rucker arm shaft CD. IN EX Rocker arm-to-rocker arm shaft clearance Valve lifter QD. Valve lifter bore LD. Hydraulic tappet adjuster assist spring Iree length Hydraulic tappet adjuster compression stroke wiih kerosene 1,274 : 196 kPa (13.0 2’20 kg/cm’. 185 2 28 pslI/4OO min" (rpm) 40 mmHg (16 ian) 0.12—0.18i0.005~0.007) 0.21—0.27 (0008—0011) 3211742357 (1288241975) 31403—32668 (11767—12861) (LOAD—0.082 (00016—00032) 27.939 —27.960 (1.1000—11008) 28.000—28.02‘l (1.1024—1.1032l 4475—4490 (01762701788) 41.46.574.480 (0.1758—0.1754) 4500—451 2 (0.1772—VOJ776) 4.500~4.512 (0.1772— .1776) 0010—0037 (03004—00015) 0.020—0047 (0.0003-00019) 10 (0.4) 10 (0.4) 1.70—2.30 (0057—01191) 1.70—2.30 (0067—0091) 31.4 (1.24) 31.4 (1.24) 34.4 (1.35) 34.4 (1.35) 8500—8515(03346—03352) 8500—8515 (03346—403352) BASS—8.484 (0.3333—03340) BANS—8.484 (03333703340) lllll 0.10 (0.004) 32.67 (1.285) 32.38 (1.275) 0.03 (0.001) 0.092 (0.0036) 27.93 (1.010) 28.03 (L104) 4.47,l0.176i 0.46 (0.1756) 4.56 (0.180) 4.55 (0.180) 0.09 (0.004) 0.12 (0.005) llll 30.2 [1.19) 30.2 (1.19) 33.2 (1.31) 33.2 (1.3“ 8.53 “1336) 5.53 (0.335) 8.46 (0.333) 8.46 (0333) Hill General information Unit: mm (in) 1’— Cylinder/Piston Item Standard Service Limit 1 Cylinder LD. 55.000—55.015 (2.1654»2.1659) 55.07 (2.168) Cylinder out of round —-— 0.10 (0.004) ‘ Cylinder taper — 0.10 (0.004) Cylinder warpage — 0.10 (0.004) Piston mark direction "IN” mark facing toward the intake side —— Piston 0.0. (D) 54370—54390 (11642—24650) 54.92 (2.168) Piston 0.0. measurement point (H) 10 (04) — Piston pin hole I.D. (d) 14002—14008 (05513—05515) 14.02 (0.552) d a H L—>. ' D i Cylinderr‘o—piston CIEarance ‘ 0.010—0045 (00004—00018) 0.10 (0.004) Piston pin DD. 13394—14000 (05509—05512) 1398 (0.550) Piston-io-piston pin clearance 0.002—0.0‘l4 (00001—011006) 0.04 (0.002) Connetsting rod-to-pision pin clearance 0.016—0.040 (00006—00016) 0.06 (0002) Top rifig-to-ring groove clearance 0015—0050 [0.0006—0.0020) 0.10 (0.004) : Second g-to-ring groove clearance (1015—0045 (0.0006a0.0018) 0.10 [0.004) Top ring end gap 0.18—0.33 (0007—0013) 0.65 (0.026) Second ring and gap 0.13—0.33 (0007—0013) 0.65 (0.026] Oil ring (side rail) and gap 0.20—0.80 (0008—0031) 035 (0037) Top rm mark “R” mark facing up — Second ring mark "-_’j mark facing up — i Crankshafl : 7 —‘ Connecting rod small end LD. 14.016a14.034 (0.551.8—05525) 14.05 (0.553) . Connecting rod his end side clearance 0.10—0.30 (0.004—0.012) 0.4 (0.02) radial clearance — —— Crankshaft runcut —- 0.03 (0.001) Crankpin oil Clearance (1028—0352 (0.0011—0.0020) 0.07 (0.003) Crankpin bearing selection See page 1140 ‘ Main journal oil clearance 0025—0049 (00010—03019) 0.07 (0003) Main journal bearing selection See page 11-10 r Kickstarler Kickstarter pinion gear LD. Kickstarter spindle O.D. Kickstarter idle gear I.D. Coumershaft 0.D. at kickstarler idle gear Kickstaner idle gear bushing 0o. LD. llllll IIHH 1-8 l l l General information Unit: mm (in) —-— Transmission Item Standard Service Limit fiansmission gear (.D, M5, M6 C2. C3, C4 Transmission gear bushing OD. M5, M6 C2. C3, Cr Transmission gear bushing LD. M5 C2 Gear-to-bushing clearance at M5, M6 gear at C2. C3, C4 gear Mainshaft 0.0. a‘ MS gear bushing Gear-to-shah clearance Gear bushing-m-shafl clearance at MS gear at C2 gear Shift fork claw thickness L C R Shin fork LD. L C R Shift lork shaft 0.0. L C R 28000728021 (1 .1024— 1 . 1032) 28000—28021 (1.1024—1.1032) 27359—27380 (1 .1007— 1 .101 5) 27:159—27380 (1.1007 .1016) 24385—25006 (09837—08845) 24385—25006 (03837—03845) 0020—0062 (00008—010024) 0.020—0.062 (00008—00024) 24367—24378 (03330—03834) 24367—24378 (03830-03834) 0007—0039 (00003—03015) 0007 —0.039 (0.0003—,Q.0015) 5.53—~6.00 (0.233—023'6) 5.93—6.00 (Olin—0.238) 5.93—6.00 (0233—41236) 11000—12021 (0.4724~O.4733) 12,000— 12.021 (O.4724—0.4733) 12.000—12.021 (04724—04733) 11.5169— 1 1 .980 (04712—04717) 11969711380 (0.4712—04717) 11359—11380 (04712104717) 28.04 (1.104) 28.04 (1.104) 27.94 (1.100) 27.94 (1.100) 25.03 (0.985) 25.03 (0.985) 0.10 (0.004) 0.10 (0.004) 24.96 (0,983) 24.96 (0.983) 0.06 (0.002) 0.06 (0.002) 5.8 (0.23) 5.8 (0.23) 5.8 (0.23) 12.04 (0.474) 12.04 (0.474) 12.04 (0.474) 11.95 [0.470) 11.95 (0,470) 11.95 [0.470) General information ,— Clutch System Unit: mm (in! ltem Standard Service Limit Clutch lever free play Recommended clutch fluid Clutch master cylinder ID. Ciutch master piston 0.D. Clutch outer |.D. . Clutch outer guide 0D. ItD. Mainshait CD. at clutch outer guide Oil pump drive sprocket LD. Clutch center E I.D One way clutch inner O.D. Clutch spring free height (As a set of apes.) Clutch spring free length Clutch disc thickness Clutch disc thickness A r B Clutch plate warpage Centriiugal clutch drum LD. bushing 0.0. Centriftigal clutch center guide LD. O.D. Centrifugal clutch center guide collar height Centrifugal clutch spring free length Clutch lining thickness Crankshaft 0.0. at clutch center 10—20 (0.4—0.8) 291300729021 (1.1417;1.14261 28367—28380 (11404—11409) 21995722015 (08659—08667) 29.025—29.075(i.1427—1.1447l 63364—63390 [2.5135 2.5193) 47365—41378 (118G48~1.8653l 5.3 (0.21) l 23273.08 (0115—0121) lHl 23.06 (1.144) 28.83 [1.139) 22.05 (0868) 29.11i1.146) 64.00 (2.520) 47.36 (1.8646) 4.8 (0.19) l 2.3 (0.110) l l 0.30 (0.012i HHHH iiiilllllllll Cooling System w Coolant capacity (Radiator and engine) M Model (Reserve tank) Radiator cap relief pressure Thermostat begins to apen Thermostat fully open Thermostat valve lift 2.1’ liters (2.22 us ft. 1.35 Imp qt) 2.0 liters (2.11 us ft. 1.76 Imp qt) 0.2 liter (0.21 us qt, 0.18 imp qt) 108—137 kPa (1.10—1.40 kglcm‘, 16—20 psi) BO—84°C (176—183°F) 95°C (203“Fl ' $.g0.237)imin. Ill llll i— Dtive Train Recummended final drive oil Final drive gear oil capacity at disassembly at draining Final drive gear backlash Final drive gear backlash difference between measurements Ring gear—tc-stop pin clearance (A) Step pin shim Ring gear spacer Pinion spacer Final drive gear assembly preload Output gear backlash Output gear LD. Output gear pushing cm. LD. Output drive shaft O.D. Output gear damper spring iree length Output shaft adjustment shim Countershaft drive shait adjustment shim llllllllllllll lllli HIHHIHHH llll 1-10 General information Unit: mm (in) r-' Wheels/Tires l ! Item ‘ Standard Service Limit l ._i l Minimum tire tread depth (FR) —— 1.5 (0.06) ran # 2.0 (0.08) Cold the pressure Driver only (FR) Driver only (RH) Driver and passenger (FH) l ) 225 kPa (2.25 kg/cm’, 33 psi) — ‘ 225 kF'a (2.25 kg/cmi, 33 psi) — i 225 kPa (2.25 kg/cm', 33 psi) —-— Driver and passenger (RR) ) 250 kFa (2.50 kg/cmz, 36 psi) — Front and rear axle runout 0.2 (0.01) Front and rear wheel rim runour (Radial) 2.0 (0.03) (Axial) 2.0 (008) Front wheel hub siandard surface , Rear wheel hub-to-rim distance Rear wheel hub Standard surface Wheel balance weight (Front) ) (Rear) } l so 9 (2.1 02) max. 60 g (2.1 02) max. Drive chain slack 15725 (5/8—1) — Drlve chain size link (DID) ——~ — (RK) ) RK GB5255M4/1o4 — l‘lill‘llll l l l l ‘ Front wheel hub-to-rim disiance l l ‘1 fl . Front Suspension l Fork spring free length 277.3 [10.92) 271.8 [10.70) Fork spring free length A — — E) ~— , u . _ Fork spring direction Tlghtly wound ccil and facing down — Fork tube runoul — 0.20 (0.008) ‘ Recommended fork oil Fork fluid — Fork oil level 122 mm (4.8 in) k ‘ Fork oil level (R) — — ‘ (L) —— —- Fork oil capacity ‘ 390 Co (112 US 02, 13.27lmp oz) — ‘ Fork oil capacity (M Model only) 404 cc (13.7 US oz, 14.2 Imp oz) — ‘ Fork oil capacity (Fl) — — a (L) 7 — , I Fork air pressure —- 7 l Steering bearing preload 1.045 kg (2.2—3.3 lb) — r— Rear Suspension I Shock absorber spring free lengrh l 158.7 (6.2 in) .12) I shock absorber spring free length (R) ‘ 7' l (L) — i Damper gas pressure F 98 kPa (1o kg/cmz. 142 psi) , Damper compressed gas l Nitrogen l Damper rod compressed force at 10 mm compressed 15~20 kg {33—44 lb) Damper drilling point See page 13—13 Shock absorber spring installed lengrh (Standard) (Adjusrahle range) Shock absorber spring adjuster standard posiiiun — Shock absorber spring direction 7 ) Recommended shock absorber oil 7 —— I 147.7 (5.81) Shock absorber oil capacity air pressure 7 lllllli lillllg d —11 General information — Brakes [tern Standard Unit: mm (in) Service Limit Front brake fluid Brake lever free play Brake pad wear indicator brake disc thickness brake disc runout master cylinder (.0. master piston O.D. caliper cylinder I.D. caliper cylinder [.D. (Upper) (Lower) caliper piston 0.D. dallper pisran 0.0. (Upper) .' (Lower) brake drum |.D. brake lining thickness brake fluid brake pedal height brake pedal free play brake pad wear indicator Rear brake disc thickness brake disc runout master cylinder LD. master piston 0.0. caliper cylinder l.D. caliper piston 0.D. brake drum LD. brake lining thickness DOT 4 4 (0.16) “LOGO—14.043 (05512—05529) 13357—13384 (05495—05506) 30130—311280(11902—11921) 25400—25450 (113000710020) 30.148—30.198 ”JESS—1.1839) 25318—25368 (09958—09987) DOT 4 6.0 (0.24) 14.000— 14.043 (05512—05529) 13357—13384 (05495—05506) 2§.400—25.450 “DOUG—1.0020) 25318—25368 (09968—03987) To the groove 1 3.5 (0.14) 0.30 (0.012) 14.06 (0.554) 13.95 (0.549) 30.29 (1.193) ‘ 25.46 (1.0024) 30.14 (1.1866) 25.31 (0.9955) lllll To the groove 2 5.0 (0.20) 0.30 (0.012) 14.06 (0.554) 13.95 (0.549) 25.46 (1.0024) 25.31 (0.996) ’— Battery/Charging System Regulator/rectifier regulated voltage/amperage Battery capacity Specified current leakage Battery specific gravity (Fully charged) (Needs charging) Battery charging rate (Normal) (Quick) Battery voltage (Fully charged at 20°C/68°F) (Needs charging at 20°Cl68°Fl Alternator lighting coil resistance (At 20°C/68°Fl AC regulator regulated Voltage (with analogue type) (With digital type) Alternator charging coil resistance (At 20"Cl68°F) ' l 0.1—1.0 rz 13545.5 woes A at 5,000 min" (rpm) 12v '— BAH (Maintenance Free battery: YTX7A—BS) 0.7 A/5—1O hr. 30 AH hr. 13.0—13.2 V 12.3 V llll llll E > 3 e. x lllllllll General information Unit: mm (inl r“ Ignition System i Item Standard Service limit I spark plug (Standard NGK) (Standard ND) | (For cold climate/below 5°C/4I“F NGK) i (For Gold climate/below 5°CI41°F NDl ' (For extended high speed riding NGK) (For extended high speed riding ND) Spark plug gap ignition timing ”F” mark Advance starts stops ' Fully advance Alternator exciter coil resistance (At 20°C/68°Fl EReEH, Y27FER ERBEH Y24FER ERlOEH Y3‘lFER 0.6—0.7 [0.024—0.028) 13° BTDC at 1,200 min" (rpm) 1.8001200 min" (rpm) 1:000:200 min“ (rpm) 37:2 BTDC at 12,000 min“ (rpm) llllllllllllllll ignition coil resistance (Primary: at 20°C/68°F) 1 2.5—3.5 9 . (Secondary with plug cap) 14—25 kl'l (Secondary without plug cap) 11 —14 id! Pulse generator resistance (At 20°C/58°Fl 7 ' 450—550 ll r— Lights/IlliéterslSwitches I Main fuse 30 A Fuse 20A 3(1, 10A x 3 Headlight (high/low beam) Tail/brake light License light Position light Front turn signal/running light Front turn signal light Rear turn signal light instrument light Oil pressure warning indicator Tail/brake light warning indicator Side stand warning indicator » Low fuel indicator Coolant temperature indicator Oil temperature indicator High beam indicator Turn signal indicator Neutral indicator Revers dicator ‘ Overdri e indicator oil temperature sensor resistance Fuel unit resistance (At rull level) (At emptyl Fuel pump How capacity (minJminute) Thermo sensor resistance (50°CI122°F) l80°Cl176°Fl l‘l 20°C/24B°Fi Far-i motor switch Starts to close (0N) Stops to open (OFF) 12V50/50Wx2(H4) 12V5/2‘1Wx2 12V5W 12V5WlE,AHl,12V4WlF,G) {SSS <<< klkikl ESE llllll 987102°C (208—216°F) SIS—97°C (199—207“) l|||l|llllllllllllllllllllllll ,—‘ Starting System f Starter driven gear 0D, | Starter reduction gear shaft 0.0. Starter reduction gear |.D. Starter motor brush length 41375—42000 (1.6525—1.6535l 9.994—10.000 (0.3935703937l 10070710110 (03965—03980) 12—13 (0.477051) 41.96 (1,652) 9.90 (0.390) 10.16 (0.400) 5.5 (0.26) 1-13 General information Torque Values _ Standard T l | orque , . Fasteners Type N~m (kg-m, h-lh) Fasteners Type 5 mm hex bolt and nut v 5 (0.5, 3.5) 5 mm screw 4 (0.4, 3) 6 mm hex bolt and nut l 10 (1.0, 7.2) , Emm screw 9 (0.9, 7) 8 mm hex bolt and nut l 22 (2.2. 16) ‘ 6 mm flange bolt (8 mm head) 9 (0.9, 7) 10 mm hex bolt and nut 1 35 (3.5, 25) 6mm flange belt (10 mm head) and nut 12 (1.2, 9) 12 mm hex bolt and nut 55 (5.5, 40) 8 mm flange bolt and nut l 27 (2.7, 20) l 10 mm flange bolt and nut I 40 (4.0, 29) l - Torque specificatiuns listed below are for important fasteners. - Others should be tightened to standard torque’values listed above. Notes 1. Apply looking agent to the threads. 2. Apply oil to the threads and flange surface. 3. Apply molybdenum disulfide oil to the threads and flange surface. 4. Apply sealant to the threads. 5. Stake. 6. Apply clean engine oil to the O-ring. 7. UBS bolt. 7 .8. Selfrlocking nut. b. Never apply molybdenum disulfide nil. ’7 Engine Th 13 T _ rea orque “9‘“ 0 ‘Y dia. (mm) N~m (kg-m. Mb» Remarks Lubricatiun: Oil pump driven sprocket bolt 7 1 5 15 (1.5, 11) Note 1 on pump mounting bolt 3 6 12 (1.2. 9) Oil pump cover bolt 3 S 12 (1.2. 9) Oil filter 1 20 10 (1.0 ,7! Note 6 Oil drain bolt 1 12 38 (3.5, 27) on pressure switch 7 1 P'T1/8 12 (1.2, 9) Note 4 ‘ Fuel system: i ‘ Carburetor Insulator band screw , 8 l 4 1 (0.1. 0.7) Coalirfg system: l \ Water pump mounting bolt 2 6 10 (1.0, 7) Water pump cover bolt 2 6 10 [1.0, 7) Note 4 Thermo sensor 1 PT1/8 7 10 [1.0, 7) Note 4 Cylinder head/cylinderlpiston: ’ Cam gear case mounting bolt 8 8 36 (Ste, 26) Note 2 Cam gear case set bolt 2 6 12 (1.2. 9) Note 2 Cylinder head cover bolt 8 5 10 (LO, 7) Camshaft holder belt 32 6 12 (1.2, 9) Rocker arm shaft plug 3 PT1/8 ' 8 (0.8, 6) Note 4 Cylinder head special bolt, 8 mm 16 8 36 (3.6, 26) Note 2 Cylinder head bolt, 6 mm 6 6 12 (1.2) 9) Spark plug 4 8 9 (0.9, 7) l Clutchlgearshift linkage: 1 Right crankcase cover 12 6 10 (1.0, 7) 1 ClutclLlock nut 7 1 20 85 (8.5. 61) Note 5 Gearshift return spring stud pin 1 3 23 (2.3. 17) Note 1 Shift drum center bolt 1 6 V 23 (2.3, 17) Note 1 Shift drum set plate bolt 2 6 12 (1.2, 9) Note 1 Shift fork shaft set bolt 1 6 12 [1.2, 9) Nate 1 Tlrning hole cap 1 45 18 [1.8, 13) Note 3 1-14 General Information ’EM'” (com d] Thread Torque ltem Q'tv dia. (mm) N-m “(94,“, ft—Ib) Remarks Crankcase(crankshaft/transmission: , Drive sprocket bolt 1 10 55 (5.5, 40) Neutral switch 1 1o 12 (1.21 9) Connecting rad bearing cap nut 8 7 24 (2.4, 17) Note 2, 9 crankcase bolt 6 mm 12 6 12 (1.21 9) 3 mm 11 8 23 (2.3. 17) 10 mm 1 10 40 (4.0. 29) Lawer case oil bolt 1 10 23 (2.3, 17) Alternator: ; Flywheel bolt 1 1 10 85 (8.5, 61) Note 7 Starter clutch: Primary drive gear bolt (starter clutch bolt) 1 10 85 (8.54 61) Note 7 Starter clutch cover bolt 3 B 28 (2.8, 20) Note 1 —‘ Frame 7 Frame/body panels: Main step holder bolt 9 8 27 (2.7, 20) Note 1 Main step bolt 2 10 45 [4.5, 33) Pillion step bracket bolt 4 8 27 [2.7, 20) Sub-frame mounting bolt . 4 10 27 [2.7, 20) Side stand pivot bolt ‘ 1 10 38 (3.8. 27) Side stand bracket bolt 2 8 35 (3.5, 25) Note 1 Exhaust system: Exhaust pipe joint nut 8 6 8 (0.8. 6) Cooling system: 1 Fan motor switch 1 16 23 (2.3, 17) Note 4 Fuel system: Fuel tank breather check valve 1 18 11 (1.1. 1.8) Fuel valve 1 18 23 (2.3, 17) Engine mount: Engine mounting bolt 7 1O 40 (4,0, 29) Engine mounting adjust bolt 2 22 11 (1.1, 8) Engine mounting lock nut 2 22 55 (5.5, 40) 1 Engine mounting nut 1 1O 40 (4.0, 29) ‘ Gearshift pedal bolt 1 6 12 (1.2, 9) ‘ Front suspension: ‘ Handlebar holder pinch bolt. 4 6 12 (1.2, 9) ‘ Ignition switch mounting bolt ,2 8 25 [2.5, 18) Note 1 Fork socket bolt 2 a 20 (2.0, 14) Note 1 Fork bolt 2 37 23 (2.3, 17) Upper lork pinch bolt 2 7 11 (1.1, 8) Lower fork pinch bolt 2 10 40 (4.0, 29) Steering bearing adjustment nut 1 35 50 (5.0, 36) Note 2 Steering Stem nut J 33 140 (140, 101i Front axle pinch bolt 4 8 22 (2.2, 16) Front axle bolt 1 14 60 (6.0, 43) 1-15 General Information '— Frame (Cont’d) 7 l Thread T e I 1 . orqu ' I [tern ‘ Oty dia. (mm) N'm “(me ftrlbi i Remarks Rear suspension: 1 Rear wheel nut i 1 18 120 (12.0. 87) Rear axle holder lock nm 1 1 38 165 (16,5, 119) Note 5 Swingarm pivot nu! ‘ 1 18 as (9.5, 69) Swingarm pivot adjust bait ‘ 1 30 15 (1,5‘ 11) Swingarm pivot lock nut i 1 30 80 (8.0, 58) Drive chain slider screw ' 4 5 4 (0.4. 2.9) 1 Driven sprocket nul l 6 a 35 (3.5, 25) Torque link boltInLri l 2 10 35 (315‘ 25i Rear shock absorber mounting bolt ‘ 2 10 , 4-5 (4.5, 33) Note 8 Rear shock absorber spring adjuster lock nut l 1 — 90 (9‘0, 65) Rear shock absorber reservoir holder band i 2 — A (0.4, 2.9) Shock linkage bolt/nut l 3 l 10 45 (4.5, 33) Note 8 Rear bearing holder pinch bolr ‘ 1 14 55 (5.5, 40) I Drive pin bolt 4 i 12 15 (1.5. 11) Nara 1 I Brake/clutch system: 1 Master cylinder mounting bolt i 4 6 12 (1.2. 9i Master cylinder oil bolr ‘ 2 10 35 (3‘5, 25) Front caliper bolt 8 8 33 (3‘31 24) Note 1 From caiiper oil ball 7 2 10 35 (3.5, 25) From brake disc bolt 12 6 20 (2.0, 14) Caliper mourning bolt 1 6 8 27 (2‘7, 20) Caliper pad pin 3 1O 17 (1.7, 12) Caliper pad pin plug 1 3 10 2.5 (0.25, 1,31 Caliper bleed valve 1 3 s e (0.6, 413) Rear brake reservoir mounting bolt 1 1 6 9 (0.9, 7) Hear brake reservoir hose joint screw 1 5 1.5 (0‘15, 111) Note 1 Rear caliper pivot pin bolt (5 mm HEX side) ' 1 8 13 (1.3, 9) Note 1 Rear caliper pivot pin bolt ‘ 1 8 23 (2‘3, 17) Note 1 Rear brake hose join: nut (hose side) i 1 10 14 (1.4, 10) Rear brake hose joint (caliper side) 1 1 10 35 (3‘5, 25) Rear brake disc mu 1 , 4 8 35 (3.5. 25) Note 8 1—16 or L General Information de5 . The newly designed tools are indicated with ‘ mark in the list Description Tool Number Application Section Compression gauge attachment, 8 mm '07KME— MHEO1OO Cylinder compression measurement 3 ; Oil pressure gauge attachment 0751014220100 Engine oil pressure measurement oil filter wrench O7HAA—PJ70100 Oil filter replacement Spark plug wrench, E mm '07KMA—MR80200 Spark plug removalfinstallation Lock nut wrench 07HMA—MR70200 Engine removal/installation 7 Valve spring compressor attachment o7959—KM301‘01 Cylinder head disassembly/assembly 3 Valve guide driver 07HMD—ML001OO Valve guide replacement Valve guide reamer, 4.5 mm 07HMH—ML001701 Valve guide reaming Valve SEat cutter, 24 mm (45" IN) 07780—0010500 — Valve seat refacing Valve seat cutter, 22 mm (45" EX) 07780—0010701 H Valve flat cutter, 24 mm (32° lN) 07780-0012500 - Valve flat cutter,21.5 mm (32° EX) 07780—0012300 - Valve interior cutter, 22 mm (60° IN/EX) 07730? 0014;02 — Cutter holdfr, 4.5 mm 07731—0010500 - Lock nut wrench, 26X 30 mm 07715-0020203 —:l— Clutch disassembly/assembly 9 Extension bar 07716a 0020500 — Gear holder 07724-0010100 Primary drive gear removal/installation Fork seal driver 07947— KA50100 —j Fork oil seal installation 12 Fork seal driver attachment 07947—KF00100 ~ Lock nut wrench, 39 x41 mm O7GMA—KS40100 Steering stern nut removal/installation Steering stem socket 07HMA—MR70100 Steering bearing adjustment nut j tightening Steering stern driver attachment O7HMD —MR70100- Steering bearing lower inner race Inner driver C 07746—00301’00 — installation Driver attachment B (2 005. required) 07946—KM90200 Steering bearing outer race removal/ l Driver assembly shaft 07946—KM90300 —— installation l Bearing remover B 07946—KM80500 * l Assembly base 07946 — KM90600 —— Driver 07749 - 0010000 Bearing Installation 13 Attachment, 42 x 47 mm 07746-001030!) Bearing holder needle bearing ‘ Attachment, 62 x 68 mm 07746—0010500 -— replacement Pilot, 40 mm 07746-0040900 ,7 l Shock absorber compressor attachment 07959aMBlOOOO —-3— Shock absorber disassemblylassembly l Shock absorber compressor 07GME—001QQOO— i Bushing driver 8 07HMF— MMSOZOO Shock absorber upper mounting bushing replacement Pivot adjust Wrench 07908i4690‘001 Swingarm pivot bolt removal/installation , Driver shaft 07946—MJ00‘100 , Right swingarm pivot bearing l Attachment. 37 x 40 mm 07746— 0010200 —3 installation Pilot, 20 mm 07745- 0040500 — Bearing remover set 07936— 3710001 — Right swingarrn pivot bearing removal —Remover handle 07936—3710100 — 7 — Bearing remover 07936 — 37107600 — —Sliding weight 07741~0010201 v i Needle bearing remover 07HMc—MR70100— Left swingarm pivot bearing l Driver shalt 079467 MJOOI oo 737 replacement Pilot, 28 mm 0774570041100 — l l 1-17 General Information Description Tool Number Application Section Pin driver assembly Bearing remover Remover handle Sliding weight Driver Anachmem, 24x 26 mm Film, 17 mm O7GMD - KT80100 07936 - 3710300 07936 41710100 07741— 0010201 07749 - 0010000 07746 7 0010700 D7746— 0040400 Shock arm needle bearing removal —3— Shock link needle bearing removal 7 Shock arm and link needle bearing fifnstallafion 13 Snap ring pliers 0791473230001 Brake master cylinder disassembly/ assembly Peak Voltage adaptor Digital multitester O7HGJ — 0020100 0741 1 —0020009 ‘3? Peak voltage measurement 16 Universal holder Roior puller 07725 -- 0630000 7:!— Flywheel removal/installation 07733 — 0130001 v 17 'l Lubrication & Seal Points General Information —- Engine Location Material Remarks Valve Stem (Valve guide sliding surlacs) Connecting rod small and baring Transmission gearshift fork groove Timing hole cap threads Connecting rod bearing Crankshaft main bearing Molybdenum disulfide oil crankcase mating surface Liquid sealant Do not apply sealant near the l main bearings. Piston Cylinder head bolt threads Connecting rod bearing cap nut Camshaft journal, cam lobe Other sliding surface Rocker arm sliding surface , 7 Rocker arm shaft plug Sealant ‘ oil pressure switch threads Do not apply sealant to the ‘ ’ switch thread head as shown l . 3—4 mm l Thermo sensor threads (0.12-0.15 in) ‘ Oil filter O-ring Engine oil CAUTION Never apply molybdenum disulfide nlL Clutch lifter rod (lifter cam contacting area) Multipurpose grease Cylinder head sealing bolt threads Shift drum center bolt threads Gearshift return spring stud pin Shift drum set plate bolt threads Shift fork shaft set bolt threads Oil pump driven sprocket bolt threads IE? 5.5-7.5 mm (0.22-0.30 in) Locking agent 1-19 General Information '— Frame Location Material Remarks Drive chain Gear oil #80-90 Axle holder bearing Side stand pivot Shock linkage bearing collar Shock linkage bearing Seat lock hook Gearshift pedal pivot Shook absorber upper mounting collar Swingarm pivot bearing Steering head bearing Step pivot Speedometer gearbox Throttle pipe flange Flear brake pedal pivot Dust seal lip Pad pin threads Pad pin plug threads Multipurpose grease Caliperpiston Caliper piston seal Caliper dust seal Master cylinder piston Master cylinder piston cup DOT 4 brake fluid Steering bearing adjustment nut threads Engine oil Fan motor switch threads Sealant Handlebar grip rubber Honda Bond A or equivalent Caliper pivot pin Caliper pivot pin boot Silicone grease side stand bracket bolt threads Drive chain slider screw threads Drive pin bolt threads Fork socket bolt threads Ignition switch mounting bolt wreads Main step holder bolt threads Hear caliper pivot bolt threads Hear brake reservoir hose screw threads Locking agent General Information Cable & Harness Routing (2) CLUTCH CABLE (6) LEFT FRONT BRAKE HOSE (8) FUEL TANK BREATHER TUBE (7) LEFT FRONT TURN SIGNAL WIRE CONNECTORS (SI RIGHT FRONT TURN SIGNAL WIRE CONNECTORS (11) OIL FIFE (10) RIGHT FRONT BRAKE HOSE 1-21 I SIGNAL WIRE CONNECTORS (3) LEFT FRONT TURN (E) SPARK UNIT (7) SEAT LOCK CABLE V (2} HEADLIGHTS (4) POSITION LIGHTS (5) RIGHT FRONT TURN SIGNAL WIRE CONNECTORS General Information (II HEADLIGHT RELAY (6) FUSE BOX (SI REAR TURN SIGNAL WIRE [10] BRAKE/TAILLIGHT WIRE CONNECTOR (11) CLUTCH DIODE (12) REGULATOR/RECTIFIER [13) TURN SIGNAL RELAY 1-22 General Information (3) sue AIR ' CLEANER TUBES (I) THROTTLE CABLES IZI FUEL LINES Y A .L E H L A N m s N R U T m [SI REAR IGNITION I4) CRANKCASE BREATHER HOSE (9) AUTO FUEL VALVE VACUUM TUBE (8) REAR SHOCK ABSORBER DRAIN TUE (10) THROTTLE STOP CONTROL CABLE (12) CLUTCH CABLE ' (13) FRONT IGNITION COIL (11) SPEEDOMETER CABLE (15) THROTTLE STOP CONTROL KNOB [14) CHOKE CABLE VA (16) FUEL TANK DRAIN TUBE (17) FAN MOTOR SWITCH 1-23 General Informafion I2) STARTER RELAY SWITCH (MAIN FUSE) III RESERVE TANK OVERFLOW TUBE (3) FUEL LINE (9) NEUTRAL SWITCH (BIHI BEAM RELAY (10) RIGHT CONNECTOR BRACKET /, (12) VIEW® (‘1' 79’44 ‘ mask 1 \ . (4) AUTO FUEL VALVE VACUUM TUBE (5) FUEL TANK BREATHEH TUBE I6) RADIATOR OVERFLOW TUBE (7) STARTER MOTOR CABLE (13) A: IGNITION SWITCH WIRE CONNECTOR (EXP-BLACK) B: PULSE GENERATOR WIRE CONNECTOR (4P-ELACK) C: OIL PRESSURE SWITCH/NEUTRAL SWITCH WIRE CONNECTOR (ZP-BLACK) D: RIGHT HANDLEBAR SWITCH WIRE CONNECTOR (ERRED) E: ALTERNATOR WIRE CONNECTOR I3P-WHITEI GEE 'IE :3 I14) VIEW® 1 —24 2. Frame/Body Panels/Exhaust System r’ 1 Service Information 2-1 Fuel Tank Removal/Installation 2-5 E Seat Cowling Removal/Installation 2-2 Windshield Removal/Installation 2-6 ’ E Upper Fairing Removal/Installation 2-2 Muffler Removal/Installation 2-8 l Side Fairing Removal/installation 2-3 Exhaust Pipe Removal/installation 210 l 3 Lower Fairing Removal/Installation 2-4 , Sub-Frame Removal/Installation 2-12 i Service Information AWARNING fr . . . . - Gasoline ls extremely flammable and explosrve under cenarn conditions. ‘ . Serious burns may result if the exhaust system is not allowed to cool before components are removed or servicedt . Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion. - This section cover removal and installation of the framejody panels, fuel tank and exhaust systemr - Frame body panel installation is in the reverse order of removal, unless noted otherwise - When removing the cover, be careful not to damage any tab or groove of the cover. - Be careful not to bind the wire harnesses when installing the sub-frame. Frame/Body panels/Exhaust System Seat Cowling Removal/Installation Unlock lhe rear seat by turning the lgniiion key clockwise. Remove the rear seat. Remove the six attaching screws. Raise the rear of the seat cowling and release the two boss- es from the grommets. Disconnect the brake/taillight wire Connector and remave the seat Cowling rearward. ' NOTE 7 . Be careful not to damage (he from of lhe Cowling. Install the seat Cowling, while inserting the heck of the Cowling under the frame, Insert the bosses into the grommet by pushing the rear oi the Cowling. ' Install the rearseat, aligning the hook with the cowling, and push the seat down to lock the seat. NOTE ' Grease the sear striker and latch. v The rear‘seat is not installed securely if any obstruc- tions are under the seat. - Be careful not to bind the wire harness etc. Upper Fairing Removal/Installation Disconnect the left and righl turn signal wire connectors, , Remove the following: , , — both side (airings (page 2-3). -— from panel (page 2—4), — both rearview mirror mounting nutss — both rearview mirrar. —— both rearview mirror mounting rubbers. — bolh turn signal lights. .. screw. - upper fairing. Install rhe upper fairing in the reverse order of reméval. CAUTION - Be careful not to bind the mountlng rubber. (3) REAR SEAT l4) BOSSES (2) SEAT COWLING TAILLIGHT CONNECTOR (E) GROMMETS l1) REARVIEW MIRROR 42) MOUNTING RUBBER (3) MOUNTING NUT (6) SCREW l4) TURN SIGNAL LIGHT l5) UPPER FAIRING Frame/Body panels/Exhaust System Side Fairing Removal/Installation i2) (3) i5) Align the tabs with the slow properly. (4i CAU110N - Be careful not to damage the tabs. , W 7 7 . Make sure that the clip nut for the tapping screw is installed proper». ll it is missing, install it securely with the threaded side facing down. Procedure , ,, Q'ty Remarks Removal Order Installation is in the reverse order of removal, (1) Quick screw 4 (2) Screw 2 (3) Tapping screw 2 (4) Left side fairing 1 (5) Right side fairing 1 2-3 Frame/Early panels/Exhaust System Lower Fairing Removal/Installation r3) ‘3’ l7) (5) CAUTION facing down. ' Mam sure tha‘ the dip nur for Xhe tapping screw is installed properly. If it is missing, install it securely with the threaded side Procedure Q‘fy Remarks Removal Order , , Installation is in the reverse order of removal (1) Trim clip screw/nut 4 (2) Front panel screw 3 (3) From panel 1 NOTE Ar installation, inser! rhe top ends under the tab of me upper fairing properly as shown. (4) Mounting screw 2 (5) Mounting belt/washer 2 (6) Mounting Dollar 2 (7i Luwer fairing assembly 1 Frame/Body panels/Exhaust System “rural fink Removal/Installation . Gasoline is extremely flammable and is explosive under cer- tain conditions. Work in a well ventilated area Smoking or al- lowing flames or sparks in the work area or where gasoline is stored can cause a lire or explosion. ' Remove the seat Cowling (page 22), Turn the fuel valve OFF. Disconnect the luel tank breather tube from the tank‘ 7 Remove the fuel tank mounting bolt. Raise the rear of the tank and disconnect the fuel line and vacuum tube from the fuel valve. install the luel tank in the reverse order of removal NOTE . Make sure that the fuel tank mounting rubber isiinstalled: onto the frame properly before installing the tank. ‘v After connecting the fuel line, connect a vacuum pump to the auto fuel valve vacuum joint and apply vacuum. Tum the fuel valve ON and check the fuel line for leakage (2) MOUNTlNG BOLT (‘1) BREATHER TUBE 7 (3) FUEL TANK 2-5 Frame/Body panels/Exhaust System Windshield Removal/Installation 2-6 ence of the pin. 1. Put the kerf around the circumfer- — Ex' (3) 2‘ Cut the pin at the kerf, being care- 3. Install with using new pins. ful rm to deform me pin. Pun am the remaining pin‘ 7 , NOTE 7 Be careful not to damage the windshield. Frame/Body panels/Exhaust System Procedure my Remarks Removal Order [1) Rearview mirror mounting nur 4 NOTE Loosen until the clearance is made. 12) Set pin/ring 6 NOTE Cm me pin to remova (3) Windshield 1 lnstallzfion Order (3) Windshield 1 (2) Set pin/ring 5 NOTE Temporarily install the set rings, pvsiticn the windshield properly and fit the pins, (1) Real-view mirmr mounting nut 4 2-7 Frame/Body panels/Exhaust System Muffler Removal/Installation (8) /‘~"- 7 x I ~ 07%. 90% (4) 77 [II/”67‘ t9 / (a) / (5) Do not 56 cAUTlON e the exhaust system while it is hot. Frame/Body panels/Exhaust System _ W ,,,I Do not bend or twist the brake hoses §uppofl the removed right step assemblv so that it does not hang from the brakg hose. I Requisite Service . Seat Cowling removal/Installation (page 2-2l . Lower fairing remavalfinstallation (page 2-4) Procedure Remarks Remaval Order Installation is in the reverse order of removal. (1) Heat guard mounting bold 1 (2) Right step bolt 2 (a) Right 5120 1 NOTE Remove together with the heat guard. Never hang it from the brake hose (4) Exhaust pipe band bolt 2 NOTE Lassen the bolts. (5) Exhaust pipe nut 3 (6) Mufllegmounting bolt/nut 1/2 NOTE 7 At installat'von, loosely install the bolt and nuts. tighten the exhaust pipe nuts and band bolts first, then tighten them. (7} Left pilliun step 1 (3p Muffler assembly 1 (9) Gasket 2 2—9 Frame/Body panels/Exhaust System Exhaust Pipe Removal/Installation E— Frame/Body panels/Exhaust System ’7 meN @mEmdimor fins in prevent them from damaging when sievicing'me 1mm aha-Ts} pipe. Requisite Service . Muffler removal/installation (page 28) Procedure Q’ty Remarks Removal Order Installation is in the reverse order 01 removalr (1) Rear exhaust pipe joint nut 4 (2) Rear exhaust pipe 1 (3) Lewer radiator mounting bolt 2 NOTE Remove the bolts, move the radiator forward and hold it with a string‘ (4) Front exhaust pipe joint nut 4 (5) ant exhaust pipe 1 (6) Gasket 4 2-11 Frame/Body panels/Exhaust System Sub-Frame Removal/Installation C 9 (0.9, 7) (6) (8) (4) (10} 1—4" '\\\\‘ [12) g (3) Frame/Body panels/Exhaust System cAUTION Requisite Service . Fuel tank removallinstallation (page 2-5) . Battery removalnnstallafion (page 15-4) - Sear ccwling removal/Tns’tallation (page 2-2) . Turn the ignition switch OFF éné dEéonnecthe battery negifive ca‘blérrom the bat'firy terrnfilal. - Be careful not to bind the wire harness when installing the sub-frame . Route the wire harness, cable, em (page 1—21). Procedure ty Remarks Removal Order Installation is in the reverEe‘o’mex of removal. (1) Spark plug cap/primary wire connector 2/2 (2) Regulator/rectifier connector 1 (3) Turn signal relay connector 1 (4) Spark unit wire connector 2 (5) Rear turn signal wire connector 4 (6) License light wire connector 2 (7) Fuse box 1 (8) Right grab rail 1 (9) S ck absorber reservoir/bracket 1 (10) Rear brake reservoir 1 CAUTION ‘ Keep the reservoir level to prevent air from entering the system. (11) Radiator raerve tank 1 (12) Muffler mounting bolt/nut 1/2 [13) Sub-frame mounting bolt 4 NOTE Remove the main Wire harness from the clamp. (14) Rear lender bolt 1 7’ v —- — I,“ -7; 2,: 7 2-13 3. Maintenance Service Information 3-1 7 Valve Clearance 77 3-7 Service Access Guide 3—2 Carburetor Synchronization 3-10 Maintenance Schedule 3-4 Drive Chain 3—11 Air Cleaner 3-5 Side Stand 3-12 Spark Plug 3—5 Service information - Refer to Common Service Manual for service procedures on items not included in this manual. . Refer to the specifications (Section 1) for maintenance service data. 3—1 Maintenance Service Access Guide - The fdllowing shows the locations of the pans that must be removed for the 111 Service Manual for items not included in mis manual. aintenance items listed below. Refer to the Common . Refer to section 2 (Frame/body panels/exhaust system], (niche parts that must be removed for service. For example: AIR CLEANER (Cantamination, clogging, replacement) — Maintenance part (service items) - Fuel tank — The pans that must be removed for service (1) SPARK PLUG (Wear, damage. color: page 3-5) - srqe fairing (1]) ,,AW ___ .. -. “g- (2) BRAKE HOSE (Leakage, degradation, damage) , (3) RESERVE TANK (Coolant level) (4) BRAKE RESERVOIR (Level check, fluid replacement) - Seat Cowling (5) BRAKE CALIPER (Padiwear) (6) TIRE (Wear, damage, pressure) (7) WHEEL (Dan-rage, runout. corrosion) (8) BRAKE LIGHT SWITCH (Operation) , _ (9) BRAKE PEDAL (Air bubbles in Eystem) (10) OIL FILLER CAP/DIPSTICK (Level check, replacemgr) _ egg/mars. .. . .. . (Cohtaminéfion, clogging, replacement page 35) - Fuel tank (12) THROTI'LE GRIP (Operation, free play) (13) BRAKE LEVER (Air bubbles in system) r14) BRAKE CALIPEVRJPVarg wear) (15) TIRE (Wear, damage, pressure) (15) WHEEL (Damage, runout, corrosion) 3-2 Maintenance (8) THROTTLE STOP CONTROL KNOB 7(1) CARBURETOR CHOKE (Operation) 7 (Idle speed adjustment) (Z) BRAKE MASTER CYLINDER (Level check, fluid replacement) (9) BRAKE HOSE (3) HEADLIGHT (Aim) (Leakage, degradation, damage) (4) BRAKE CALIPER (Pad wear) (10) DRIVE CHAIN (Free play) lubrication, I5) OIL FILTER (Replacement) replacement: page 3-11) - Front panel (6) OIL DRAIN BOLT (Oll replacement) . anerfalring (11) SIDE STAND (Operation: page 112) 7 " '7 77} VALVE CLEAmncmaaTe 371* 3-3 Maintenance Maintenance Schedule Perform the FREVFIIDE lNSPECl’lON in the Owner’s Manual at each scheduled maintenance period. I: Inspect and clean, adjust, lubricate, or replace if necessary. R: Replace C: Clean L: Lubricate A: Adjust The following items reouier some mechanical knowledge Certain items {particularly those marked ‘ and ‘ ' I may require more techni. cal information and tools. Consult their authorized Honda dealer. Odometer Reading (Note 1) Frequency 2:?“ -> x 1,000 km 1 6 12 ‘7l787 24 so 367 ; x1000, mi 0.6 4 5 12 16 20 24 Refer to Item Note Months 6 1 2 71 8 24 30 36 page ' Fuel Line I | l Note74 r ThrottJe Operation 7 I I l 7 Note 74 " Carburetor Choke l l | Ngte 4 Air Cleaner Note 2 7 R Fl 3-57 “ Valve Clearance I | 3-7 Spark Plug l n I 7R7 I H 773-5 Engine on 7 7 R n R R Note 4 Engine Oil Filter 77 777 7R 7 R 7 H R Note 4 ‘ Carburetor Synchronization 7 7 7 I 7I7 77 I I 310 ' Carburetor Idle Speed 7 77 7 7 l7 77! 7 7l7 I7 7 l I Note 4 Radiator Coolant 77 7 nga 7 7 7 I7 I R Note 4 ' Cooling System I I7 I Note 4 Drive Chain 7 7 I, L Every 1,000 km (600 mi) 7 73—11 Brake Fluid 7 N07te 3 7 | l R | l R Note 4 Brake Pads Wear 7 77 I I I I I I Note 5: Brake System 7 7 7 I I I l Note747 ' Brake Light Switch 7 77 7 | I I Notej7 - Headlight Aim 7 _ 7 I I I Note 4 Clutch System 7 7 I I I7 71 l I 7 1 Note 4 Side Stand 7 I l | 3-12 ' Suspension I I I Note 4 ’ Nuts, Eols, Fasteners 7 I I I I N70t7e 747 k " Wheels/Tires 7 7 7 7 7 I 7 I7 I Note 4 “‘ Steering Head Bearings I l l 7 | Note 4 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 recommend thue items be serviced only by an authorized Honda dealer. Notes: 1. At higher odometer readings, repeat at the frequency lnteNal atablished here. 2‘ Service more frequently when riding in unusually wet or dusty areas 3. Replace every 2 years, or at indicated odometer interval, whichever comes first. Replacement requires mechanical skill. 4. Refer to Common Service Manual. 7 Spark Flue 7 Air Cleaner Remove the following: — seat Cowling (page 272). — fuel tank (page 2-5). — air cleaner case cover screws. — sub air deaner tubes. — air cleaner case cover. Remove the air cleaner element, and replace i1 with a new one lnsTall the removed pars in the reverse order of removal. - Do not touch the exhaust pipe wh Rear Cylinder: Remove the No. 1 and No. 3 cylinder spark plug caps, and remove the spark plugs with the spark plug wrench. Front Cylinder: Remove the following: — both side fairings (page 2-3). . ~ upper radiator lower mounting bolt. Move the upper radiator forward, remove the No 2 and No. 4 cylinder spark plug caps and remove the spark plugs with me spark plug wrench. CAUTION . , , - . Be careful not to damage the radiator fins whaa servicing; . . Q, ,7. NOTE - For inspection, refer to seciion 2 of the Common Service-1 Manual. - For recommended spark plug and specified spark plug gap, refer so section 1 (Specifications). ,‘,jr Maintenance \J/ [1) AIR CLEANEITCASE COVER (2) COVER SCREW \, \ , ~ « \ l3) SUB AIR CLEANER TUBES (1) AIR CLEANER ELEMENT l2) SPARK PLUG WRENCH (5, UPPER RADIATOR (3) FRONT (4) SPARK PLUG WRENCH ll Ell 3-5 Maintenance Using- me—spark Eng wgnch, hand tlghten the spgrk plug until it is (1) INDEX PLATE seated, than tighten It to the specified torque: Torque: 8 N-m (0.9 kg-m. 7 ft-lh) When the spark plug Wrench (07 MA~MR80200) is used: Hand tighten the spark plug until i s seated, using the spark plug wrench. Turn the Eidex plate to align the starting line of the tightening, and install the handle onto the spark plug wrench. When a new spark plug is used (the sealing washer is not com- pressed). tighten the plug from the starting line to the " O " mark of the index plats When the spark plug is reused {the sealing washer is compressed), tighten the plug from the startig line to the " o ” mark of the index plate. CAUTION E (5) SPARK PLUG WRENCH (120°) K9 (4) REUSED PLUG ; L Navel tighten the plug over the " 0 " and " I " masks. ‘J ; 3—6 Maintenance Valve Clearance NOTE 7 7 ,7 . inspect and adjust valve clearance while the engine is cold [2’ MOUNTING BOLT [below 35°C/95aF). 7 _ _ (1LUPPER RADIA'QR (3i MOUNTING BOLT Cylinder Head Cover Removal Front Cylinder Remove the iower fairing (page 2~4L Remm/e the upper and lower radiator mounting bolts and move the radiators forward. Remove the following: — fuel tank (page 2-5i. — air cleaner case (page 6—4l. —- air cleaner case base , 7 — heat protector. , " 7 : — front spark plug caps, — front cylinder head cover bolts. — front cvlinder head covert CAUTION 7 , i 7 - Covenhe radialorfins to preventthem from damaging when (6) MOUNTING l4) MOUNTING BOLT servicing. BO LT - Be careful not to damage the front fender. (5i LOWER RADIATOR Rear Cyfinder Remove the following: — seat cowling {page 272). — fuel tank (page 2—5). — rear cylinder head cover bolts. , — rear cylinder head cover. ” l1) REAR CYLINDER HEAD COVER Inspection Remove the timing hole cap, Turn the crankshaft clockwise and align the ”T” mark (front: T2, 7 v rear: T‘ll on the starter clutch cover with the index mark on the right cankcase cover. l Maintenance Whenthe émTe marks on the right sides ofile ca: 555615}; lac-v ing up, the piston of the following cylinder is at TDC (Top Dead Center) on the compression stroke Front (TZI: Not 4 wlinder Rear (11): Na. 1 cylinder Whefihe e'B—ge ma‘ris ar'e va'cihg Joihffilmn'o’v‘fig wc'y TDC?n the compression stroke. mg is 7a: Front (T2): Nut 2 cylinder Rear lT‘lI: No. 3 cylinder Relatiqn between the timing mark and edge marks: . [1) EDGE MARK - Piston at TDC on the Timing mark Edge marks compression stroke T1 Facing up 7 No. 1 cylinder Facin down No. 3 l‘ der 9 7 cm (1) EDGE MARK Facin u Nq4 linder W 7 , W, TI 9 p ‘ _6y 7, z , Facing down No‘ 2 cylinder— Make sure that the piston is at TDC on theTSomprission strike Measure the valve clearance by inserting the feeler gauge between the rocker arm and adjusnnent shin-no Valve clearanu: , , Intake valve: 0.12~0.18 mm (DADS—47.007 in) Exhaust Valve: 0.21—0.27 mm (0.003~0.D‘l1 in] Shim Removal Make sure that the piston is at TDC on the commission stilts. Place teh shop (awels in the spark plug hole and cam gearcase hole and place the magnet near the shim to prevent the shim from failing. Move the rocker arm inward by pushing it. CAUTION If the valve clearance Is loo small, the slim may jump out 7 when moving the rocker arm. NOTE (2i EDGE MARK (1| CAMSHAFI' [3) FEELER GAUGE ' l5) yggvsjram (1) CAMSHAFT HOLDER (2) SHlM (337ROCKEH ARM t- , . ,. - To hold the moved rocker am, it is convenient to use the snap ring pliers (07914— 567Q199). Remove the shim with a tweezers. 3-8 Maintenance éhimiéeEtigrr 7 7 I ' ‘ H ' r2) CAMSHAFT r3) SHIM NOTE 0 Sixty-five shims are available in thickness intervals of 0.025 [ r . mm. The thinnest is 1.200mm and the thickest is 2,800 mm. Clean the shim with a clean shop tawel. Measure the shim thickness with a micrometer and record it. 7 To select the shim needed to bring the valve clearance within specificalion, use the following formula: 3 = b - c + d a: new shim thickness , reggdeflalve cleaning; , , , c: pecifiedvalve clearance 7 , 7 7779; old shimhickhfis Example: Recorded Valve clearance 0.20 mm (bi Specified valve clearance = 0.15 mm (C) Old shim thickness = 2.200 mm (d) 0.20 — 0.15 + 2.200 2.25 (2) SHIM a » New shim thickness = 2.250 mm NOTE 7 7 - If the required thickness of the new shim is more than 2.800 mm, the valve seat is probable heavily carboned. Reface the seat, recheck valve clearance and reselect the shim. Shim Installation , , l1) CAMSHAFT HOLDER l2) ROCKER ARM 3 “7/7, )7, / Make sure that the piston is at TDC on the compression stroke ’ ‘ . . Apply molybdenum disuifide oil to the shim and rocker arm slipper. Place the shop tawels in the spark plug hole and cam gear case hole and place the magnet near the valve to prevent the shim from falling. Move the rocker arm Inward by pushing it. NOTE 7 fl - To hold the moved rocker arm. it is convenient 10 ,use the \ l3) mMSHAl-T snap ring pliers “WSW—5670100). 7 ' 7' install tireEm wit’h’the’tweé’zers’. Maintenance Carefully slide the rocker arrn ck to the original position. Make sure that the shim contacting sun‘ace of the rocker arm is positioned in the center of the shim and theshim is completely seated. CAUTION ‘ Be careful not to bound the shim out when sliding the rocker arm. Turn the crankshaft clockwise several times. Recheck the valve clearance. , Apply Honda band A or equivalent to the gasket groove in the cylinder head cover. Install the cover gasket with the “[N" mark facing toward the in- take side. Install the cylinder head cover with the "1N” mark facing toward the intake side. Install the cover bolt washers with the ”UP” mark facing up. Install the cover bolts and tighten them. Torque: 1n mm (1.0 kgm, 7 rub) Install the removed parts in the reverse order of removal. Carburetor Synchronization NOTE - Refer to section 2 ol Common Service Manual for carburetor synchronization procedure - Synchronize the carburetor with the engine at normal oper- ating temperature, transmission in neutral and motorcycle supported upright. Disconnect the vacuum tube from the No 3 wlinder intake manifold, apply vacuum to the auto fuel valve and plnch the tube with a clip. Removelhe plugs from the No. l, 2 and 4 cylinder intake manifold and install the vacuum gauge adaptors. (1) ROCKER ARM i‘l) COVER GASKEF (3) “W" MARK (2) SHIM (3) VALVE RETAINER (2) CYLINDER HEAD CQVER (1) COVER BOLT WASHER (2) “UP" MARK 3-10 Maintenance Connect the vacuum gauge adaptor to the auto fuel valve vacuum tube ioin! of the Na. 3 cylinder intake manifold. NOTE . The base carburetor is the No. 2 carburetor. . ,, Adjust the carburetor synchronization by turning the synchroniza- tion adjusting screw. . v Drive Chain - Never Inspect 0v adjust the drive chain whllejha engine ls running. Place the motorcynle on its side stand and shift the transmission into neutral. Check slack in the drive chain lower run midway between the 7 sprockets. Slack: 15—25 mm (SIS—4 in) Adjust the chain slack as follows: Loosen the hearing holder pinch bolt. Turn the axle bearing holder with the pin spanner pvavided in the toll kit until the cancer drive chain slack is obtained. NOTE - To ease the adjustment, raise the rear wheel with an optional stand and turn the wheel in the same direction as the bearing holder rotation. (1) VACUUM JOINT v w [2) PLUG [1) SVNCHRONIZATIDN ADJUSTING SCREWS (2] BEARlNG HOLDER \\ _ ,. PlNCHBOIJ' \ TX (3) PW SPANNER 3—11 Maintenance After adjustment, check the chain wear labelt ii the red zone on the label reaches the outside diameter of the driven sprocket, replace the drive chain with a new one. . m DRIVEN SPROCKFr / Replacement chain: RK 635258M4 , Because the endless type drive cha is u d, the swingarm must be removed tn replace the dr 9 ch fighten the bearing holder pinch bolt. Torquez'SS him (55 kg—m, 4o ft~lbl Side Stand Checkthe side stand rubber For wear. 7 Replace the rubber it wear extends to the wear rnarltt 1 Check the side stand operation. The side stand should lower easily to its first stop, then lock after moving farther forward to support the motorcycle as the rub- ber touches the greund. ' f (1) RETRACTED :’ ~ POSITION / (a) WEAR MARK When the motorcycle is lifted upright, the stand should automati- cally move the first position, and retract when kicked up. & If the side Stand does not move freely, disassemble it: Remove the return spring at the retracted position. (2] FIRST STOP Remove the pivot bolt and remove the side stand assembly from POS'TION the frame ,, 7 , Check the following parts for wear or damage: — inside of the pivot and pivot collar. — pivot dust seals. Lubricate the pivot area with clean grease and reassemble the side stand. CAUTION ~ Install the dust seal with the spring side facing out. . Make sure that the dust seal spring is not removed then in- stall the side stand. , . i3) SPRING Torque: ._,_—» © Side stand bracket bolt: 35 Nm (3.5 kgm, 25 ft-lb) r‘fi’l /’@3@¥ \.C¢\ (4) DUST SEAL (5) PIVOT COLLAR Flecheck the side stand operaticnt 3-12 4. Lubrication System Service Information 4-1 Oil Cooler Removal/Installation 4~3 Troubleshooting 4-1 Oil Pump Removal/installation 44 Lubrication System Diagram 3-2 ' Oil Pump Disassembly/Assembly 46 Service Information - The service procedures in this section can be performed with the engine oil drain, . When removing and installing the oil pump use care not to allow dust or dirt to enter me engine - If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. ~ After the oil pump has been installed, check that there are no oil leaks and that oil pressure is correct. Troubleshooting on Level Low 7 - Oil consumption - External oil leakr - Worn piston ring or incorrect piston ring installation. - Worn valve guide or seal. on Contamination - From coolant mixing with oil — Faulty water pump mechanical seal. w Faulty head gasket — Water leak in crankcase Na Oil Pressure - Oil level toolow. - Oil pump drive chain or drive sprocket brokenr - Oil pump damaged (pump sham - Internal oil leaks. , Low Oil Pressure Pressure relief VaIvEsruck open, Clogged oil filter screen. Oil pump worn or damaged. Internal oil leak. Incorrect oil being used Low oil level. High Oil Pressure Pressure relief valve stuck closedr Plugged oil filter, gallery, or metering orifice. Incorrect all being used. ,Seized Engine No or low oil pressure Clogged oil orifice/passage. on leakage inside the engine Use of oil not recommended. 4—1 Lubrication System Lubrication System Diagram I1) OIL PIPE (3) OIL PIPE (4) OIL PUMP [5) OIL STRAINER (2) CONNECTING ROD 01L JET (7) OIL FILTER (SI OIL PRESSURE RELIEF VALVE I8) OIL COOLER 4—2 Oil Cooler RemovaI/lnstallation Lubrication System @‘V (4) Requisite Service . Lower fairing removal/instaflation (page 2-4), ~ Engine oil draining (lacafion: page 3.3, step: section 2 of the Common Service Manual). Procedure Q’ty Remarks Removal Order lnstallaticn is in the revers'e'order’of remaval. (1) Oil cooler bolt 5 12) on cooler 1 (3) Osri ng 2 (4) Tube 2 4—3 ll Lubrication System Oil Pump Removal/Installation : OiRlNG @ (11) 4-4 E Lubrication System I 7 ”NOTE T - :- l . Removirhe drive sprocket bolt before removing mé’on pump mount/wig bolrsl . Remove the oil pump drive sprocker bolt with care as it is coiled wigh mread lockianrgenn v , r“- V “f. .. Requisite Service Engine oil draining (location: page 373, step: section 2 of the Common Service Manual). . Lower fairing remwalfinsrallation [page 2-4). . Oil pump driven sprocket remcwalflnsiallation (pages 3-4 and 9-6)r - Front exhaust sysuem (page 2-10). . Right crénkcase cover remuvalfinstallation (page 9-2]. ” , Procedure 7 i Flen'larks ; ‘ 7 1 , fl 7 .1 v as . .— 9 - ‘ Removal order Installation is in the reverse order of removal (1) Oil pan bolt 12 (2) Oil pan 1 NOTE Loosely tighten the bolls first to set the oil pan in correct position. ' (a) Pressure relief valve 1 NOTE Align the cumm in me stopper wirh the pipe. (4) Oil s‘rainer/O-ring 111 NOTE I Install the oil stminer aligning the bass in the strainer with ‘ the slit on the oil strainer. (5) Oil pipelO-ring 2/4 (6) Oil pipe bolt 2 (7) Oil pipe/O-ring 1/1 NOTE Remove the drive sprocket bull before removing the oil pump mounting bolts. (8) Oil pump bolt 3 (9) Oil pump assembly 'l NOTE When installing the oil pump assembly, align the projection on the pump shaft With the cutout in rhe water pump shah by romu'ng the pump shaft. Disassembly: see page 4-6. (‘10) Dowel pin 2 (11] Oil orifice/O-ring 1/1 NOTE i If the orifice is removed, check it for clogging before rein- , stallation , _._ n... Lubrication System Oil Pump Disassembly/Assembly ‘M-L:_ \l fi *1 NOTE Clean each part with cleaning solvent and coat with clean ensme all before assemny lubrication System Requisite Service . oil pump removalfinstallation (page 4-4). Procedure Q’ty Remarks Disassembly Order Assembly is in the reverse order of disassembly (1) Oil pump body bolt 3 (2) Cooler pump cover 1 (3) Dowel pin 2 (4) Cooler outer roter 1 NOTE ' - Install the outer rotor with its punch mark facing cooler pump cover. (5) Cooler inner rater 1 (6) Drive pin 1 (7D Thrust washer 1 (Bl on pump budv 1 (9) Dowel pin 2 (10) Feed pump outer rater 1 NGTE . Install the outer rotor with its punch mark lacing feed \ pump Coven (11) Feed pump innsr rater 1 (12) Drive pin 1 (13} Oil pump shaft 1 NOTE - Install with the tab side facing the never [water pump side). (14) Feed pump cwer 1 (15) Omar pin 1 (16) Spring retainer 1 (17) Spring 1 (13) Piston 1 (19) Cotter pin 1 7 (20) on strainer pipe/0mg 1 n 5. Cooling System Service Information 5V-1 (Wat; Pump Disajsembly-lAssembly 5-5 ‘li'oubleshooting 5-1 Radiator Removal/Installation 5—6 System Flow Pattern 5.2 Radiator Disassemny/Assembly 5—8 Coolant Draining 5.3 : Thermostat Removal/Installation 5-4 T Service Information .. . 2-: ..._ lush... . Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is not and the coolant is under pressure may cause serious scalding. . Radiator coolant is toxic‘ Keep it away from eyes, mouth, skin and clothes. — If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. — If anyAQoolant' Is swallowed, induce vomiting, gargle and consult a physician immediately. 7 If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. . KEEP OUT OF REACH OF CHILDREN .7 a; __ ,7: .. g r Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. All cooling system service can be made with the engine in the frame Avoid spilling coolant on painted surfaces 7 After servicing the system, check for leaks with a cooling system tester‘ Refer to section 18 for fan motor switch and thermo sensor inspections. Troubleshooting Engine Temperature Too High - Faulty Iadiator can - Insufficient coolant. - Passages blocked in radiator, hoses. or water jacket. - Air in system. - Faulty water pump - Thermostat stuck closed. - Faulty temperature gauge or thermo sensor. . . Faulty cooling fan motor. - faulty fan motor switch, - fin shround installed improperly. Engine Temietature ‘roo Low - Faulty temperature gauge or gauge sensor. . Thermostat stuck Open. - Faulty cooling fan motor switch (see section 18). Coolant Leaks Faulty pump mechanical seal - Deteriorated O-rings - Faulty radiator cap. - Damaged or deteriorated gaskeL - Loose hose connection or clamp. . - Damaged or deteriorated hoses, Cooling System System Flow Pattern (5) RADIATORS (2) RESERVE TANK (1) SIPHON TUBE (4) WATER PUMP 5-2 Cooling System Coolant Draining . The ladiator cap is under high pressure and radiator coolant could spurt out. resulting in scalds on your hands etc. If the cap is removed while the radiator is hot Wait until the radia- tor cools down and remove the cap. Remove the side fairing and the lower fairing (pages 2-3 and 2-4). Remove the radiator cap, Remove the drain bolt {on which a copper washer attachedl from the water pump and drain the coolant. Remove the two drain bolts from the cylinder and drain the coolant. \/ ~>/m DRAIN son's Cooling Sysiem Thermostat Removal/Installation LW J :- (81 " ' - 12’ 010 (1.0, 7) Requisite Service ~ Fuel tank remm/al/insrallation (page 2-5). - Lower fairing removalfinstallatiun (page 24). - Coolant draining (page 5-3). - Coolant refill (section 5 of the Common Service Manualll Procedure Q'tv Remarks Removal Order Installation is in the reverse order of removal. (1) Band/water hose 2/2 NOTE . Loosen the hose band. (2) Thermostat cover bolt 2 (3) Thermostat cover ‘I (4) O-ring l (5) Thermostat 1 (6) Theme sensor connectar 1 (7) Themisensor ’1 NOTE - At reassembly, apply a sealing agent m the threads [8) Thermostat housing bolt 2 l9) O-ring 1 Cooling System Water Pump Disassembly/Assembly 7,7,1 "Tf'r’gsru 7, .vv 14) 10 (LO, 7] NOTE 7 ' " ~: -~=-—E- , :pr-fi: ~ Before removing the Maker pump, place an oil pan under xhe engine to catch the leaked engine __ .fi _ , _ if. Requisite Service - Lower fairing remavalfinstallation (page 24). ' Coolant draining (page 5-3)‘ - Coolam refill [section 5 of the Common Service Manual]. Procedure Remarks Removal Order Installation is in the reverse Ode! of removalu (1) Hose band/wa‘er hose , 2/2 NOTE - Loosen the band and pull om the water hose. (2) Bolt 2 NOTE - Belore removing bolls, luosen the pump cover bohs. (3) Water pump assembly 1 NOTE - At installation, align the pump shaft slot with the oil pump shafL (4) Housing cover bolt 2 (5) Cover 1 (6) O-ring 2 (7) Dowel pin 1 (8) Water pump 1 CAUTION 7 7 ‘ Avoid further disassembly‘ 5-5 Cooling System Radiator Removalllnstallation (5} Cooling System CAUTION 7 7 i , , ,, .- ,. , , . - Protect the radiator fine by attaching a piece of adhesive tape or equivalent and remove/install the radiator with care not to break the fins. - Take care nut to damage the iron! fender. Requisite Service - Lower fairing removalflnstallation (page 2-4lt - Coolant dra ng (page 53). . Coolant refill (section 5 of the Common Service Manuallt 7 ._ v7 m . , , rs Procedure O’ty Remarks Removal Order Installation is in the reverse order of removal. (1) Upper radiator hose 1 12h Radiator breather tube 1 (3) Fan motor mnnector/fan motor switch con» nectar 1/1 ‘ (4) Lower radiator hose 1 (5) Upper radiator bolt 2 NOTE - Remove the two bolts, pull the upper radiatar to the flywheel side, and disconnect at the upper connection of the radiator mount. (6) Lowe} radiator bolt 2 NOTE - - Remove the two bolvs, pull the lower radiator to me clutch side, and disconnect at the upper connection of the radiator mount. (7) Upper/lower radiator 1/1 NOTE - Remove as an assemny 7 _ , ., ”#4:“,Au. , , ;; i Cooling System Radiator Disassembly/Assembly GROUND J‘m c 18 (1‘8, 13) 2% 5-8 ' Cooling System CAUTION - Protect the radiator fins by attaching a piece oi adhesive 1;); er equivalent and grnerr'ehn‘stali'tie radiate not to break the fins, _ , , .. a, s v . , . . :— NOTE , r Set the fan motor wire in the fan shround clamp properly m avoid interterencTa Between tnE-ranamfiie sari-l.“ “‘ ‘ J ' ’ Requislte Service . Radiator removainnstailatlon (page 5-6). ,. _ -.__ ,,_ , __!V , __ ._._ V A _ , . 1 Procedure Q'ty Remarks Disassembly Order 77 Asgnag islrrthe re'VA‘ersefiriof de'es'séirlbrrf V 7 (‘1) Radiator grille 1 (2) Right radiator hose 1 l (3) Left radiator 1 (4) fin motor switch 1 NOTE ‘ . At installation, apply sealant to the threads. CAUTION - Do not over-fighten the fan motor switch. or the radiator may be damaged. (5) Fan motor bolt 3 NOTE ' a 0n reassembly, tighten the ground wire together with the upper bolt. (6] Fan motor assembly 1 NOTE ' Disconnect the connector and the wire from the clamp of the lower radiator. (7) Nut 1 (8) Cooling fan 1 NOTE - When reassembling, align the fan motor shaft and the cutout in the fan blade (9) Fan motor not 3 (10) Pan motor 1 NOTE - Install the fan motor on the fan shroud wim the water l drain hole facing down. 5-9 6. Fuel System , i 7 g , , W K 77 , , Service Information Carburetor Removal/Installation 6-8 Troubleshooting Carburetor Separation 6-1 0 Fuel Tank Disassembly/Assembly 6-3 Carburetor Combination 6-12 Fuel Valve Disassembly/Assembly 6—4 Carburetor Disassembly/Assembly 6-14 Air Cleaner Removal/Installation 66 Service Information , _ e . J » , .7 . - . Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing names or sparks in the work area or where gasoline is stored can cause fire or explosion. 7 .. . . )— s. ,. fi A . 7 QAUTION 7 _ _ A _ _ .m , . . , - Bending or twisting the control cables will lmpair smooth operation and could cause the cables to stick or bind, resulting In loss of vehicle cum-ml. - Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might be damaged. NOTE ' ' - If the vehicle is m be stored for more than one month. drain th—efloatbowls. Fuel left in the float bowls may cause cloggédj’ats resulting ln hard starting or poor driveability. - Carburetor disassembly is not required for servicing the vacuum piston and the float chamber. - Refer to section 2 for fuel tank removal and installation - When disassembling fuel system pars. note the locations of me O-rings. Replace them with new ones on reassemny . Before disassembling the carburetor, place the suitable container under the carburetor drain bolt, then loosen the bolt and drain the carburetor, . After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with piece of tape to prevent any foreign material irom dropping into the engine. 7 ¢ Carburetor number is set so that it corresponds to the cylindiinumbgr. 6-1 Fuel System Troubleshooting Engine Won’t Start - No fuel to Carburetors — fuel strainer Clogged —— fuel tube clogged -— faulty fuel valve — float level misadjusted — fuel tank cap breather hole clogged . Too much fuel getting to the engine —- air cleaner clogged — flooded carburetors - intake air leak - Fuel contaminated/deteriorated - Slow circuit or bysmrter circuit clogged - Ignition malfunction Engine Stalls, Hard to Start. Rough Idling ~ Fuel line restricted ~ Ignition malfunction ~ Fuel mixture too lean/rich - Fuel contaminated/deteriorated - intake air leak - Idle speed misadjusred . Pilot screw mlsadjusted , , fl - Slow circuit or bystarter circuit clogged - Float level misadjusted - Fuel tank breather tube clogged Afterbum on Deceleration - Lean mixture in slow cimuit Baekfiring or Misfiring During Acceleration - Ignition system faulty - Fuel mixture too lean Poor Performance (driveability) and Poor Fuel Economy - Fuel system clogged - Ignition malfunction Lean Mixture - Fuel lets clogged - Float valve faulty ~ Float level (00 low ~ Fuel line restricted - Carburetor air vent hole {or tube) clogged - Intake air leak - Vacuum piston faulty . Throttle valve faulty Rich Mixture - Bystaner valve in ON position - Float valve faulty ~ Float level tuo high - Air jets clogged - Air cleaner element contaminated - Flooded carburetors 6-2 Fuel System Fuel Tank Disassembly/Assembly e 11 (1.1. 8) (5) (6) (3) (4) l - Gasoine is extremely flammable and Is explosivefid’er’éér‘nrin conFifions. Work'in-a‘wellvvaifla‘ted Elsa. SmokiRJur alluwing flames or sparks in the work area or where gasoline is stored can cause a fire or exploslon. Requisite Service - Fuel tank removal/Installation [page 2-5). , Procedure , V "v V (It? > Era-mark; ‘ Disassembly Order _ Assembly is in theireverse order of disassembly‘ , (1) Bolt/tank cap 7/1 (2D Fuel valve bolt 3 (3) O—ring 1 NOT E - When assembling the fuel tank, take care not to get the O-ring caugh: or pinched in the pans. (4) Fuel valve assembly 1 (5) Breather tube ioint 1 (6) Fuel tank l 1 fl , _s,“. ,_ .-- ,...‘,v_..—. if.“ - . ., . ;_: Fuel Sys‘em Fuel Valve Disassembly/Assembly (Bi (2) ‘ Gasaline is extremely flammable and is explosive under certain conditions. Work In a well vantilaxed area. Smoking or allawing flames or sparks in [he work area or where gasol stored can cause a fire or explosion. 7 ~ --e - — _. : , Au ' Requislte Service - Fuel tank flisassembly/assembly (page 6-3)' g Procedure 7 ,. Qty 7 Remarks Disassemhly Order Assembly is in the reverse order of disassemblv. (1} Fuel valve lever 1 (2) Fuel filter 1 [3D Diaphragm cover screw 4 NOTE - 0n assembly, tighten the screws equally. (4) Diaphragm cover (5) Spring (6) Diaphragm (7) Set plate (8} Fuel valve body 6-4 Fuel System MEMO Fuel System Air Cleaner Removal/Installation (6) 6—6 p,» ( Requisite Service . Fuel tank remm/alhnstallation (page 275). Fuel System Procedure Rfinérké Removal Order (1) Air cleaner case cover screw (2) Air cleaner case cover (3) Sub air cleaner tube (4) Fuel tank drain tube (5} Air cleaner element (5) Sub air cleaner element Installation is in the reverse orcler of removal. Fuel System WW, Carburetor Removal/Installation 6-8 Fuel System . Gasoline s extremely flammable and is explosive undemenean’wmfnions. Work in a well venliéred area. Smoking or allowing flames or sparks in the work area or where gasoline is stored pan cause a fire or explosion , i , ._ . .r. NOTE i ,v,._ a» - ,_ ,.., e ,,,, - After removing the carburetor. cover the engine intake pen with a shop towel or tape to prevent foreign materials from entering the engine through the pun. RequisiteService - Air cleaner removalfinsiallation (page 6-6). Procedure Q‘ty Rernarks Removal Order Installation is in the reverse order of removal. (1) Air cleaner case base screw 4 (2) Air cleaner case base 1 l3) Throttle cable 2 NOTE - Loosen she adjuster. (4) Choke cable 1 (5) Insulator band 4 NOTE - Loosen the screws on rhe carburetcr side Install Lhe insulator bands as shown in the drawing. (6) Carfiuretor assembly 1 Fuel System Carburetor Separation #3 CARBUHETQB #1 CAREURETOR #4 CAREURFI'OR (13) #2 CAREUREI'OR kT (l . * @ saw \ r# ”J “—J (8) (C) (B) (A) THRUST WASHER A (D) (A) (E) (B) PLASTIC SPRING WASHER (C) PLASTIC THRUST WASHER " f (D) CDTTER PIN 6~10 Fuel System - Gasoline is extremely flammable and is explosive under certain conditions Work in a well ven'lfiéled area. Smoking or allowing flames or sparks in the work area or where gasoline ls stared can cause a fire or explosinrll . 7 _ .. _. I ‘ _ a Requisite Service ~ Carburetor removal (page 6-8I. Procedure O’ty Remarks 7 Separation order ' ' (1) Air chamber screw 8 (2) Lock plate 4 {3) Air chamber/air cleaner duct 1/4 [4) Dow'el pin 8 (5) Bracket screw 2 (6) Carburetor set screw 2 NOTE - Separate the carburetors. l7) By—starter link ‘1 NOTE - Remove lrorn the No. 2 and No. 3 carburetors. (8) Thronle link 1 NOTE - Disconnect from the Na 2 and No. 3 carburetors. l9) By-starter arm 2 NOTE A - Loosen the screws. (10) #144: #2-4 mrusl spring 2 NOTE ' - Loosen the synchronizing screws. 1 (11) Fuel tube 1 ~r- NOTE [12) Air bent tube 1 J ‘ Note and record the joint pipe installation direction. (13) Sub air cleaner tube 2 6-11 Fuel System Carburetor Combination # 4 CARBURETOR 5 r _ £0; .OR!NG,CO‘|’TER PIN # 3 OARBURETUR (3) 7 (5) (A) THRUST WASHER (B) PLASTIC SPRING’WA’S'HER (C) PLASTlC THRUS’T WASHER (D) COTTER PIN (5) #1 CARBURETOR [2) 6—12 Fuel System Requisite Service - Carburetor installation (page 5—8). CAUTION . After assembling me carburetor. check the rhroflle link and me hystaner link human nperation. - After assembling me carburetor. move the byslaner link lever to "CLOSED" position and be sure um me bystaner valve is no: pulled by the bystaner rad claw. Procedure O’ty Remarks Combination Order V _ (1) Bv—starter link , 1 NOTE - Refer to the drawing for the combination of the washer. [2) Throttle link 1 [3) Sub air cleaner tube 2 (4) Air bent tube 1 (5) Fuel tube 1 (6) Bynsmrter arm 7 7 2 NOTE - Ser the claw of the Ely-starter rod and arm on the by- ‘ starter valve securely. (7) Carburetor set screw 2 CAUTlON - Take care not to damage 1he fuel joint pipe O-rings, (8) #1-3; # 2-4 thrust spring 2 (9) Bracket screw 2 (10) Dowel pin 3 (11) Air chamber 1 (12) Lock plate 4 (13) Air chamber screw , 8 Fuel System Carburetor Disassemny/Assembly (16) 6-1774 Fuel System A WARNING - Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilaieii area. Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. .JELQ'EE _, , _ - The service procedure is for the No. 2 carburetor on this page . The procedures or the No. 1, 3, and 4 are the same as the Na 2, . The VaCulen chamber and float chamber can be serviced with the carburetor assembly. - The pilot screws are factory pre-set and should not be removcd unless lhe carburetors are overhauled. Turn each pilot screw in and carefully count the number of turns before it seem Iigmly. Make a note or this to use as a reference when reinstalling the pilot screvls. If new pllul screws are installed, rurn pilot screws out to the initial opening (page 1-6) Requisite Service . Carburetor remuval/lnstallation Ipage 68]. Procedure Remarks Disassembly Order Assembly is in the reverse order of disassembly, Froar Chamber (1) Screw 3 (2) Froar chamber cover 1 (3) O-ring \ 1 (4) Roar pin~ 1 (5) Froat 1 (6) Froat Valve 1 (7) Valve seat , 1 (8) Washer 1 (9) Filter 1 (10) Main jet 1 (11) Needle jet holder 1 (12) Slow jet 1 (13) Pilot screw/spring 1/1 (14) Washer/O-ring ' 1/1 (15) Throttle cable holder 1 Vacuum Piston 1 116) Vacuum chamber cover screw 4 NOTE 3 . Install with care not to pinch the diaphragm. (17) Vacuum chamber cover 1 (13) Spring 1 (19) Vacuum piston 1 120) Jet needle hoder 1 NOTE - Turn counterclockwise while pushing the holder lightly. [21) Spring 1 122) Jet needle 1 6-15 7. Engine Removal/Installation Service Information 7-1 Engine installation ‘ 7—4 Enging Removal 72 Service Information o A floor jack or other adjustable support is required to support and maneuver the engine CAUJ'LQN,_ ,_ , "‘ ' T, '— art's—'WWV ,- as v: r- Do not iack up the murorcvcle using the 0 filter. , 7 7 , w e. _ . - 1.3. 7W: To protect the engine, place a rubber board or equivalent on the floor before removingfinstalling the engine Place a jack under the engine and support the motorcycle securely. Remove and install the engine with care not to damage the frame engine, cables, and the harnesses. , When removingfinstalling (he engine, rape the frame to protect it. The following components can be serviced with the engine installed in (he frame: # al‘emator (Section 14) — cylinder head (Secrion) — clutch (Section 9) — gearshift linkage (Section 9) 7 oil pump (Section All — starter motnr (Section 16) — water pump (Section 5) The following components require engine removal for service: — connecting rod (Section 10) 7 cvankshaft (Section 10) — piston (Section 8) -— transmission (Section 10) 7-1 Engine Bernovalllnstallation Engine Removal [23) (18) Engine Removal/Installation CAUTION . Place a iack under the engine and support the motorwcle sewrely. . Tum the ignition switch OFF before disconnecting the cable from the battery negative (— ) terminal. . When placing the jack under the engine, take care not to set the jack against the oil filter. . Take care not to pinch the wire harnesses. NOTE . when the clutch lock nut, primary drive gear bolt, and the flvvvheel bolt are removed after removing the engine loosen them in advance to case removal. Requisite Service . Engine Qil draining (location: page 343, step: section 2 of the Common Service Manual). - Exhaust pipe removal (page 2-10). - Coolant draining (page 5-3). - Fuel tank removal (page 2-5). - Radiator removal (page 5-6li - Carburetor removal (page 6-8). . Loosen the drive chain (page 3711), Procedure ,, , my 7 Remarks Removal Order (1) Altemator wire connector : : 1 (2) Pulse generator wire connector ’ ‘l (3) Neutral switch wire connector 1 NOTE - Disconnect the which is integrated with the oil pressure switch (4) Spark plug cap 4 (5) Starter motor cable 1 l6) Gearshift spindle joint bolt 1 (7) Gearshift spindle iornt 1 (8) Clutch cable 1 NOTE . Loosen the lower adjuster lock nut and remove (9) Speedometer gear box ‘ 1 NOTE - Remove the mounting bolt. [10) Drive Sprocket cover 1 (11) Drive sprocket 1 NOTE - Remove the sprocket and remove the drive chain. (12) Heat protector 1 (13) Oil pipe joint. bolt 4 (14) Lower radiator stay 1 (15) Oil pipe bolt 2 (16) Rear lower engine mounting nut 1 (17) — adjusting bolt lock nut 1 1 (18) — mounting adjusting bolt NUFE ’ ~ Tum counterclockwise together with the mounting bolt and remove (19) Rear upper halt lock nut 1 (20) — mounting bolt 1 (21) —radjusting bolt 1 , NOTE ' . Loosen until the bolt end is not sxtruding inside the frame. 122) Left mounting bolt/collar 3/1 NOTE - Front bolt must be tightened together with the radiator bracket (23) Right mounting bolt/collar 2/2 (24) Engine assembly 1 NOTE - Lower the engine straight. then raiseI “1e frame Engine Removal/Installation Engine Installation (9) (7) (5) e 11 (11.3) (a) 6 9 e 40 (4.0, 29) 55 (5.5, 40) FRO NT CYLINDER CRANKCASE SIDE COLLAR SIDE COLLAR RIGHT: 9mm (4) c (40, 29) ”5F“ 15"“ 0 12 (1.2, 9) NOTE - The belt must be tightened together with the radiator (22; (24) (23) bracket. I Check for the correct position. Engine Removal/installation CAUTION . Place a jack under the engine and support the motorcycle securely. Take care not to damage the lrarne, engine, etc. - take care not to pinch the cable and wires. - when placing the jack under the engine, take care not to set the jack against the oil filter. . Loosely tighten the all maunu‘ng bolts and check to see that the engine is placed in correct position. Tighten the mounting bolts first that are tightened together with the adjusting bolts (page 7-6). ' Requisite Service - Exhaust pipe installation (page 2-10) - Radiator installation (page 5-6). . Carburetor installation (page 678). - Fuel tank installation (page 275). - Coolant refill (Section 5 of the Common Service Manual). Procedure , i 7 Cl’ty 7 .i Remarks , W 7 Installation Order (1) Engine assembly 1 (2) Rear lower engine mounting boldadjusting bolt 111 NOTE - Insert the mounting bolt into the adjusting bolt. engage them. and tighten them together. (31 — adjust bolt look nut 1 (4] - mounting nut 1 (5) Hear upper adjusting bolt 1 NOTE N - Loosely tightenr (6] — mounting bolt 1 NOTE ' - Loosely tighten the bolt first, tighten the adjusu'ng bolt as much as it goes, and install the lock nut. l7) — lock nut 1 (8) Left mounting bolt/collar 3/1 NOTE - The rearward bothas acoller (15mm of withlr The forward bolt must be tightened together with the radiator bracket. Loosely tighten to check the correct in- stallation position. (9) Right mounting bolt/collar , 7 , 2/2 NOTE - Install the collars in proper positions. (10) Oil pipe bolt (11) Lower radiator stay 1 NOTE - Install the drive chain on the drive sprocket. (12) Oil pipe joint bolt 2 NOTE - Interlock the lifter arm with the lifter rod (13) Heat protector (14) Drive sprocket (15) Drive sprocket cover 115) Clutch cable (17) Speedometer gear box NOTE ' - Engage with the drive sprocket bolt [page 10-2i. (18) Gearshift splndle icint (19) Gearshift spindle joint bolt 1 NOTE - Install the punch mark on the arm aligned with the mark on the spindle (page 10-2). (20) Starter motor cable (21) Spark plug cap (22) Pulse generator wire connector (23) Alternator wire connector , £4) Neutral switch wire connector , 7-5 Engine Removal/Installation V Enginfillountingialt Vlnétéll’a’tidni 7 [Rear Upper Mounting Bolt] Set the adjusting bolt over the mounting bolt and engage mam. Push the mounting bolt into the place shown in the drawing as full as it goes. Tighten the mounting bolt and the adjusting bolt by using a hex wrench TORQUE: 1‘l N'm (1.1 kq-m, 8 {NM Install the lock nut, Hold the adjusting bolt and tighten the lock nut by using the lock nut wrench. TORQUE: 55 Nm (5.5 kg—m. 40 ft—lb) - ' LOCK NUT WRENCH 07HMA—MR70200 [Rear Lower Mounting Bolt] Apply a thin coat of gvease to the mounting bolt. Set the adjusting bolt over the mounting bolt and engage them. Push the mounting bolt into the place shown in the drawing as full as lt goes. ‘ l1) ADJUSTING BOLT ‘ l i (2) MOUNTING BOLT (1) HEX WRENCH (1) LOCK NUT WRENCH (1] ADJUSTINGEOLT (2) MOUNTING BOLT Engine Removal/Installation Tighten the mounting bait and the adjusting bolt Ey using a hexi wrench. TORQUE: 11 N1" (1.1 kg-rn. 8 h—lb) Install the lock nut. Hold the mounting bolt and tighten the lock nut 7 by using the lock nut wrencht TORQUE: 55 N'm (5.5 kg-m, 4O ft-ih) LOCK NUT WRENCH O7HMA7MR70200 , Tighten the mounting nut on the other side 7 ’ TORQUE: 40 'm (4.0 kgm, 29 ft-lb) (1) LOCK NUT WRENCH (2) HEX WRENCH 7-7 8. Cylinder Head/Valves Senlice information 8»1 VCylinder Head Disassembly/Assembly 8—6 Troubleshooting 8-1 Camshaft. Cam Gear Case Installation 8-8 Camshaft/Cam Gear Case Removal 82 Cam Gear Case installation 8-10 Cylinder Head Removal/Installation 8-3 7 Camshaft Installation 8-1 1 Service information . The cylinder head, camshaft, and the cam gear case can be serviced with the engine mounted on the frame . Ifthe front or rear camshaft is removed, be sure to check the valve timing on the other cylinder from whichthe shaft is not removed, then reinstall the removed shaft . When servicing the cylinder head note and record the shim numbers and locations so that they can be set in their original position. . When assembling the cylinder head, apply molybdenum disulfide grease to the sliding surfaces of the lee stem, rocker arm rocker arm shaft, and the camshaft . Be sure that the No 1 cylinder is at the top dead center of the compression stroke when the T1 mark is aligned with the alignment mark omhe clutch cover (cutout) and the camshaft edge mark is toward up (ie aligned with he scribe line on the camshaft holderi, Each mark should be positioned as shown injhe drawing. - The crahkshaft should rotate clockwise and the carrLshaft counterclockwise viewed from the clutch cover side - The cylinders should be arranged as shown in the drawing. (5) CAMSHAFI' (1) LEFT SIDE : ® ® (2) FRONT —> , I4) CAMSHAI-‘r HOLDER (3) CYLINDER ARRANGEMENT (6) STARTER CLUTCH COVER ,_J (CRANKSHAFT) - Be sure that the No. 4 cylinder is at the too dead center of the compression stroke when the T2 mark' :5 aligned with the alignment mark on the clutch cover (cutout) and the camshaft edge mark is toward up (is. aligned with (he scribe line on the camshaft holder). Each mark should be positioned as shown in the drawing (1) CAMSHAFI' HOLDER 6@ l2) mCAMSHA/::§ 1i"Jl-lbleShOO‘i'ng (3) STARTER CLUTCH COVER _; The cylinder head troubles can be detected by the cylinder compression and the abnormal engine noise. Cylinder Compression Too Law ~ Valve Cylinder Compression Too High — Misadjusted valve clearance - Carbon deposits on the piston and in the combustion — Seized or bent valve chamber — Damaged valve spring 7 Abnormal Noise — Improper valve timing - - Misadjusted valve clearance —- Improperly seated Valve seat - Seized valve or damaged valve spring - Cylinder head - Damaged or worn camshaft holder and camshaft —— Leads from the cylinder head - Damaged or worn rocker arm — Distorted or cracked cylinder head , - Damaged or worn cam gear Cylinder Head/Valves Camshaft/Cam Gear Case Removal (6) (7) (5) Cylinder HeadNalves NOTE 7, , , i . Service on the front side is described on this page. Perform the rear side service in the same manner. . Take care not to drop any pan into the hole in the cam gear case . The cam gear case is stamped with the front and rear LD. marks. Do not confuse the front and rear gear cases when the both are rem oved. ' : , . When removing the camshaft holders, be sure that the camshaft of one cylinder is at the top dead center of the compression stroke. Loosen the holder bolts on the side of the other cylinder (which camshaft is at the top dead center of the exhaust stroke) equally in 2 or 3 steps, then loosen the remaining holder belts in the same manner. Remove the holders as straight as possible ~ Each camshaft is stamped with the LD. mark; F for the front cylinder and R for the rear cylinderr Also each camshaft is marked )7 with IN or EX respectively. Requisite Service . Radiator removal (page 5~6)r ,, 7 . Carburetor removal (page 68), - Water pipe ~ Spark plug removalt Procedure 7 V ‘ Q‘ty— "i her-harks Removal Order (1) Carburetor insulator 2 (2) Cylinder heed cover bolt/washer 4/4 (3) Cylinder head cover (4) Gasket 1 (5) Camshaft holder bolt 16 NOTE - Check that the camshaft of one cylinder is at the top dead center of the compression stroke. - Loosen the holder bolts on the side of the other cylinder which camshaft is at the tap dead center of the exhaust stroke in 2 or 3 steps equally, then loosen the remaining holder bolts. (6) Oil pipe stopper plate 2 (7) Oil pipe 7 1 l8) Camshaft assembly 2 NOTE - Check for the cam gear and drive gear eagagement. (9) Cam holder dowel pin ' 8 NOTE - The cam holder dowel pins must not necessarily removed, (10) Camshaft holder , 4 NOTE - Check the mark on the camshaft holder and erase either l‘ront (F) or rear (R) mark (11) Camshaft 2 NOTE - Remove by aligning the cam lobe with the long hole in the cam holdert (12) Cam gear case set bolt 1 NOTE - with copper washer. (13) Cain gear case mounting bolt 4 NOTE - Vlfith conical washer Loosen in 2 or 3 steps equally. (14) Cam gear case , 1 NOTE - Do not confuse the from and rear when both are removed. $115) Dowelpin(8mm) ,, 2 Cylinder HeadNalves Cylinder Head Removal/Installation 8-4 Cylinder HeadNalves 7NDTE ‘ , , _ A_ , r - 4“ .9 E . Service on the from side is described on this page. Perform the rear side service the same manner. . When removingfinstalling the front engine mounting bolL be sure to protect the oil pan by attaching it with 2 suitable weed board and support the engine with a jack to prevent load on the bult. CAUTION . Apply engine oil to the threads and theiseatiné face or th 1 ,_.. I Requisite Service . Operations related to the front cylinder: . Radiator removal/installation (page 5-6). - Thermostat removalfinstallation (page 54). - Operations related to the both cylinder: . Camshaft holder/cam gear case removal (page 8-le - Exhaust pipe removalflnstallation [page 2-10). ‘ Coolant draining (page 5-3), - Carburetor removal/installation (page 6-8). 7 7- Engine mounting bolt removalr Procedure Q'ty Remarks > Removal Order Installation is in the reverse order of removal. (1) Cylinder head buld 8 x 84mm 4 NOTE - Loosen/tighten the conical washer attached special 3 bolts together with the 6mm balls in 2 or 3 steps . equally. (2) Cylinder head hold 6 x 62mm 3 (3) Cylinder head assembly ‘1 (4) Gasket 1 NOTE . Install with the "UP" mark facing up. : l5) Dowel pin 2 7 ' i, ‘— , 7‘» at 'W' ce;x ; f! 5.2.51.5; 3.12.23 4.2:... a». 9%? 93% 3% Cylinder Head Disassembly/Assembly Cylinder HeadNalves 3% I remove excem un replacement. Do no (page 1—17) (3) nu .wfi mm b mm ‘05 cm 8—6 Cylinder HeadNalves = CAUTION ~ Before servicing the cylinder head. note and record the 5 Im Richie’s? and corn in their original position. - Do not compress the valve springs more than necessary. . Note the location or each part and reinstall them in their original position. . When installing the valve springs. install with the narrower con pitch side toward the combustion chamber. - Do not remove the rocker arm shaft plug except when it is replaced as it has the tapered threads, When the rocker arm shaft plug is replacedapply sealing agent to the threads and installr installed the shims NOTE , r Servicing on the front bank is described on this pangerformThe' reaThank se‘ 3% sér‘ne' manner. 7 J Requisite Service . Cylinder head removalfinstallation (page 8.4). Prooedure ‘_ W O'ty ’ 7 ‘ W” Remarks Disassembly Order . - 7 7’ Asselnblt is in the reinse order of disassembly (1) Shim 8 NOTE . Note the location and thickness of the shims. (2) Rocker arm shaft 4 NOTE \ r The rocker arm shalt can be easily removed by pressing the spring with the two rocker arms and moving the shaft inward. When installing the rocker arm shaft, align the groove in the rocker arm shah: with the [2655 groove of the camshaft holder bolts. l3) Rocker arm 8 NOTE - Check for missing spring. (4) Thrust spring 4 (5] Valve cutter 16 (6) Valve retainer 8 (7) Outer spring 8 NOTE - lnstall them with the narrow pitph end facing down. (8) Inner spring 8 {9) Outer Spring seat 8 NOTE (10) Inner spring Seat 8 0 Install flushr There should be no step between the spring seats. (11) Stem seal 3 (12) Valve lN/EX E (13. Valve guide 3 8-7 Cylinder HeadNalves Camshaft, Cam Gear Case Installation _ g H}? (15) (2) (4, c 1 (0.1, 0.7i $12 (1.2, 9) “i NOTE .t, u- 5 M‘, a The’iront cylinder service is described on this page. Perform the rear cylinder service in the same manner. - Check thatthe shim is installed on each valve retainer securely. Take care not to drop any part into the hole in the cam gear case. - when installing the cam shaft holders, check that the camshaft of one cylinder is at the top dead center of the compression stroke. Loosely tighten the holder bolts on the side olthe other cylinder which camshaft is at the top dead center of the exhaust stroke in 2 or 3 steps equally, then tighten the remaining holder bolts (page 8-11). ¢ The camshaft are marked with F for front cylinder and R for rear cylinder. Each camshaft is also marked with IN or EX respective- ly (page 8-i1il .‘ —~' " Requisite Service - Radiator installation (page 5-6}. - Carburetor Installation (page 6-8). . Water pipe installation. . Spark plug installation. 8-8 Cylinder HeadNalves Procedure O’ty Remarks Installation Order '— (1) Dowel pin (8mm) 2 NOTE . Push the dowel pins fully and install. (2) Cam gear case 1 NOTE . Check the flange for F (for front) or R ('01 rear) mark and install accordingly with the set bolt installation hole ‘ toward the carburetor (page 8-10), (3) Cam gear case mounting bolt 4 NOTE . Loosely tighten, check for proper engagement of the se- cond gear and the crankshaft timing gear, and push the cam gear case as much as it goes. (4} Cam gear case set bolt 1 NOTE - With copper washer. mosely tightent Tighten the cawfiear mounting bolts of the dowel pin side first, then the remaining mounting bolts diagonally. ‘fighten the set belt (page 3710). (5) Camshaft 2 NOTE - install by aligning the cam lobe with the long hole in the cam holder. (6) Camshaft holder 4 NOTE - Check the mark on the camshaft holder and assemble -Y with the camshaft accordingly (7) Camshaft holder dowel pin 8 (8) Camshaft assembly 2 NOTE ~ Check the timing mark on the starter clutcht Check the engagement of the cam gear and the drive gear and install by aligning the edge mark with the scribe line on the holder‘ (9) Oil pipe 1 (10) Oil pipe stopper plate 2 (11) Camshaft holder bolt 16 NOTE . Check that the camshaft of one cylinder is at the top dead center of the compression stmks‘ Loosely tighten the holder bolts on the side of the other cylinder which camshaft is at me top dead center of the exhaust stroke in 2 or 3 steps equally, then tighten the remaining holder bolts. The outer rows of the camshaft holder bolts tightened an the cylinder head are the stepped bolts. (12) Gasket 1 NOTE - Align the in mark wim the mark on the cover and attach by using the recommended adhesive agent (page 3-10), (13) Cylinder head cover 1 NOTE - Install with the W mark toward the carburetor (14) Cylinder head cover washer/bolt 4 NOTE - Install the washer with the "UP” mark toward out. (15l Carburetior insulator 2 NOTE - install with the ”CARE" mark toward the carburetor and the "UP" mark toward up. H‘s—A _ t m... ,A_ , Cylinder HeadNalves ‘ ""CaiTGeTF Cis'e Installation NOTE ‘ The cam gear case is marked with F or R an the flange, install the gear case marked F on the front cylinder and the case marked R on the rear cylinder. - When the identification mark is not clear, the gear case can be identified by the sub gear of the second geart With the sub gear toward you: 7 for from cylinder: the sub gear is off to the left side from the main gear. — for rear cylinder: the sub gear is off tn the right side from the main gear. Push the gear case dowel pins fully into the cylinder head, NOTE , - The second gear and the crankshaft timing gear do not engage properly when the dowel pins are not pushed into the full. Check the Lil mark on the gear case and install the case on the designate cylinder head Check for the proper engagement of the timing gear and the seconds gear in the following procedures Lightly move the third gear back and forth with the gear case lightly pushed down. The engagement is correct if the flange of the gear case is pushed by the timing gear and raised off the cylinder head slightly, Remove the gear case and reinstall it if necessary. ’ Tighten the four gear case mounting bolts fully with your fingers. Install and loosely tighten the gear case set bait and the cap- per washer. NOTE - When tightening the set bolt, take care not to damage the gear use threads and the bolt threads. TighterTzhe gear case mounting bolts of the dowel pin sfie m the specifiled torque. TORQUE: 36 N'm (3.6 kg-m4 26 h-lbl Then tighten the remaining mounting bolts. Tighten the gear use set bolt. TORQUE: 12 N‘m [1.2 kg-m. 9 ft-lb) 7 ' is) abdomen; (1) LD, MARK (F OH R) (1) THIRD GEAR (2) GEAR CASE (4) CRANKSHAH I'llq' TlMiNG GEAR Q (2) FRONT SIDE m we (3) REAR SIDE (ii 8 mm BOLTS (2) wAsl-ien Camsfiftifistallation Remove the lower fairing (page 2-4l. Remove the timing hole cap. When both from and rear cylinders are disassembled: CAUTION :-.— . Install all the camshafts with the edge mark toward the right crankcase saver. \ ,, ,r _ Apply molybdennum disulfide solvent to the sliding surface of the camshaft, camshaft holder, and the rocker armr Refer to me marks on the camshaft holders and the cylindei: head and note each camshaft holder installation position. 7 CAUTION The camshaft holders make up the oil passage. Be sure to install them in the current positions as instructed with the marks. Check the LD. marks ml each bank’s camshaft and assemble the Camshafts with the respective camshaft holders. LD. MARKS: RR: Rear bank FR: Front bank IN: Intake EX: Exhaust Cylinder Head/Valves l1) TIMING HOLE CAP 5% a HOLDERS A l V re m CAMSl-lAlTTS 12) CAMSHAFI' HOLDER 8—11 Cylinder HeadNaIves Align the 'cam lobe with- the long hole in the camshaft holder and insert the camshaft into the camshaft holdert , , CAUTION - Apply molybdeum disuifide solution to ,the cam lobe, camshaft, end the camshaft holder journal and Insert the camshaft with care not to damage them. lRear bank side installation] Rotate the crankshaft clockwise and align the starter Clutch T1 mark [scribe line) with the cutout (alignment mark) In the, right crankcase cover. (The No.1 cylinder should be at the top dead center of the compression stroke.) 7 , 7 CAUTION ' Be sure to Install the camshaft holder of the No.3 cylinder first, as It is at the top dead center of the ex- haust stroke. Install the assembled intake side and exhaust side camshalt holders on the cylinder head with the camshaft edge marks facing up and aligned with the scribe line on the holders. CAUTION - Be sure each shim ls installed properly. . Check for proper engagement of the cam gear and the camshaft side driven gear, and install with care not to let (I'm edge marks out of the alignment with the scribe lines. ' Do not strike to install the camshaft holderr Set the oil pipe and the pipe plate between the camshaft holders and loosely tighten all the camshaftholder bolts. CAUTION (2) sons (STEPPEDI i3) BOLTS (STEPPED) - Before loosely tightening the camshaft holder bolls, be sure that the bolt holes at the cylinder head corners align with the recess holes for fixing the maker arm shafts ~ After confirming the alignment of the recess holes and the bolt holes, insert a 6 mm pin Into the holes to ease the rear bank side installationr - Do not remove the sealing plug. (3) THRUST SPRING (a ,, J Tighten the eight No.3 side camshaft holder halts (IhLand EL sides) until the camshaft holders closely set on the cylinder head. CAUTION - The Camshafts on the No.3 cylinder are so close that they get "overlapped". Tighten the eight holder bolts (No.3 side only) in 2 or 3 steps equally. . Tighten the stepped bolts at the corners of the cylinder headk Recheck that the both camshaft edge marks align with the “scribe lines on the camshaft holdersi Tighten all the camshaft holder bolts in 2 or 3 steps diagonally. TORQUEL‘IZ N.m [1.2 kg-m, 8 ft-lb) CAUTION - The No.1 cylinder is at the top dead center of tiresom- presslon stroke. Tighten the No.3 cylindar’s camshaft holder bolts first until the No.3 camshaft holders close- ly set on-the cylinder head, then tighten the remaining bolts in 2 or 3 steps equally. After the installation. slowly turn the crankshaft 2 or 3 revo- , lutions cleckwise and adjust the shims to fit. ’ Valve clearance adjustment: see page 377. W 7 [Front bank side installation] , Turn the fiankshal’t clockwise and align the starter clutch Tl mark (scribe line) with the cutout (alignment mark) ll’Lthe rig h; crankcase cover. Be sure that the camshaft edge mark facing up and aligning with the scribe line on the camshaf; holder_ If it not, align by turning the crankshaft on emore clockwise revolution, (The No.1 cylinder hould be at the top dead center of the compression stroke.) 7 , 7 Turn the crankshaft further 90 degress clockwise and align the starter clutch TZ mark (scribe line) with the cutout (align—7 ment mark) in the right crankcase cover. , Be sure that the camshaft edge mark is facing up and aligning , with the scribe line an the camshaft holder. (The No.4 cylinder should be at the top dead center of the compresslon stroke.) Now install the camshaft in the follwoing procedures. Set the oil pipe and the pipe plate between the camshaft holders and tighten all the camshaft holder bolts. ,7 CAUTION , =1— ‘ Before loosely tightening the camshaft holder bolts, be . sure that the bolt holes at the cylinder head comers align with the recess hales for fixing the rocker arm Shafts, balore loosely tightening the camshaft holder bolts, Do not remove the sealing plug. Cylinder HeadNalves l2) SCRIBE LINE’ (1) BOLT ON HOLDER (4) Na.3 CAMSHAFT HOLDERS (1) BOLT /"O\V(2)i'l'727MARK "M 1 (4] ROCKER ARM SHAFT (2) PLUG (DO NOT REMOVEJ ‘l (3) BOLT (STEPPED) ll‘ Cylinder Head/Valves lighten the eight camshaft holder Erin‘s at both No.2 cylinder camshafts (1N and EX sides] until the camshatholders close- ly set on the cylinder head,as did on the rear hank side. CAUTION 7 - Be sure each shim is installed properly - Check ior proper engagement of the cam gear and the camshaft side driven gear, and install with care not to let the edge marks out of the alignment with the scribe lines. ' Do nut firike to install the camshaft holder. , Tighten the all bolts including the camshaft holder bolts 6? the No.4 cylinder side in 2 or 3 steps. TORQUE: 12 “Pm (1.2 kgAm. 9 ft-lb) CAUTION ‘ No.4 cylinder is at the top dead center of the compres- slim strokel Be sure to tighten the No.2 cylinder‘s cam- shaft holder bolts filst until the camshaft holders closely set on the cylinder head, then tighten the remaining bolts in 2 or 3 Sta [as equally. Valve clearance adjustment: see page 3-7t Headecovereinstallation: see page 3—10, Aapthe'rBbedEnum disulfid; solntion t6 the tihfirg hole 7 cap O-ring and install the cap ' ' [When the front side is disassembled] Remove the rear cylinder head cover and check that the No,1 cylinder is at the top dead center of the compression stroke (page 3-7ll Turn the crankshaft 90 degress clockwise from the timing mark T1 pnsitlon and align the starter clutch T2 mark (scribe linel with the cutout lalig nment mark) in the right crankcase cover. (The No.4 cylinder should be at the top dead center of the corn pression stroke.) Now install the lront camshaft. (2) Nn,2 CAMSHAFT HOLDER (ll BOLT (STEPPED BOLT AT THE CORNERS) % M) T2 MARK 8-14 t mew-anisnrmwu Cylinder HeadNalves [when the rear side is disassembled] Remove the front cylinder head cover and be sure [hat the NoA cylinder is a the tzfi dead center of the compression stroke, (The camshaft edge mark should face up at the T2 position.) ,, (Page 3—7) Turn the crankshaft clockwise 630 degress (one revolution and 270 degrees) from the timing mark T2 position End a'lién the 7 starter clutch T1 mark {scrlba line} with the coutout (alignment mark) on the right crankcase cover, (The N01 cylinder should be at the top dead center of the compression stroke.) Now install the rear camshaft. (1) Relationship between the top dead center marks and cylinders W l Timing mark Camshaft Cylinder at iop , (starter clutch) edge mark dead center T1 Toward up # 1 Toeard down we 3 Toward up #4 T2 Toward down #2 8-15 Service Information , , 9-17 7, Clutch Removal 9-4 Troubleshooting 9-1 clutch Installation 9-6 Right Crankcase Cover Removal/Installation 9-2 Service information ~ Clutch masimenance can be done with the engine in the frame. - Clean any gasket off the crankcase cover-crankcase mating surlace. - Do not damage the cover-case mating surface. - Never allow foreign materials to get into the engine. - If the transmission require servicing, remove the engine and separate the crankcase (Section 10}. Troubleshooting Most of the clutch malfunction result from the improper clutch tree playv Check the clutch free play and adjust, it necessary, before disassembling the clutch. Clutch is Slippery When Accelerating Clutch is Hart to Disengage or the Motorcycle Moves with E ¢ Too small‘clutch lever free play the Clutch Disengaged. - Worn clutch disc , - Excessive clutch lever free play l - Deteriorated diaphragm spring ‘ Bent clutch plate ‘ - Excessive engine oil - Loose clutch lock nut - Excessive engine oil or excessive oil viscosity Clutch Operation is not Stabilizedl. , ,, , - Clutch cable not routed properly - Worn clutch outer groove , Gear is Hard to Engage. p e , - Clutch misadjusted 7 clutch Lever is Heavy. - Poor clutch cable operation due to damage or rust 0 Damaged clutch lifter mechanism - Damaged clutch litter plate bearing - Clutch cable not routed properly ‘ Bent clutch lifter arm * 9-1 C|utch Right Crankcase Cover Removal/Installation (4) c 1or1.o,7) (I) Requisite Service , - Engine oil draining (drain bolt location: page 3-3, slep: sermon 2 or the Common Service Manual). - Lower fairing removal/Installation (page 2-4). , _ , _ . -t “,1: Procedure Q’ty Remarks ‘ Removal Order Installation is in the reverse order of removal. ’1] ‘ Righr crankcase cover bolt 12 [21 r Right crankcase cover ' ’ 1 ‘3) I Gaskat 1 2 4» | Dowel pin 9-2 Clutch Clutch lock Nut Removal Straighten me locking tabs of the lock nut with care not to 7 damage the main shaft NOTE - With engine moumed: move the Shift lever to the 6th speed] operate the rear brake, and louse" the lock nut. Wirh engine dismounted: move the shift lever to the 6th speed, hold the drive sprocket with a universal holder, and loosen the lock nut. Loosen the lock nut by using the lock nu‘ wrench, LOCK NUT WRENCH. 26 x 30 mm 0771641020203 EXTENSION BAR 0771643020500 (1t LOCK NUT WRENCH (2) EXTENSION BAR , 9-3 Clutch Clutch Removal Clutch NOTE ,, , , A, .Vs .ua.‘ _- . . . To loosen the clutch center lock nut, straighten the looking tabs with care not to damage them, then; Move the shift lever to the 6th speed and operate the rear brake. when the engine dismounted from the frame, move the shift lever to the 6th speed and hold the drive sprocket with a universal holder or equivalent. . Loosen the oil pump driven sprocket bolt with the clutch assembly installed before removing the bolt. Note that the bolt threads are coated with the thread locking agent. - Note the connection and installation direction of the Iifteuod once it is removed. Special alignment is required at the left lifter cam connecting section (page 10-2). , v. s. db . _— e : Requisite Serice . Right crankcase cover removal/installation (page 9-2l. - Starter clutch removal (page 17—2}. Procedure Q‘ty Remarks Removal Order (1) Snap ring 1 NOTE' ’ N - when removing the oil pump driven sprocket bolt, loosen it first with the clutch outer installed. [2) Clutch'lifter plate 1 NOTE ~ Remove the bearing only on replacement. (3) Lifter guide 1 NOTE . Remove the stopper ring only on replacement. (4) Lifter rod 1 NOTE - Do not depress the clutch [ever with the rod removed. (5) Clutch center lock nut 1 NOTE - Straighten the locking tabs first (page 3-3) (6) Lock washer 1 (7) Clutch spring set plate 1 (8] Diaphragm spring 3 NOTE - Replace the three springs as a set. (9) Pressure plate 1 NOTE ' Remove the stopper ring only on replacement. (10) Thrust washer 1 (11) Clutch disc 10 NOTE - Disc contact surface of the two end plates is black. (12) Clutch plate 9 (13) Clutch center B , 1 (14) One-way clutch assembly 1 NOTE - Do not disassemble unnecessarily. (15) Thrist washer ‘l (16) Clutch center A 1 (171 Clutch outer 1 (18) Oil pump driven sprocket bolt 1 (19) Oil pump driven sprocket 1 (20) Oil pump drive chain/sprocket 1/1 NOTE ‘ Remove the oil pump drive chain and sprocket together. (21) Clutch outer guide 1 Clutch Clutch Installation Bend the locking :abs. § 9 «17) c 35 (8.5, 611/ (page 9-8) 1015(15, 11 Install with the driven sprocket mark facing in. 9—6 Clutch NOTE - Tighten the clutch center lock nut as follows. Move the shift lever to the 5th speed operate the rear brake, and tighten the clutch center lock nut. When the engine dismounted from the frame, move the shift lever to the 6th speed and hold the drive sprocket with a universal holder or equivalent. - Tighten the oil pump driven sprocket bolt with the clchh assembly installed. Apply the thread locking agent to the bolt 5. 5 to 7 5 mm from the tip - The disc contact surface of the two clutch end discsjlre different in material (blacklr Do not interchange them. - install the lifter rod with the long iron ends toward left. Requisite Service - Right crankcase installation (page 9-2). - Starter clutch installation (page 17-4). Procedure Q‘ty Remarks ‘ , 7' v fl Removal Order (1) Clutch outer guide 1 (2) Oil pump drive chain/sprocket 1/1 (3) Oil pump driven sprocket 1 NOTE \ - Install with a scribe line on the gear toward in and tighten . , with a bolt. 1 [4) Oil pump driven sprocket bolt 1 (5) Clutch outer 1 NOTE - Engage with the drive sprocket and installt (6) Clutch center A 1 NOTE - Take care not to damage the main shaft spline. (7) Thrust washer 1 l (8) One-way clutch assembiy 1 NOTE I - Coat the sprag roller and inner with clean engine oil and assemble with the clutch center B with the roller flange toward the case cover. (9) Clutch center B 1 (10) Clutch disc 10 NOTE 7 - Contact surfacepf the both end plates is black. Coat the discs with celan engine oii and asembie with th clutch plates alternately. (11) Clutch plate 3 (12) Thrust washer 1 (13) Pressure plate 1 (14) Diaphragm spring 3 NOTE - install with the projected side toward out. (15) Clutch spring set plate 1 NOTE - Set the thrust washer an the stepped portion at the bot» tom at the set plate (page 9-8). (16) Lock washer 1 NOTE . install with the OUTSIDE mark facing out. (17) Lock nut 1 CAUTION - Check that the drive sprocket and the clutch uuter are properly engaged. then bend the locking tabs with care not ta damage the threads. (15) Lifter rod 1 NOTE - Install with the long iron ends toward left. Apply moiybde- rIum disullide grease to the ietl end. Alignment with the lifter cam: see page 1072. (19) Lifter guide 1 NOTE . Assemble with the lifter plate bearing. (20) Lifter plate/bearing 1 (21) Snap ring 1 Clutch ‘ ‘ ’ ’CiiithDiépWagi'fi Spring InstallgtioAnWA When installing the clutch, install the three diaphragm springs on the pressure plate with the projected side toward the lock nut, then assemble with the spring set plate. Be sure that the thrust washer is securely set on the stepped sectionjt the hottorn of the set plate. , 7 CAUTION - Replace the three diaphragm springs as a set. - Note that the thrust washer is set in the correct posi- tion of the set plate. Otherwise, the diaphragm spring and the luck nut cannot be set properiy. - Coat the thrust washer with clean engine oil to ease i stallation. , , Clutch Lock Nut Installation Assemble the clutch (page 9-6). , , 7 NOTE (1 ) THRUST WASHER (4) PRESSURE PALTE ,79 12) SPRlNG SET PLATE (3) DIAPHRAGM SPRING ' With engine mounted: move the shift lever to the 6th speed, operate the rear brake, and tighten the clutch- lock nutt With engine dismounted: Move the shift lever to the 6th speed, hold the drive sprocket with a universal holder or equivalent, and tighten the clutch lock nut. Tighten3re 1ch nut by using the lock nut wrenm, LOCK NUT WRENCH, 25 X 30 mm 077160020203 T EXTENSION EAR 077160020500 Bent the lacking tabs of the lock nut. 7 NOTE - TaKe care not to damage the main shaft. (2) EXTENSIONFBAR (1) LOCK NUT WRENCH 10. Gearshift Linkage Service Information _ V1—0—1 Gearshift Linkagtfsnift Erum Troubleshooting 10-1 Rem“ 10'4 Drive Sprocket Cover (1:71:ng Linkage, Shlft Drum In- 10.6 Removal/installation 19-2 5 Service Information - The gear shift linkage (including the shift drum, shin fork, and the shift fork shaft) can be serviced with the engine mounted on the frame. - Take care not to lei dust, dim, and any other foreign mateflais enter the engines . Separate the crankcase when the transmission service is requied. 7 Troubleshooting Gear Slips out or Engagement. - Worn gear dog - Bent shift shaft - Damagedsopper arm - Bent or damaged shift fork - worn shift drum groove , 7 Gear is flag to Engage. 0 Bent shifl fork ‘ Damaged shift drum cam groove - Bent gear shift spindle claw 10-1 Gearshift Linkage Drive Sprocket Cover Removal/Installation (2) 1 0-2 Requisite Service Lower iairing removal/installation (page 24). Gearshift Linkage Procedure G‘ty Remarks Removal Order (1) Clutch cable holder 1 (2] Clutch cable 1 NOTE - Disconnect from the lifter arm. (3) Speedometer gear box bolt 2 (4) Speedometer gear box 1 NOTE ~ Remove the gear box. (5) Drive sprocket cover bolt 4 (6] Drive sprocket cover 1 (7i Dowel pin 2 Installation Order (7) Dowel pin 2 (6) Drive sprocket cover 1 NOTE ’ Turn the lifter arm counterclockwise and connect the cam " and lifter rod by engaging their projections and dents. Ap- - ply molybdenum disullide grease to the lifter rod endt (5) Drive sprocket cover bolt 4 l4) Speedometer gear box 1 NOTE - Connect the gear box side joint to the sprocket bolt (3) Speedometer gear box bolt 2 NOTE - Install with care not to disconnect the joint. (2) Clutch cable 1 NOTE ‘ Connect to the lifter arm (1) Clutch cable holder 1 NOTE - install by aligning the hole with the stopper pine n- x. Gearshift Linkage Gearshift Linkage, Shift Drum Removal [3) Gearshift Linkage The shift fork, shilt fork shaft, and the shift drum can be removed, installed, and/or disassembled with the engine mounted on the frame. ~ The water pump mounting bolts must be removed tojervice the gearshift linkage. ngever, it can be serviced without disconnecting the cooling system hoseisl, - Remove/install the clutch assembly and the oil pan to remove/install the shift fork, lork shalt, and shift drum. , , 7. 1.. _ . .4--. .s. Requisite service V 7 . Lower fairing removal [page 2-4]. - Water pump removal (page 55). . Drive sprocket cover removal {page 10-2). - Oil pan removal (page 4-4), - Clutch removal (page 9-4). Procedure ‘ ' Q'ty Remarks 7 fl Removal Order . 77 7 if 7 7 r . V i 77 W L ‘ Gearshift Linkage [ (1) Gearshift spindle joint bolt/gearshift spindle { joint 1/1 . (2) Gearshift linkage cover bolt 5 (3) Gearshift linkage cover 1 NOTE 'x - Pull out straight withpare not to damage the dust seal. (41 Dowel pin 2 (51 Gasket 1 [6) Gear shift spindle/spring 1/1 NOTE . Do not remove the spring except on replacement. l7l Thrust washer 1 (Bl Shifter collar 1 (9) Bolt 2 [10) Guide plate/drum Shifter assembly 1 NOTE - Remove slowly with care not to let the plunger and spring scatter around from the shifter body. (1 1 l ThrustT/vasher 7 ,1 (12) Stopper arm spring 1 (13) Stopper'arrn assembly 1 NOTE - Snap ring, washer, arm, and collar: Do not disassemble unnecessarily. (14) Spacerpollar 1 [15} Dowel pin 2 (16) Shift drum set plate 1 (17) Shift drum center bolt 1 NOTE - The threads are coated with the thread locking agent. (181 shift drum center 1 (19) Shift drum pin 1 Shin Drum (20) Bolt/stopper washer 1 NOTE - The belt threads are coated with the thread locking agent. (21) Shirt fork shaft 1 NOTE - Push out to the right side. (22) Shift fork 3 (23) Bearing/Shift drum 111 NOTE 7g ~ PUll out to the left side. 10-5 Ill Gearshift Linkage Gearshift Linkage, Shift Drum Installation 612112.55) 10—6 NOTE Gearshift Linkage When installing the water pu'up, check the water pump shaft and oil pump shaft connection. Requisite Service - Oil pan installation (page 4-4). - Drive sprocket cover installation (page 1072). - Water pump installation (page 5-5). . Clutch installation (page S-Gl, - Lower fairing installation lpage 2-4). Procedure , Q’ty Remarks Removal Older Shift Drum (1) Shift drum/bearing 1/1 (2) Shift fork 3 NOTE - install the left shift fork on the C6 gear, center shift fork an the M3/M4 gear, and the right shift fork on the C5 gear respectively with the marks faxing right (page 11-4). (Si Shift iork shalt 1 NOTE - Apply engine oil and push in from the right side. (4) Stopper washer/bolt Gearshift Linkage (5) Shift drum pin (6) Shift drum center l7) Shift drum center bolt (8) Opel pin (9] Shift drum set plate (10) Spacer collar (1 1) Stopper arm assembly/spring (12) Thrust washer 113) Guide plats/drum shifter assembly (14) Bolt (15) Shift collar 7 i1 6) Thrust washer (17) Gearshift spindle/spring (18) Gasket (19) Dowel pin (20) Gearshiit linkage cover (21) Gearshilt linkage cover bolt (22] Gearshift spindle joint/gearshift spindle joint bolt :_-N- 1/1 NOTE - install the shift drum pin on the shift drum. CAUTION . Install by aligning the shift drum pin with the longhole in the drum center. NOTE . Loosely tighten the two set bolts and install the roller on the drum center with the spring hock set on the arm and the reerse side set on the crankcase. Remave the set bolts. NOTE . Assemble the shifter body, plunger, spring, and reatched pawl with the shifter plate. Pushing the pawl with your fingers, install the assembled plate on the shift drum center. NOTE . lnstall by aligning the long hole with the shifter collar and the two return springs with the stud pins on the case. NOTE' 7 ‘ Install with care not to damage the dust seal. NOTE - Align the punch mark with the one on the shift arm and install on the spindle. 1 0—7 1 1 . Crankshaft/Pistonerransmisision Service Information 1 1~1 Trouble shooting 1 1-1 Crankcase Separation 1 1-2 Shift Fork Installation 114 Mainshaft Disassembly/Assembly 11-5 Countershaft Disassembly/Assembly 1 1 -6 Piston DisassemblylAssembly 1 1 v8 Bearing Selection 1 1 ~10 Crankcase Assembly 1 1 -12 Service Information eventually crankshaft seizure. be reinstalled in their original position. Troubleshooting Cylinder Compression is Too Low. or Engine is Hard to Stan. - Blown out cylinder head gasket - Worn, stuck, or broken piston ring - Worn or dmaged cylinder or piston - Bent valve, or bent and deteriorated valveseap Cylinder Compression is Too High, or Engine Overheats or Knocks. - Carbon deposits on the cylinder head and/or piston Piston Sounds. ' Worn cylinder, piston, and/or piston ring 0 Worn piston pin hole and piston pin ° Worn connecting rod small end Smokes from Muffler ' Worn, stuck, or broken piston ring ’ Weak valve stem seal - Identify the connecting rods and the connecting rod bearing caps and store them neatly whenever they are removed. Do not confuse them as improperly installed connecting rods and bearing caps result in lack of oil clearance and - The piston, connecting rod, crankshaft. cylinder, and/or the transmission services must be made by separating the crankcase after the engine is removed (see section 7!. 7 - When the crankcase is separated, take care not to drop any foreign materials in the oil orifice. - Do noLdamage the cylinder wall and the outer surface of the piston ~ Store thapiston, piston ring, piston pin, piston pin clip, and the connecting rods for each cylinder so that they can - Selectsthe'bearings hy the color code numbers. Use the code table to select the replacement bearings. 0 After replacing the bearings. check the oil clearance by using the plastigauge. . Apply molybdenum disulfide oil to the main journal bearing and the crank pin bearing on reassembly lPage 1-16). - Remove the carbon deposits and sludge from the cylinder top before removing the piston and the connecting rod. - Check the crankcase breather pipe for smoke when the engine is hard to start or poor operation at low speed, . When there is smoke from the crankcase breather pipe, it might indicate broken or seized piston ring. ‘ Gear is Hard to Engage. - Clutch is misadjusted (excessive free play). ' ,Eent shift fork, — Bent shift fork shaft - Damaged gear shift spindle - ,Demageo shift drum guide groove - Damaged shift drum guide pin Gear Slips Out of Engagement. - Worn ger dowel - Bent shift fork shaft - Damaged shift drum stopper ' Worn shift drum guide - Worn shift fork groove of gear Abnormal Engine Noise - Worn connecting rod large end bearing ' Bent connecting rod . Worn crankshaft main bearing - Worn transmission gear 11—1 Crankshaft/Pistoanransmissinn Crankcase Separation l1) LOWER CRANKCASE SIDE: (19} (2) UPPER ’ CRANKCASE SIDE: ,, , , 7 7 “guano" Select and replace the main hearing by using the selecti journal (page 11-10). Select and replace the connecting rod hearing by using th (page 11-10). Note the location of each part to reinstall them in their If the crankcase cannot be separted by lighting tapping sn'll lightened with a bolt, Requi rte Service Engine removal (page 7—2ll Primary drive gear rmoval (page 17-4). Water pump removal (page 5-5L Starter motor removal (page 17-7). Oil filter removal. The gear shift linkage such as the shift fork and fork shaft can he removed after separating the crankshalt. Crankshafthiston/Transmission on talie to make it a good match vvith the crankshatt'main' e selection table to make it a good match with the crankshaft original position, on the upper case, check whether the crankcase halves are Cylinder head removal (page 8-4). Gearshift linkage removal [page 10-4l Oil pump removal (page 44). Alternator removal (page 15-8). Procedure Remarks Removal Order Upper Case Side (1) Mainshaft bearing set plate 1 (2) 6 film bolt 5 - -NOTE (3) 8 mm bolt 1 e - Loosen the bolt in a crisscross pattern 2 or 3 steps. (4) 10 mm bolt 1 _ Lower Case Side (5) 5 mm bolt 7 j—NOTE (6) 8 mm bolt 10 - Loosen the bolt in a crisscross pattern 2 or 3 steps (7) Lower crankcae 1 NOTE 7 ~ Set the crankcase with the upper case toward down. Lift the lower case to separate the upper and lower halves) l8) Dowel pin 3 {9) Transmission assembly 1 (10) Mainshait bearing 1 (11) Bearing cap stop pin 1 (12) Countershait oil seal 1 (13) Countershaft bearing 1 (14) Thrust washer 1 (15] Bearing stopper ring 7 fl 1 (16) Connecting rod bearing cap nut B (17) Bearing cap 4- NOTE ' Do not remove the connecting rod caps with force but pull them out straight, Remove the bearing (18) Crankshaft 1 NOTE - Remove with care not to damage the crankshaft journal. (19) Side main bearing 4 NOTE 7 - Remove from the upper and lower cases and record the installation location. (20) Center main bearing 4 (21) Connecting rad/piston 111 NOTE ' Remove to the cylinder head side. Piston removal! installation: page 11-3 11—3 CrankshahlPiston/Transmission Shift Fork Installation (1) : E : Apply to each sliding surfacer Requisite Service - Crankcase separation (page 11—2. , ,, - ; afl— , Emcedwe , ,O'tv _ Bawarks Installation Order (1) Left shift 1ork ‘l v NOTE (2) Center shift fork 1 — - Install an the shift fark shaft with each mark (RC, (3) Right shift fork A 1 — afld L) toward tflclugch. 7 11—4 1 Crankshafl/Pistcanransmissian 7 Mainsrlaft I3isa§semblylAssembly m (2) (a) (4) (a) L (a) (2) ‘4’ 47) YT (10) f': (5) bmofiggfi ,fi/(‘IO‘ E) SE}? 9 (12} (S? (7) (11) (12) BEARING: 5205 Z a : Apply to each sliding surface. Requisite Service - Crankcase separafion (page 11-2). figmvsrks Procedure Removal Order (1) Thrust washer (2) M2 gear HST) ’ (3) Thrust washer (4) M6 gear (22T) (5) Spline bushing (6) Thrust washer/snap ring (7) M4/M3 gear (22TI20T) (8) Snap ring/thrus1 Washer (9) M5 bushing (10) M5 gear (237) 7 (11) Thrust washer , (12) Mainshafl M’l gear (14T) 7— ,1 ‘r , m Assembly is in the reverse order of disassembly. Orankshafl/Piston/Transmission Countershaft Disassembly/Assemly ‘v (12) (11) (10) (9) (8) . (7) (14) [11) (2) : Apply to each sliding surface‘ ,,..~_._ _4- a » ’l'w": 7% 11—6 Crankshaft/Pisteanransmission Requisite Service - Crankcase separation (pageH-Z}. Re‘rfiarks‘ Procedure Q‘ty Disassembly Order Assembly is in the reverse order of disassembly. (1| Thrust washer 1 (2) C1 gear (41T) 1 (3) Needle bearing 1 (4) Thrust washer 1 (5) C5 gear (EST) 1 (6) snap ring/thrust washer 1/1 (7) (:3 gear (361’) 1 (8) Spline bushing 1 (9) Lock Washer 1 NOTE 7 - when assembly, insert the tang of the washer (me the lock washer groove securelyr (10) Spline washer 1 (11) C4 gear (35T) 7 1 (12) Spline bushing ’ 1 (13) Thrust washer/snap ring 1/1 (14) C6 gear (ZST) 1 (15) Snap ring/thrust washer 1/1 (16) C2 gear (SET) 1 (17) (:2 gear bushing/1hrust washer 1/1 (18) Countershah 1 11-7 Crankshaft/Piston[Transmission Piston Disassembly/Assembly (5) ’73 ( FRONT SIDE: REAR SIDE: MARK @ 11—8 Crankshaft/Piston/Transmission cAUTlONi , ~ Take care not to damage the pistons. - classify and store the pans for each cylindert - Number of Q‘ty listed in the table indicates the numbers that are shown in the drawing. - Before assembling the piston pin with the conneming rod, apply molybdenum disulfide oil to the sliding surfaces. - Select the appropriate connecting rod and/or hearings by using the selection table to make a good match. Also select the connecting rods oi the most appropriate weight by usmg the table (page 11-10). Requisite Service . Crankcase separation (page 11-2)r * Procedure Q’ty Remarks Disassembly Order Assembly is in the reverse order of disassembly. (1) Front connecting rod bearing 1 NOTE - Note the color codes of the connecting rod bearing and the connecting rod cap and Store. (2i Rear connecting rod bearing 1 NOTE - Note the color codes of the connecting rod bearing and the connecting rod cap and store. (3) Piston pin clip 4 NOTE . Do not lose. (4) Pisbtn pin 1 (5) Front piston assembly 1 j—NOTE (6) Rear piston assembly ‘I - Do not remove the piston ring except on replacement. Assembly Order , (6) Rear piston assembly 1 NOTE - Check the connecting rod |.D. markt Install with the IN mark toward the carburetor and the connecting rod oil jet port toward the other side (5) Front piston assembly 1 NOTE ' ' Check the connecting rad LD. mark. Install with the IN mark and the connecting rod oil iet port toward the carburetor. (4) Piston pin (3) Piston pin clip 4 (2) Rear connecting rod hearing 1 NOTE ' ' Install with the oil passage hole aligned with the con- necting rod hole. (1) Front connecting rod bearing 1 NOTE - Connecting rod bearing selection: see page 11710. 11-9 Crankshaft/Pisten/Transmission Beafing Sebcfion Main Bearing Record the crankcase ID. Code. NOTE ' A or B stamped on the No.4 journal of the upper crank- case is the LD. code a! the journal. The code letters, from left to right, indicate each journal LD. respectively. (Refer to the drawing to the right.) Record the crankshaft mainjourna! O.D. code (or measure the main journal O.D.). NOTE - 1 or 2 stamped on the crank weight the main journal O.D. code. (Refer to the drawing to the rightL Determine the hearing I D. code by referring to the case I. D. code and the main journal node. . Main journal 0.0. pide 1 7 2 , 29.994—30.002mm 30.002—30.0]0mm Imaos—maung (1.18127lla15m1 H) CRANKCASE (2) LD. CODE ; , . (1) CRANKSHAFI' same—33.0mm“ 7 ICES: A n.2992—1.2955in) C(Yellow) BIGreen) ,, ' é sauna—33.0mm w B e I1.299§;1.299§in) BlGreen) _ Alfilown) A (Brown): 1.498—1502 mm (0.0590—o.0591 in} BlGreenl: 1494—1498 mm (mouse .0590inI c (Yellowl: 1.490—1.494 mm (0.0537—0.0588 ln) Thickness of the bearing metal can be identified by the color, cede. Connecting Rod Bearing Record the connecting rod ID. Code number. NOTE 1 or 2 stamped on the connecting rod IS the connecting rod I. D. code number. [fieler to theorawingvto‘gyit I (1) COLOR CODE l {2) ID. CODE 11-10 F Crankshaft] Piston/'1' ransmission /’ Record the crank pin 0.1). code number (or measure rhe crank N" 0.0.]. 7 noTE 7 = 7 F ‘ Aor B Stamped on the crank weight is me crank pin 0.0. code Q i c rhe drawin to the ri ht. , A -\ (Refer a > g g ) _v 7. 4 .5. 5 A A select the appropriate bearing metal by referring to the crank 1 ll 1 1 pin 0.0. code letter and the connecting rod I.DV cede numberr \ NOTE - There are two types or the cannecting rod hearings: one (TS CRANK WEIGHT lor the front cylinder (marked with the one LD. paint) and 77 7 the other for the rear cylinder (marked with the two |.D. paints). Do not confuse. '7 (2) FOR REAREYEINDER (1) FOR FRONT CYLINDER Cannecfing rad Lu. cude 1 z slow—sacrum". 31008—310l3mm _ (1.2992—1.2995in) n.2995—11353an) “ From Rear From Rear 7. 7 c a 7 29.932—30V000rnm c a .5 % (Yellow, (Green, :8 rLiaoa—Manrni (Yeilcw) Yellow) (Green) Glee“, E _ 7 7 9'4 mew—29.9mm a 5 A A 00 0 1305—1 raosinr isreen) [G'm' (Brown) ‘B'uwn' ' ' Green) grown. (3) BEARING METALS Selmive hearing metals: A (Brown) (Brawn, Brawn): L494- 1ASE mm (0.0588 -D.0590 in) B (Green) (Given. Green): 1.450 < 1.494 mm (0,0587 r {0588 in) L C [Yellow] IYelloW, Yellow): 1485-1490 mm 10.0585 - [10587 in) 7, Connecting Rod Weight Selection The connecting rods are stamped with the mark A. B, or C 7 7 which indicates the weight of the rod 7 7 7 7 When replacing the connecting rod. refer to theselection ta- 7 7 bie and selecr rhe connec-nng rod of the appropriate weight. Weight cade of Weight code or Weighl code at the connecting the remaining con- the new connect- rod which is to necting rod on the ing rod be replaced same crank pin 7 A B A. B or c C A 0' B 7 m CONNECTING ROD A B or C 7 B B A, a, or c c A or B A a or c c 7 B A, B, or c 7 (2] WEIGHT CODE 11—11 Crankshaft/Pismn/Transmission Crankcase Assembly 277 .2; Jim : Apply to the omer mating surfaces : CONNECTING ROD BEARING ‘ MAIN BEARING I5) UPPER CRANKCASE SIDE BOLTS (19) 23(2.3, 17) c 12 (12,9) 118) (20) 12 (1.2, 9) I211 a fit SIDE BOLTS r22) _ 40 (4.029) 23 [2.3, 17) LOWER CRANKCASE 11-12 III CAUTION - Select and replace the main hearing by using the selection tabE to make it a good match with the crankshaft main journal (page 11-10]. - Select and replace the connecting rod hearing by using the selection table to make it a good match with the crankshaft (page 11-10). - Clean the crankcase mating surfaces and apply the sealant to the outer mating surface of the crankcase halves with care not to get the sealant on and around the main bearing. Assemble the crankcase halves, O Assemble the cranknase halves with the upper case toward down If the upper and lower cases are not assembled properly, check the transmission assembly ler prepe nstallation. Requisite Service - Alternator installation (page 15-8). - Oil pump installation (page 4-4). - Primary drive gear installation (page 17-4}. - Clutch installation Spage 9-6]. - Water pump installation (page 5-5). - Oil filter installation, ' Coolant filling. Crankshaft/Fistoanransmissl'on - Starter motor installation (page 17-7). - Gearshift linkage installatinn (page 'lO-6l. - Starter clutch instalia ' n (page 17-4). - Cylinder head installa n (page 874), - Engine installation [page 7-4). - Engine oil filling. Procedure O’ty Remarks Assembly Order Lower Case Side (1) Connecting rod/piston " 4/4 NOTE I Install from the cylinder head side. (2) Center main bearing 4 (3) Side main bearing 4- (4) Crankshaft 1 NOTE ~ Take care not to damage the journa. (5) Bearing cap 4 (6) Cap nut 8 (7) Bearing stopper ring 1 (8) Hearing can stop pin ‘1 (S) Tfirust washer ‘l (10) Countershal‘t bearing 1 (11) Countershaft oil seal 1 (12) Mainshaft bearing 1 (13) Needle bearing cap 1 (14) ‘ITansmission assembly 1 NOTE - Align the cauntershaft bearing groove with the stag» per ring, and the hole in the mainshaft bearing cap with the stop pin, (15) Mainshalt bearing set plate 1 (16) Dowel pin 1 (17) Lower crankcase 1 NOTE - Apply sealant to the mating surfaces with care not to get it on and around the main hearing. (18) 6 mm bolt 7 j—NOTE (19) 8 mm bolt 10 ' Tighten the bolt in a crisscross pattern 2 or 3 steps - Tighten at the lower side first, then raise the engine to tighten at the upper side Upper Case Side (20) 6 mm bolt 5 —— ~NOTE (21) 8 mm bolt 1 — ' Tighten the bolt in a crisscross pattern 2 or 3 steps. (22) 10 mm bolt 1 # 11-13 _12 Front Wheel/SuspenSIon/Steerlng Service Information Troubleshooting Left Handlebar Disassembly/Assembly Right Handlebar Disassembly/Assembly Front Wheel Removal/Installation Front Wheel DisassemblylAssembly 12-1 12-1 12-2 12-4 Fork Removal/Installation Fork Disassembly Fork Assembly Steering Stem Removal 12-(L Steering Stem Installation 1 2-8 12-10 12-12 12—13 12-14 12-16 Service Information i W on damaged rims impairs safe operation of the vehicg: V A I V W - When servicing the front wheel. support the motorcycle securely with a jack or other support under the engine. - When installing the front wheel, note the normal rotating direction. - Tubeless tire removal, repair, and remounting procedures are covered in the section 16 of the Common Service Manual. _When remounting the tire, note the normal rotating direction. - Refer to the section 14 for brake system information - Refer to the section 18 for light, meter and switch lnlgmation. Troubleshooting Hard Steering - Steering head bearing adjustment nut too tight . Faulty steering head bearings - Damaged steering stern races - Insufficient tire pressure - Faulty tire Steers to One Side or Does Not Tmck Straight ‘ Bent (ark - Bent {rant axle: wheel installed incorrectly - Faulty steering head hearings - Bent frame ~ Worn wheel bearing - Worn swingarm pivot Front Wheel Wobbling ‘ Bent rim - Worn front wheel bearings - Faulty tire ‘ Unbalanced tire and wheel Wheel Turns Hard - Faulty wheel bearing - Brake drag (page 14-1} - Bent Iron axle Soft Suspension - Weak fork spring ' Insufficient lluid in folk ' Low f d level in fork - Low tire pressure Hard Suspension - Incorrect fluid weight - Bent rork tubes - Clogged fork fluid passage . High tire pressure Front Suspension Noisy - Insufficient fluid in fork ' Loose fork fasteners Front WheellSuspensian/Steering Left Handlebar Disassembly/Assembly (b) 0 11 (1.1,s) 47-"): Front Whee”Suspension/Steering Procedure my 2 Re’nia’r’ks Disassembly Order 7 [1) Clutch switch wire 2 Disconnect from the switch terminals. [2) Clutch lever holder bolt 2 (3) Clutch lever holder/bracket 1/1 (4) Attaching screw 2 (5) Left handlebar switch 1 (El Left handlebar weight/attaching screw 1/1 (71 Left hadlebar grip 1 (8) Handlebar holder pinch bolt 2 Loosen the bolts. (9) Left handlebar pinch bolt 1 (1 0) Left handlebar 1 NOTE ‘ Spread the slit slightly and push the handlebar out. Handlebar holder removal order Installation is in the reverse order of removal (3) Lower fork pinch bolt 1 Loosen the bolt. (b) Upper fork pinch bolt 1 Loosen the bolt Remove the wire bands (c) Left handlebar holder 1 NOTE’ - Remove the front wheel (page 12-6) and lower the fork. Assembly Order (10) Left handlebar 1 (9) Left handlebar pinch bolt 1 (8) Handlebar holder pinch bolt 2 NOTE - Align the locating pin on the holder with the groove in the fork top bridge, and tighten the upper bolt first l7) Left handlebar grip 1 (6) Left hadlebar weight/attaching screw, 111 NOTE - Apply locking agent to the screw thread. (5) Laft handlebar switch 1 NOTE ' Align the locating pin with the hole in the handlebar, (4) Attaching screw 2 NOTE - Tighten the front sErew first. (3) Clutch lever holder/bracket 111 NOTE - Install the holder with the "UP" mark facing up. (2) Clutch lever holder bolt 2 NOTE - Tighten the upper bolt first. (1) Clutch switch wire 2 Connect to the switch termInals. 1 2-3 Front Wheel/SuspensionlSteering Right Handlebar Disassembly/Assembly 1 2-4 l ‘ Front Wheel/Suspensinn/Steering ; Procedure Q’ty Remarks Disassembly Order ' Z (1] Front brake switch wire 2 Disconnect from the switch terminals 12) Master cylinder holder bolt 2 (3) Master cylinder holder 1 (4) Brake master cylinder assembly 1 CAUTION - Keep the master cylinder upright. (51 Throttle housing screw 2 l6) Throttle grip 1 Disconnect the throttle cable. (7) Engine stop switch ‘1 Remove the screws. (8) Right handlebar weight/attaching screw 1/1 (9) Handlebar holder pinch bolt 2 Loosen the bolts, (10) Right handlebar pinch bolt 1 (11) Right handlebar 1 NOTE - Spread the slit slightly and puch the handlebar out. Handlebar holder remiwal order installation is in the reverse order or removal. (3) Lower fork pinch bolt 1 Loosen the boltr (bi Upper fork pinch bolt 1 Loosen the bolt. Remove the brake hose band. (:1 Left handlebar holder 1 NOTE - Remove the front wheel (page 12.6} and lower the , , fork. Assembly Order 7 V (11) Right handlebar 1 (10) Right handlebar pinch bolt 1 (9) Handlebar hulder pinch bolt 2 NOTE - Alighn the locating pin on the holder with the groove in the fork top bridge, and tighten the upper bolt first. {6i Throttle grip 1 Connect the throttle cables. (5) Throttle housing screw 2 NOTE - Align the mating surface with the punch mark on the handlebar and tighten the front screw first. (7) Engine stop switch 1 NOTE l ' Tighten the front attaching screw first. i (4) Brake master cylinder assembly 1 (3) Master cylinder holder 1 NOTE - Install with the "UP” mark facing up. [2) Master cylinder bolt 2 NOTE - Align the end of the holder with the punch mark on the handlebar and tighten the Upper bolt first. (1) Front brake switch wire l 2 ‘i Connect to the switch terminals. , , . z _ _ g— a . -—.. ~ _ . ,_ 12—5 Front Wheel/Suspension/Steering Front Wheel Removal/Installation Front Wheel/Suspension/Steering mm , - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. - Inhaled asbestos fibers have been found to cause respiratory disease and cancer Never use an air hose or dry brush to cllean brake assembiles. NOTE - install the iron: wheel with the arrow mark lstamped on the rightrslde) facing to the normal rotating direction - Do not depress the brake lever when the caliper' is removed or it will be difficult to reiit the disc b tween the brake pads. Requisite Service - Raise the wheel 0" the ground by placing a jack or other support under the engine Procedure , Q’ty Remarks Removal Order (1) Caliper mounting bolt 4 (2) Front caliper assembly 2 CAUTION - Do not hang the caliper by the brake hose. (3) Right axle pinch bolt 2 Loosen the bolts (4) Axle bolt 1 (5] Lefhaxle pinch bolt 2 Loosen the bolts. (6) Axle shalt 1 (7) Front wheel assembly 1 Disassembly/assembly (page 12-8} (8) Side collar 2 Installation Order [8) Side ccllaL , 2 NOTE 7 ' Right side collar is longer ihan the left side collari - Apply grease to the dust seal lips before installing (7) Front wheel assembly 1 (6) Axle shaft 1 NOTE - Apply thin coat of grease. l4) Axle bolt 1 (5) Left axle pinch bolt 2 (3) Right axle pinch bolt 2 NOTE 7 - Tighten after tightening the axle bolt. (Zl Front caliper assembly 2 CAUTION ~ Be careful not to damage the pads. i1) Caliper mounting bolt 4 12~7 Front Wheel/Suspension/Steering Front Wheel DisassemblylAssembly Arrow marks on the Wheel are stamped on the right side only, (3) 1 2—8 Front Wheel/Suspension/Steering A contaminaled brake disc or pad reduces stopping power. Discard canmifiinared paEs’and clean a Contminated disc with a high quality brake degreasing agent. v _ a NOTE . The left and right brake discs should be insianea on the original side unle’ssfiey‘ér’e‘iebiac’ed. . when remuuming me (ire onto the wheel, lace rhe arrow marks on the wheel and tire to the same direction. . Do not add more than 60 9 (2A 02) of the wheel balfice weight. ’ . Always replace wheel bearings as a sen Hequisite Service " - Front wheel removal/installation PIOCEdLlfe fl ‘Ffemarks Disassemhly Order Assembly is in 1he reverse order of disassembly, [1) Dust seal 2 (2) Brake disc bolt 12 (3) Brake disc 2 (4} Right wheel bearing (6004UU) ‘1 (5) Distance collar 1 (6) [sh wheel bearing (6004UU) 1 At installation, drive a new left bearing into the hub first, then drive a new right bearing. [7) Front tire 1 NOTE - At installation, face ihe arrow mark to the same direc- ,, W, xion as the arrow mark on the wheel. a m— s , t z : 1 2—9 'it Front Wheel/Suspensian/Steering Fork Removal/Installation 7 , m_ ._ .. ,, -»‘; >W ‘— Loosen when the fork is TOP BRIDGE ta be disassembled. fl” l8) > ‘y {6) (8] / _. 5% ‘ 5 V \// (9) Front Wheel/SuspensionISteering NOTE 7 - When the fork ls to be disassembled, set the [are-load adjuster to me ”softest" position, loosen the upper fork 'pinch bolt and loosen the lork bolt but do not remove it yet. - After assembling the fork, tighten the fork belt which is temporarily tightened before tightening the upper fork pinch bolt, Requisite Service 7 7 7 - Fronr wheel removal/installation (page 12-6) Procedure O'tv Remarks Removal Order (1) Front fender mounting bolt 4 (2) Front fender 1 l3) Handlebar holder pinch bolt 2 Loosen the balls. (4) Upper fork pinch bolt 1 Loosen the bolt (5) Lower fork pinch bolt 1 Loosen the bolt. (6) Wire band 2 NOTE ‘ On the right fork, remove the brake hose band. (7) Handlebar assembly 1 Lower the fork part way and remove from the fork. CAUTION - 0n the right side. keep the master cylinder upright. (3) Stopper ring 1 (9) Fork assembly 1 Disassembly (page 12-1 Installation Order (9) Fork assembly 1 [8) Stopper ring 1 Support the fork and install into the groove securelyr l7} Handlebar assembly 1 NOTE - Install onto the fork and raise the fork through the top bridge, aligning the locating pin or the handlebar holder with the top bridge groove. (Ell Lower fork plnch bolt 1 (4) Upper fork pinch bolt 1 (3l Handlebar holder pinch bolt 2 (5) Wire band 2 [2| Front fender 1 (1) Front fender mounting bolt 4 12-11 Front Whee”Suspension/Steering Fork Disassemb1y (1) (18) Q (21 \ (16) (13) S (14)\——.@ (151% (17)::g (3), (5) g“; (6) § ®‘— (4) Q \ D‘\ m (3) ADJUSTER NOTE Requisite Service - Fork removal/Installation (page 12-10L - Set the pre-luad adjusrer tn rhe “softest" position before Igsening the fork boll: , Procedure Oityi W Remarks Disassembly Order (1) Stopper ring 1 (2) Fender bracker , 1 (3) Fork bol‘ 1 Remove from the fork tube. (4) Stopper seat 1 NOTE - Drain the fork oil from the fork rubs and piston rod afr ter removing. (5) Fork bolt 1 Hold the preAload adjuster and remove the fork bolt as shown (6) O-ring 1 (7) Spring seat 1 (8) Spacer 1 (5) Spring seat 1 (10) Fork spring 1 (11) Socket bolt/washer 1/1 (12) Fork piston assembly 1 CAUTION - Du n01 remove the adjuster from the fork piston, (13) Oil lock piece 1 (14) Dust seal 1 (15) Stopper ring 1 (16) Fork tube 1 (1 7) Oil seal 1 (18) Back-up ring 1 (19) Slider bushing 1 (20) Fork tube bushing 1 CAUTION - Do not remove (he bushing gnless it is replaced. 12—12 Fork Assembly e 20 (2‘04 14) Front Wheel/SuspensionlSteering [10) 20 (2.0, 14) g/ne), 11a) \ /(15) 9;? g/UW NOTE - Ser the pre-Ioad adjuster to the "softestTprosition berfi tighini'rrgwtfie ro'ri'fii. ' ’ Procedure ' O’ty Assembly Order (11 Fork tube bushing 1 (2) Slider bushing 1 Install onto the 'ork tube (3) Fork tube 1 (4) Oil lock piece ‘1 Install onto the end of the fork pismn. (5) Fork piston 1 (6) Sealing washer/socket bolt 1/1 NOTE - Apply locking agent to the bolt threads. (7) Back-up ring ’1 (8) Oil seal 1 Use the fork seal driver (07947eKA50100) and attach- ment (07977KFOO1’OO). (9) Stopper ring 1 (10) Dust seal 1 NOTE ' ' Pour fork oil to the specified level before installing the spring (page 1-11). (1 1) Fork spring 1 NOTE - Install with the tapered end facing down. 1121 Spring seat 1 {13) Spacer 1 (14) Spring sear 1 (15) Owing 1 (16) Fork bolt 1 Install onto the adjuster. (17) Stopper seat 1 (18) Fork bolt 1 Screw mm the fork tube, but do not lighten yetr CAUTION ' Be careful nor to cross-thread. (19) Fender bracket 1 (201 Stopper ring 1 12:13 ,,,,_ 7—: ~—~» , 7 -— ~ Front Wheel/Suspension/Steering Steering Stem Removal ”£22! (171 ' 7 7 \®/ f (13) (141\%§ ( 7’ , (s) / a WxA 12—14 Front Wheel/Suspension/Steering NOTE - Replace the steering bearing and races as a star. _ . Do not reuse the lock washer. , Requisite Service . Front wheel removal (page_12-6) - Fork removal (page 12-10} Procedure u'ty Remarks Removal Order (1) Brake hose ciamp (2) Horn (3) Steering stem nut cap (4) Steering stern nut (5) Top bridge (6) Lock nut (7) Lock washer (8) Steering bearing adjustment nut ’ (9) Upper dust seal (10) Upper bearing inner race (11) Upper bearing (12) Steering stem 113) Lower bearing (14) Lower bearing inner race (15) Lower dust seal (16) Upper bearing outer race (‘17) Lower bearing outer race Disconnect the horn wires. Straighten the lock washer tabs. Use the steering stern socket (07HMA—MR70100). —Remove frcm the steering stem. —Use the driver attachment 3 (0794I5~KM90200)v driver assembly shaft (07946—KM90300), bearing remover E (07946—KM90500] and base (07946—KM90600), l_|i|[ 12-15 From Wheel/Suspension/Steering Steering Stem Installation Bend down the two tabs into me adjustment nut grooves and bend up two tabs into the lock nut grooves. (2) / E (5» :‘S WW4 (6) (17) (16’ (15) .V (we y 140(14.0, 101) (13) Front Wheel/Suspensinn/Steering NOTE Requisite Service . Fork installation (page 12-10) . Front wheel installation [page 1276) [T Check the steering bearing preload after installing Procedure Q’ty Refirgs (1) (2) (3) (4) (5) (6) (7) (8) (9) (lol (1 1) (12) (13) (14) (15) (16) (17) Installation Order Upper bearing outer race Lower bearing outer race Lower dust seal Lower bearing inner rate Lower bearing Steering stem Upper bearing Upper bearing inner race Upper dust seal Steering bearing adjustment nut Lock washer Lock nut Top bridge Steering stem nut Steering stem nut cap Horn Brake hose clamp 1 j-Use the driver attachment E (07946—KM90200). driver assembly shalt (079467KM90300l, bearing remover E (07946—KM90500) and base (C7946eKMQOGOOl. Use the stem driver attachment (07HMDeMR70100) and inner driver C (0774670030100). Use the steering stern s‘ecket (O7HMD—MR70100). Bend down the two tabs into the adjustment nut grooves. Hand tighten, align the grooves with the lock washer tabs and bend up the tabs into the grooves. NOTE Temporarily install the iron forks and tighten the nut. Connect the horn wires. 12-17 1?..7Rear Wheel/Suspension Service information , 13-1 Shock Absorber, Linkage Removal/ Troubleshooting 134 Installation 1 38 Rear Wheel, Driven Sprocket Removal/ SAggggabsorber Dlsassembly/ 1342 Installation 13-2 V . . Shock Linkage Disassembly/ Bearing Holder Removal/Installation 134 7 Assembly 1314 Bearing Holder. Axle Disassembly/ . . Assembly 1345 Swlngarm Removal/installation 13-16 Swingarm Disassembly/Assembly 1 3-18 Service Information - The shock absorber eentains nitrogen under high pressure. Do not allow fire or heat near the shock absorbart . Before disposal of the shock absorber, release the nitrogen (Step: section 19 crime Common Service Manual; Drilling point: age 1-11). A - Riding n damaged rims impairs safe operation of the vehicle ‘ Tubeless tire removal, repair, and remountirlg procedures are covered in the section 16 of the Common Service Manual. When remounting the tire. note the normal rotating direction. - Refer to the section 14 fur brake system information. - Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. Troubleshooting Rear Wheel Wobbling Hard Suspension - Loose wheel nut , , ' Bent damper rod - Bent rim ‘ Damaged swingarm pivot bearings ‘ Loose bearing holder ‘ Damaged shock absorber bushing 1 Damaged axle bearing(sl - Incorrect suspensionadjustment ' Faulty swingarm pivot bearingls) ' Faulty shock linkage bearings - Loose shock linkage/swingarm tastenerlsl - Insufficient lubrication of suspension pivots ~ Faulty tire - Damaged mount bushing ‘ Unbalanced tire and wheel Rear Suspension Noise Soft Suspension - Loose fasteners - Weak spring . incorrect suspension adjustment - Faulty damper unit ~ Oil leakage from damper unit Rear Wheel/Suspension Rear Wheel, Driven Sprocket Removal/Installation Align the pins with me holes‘ Requisite Service Rear Wheel/Suspension Raise the rear wheel ofr the ground and support the mmarcyoler Procedure Removal Order 7 Remarks (1) Center cap/cotter pin (2) Wheel nut l3) Shim (4] Center lock spacer (5] Rear wheel Driven Sprnckel Removal Order installation is in the reverse order of removal. (a) Driven sprocket nut (b) Driven sprocket NOTE - Loosen the drive chain before removing (page 3-11). Installation Order (5) Rear wheel NOTE - Align the holes with the drive pins of the axle. (4) Center lock spacer 1 (3| Shim 1 (2) Wheel nut 1 / (1) Cutter pin/center cap 13—3 Heat Wheel/Suspension Bearing Holder Removal/Installation Rear Wheel/Suspension - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degveasing agenti - Inhaled asbestos fibers have been lound to cause respiratory disease and cancer. Never use an alr hose or dry brush to clean brake assemblies. NOTE - be no? depress the brake pedal when the caliper is removed, or izwill be difficult to refit ihe disc between the brake pads. . Suppnr‘l the removed caliper with a piece or wire so that i! does not hang by the brake nose. Do not twist the brake hose. Requisite Service - Rear wheel removal/installarion (page 13-2) - Loosen the drive chain (page 3-1 1). Procedure , , Q’ty Remarks Removal Order , l1) Axle bolt 1 NOTE ‘ Tap out the bolt to the left side with a plastic hammer when it is to be replaced. {2) Lock nut 1 Loosen after unstaked. l3) Sbring washer 1 (4) Thrust washer 1 (Si Brake caliper mounting bolt 2 (6) Brake caliper 1 CAUTION - Do not hang by the brake hose. (7) Axle/brake disc assembly 1 Pull out to the right side while holding the driven flange. Disassembly [page 13-6) (8) Driven flange 1 Remove from the drive chain (Q) Snap ring 1 (101 Caliper bracket 1 (111 Bearing holder pinch bolt 1 Fully looseni (12) Bearing holder 1 Pull out of the swingarm. Disassembly (page 13-6) Installation Order (12) Bearing holder 1 (11) Bearing holder pinch bolt 1 Loosely install (10) Caliper bracket 1 (Q) Snap ring 1 (7) Axle/brake disc assembly 1 Install from the right side while holding the driven flange. (8) Driven flange 1 install the drive chain, than Install aligning the splines. (6) Brake caliper 1 CAUTION ' Be careful not to damage the brake pads. (5) Brake caliper mounting bolt ,, 2 l4) Thrust washer 1 , (3) Spring washer 1 NOTE - Install with the dished side facing in. (2) Lock nut 1 Use a new nut and stake it after tightening. (1) Axle bolt 1 Install a new bolt from (he left side while aligning the splines when it is replaced. NOTE - Adjust the drive chain slack after installing the rear wheel ibage Sell Rear Wheel/Suspension Bearing Holder, Axle Disassembly/Assembly Wheel side m NOTE - Replace the axle bearings as a set, Requisite Service - Bearing holder removal/installation Ipage 13-4) Procedure 7 7 Q'ti Remarks Bearing Holder Disassembly Order Assembly is in the reverse order of disassembly. (1) Collar ‘l (2) Outer dust seal 2 (3) Bearing set ring 2 (4) Left bearing (BSOSLU) , 7 1 [5) Right needle bearing 1 Replacement (page 13-7) (6) Inner dust seal 7 ‘l Axle Disassemhly Order Assembly is in the reverse order of disassembly. [al Brake disc bolt/um 4/4 (bl Brake disc 1 NOTE ‘ At assembly, install with the ”MIN. TH. 5 mm" mark facing tuward the wheel. (a) Drive pln/pin bolt 4/4 NOTE - Carefully remove as the thread locking agent is used. Rear Wheel/Suspension Axle Needle Bearing Replacement l m DRIVER Press the needle bearing cm of the bearing holder. ‘ , l l Driver o7749—oo1oooo , ‘ Attachment, 42 x 47 mm 0774670010300 , l (2, ATTACHMENT Film. 40 mm u774s-oo4osoo , ! , Grease the new needle bearing and press it into the bearing holder until i! bonoms‘ (1) DRIVER , Dviver 07749—0010000 (2) AWACHMENT Attachment, 62 x 68 mm 07746—0010500 ; 1 I ill *' I 1 3-7 Rear Wheel/Suspension Shock Absorber, Linkage Removal/Installation Rear Wheel/Suspension Do not service the shock abgoeeym linkage while in; axhafi :ysslem is h?» ‘ ' 7 J , _ , , a. , , , .. . - Requisite Service . Seat cowling removal/installation (page 272) .Remarlks Procedure Q'iy Removal Order Installation is in [her reverse order of removal. (1) Holder band 2 Loosen the band screws [2) Shock absorber reservoir 1 Remove from the bracket. (3) Shock absorber upper mounting bolt 1 Removal (page 13-10) (4) Schock link-to-irame bolt 1 (5) Shock absorber lower mcuming bolt 1 (6) Shock arm-Io-swingarm bolt 1 (7) Shock linkage assembly 1 Remove through the space between the exhaust pipes. Disassembly (page 13-14) (8) Shock absorber assembly 1 Disassembly (page 13-12) (9) Upper mounfing collar 1 A- ,m 1 3—9 we .r Rear Wheel/Suspension SHOCK LlNK-TO-FHAME Rear Suspension Bolt Removal I (1) BOLT Raise the rear wheel 0" the ground and support the motorcycle securely. Remove the seat cowling. 7 7 7 , Remove the shock |inl<~to frame bolt. 7 7 NOTE - Loosen the nut first men remove the bolt for easy removal. 7 Remove the shock absorber upper mounting bolt while (1) UPPER MOUNTING BOLT supporting the rear wheel by hand. l l Laosen’the shock absorber lower mounting nut. Raise the wheel further by hand and remove the shock absorber lower mounting bolt. (1) SHOCK ABSORBER ‘ NOTE 7’ 0 Be careful not to damage the exhaust pipe while I l l V ‘l SENICIHQ. 777 —‘ - - 7:! ' i l l l / (2) LOWER MOUNTING BOL \ Remove the screw and the lower portion of the drive chain slider from the swingerm. ‘ Remove the shack arm—to-swingarm bolt. ‘ ! (31 DRIVE CHAIN l W 13-10 Hear Wheel/Suspension Rear Suspension Bolt Installation [nstall the shock absorber with the drain tube foryyard an; temporarily install the upper mounting bolt Install the shock linkage assembly, and install and tighten the check arm-to-swingarm bolt. Torque: 45 him (45 kg Cl'ty_ 7 Hernarks Removal Order Installation is in the reverse order of removal. (1) Dust cover 1 (2) Pad pin plug 1 l3) Pad pin 1 (4i Pad spring 1 NOTE . Al installation, align the tabs with the caliper grooves as shown (5) Pad 2 NOTE . Push the piston all the way into provide clearance for new 1 4—2 ,. “My Brake System Rear Brake Pad Replacement (5) van 3 17 (1.7, 12) 2,510.25,1.8) — 7- vf‘fsr ~‘r:*‘ ._ mi m ~ ~ _r_t ‘, 7 _ . v . - A contaminated brake disc or pad reduces stopping power. Discafi contaminatefiapads and clean a cnnramicaled disc with a high quality brake degraasing agent. - Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. 7 - After replacement. operate the brake lever to seat the caliper pistons against the pads. 7 . ~21 Kna- . :g 4.1,; NOTE 7' V 7 7' I ' , . .- fl . . 2' : . W . 0 The brake pads can be replaced Wlthout disconnecting the fiydrafilc systEm. - Replace the brake pads as a set. Apply a thin coat of grease o to the ad pin an E d pad pl breads so as not to rus Froced ure Remarks rwfi._ , .. Removal Order (1) Pad pin plug Loosen the pad pin after removing the plug. (Zl Caiper mounting bolt Remove the front bolt. (3) Caliper assembly Pivot downward out of the disc. 1 1 1 (4) Pad pin 1 Pull out while pushing the pads in slightly. 2 (5) Pad/shim NOTE ~ Push the pistons all the way in to provide clearance for new pads. Removal Order [5) Pad/shim 2 Do not larger to install the shim. (4) Pad pin 1 Loosely install while pushing the pads in slightly. (3) Caliper accembly 1 CAUTION ' Be careful not to damage the pads. l2) Cariper mounting bolt 1 (1) Pad pin plug 1 Tighten the pad pin before installing the plug. -wv . «'7 a.-- 1 4—3 Brake System (4) (9) Front Master Cylinder Disassemny/Assembly (7) (2) [6D Brake System 7 m _ -e , y . check the brake system by applying the brake after the air bleeding, j cAUTlON 7 :7 . Avoid apilling fluid on painted. plastic, or rubber parisflvlace a reg mier'th’es'e lea—rtIiNheKever the system is serviced, 7 when remoing the oil bolt, cover the end of the brake hose to prevent contamination. Do not allow the foreign material to enter the system. . Do not allow the lips of the cups to turn insie and be certain the snap ring is firmly seated in the groove. . _ _. , A} 77-7,” fi, , NOTE ’ “A _ [Use only nor 4 brake fluid from a sfiled fintainer: , ' ' ' Requisite Service , 0 Front brake fluid draining/air bleeding ,7 77 Procedure 1 O’ty Remarks 1 Disassembly Order , Assembly is in the reverse order of disassemblv. ? 11) Brake oil bolt 1 l 121 Brake hose 2 NOTE E ‘V - Do not twist the hoses. l (3) Sealing washer 3 i 4 14) Master cylinder assembly 1 Disconnect the brake switch wires and remove the holderl I 15) Reservoir hose 1 g (6) Reservoir assembly 1 I‘ (7) Brake switch 1 i (8) Brake lever pivot bolt 1 E (91 Brake lever assembly 1 ‘ (101 Rubber cap 1 f (111 Snap ring 1 (12) Reservoir hose joint l l {13) O-ring 1 I [14) Piston boat 1 i 115) Snap ring 1 Use the snap ring pliers (0791P3230001). - CAUTION ,, 1 - At installation, be certain the snap ring is firmly seated i in the groove in the master cylinder body. I (16) Master piston assembly 1 NOTE ' - Do not remQVe the piston cups from the piston. (17) Spring 1 NOTE ’ - At installation, install with the small coil end facing toward the primary cup. 1 4-5 Brake System Front Brake Caliper Disassembly/Assembly ‘, fl- .VJV'TT: 7 if "‘ ' :s—%- A', ' ' - w}: 0- -ring, seal and sealing washer (1) 35 (3.5, 25) @2 (6) HM Brake System - Dsicard contaminated pads and clean a Jfiifia'ma'afi with; a high quality—Eakifie’greasing agent. ' - Checluhe brake system by applying the brake after the air bleeding. ,7, r, .5 CAUTION 7 7 H V __ t. _ ESpilled brake fluid will damage painted, plastic, or mbber parts. NOTE , E Do not remove the bleed valve unless i is replaced. 7 — ‘ h u I .. _ _., _ e. ,,,,-a. ...,. ~ Requisite Service - ant brake fluid draining/air bleeding 7 , " ’ ' 7 : . ' E . , .. 7 T ,7 ,. , Procedure j Q’ty Remarks Disassembly Order ' . l Assam is in til—éK/ers‘e‘order bi disassembly. (ll Brake oil bolt/hose ’ 1/1 NOTE - Do not twist the hose. ' At installation, install the hose wflh the joint pipe facing toward the fork. (Z) Sealing washer [3i Fad ' Removal/installation {page 14-2} (4) Caliper mounting bolt NOTE ‘ Loosen the torx bolts before removing the mounting bolts. NNN (5) Brake caliper assembly (6) Torx bolt 4 NOTE ’ - At installation, tighten after installing the caliper mounting bolts. l7) Caliper piston [large diameter) 2 CAUTION (8) Caliper piston (small diameter) 2 - Mark the piston to ensure that they are reinstalled in their original positions. (9) Dust seal 4 CAUTION (10) Piston seal 4 - Be careful not to damage the caliper cylinders. , . . _. . . .T—b..- z 14—7 Brake System Rear Master Cylinder Disassemny/Assembly 35 (3‘5, 25) (1) (8) / 67.5 mm (2.86 in) 1 4—8 IA .. Brake System Check the brake system In} applying the bra—ks aflerme airzbleeding. CAUTION - Avoid apilling fluid on painted. plastic, or rubber parts. Place a rag ov’er‘th‘ese ps'r'ts‘wnei‘ieVei the systém is‘ serviced. material to enter the system. - Do not allow the lips of the cups to turn insie and be certain the snap ring IS tirmly seated in the groove. When remoing the oil bolt. cover the end at the brake hose to prevent contamination. Do not allow the tnreign Li v.-.) . . NOTE 7 . W . _ . ? -v . ,1. 1: Use only DOT 4 brake fluid from a sealed contai er. Requisite Service ' Front brake fluid draining/air bleeding Procedure 1‘ t ‘ 0W Remarks Disassembly Order ‘ — ‘ 7- fl ' V ' " ’ (1) Brake oil bolt/hose 1 (2) _Sealing washer 2 (3) Reservoir hose joint/screw 1(1 (4) O-ring 1 (5) Master sylincer mounting bolt 2 Loosen the bolts. (6) Cotter pin 1 (7) Joint pin 1 (8) Master cylinder assembly 1 Remove from the right step braket. (9) Pedal joint 1 Remove by lousening the lock nut. (10) Rubber boot ‘1 (11) Snap ring 1 Use the snap ring pliers (07914—3230001). (12} Push rod 1 (13) Master piston assembly 1 NOTE 7 - Do not remove the piston cups from the piston. (14) Spring 1 Assembly Order fi ‘ (14) Spring 1 NOTE . Install with the small coil end facing toward the piston. (13) Master piston assembly 1 (12) Push rod 1 (1 1) Snap ring 1 CAUTION - Be certain the snap ring is firmly seated in the groove in the master cylinder body. (10) Rubber boot 1 (9) Pedal joint 1 NOTE ' Adjust joint installed length as shown. (8) Master cylinder assembly 1 (5) Master cylinder mounting bolt 2 Loosely install. (7) Joint pin 1 (6] Cone! pin 1 Tighten the master cylinder mounting bolts after installing. (4) O-ring 1 (3) Reservoir hose joint/screw 1/1 (2) Sealing washer 2 (1) Brake ail bolt/hose in Best the joint against the master cylinder boss. 14-9 Brake System Rear Brake Caliper Disassembly/Assembly \ g : O-r‘mg, seax and sealing washer , 7 Brake System - Dsicard contaminated pads and clean affirarnhzatad' 7a high qualityfiake Sabreasing agent. ~ Check the brake system by applying the brake after the alr bleeding. CAU’HON ,iflOJ'E ,, 7 F Do not remove the bleed valve unless u Is repmed. ass“ ,i7 a. ,1 - 4 Requisite Service 7 ‘ Rear brake fluid draining/air bleeding Procedure 7 Q'ty fiernarks Disassembly Order _ ' Assefirbly is hi the rgerse brher or aisassembly. ' (1) Brake oil bolt/hose 1/1 CAUTION - Do not twist the hose. NOTE - Remove the hose by loosening the joint nut while holding the hose nut. (21 Sealihg washer (3) Caliper mounting bolt 2 NOTE - Loosen the pad pin before remavlng. (4) Pad 2 Removal/installation (page 14—3) (5) Caliper assembly 1 Separate the bracket from the caliperl (6) Pad retainer 1 NOTE - At installation, note the installation direction. (7) Pad retainer 1 (B) Pivot boot 1 (9) Pivot pin bolt 1 NOTE (10) Pivot pin bolt 1 ‘ Do not remove the pivot pin bolt unless it is replaced (1 1) Caliper piston 2 CAUTION - Mark the pistan to ensure that they are reinstalled in their or al positions ' (12) Dust seal 2 CAUTION ] [13) Piston seal 2 ' Be carelul not to damage the caliper cylinders. ‘ 14—11 Brake System Rear Brake Pedal Removal/Installation Em”? Procedure A A Removal Order lnstallaxion is in the reverse order of removaL (1) Spring hook plate bolt 1 (2) Spring hook plate 1 (3) Step bolt 1 NOTE ‘ At installation, aiign xhe flats of the step and step holder (5) Brake pedal/thrust washer 1/1 (6) Caner pin 1 (7) Jojm gig 14-12 \L’ , Service Information 15-1 Charging System Inspection 15-5 System Location 15-2 , Regulator/Rectifier Inspection 15-6 Troubleshooting 15-3 Alternator Inspection 15—7 ; Battery Removal/Installation 15-4 Alternator Removal/Installation 15-8 i 7. , 15. Eharging System/Alternator Service Information The battery gives off explosive gases; keep sparks, flames. and cigarettes away. Provl e adequate ventilaflon when charging or using the battery in an enclosed space. The battery contains sulfuric acid (electrolyte). Contact With skin or eyes may cause severe burns. Wear protective clothing and a face shield. . — If electrolyte gets on your skin, flush with water. — If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately. Electrolyte is poisonous. lf swallowed. drink large quantifies of water or milk and follow with milk of magnesia or Vegetable oil an call a physician. KEEP UT OF REACH OF CHILDREN. CAUTION Always turn off the ignition switch before disconnectingumy electrical component. - Some electrical components may be damaged it terminalsbr connectors are connected or disconnected while the Igni- tion switch is ON and current is present. For extended storage, remove the battery, give it a full charge, and store it in a cool, dry place For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal. NOTE I - The maintenance free battery must be replacea'when ifieaches the end of its service life. I CAUTION L- The battery caps should not be removed. Attempting to remove the sealing caps iron. the cells may damage the battery.l Battery can be damaged it overcharged or undercharged,or ii left to discharge [or long periods. These same conditions contribute to shortening the "life span" of the battery. Even under normal use, the performance of battery deteriorates after 2—3 years. Battery voltage may recover after battery charging, but under heavy load, battery voltage will drop quickly and eventually die out. For this reason, the charging system is often suspected to be the problem. Battery overcharge often results from problems in the battery itself, which may appear to be an,oyercharge symptom. If one of the battery cells is shorted and battery voltage does not increase. the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently under heavy load, such as having the headlight and tailight UN for long periods of time without riding the motorcycle. The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sulfation from forming. Filling a new battery with electrolyte will produce some voltage, but order to achieve its maximum performance. always charge the ba't‘lery. Also, the battery life is lengthened when its is i tial—charged. When checking the charging system, always follow the steps in [he troubleshooting flow chart(page 15-3it For battery testing/charging, refer to section 22 of the Common Service Manual. For charging system location, see page 15-2. 15—1 charging System/Alternator System Location (I) IGNITION SWITCH (2) MAIN FUSE (3) BATTERY (5) ALTERNATOR v I Y (2) MAIN FUSE [—— v r R/W G U I (3) BATI'ERY / I—~'——|—:—l 7 L$/Ez,,>\‘ (4) REGULATOR/RECTIFIER (5) ALTERNATOR 7 1 5—2 Charging System/Alternator ‘ Troubleshooting Battery Overcharging . Faulty regulator/rectifier Battery Undercharging NOTE “.1.-. - , d ‘2 '¥ , w - In orde to obtain accurate test readings when charging system, the battery must be fully charged and in good condi- tion. See Common Service Manual section 22 for chggb the atter conditio‘n. "7 ,A , - l 0* e- . ,1 ' Measure the battery current leakage ampere {Leak Incorrect Check the regulator/rectifier unit inspection (page test) (page 1575) ‘ - 15-7) u» A__ .«4— _-i._r lnco rrect Correct ~ shorted wire harness Correct , . Faulty ignition switch . Faulty regulator/rectifier ,Qpen gigcuim Mire harness - Poorly connected connectors V 7 Inspect the regulated voltagerlpg‘ Nut Charging Check the voltages at the regulator/rectifier bat- Abnmmal . . . t . h tery charging line and ground line (page 126) 0”" “mu" '" W're amass : , 7‘ ~ Poorly connected connectors Normal V Abnormal Check the alternator (charging coil) resistance at the regulator/rec‘tifieflgnnegtor (gage 15-6) _ C Abnormal Normal - Poorly connected alter- NDII'I'IBI 713(1)! connector - Faulty alternator ' , .. “'- "Atrmmar‘ " ' ' :ZEeeclkthe regulator/rectifier unit inspection {page . Faulty regumomemmer 1 5-3 Charging System/Alternator Battery Removal/lnatallation CAUTION , _ _ R IV A A \ - Turn the ignition switch oft A 7A _ 7 t A , —| Requisite Service - Seat cowiing removal/installation (page 2-2) ,i W ,, , i . 7,—777: »; fir. ,- Procedure 7 i7 Q’i_ ~ _A_Remarks , Removal Order lnsiallation is in the reverse order of removal. (1) Battery holdev band 1 (2) Negative (—) cable 1 Remove the bolt and disconnect the cable. (3) Positive (+i cable 1 NOTE ‘ At installation, connect the positive H) cable first, apply grease and caver :he terminaL (4) Battery 17 _ . 1 5—4 if n Charging System Inspection Leak Test Remove the seatccwling (page 2-2). Turn the ignition switch off, and disconnect the negative (—l cable from the battery. Connect the ammeter (+l probe to the negative (—) cable and the ammeter (a) probe to the battery negative (7i terminal. With the ignition switch off, check for current leakage. NOTE ' ' - When measuring current using a tester. set it to a high range, and then bring the range down to an appropriate, level. Current llow larger than the range selected mav blow out the fuse in the testert - While measufing current, do not turn the ignition on. _ Asudden surge of current may blow out the fuse in the testerr W Specified current leakage: 1 mA If current leakage exceeds the specified Value, a shorted cir- cult is likelyt Locate the shartby disconnecting connections one by one and measuring the current. i * Regulated Voltage/Ampere inspection NOTE - Before performing this test. he sure thatthe battery is fully charged and that the voltage between its terminals is greater than 128 v. , , Start the engine and warm it up to operating temperature, then turn the Ignition switch OFF. ' Remove the seat Cowling (page 22). Connect the multitester between the battery terminals. ' W Digital multitester 0741 1 ~0020000 f ‘ If the engine must be run ing to do some work, make sure the area ls well~vantilatedr Never run the engine in an enclosed area. 7 , - The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. Disconnect the starter relay switch connector and remove the main fuse. Reconnect the connector securely. Charging System/Alternator l1) BATTERY NEGATIVE TERMINAL } (2) BATTERY NEGATIVE CABLE f :3 (1i CONNECTOR ,_ 1 5-5 Charging System/Alternator Connect the ammeter between the main ruse terminals. CAUTION - Be careful not to short any tester probes. - Although the current could be measured when the ammeter is connected between the battery positive terminal and posltlve cable, a sudden surge of current to the starter motor could damage the ammeter. ~ Always turn the ignition switch off when connecting one disconnecting the ammeter. Disconnecting the ammeter nr wires when current is flowing may damage the ammetor. Start the engine and increase the engine speed gradually. Regulated voltage: 13.5—15.5 Vl5,000 rnin" (rpm) Regulated current: 0—9 A15,000 min“ (rpm)' 7 Regulator/Rectifier Inspection Wire Harness Inspection Remove the seat cowllng (page 2-2L Disconnecuhe 6P Lwhlte) connector from the regulatoureclifier- and check it for loose or corroded terminals. 7 7 7 Measure the following between connector terminals of the wire? 7 harness side. ltsm Terminals Specification Battery Red/white l+) Battery voltage charging line and ground (~l should register. Ground line Green and ground Continuity exist, Charging coil Yellow and yellow 0.1 —1.0 9 line (20°C168‘7F) If the charging coil line reading is out of specification. check the alternator (page 157). (1) STARTER RELAV SWlTCH 1 5—6 Charging System/Alternator Unit Inspection The circuits on the wire harness side are normal and there are no loose connections at the connector, inspect the regular tor/rectifier unit by measuring the resistance between the ter- minels. NOTE - You’ll get raise readings ifthe probes touch your fingers. . Use the specified multitesters. Using other equipment may not allow you to obtain the correct results This is due to the characteristic of semiconductors, which have different resistance values depending on the applied voltage Specified multitester — 07411—0020000 (KOWA Digital type) — 07308—0020001 lSANWA Analogue type) — TH—5H (KOWA Analogue type) - Select the following range: SANWA: kn KOWAL‘X 1009 ~ An old battery stored in the multitester could cause inaccurate readings. Check the battery if the multitester resgisters incorrectly, ’ When using the KOWA multitester, remember that all readings should be multiplied by 100. ,, Replace the regulator/rectifier unit if the resistance value be; tween the terminals is abnormal. fl (1) REGULATOR/RECTIFIER CONNECTOR G) probe Red! ' r 9 prune White Ye low Yellow Yellow Green Red/white m no u: no Vallow O 5—10K 30K7500K ZOK—EOOK IOK—ZDOK ,, Yellow 0‘5—1UK SDK—SOOK ”i aux—300K @7209} Yellow 0 5—10K EOK-SODK 30K75DDK IOK—ZOOK 7 Green 1K~20K 0V5—10K 0,5—10K 0.5-10K 7 Alternator Inspection NOTE : ' it is not necessary to remove the stator coil to make this test. Remove the seat Cowling (page 2-2]t Disconnect the alternator 3F (white) connector. Measure the resistance between the yellow wire terminals and check for no continuity between each terminal and ground. Standard: 0.1 ——1.0 fl (MPG/68°F] , Replace the stator if the resistance is out or specification or if there is continuity between any yellow wire terminal and ground. Charging System/Alternator Alternator Removal/installation (2) RIGHT CONNECTOR BRA’C‘KETN' (5) m. _ _ c 85 (8.5, 61) NOTE 7 7 7 7 - The engine oil will spill out when the left crankcase cover is removed. Place a clean oil pan under the engine to catch the oil and add the recommended oil to the specified level after installing the cover. Requisite Service - Lower fairing removalfinstallation (page 2-4) Procedure Q’ty Remarks Removal Order Installation is in the reverse or der of removlal. (1) Alternator wire connector 7 7 1 Disconnect the connector. (2) Left crankcase cover bolt 6 (3) Left crankcase cover 1 (4) Vifire clamp/bolt 1H (5) Flywheel boll/washer 1/1 Hold the flywheel with the universal holder [07725—0030000} and remove the bolt. (6) Flywheel 1 Use the rotor puller (0773370020001). (7) Stator mounting bolt (8) Stator l 1 5-8 7176 Ignition System Service Information ‘ _‘lG-1 ’ Pulse Generator Inspeotion 16-6 System Location 16-2 lngipn Timing 16-7 Troubleshooting 16-3 Pulse Generator Ignition System Inspection 16-4 Remwamns‘aua‘m" 16'8 Ignition Coil Inspection , 16-6 7 . .i.-. fi-r‘F Us. 2 Service Information - The digital transistorized ignition sytstern uses an electrically controlled ignition timing system. No adjustments can be made to the ignition timing. - A rough diagnosis can be made by identifying the cylinder whose spark timing is incorrect. - The spark unit may be damaged it dropped. Also, if the connector is disconnected when curent is (lowing, the excessive voltage may damage the unit. Always turn off the ignition switch before Serviceing. - A faulty ignition system is often related to poorly connected connectors. Check those connections before proceeding. - Make sure the battery is adequately charged, Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at therspark plugs. 7 - Use spark plugs of the corect heat range. U§ing spark plugs with an incorrect heat range can damage the engine. Refer to section 2 eithe Con-ion Service Manual. 7 ; - For the ignition switch and engine stop switch inspection, checkfor continuity onThe continuity chart of the Wiring Dias gram, page 19-1. Disconnect the ignition and engine stope switch connectors on the right conector bracket (Page 1-24) and check them. ’ 16-1 Ignition System System Location (1) IGNITIN SWITEi-Lfg (2) ENGINE STOP SWITCH . [3) FRONT SPARK PLUGS (17) BATTERY (14) sua FUSE (16) MAIN FUSE “ 4ch 'M' e e ,- 7 (131 ENGINE STOP (15) IGNITION SWITCH ”V 5 Ah SWITCH 7 k _ 4 (12) IGNITION con. i I __I i GP ‘ Y/Bu EuIY Whi‘e BI/w BI/W m m V m m (20) SPARK UNIT 330E E , (19) PULSE GENERATORS 4 , V V V V 7 , s , (18) TACHOMETER I I I ‘ lgnl on System Troubleshooting Before troubleshooting, check that no spark jumps at the spark plug using a known good spark plug (to ensure that the plug does not cause the problem). . Moreover, check for proper spark plug gap and loose spark plug wire as well as for leakage of the ignition coil secondary current caused by moisture. It no spark jumps at one part of the ignition system, exchange the ignition coil with the other good one and perlorm the spark test. if good sparks jump, the exchanged ignition coil is faulty Astor peak Voltage inspection, first measure the primary coil voltage of the ignition coil. if the oltage is abnormal. chaeck each item in numerical ordr in the ”Probable Cause" column dexcribed on the Troubleshooting chart. "lntial voltage" of the ignition primary coil is the voltage measured with the ignition switch ON and engine stop switch at RUN (when the engine is not cranking with the starter motor). No Spark At All Plugs Unusual condition 7 7 Probable cause (Check in numerical order) ignition coil No intial voltage with the ignition 1. Faulty engine stop sw ch. primary switch ON and engine stop 2. Open circuit in BINV wire between the ignition coil and engine stop voltage switch at RUN. switch. (Other electrical components are 3. Loose or poor connection of the ignition coil primary wire termlnal normal.) or open circuit in primary coil , A. Faulty spark unit, when thei tial voltage is normal with the spark W. ' unit connectors disconnected. Initial voltage is normal, but it ‘I. Incorrect peak voltage adaptor connections. drops by 2—4 volts while orank- 2. Battery is undercharged. (Voltage drops largely when the engine ihg the engine. is started.) 3. No voltage at BINV wire of the spark unit 6P white connector, or loose or poorly connected spark unit connector. 4. Poor Connection or open circuit in G Wire of the spark unit 6P white connector. 5. Loose or poor connection, or open circuit in Y/Bu or Bu/Y wire be- tween the ignition coil and spark unit. 6. Short ciurcuit in the ignition primary coil. 7. Faulty pulse generator. (Measure the peak voltage.) 7 B Faulty spark unit (when above No, 1—7 are normal). initial voltage is normal, but no 1. Incorrect peak voltage adaptor connections. peak voltage exists while crank- 2. Faulty peak volage adator. ing the engine. 3. Faultv spark unit (when above No. 1 and 2 are normal). Initial voltage is normal, but peak 1. The multitester impedance is too low. voltage is lower than the stan- 2, Cranking speed is too slow. (Battery is undercharged.) dard value. 3. The sample timing of the tester and measured pulse were not syn- chronized. (System is normal it measured voltage is over the stan- dard voltage at least once.) . . 4. Faulty spark unit (when above No. 1 —3 are normal). initial voltage and peak voltage 1. Faulty spark plug or leaking ignition coil secondary current ampere. are normal, but no spark jumps 2. Faulty ignition coil. 7 .. at plug. Pluse Peak voltage is lower than the 1. The multitester impedance is too low. generator standard value. 2. Cranking speed is toq'slow. (Battery is underchargedJ. 3. The smple timing of the tester and measured pulse were not syn- chronized. {System is normal ii measured voltage is over the stan- dard voltage at least once.) 4. Faulty pulse generator (when above No. 1—3 are normal). No peak voltage. 1. Faulty peak voltage adaptor. 7 .. 2. Faulty pulse generator. 16-3 ignition System Ignition System Inspection 'NQTE ' - 11 no spark jumps at all plugs, check all connections for loose or poor contact before measuring each peak voltage. - The reading difrers depending on the multirerster input impedance. Use only genuine digital multiterster or com- higher than 10 MD/DCV. Connect the peak voltage adaptor to the digital multitester. ' 7 Peak voltage adaptor D7HGJ—0020100 , Digital multitester 07411 —0020000 Ignition Coil Primary Voltage Inspection ignition Coil Primary Voltage Inspection NOTE ' Check all system connections before this inspection. Poor connected connectors can cause incorrect readings. - Make sure that all cylinder compressions are‘norrrral and check that the spark plugs are installed corectly in all cylinders mercially available multitester with the input impedance . _s.=, Place the motorcycle on its side stand and shift the transmis- sion into neutral. z; Remove theseat cowling [page 2-2) and the lower fairing (page 2-4’. Disconnect all spark plug caps from the spark plugs. Leave the spark plugs installed in all cylinder heads, install good known spark plugs into the spark plug caps and ground them to the engine. NOTE 0 The peak voltage must be measured under the normal cylinder compressions and with the ignition secondary circuits closed. (1) DIGITAL MULTITESTER Q? Iillltll‘l -i rim (2) PEAK VOLTAGE ADAPTOR lll " Connect theFeakCuTrage adaptor probes between the primary ignition coil terminal and ground with the connector connected. n coil: Bu/Y terminal (+) and ground (—) Rear ignition coil: YlBu terminal (-1-) and ground [—) Turn the ignition switch ON and engine stop switch to RUN position, and measure the initial voltage. The battery voltage should be registered. Ignition System Measure the ignition coil primary peak voltage while cranking the engine with the starter motor. Connection: 7 Front ign on co Bu/Y terminal (+) and ground l-) Rear ignition I: YIBu terminal (+) and ground (—l Peak voltage: 140 V minimum W” - To avoid possible electrical shock during voltage meas- urements, do not touch the tester probe metal parts. NOTE l . As long as the measured voltage exced the specified value. the svstem is normalr Pulse Generator Peak Voltage Inspection ‘t NOTE’ , 7 The peak voltage must be measured with all spark plugs installed in the cylinder heads and under normal cylinder compression. Remove the seal Cowling (page 2—2). Disconnect the spark unit 4P black connector. Connerzt the peak voltage adaptor probes to the pulse gener- ator wire terminals of the wire harness side connector, Connection: : Pulse generator 1: WIV terminal (+i and Y terminal [—) Pulse generator 2: W/Bu terminal [4-) and Bu terminal l—l Measure the pulse generator peak voltage while crankingthe engine with the starter-motor. * Peak voltage: 1.8V minimum To avoid possible eiectroal shock during Voltage measV uremants, do not touch the tester probe metal parts It the peak voltabe is abnormal, disconnect the pulse genera- tor 4P black connector on the right connector bracket (page 1-24). Connect the peak voltage adaptor probes to the pulse gener- ator wire terminals. Connection: , Pulse generator 1: W/V terminal (+) and Y terminal l—l Pulse generator 2. W/Bu terminal (H and Bu terminal} — ) Measure the guise generator peak voltage while cranking the engfi with'the starter motorr I L : : ignition System if the peak voltage measured at the spark unit is abnormal and the one measured at the pulse generator wire connector is nor- , mal, the wire harness has an open circuit or ioBse connetian," NOTE - As long as the measured Voltage exced the specified value, the system is normal. Ignition Coil inspection Remove the seat cowling (page 2-2) and the lower fairing (page 24). Disconnect the primary wire connectors and measure the primary coilJesistance between the teminals. Standard: 2.5 — 3.5 fl (20°C!68°Fl Remove the spark plug caps from the plugs and measure the 7 secondary coil resistance between the spark plug caps. Standard: 14 —- 25 k9 (20°CI68°F) If the resistance is out of range, remove the ignition coil, re- move the spark plug wires from the ignition coil and measure , , the secondary coil resistance. Standard: 11 — 14 k9 (20°C/63°F) Pulse Generator Inspection , NOTE M . ~ it is not necessary to remove the pulse generator to make this Inspection. l1) lGNlTlON COIL Remove the lower fairing (page 2-4). Discunnectihe pulse generator wire connector on the right connector bracket (page 1-24L Measure the pulse generator coil resistance between the WW and Y wire termines and between the W/Eu and EU wire ter- minals. Standard: 450 — 550 [Z (20°C/GB°F) 16—6 Ignition Timing NOTE , , ",Wir ,, s ~ The spark unit system is factory preset and cannot be adjustedt Ignition timing inspection procedures are given to inspect the iuntion of the spark unit components - Conect the timing light to the other spark plug wire it you see that the ignition timing is incorrect, and you might be able to see the timing is correct. Warm up the engine to operating temperature. A WARNING If the engine must be running to de some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. - The exhaust contains poisonous carbon monoxide gas’ that may cause loss of consciousness and lead to death. 7 - ,, , ‘r . Remove th’e lower fairing (page 2-2). Remove the timing hole cap from the right crankcase cover. Cannecfthe tin'fiig light to the No. 1 cylinder spark plug wire. The timfitg is correct if the "F" mark of the ”T1 " mark sidé aligns with the index mark at idle. Idle speed: 1,300 min"(1pm) Increase the engine speed and check the “F" mark begins to move to the left side. Apply molybdenum disulfide oil to the mm and timing hole cap threads, and install the timing hole cap. Torque: 123 Mm (1.8 kg-rn. 13 Mb) ignition System 1 6—7 'li Ignition System Pulse Generator Removal/Installation u (5] e: NOTE 7 Remarks Procedure Removal Order ( 1) Wire connectoe 2 (2) Oil pressue switch terminal screw 1 (3) Neutral switch wire connector 1 (4) Wire grommet 1 (5) Pulse generator mounting bolt 2 (6) Pluse generator 2 , r, e m ts - Installation is in the reverse order of removalr Disconnect the connectors. Disconnect the connector, 1 6-8 7 A455; gr i :i fi= _: r - Route the pluse generator wires above the wire guide. , , , , .s._.e ,,. 4* “A A- W Requisite Service . Right crankcase cover removal/installation (page 9-2) , 4» «:- 7 17. Electric Starter/Starter Clutch Service Information W 7717;1iflsrtgterrCIotch Esags;m— W System Location 17-2 ,, bly/Assembly W 17-6 Troubleshooting 17~3 Starter Mater Removal/installation 17-7 Starter Clutch, Primary Drive Gear ,, , :3fixflfimsassew 1H5 Hemoyal/lnstallatlon , 17-4 Service Information Alwa 5 turn the ignition switch OFF hefqre servicing the starter motor. The motor could suddenly Stan, causing serir ous Injury. - A week battery may be unable to turn the starter motorjiuickly enough, or supply adequate ignition current. - If the current is allowed to flow to the stafier motor to tgn it while the engine j; not cranking over, the sxarter motor may be damaged. For the following component in spections, refer to the following pages; for the parts locations, see page 17-2 of this manual (System Location). ’ Clutch swltoh diode Section 24 of the Common Service Manuali Starter motor Section 24 of the Comon Service Manual. Clutch switch Section 25 of the Common Service Manual, ' Section 25 of the Common Service Manual Neutral switch Ignition switch Check for continuity on (he cominuity char of the Wiring Diagraml page 1971. Disconnect the switch conne'mor onthe right connector bracket (page 1-24) and check it. 17—1 Electric Starter/Starter Clutch System Location (3) STAEER SWITCH l2) IGNITION SWITCH (4) STARTER RELAY SWLTCH T (5) MAIN FUSE I6) CLUTCH DIODE (8) STARTER MOTOR _ .l (7) NEUTFEL SWITCH (12) IGNITION SWITCH ; ‘1‘” 33:2" (16) STARTER RELAY SWITCH 7 7 r m» e I A WEI ‘ (17) STARTER T , ,, MOTOR (1o) SUE FUSE I11) SUB 1° A FUSE (15! MAIN FUSE a 10 A 30 A BI BI/Br I—O/b— WI»? (13) STARTER SWITCH I9) NEUTRAL T T T ' T ' INDICATOR — Lg/R , 7 7 7 7 (Is) CLUTCH SWITCH Lg/R ~K G/R 40/ I20) NEUTRAL (19,};me SWITCH VDIDDE 17—2 Troubleshooting NOTE 1 t . Check for a blown main or sub (use before servicing. Make sure the battery is lully charged and in good cond't'on. Starter Motor Will Not Turn. With the ignition switch "ON" and engine stop switch at "RUN", check [or a "click” sound from starter relay switch. NO CLICK ‘\ Disconnect starter relay switch connector, and chegk the relay coil grounq wire, 6” =5 CONTINUITY Connect the starter relay switch connectors Measure the starter relay voltage at the starter relay switch connector. VOLTAGE MEASURED ABNORMAL Starter Motor Turns Slowly - Low specific gravity in battery (or Dead battery) - Poorly connected battery teminal cable - Poorly connected staarter motor cable . Faulty starter motor - Poorly conected battery ground cable Starter Motor Relay licks", but Engine Does Not Turn Dver - Crankshaft does not turn due to engine problems - Excessive reduction gear triction CLlCS‘> N0 CONTINUITYO' ——-_ Electric Starter/Starter Clutch ' J g . . Connect the starter motor (+l terminal to the battery positive terminal. [Because a large amount of current flows, do not use thin wlres). , i 1 Starter motor turns Starter motor does not turn Loose or discon» - nested wire or cable Faulty starter relay switch Faulty starter motor Faqu neutral switch - Finilfi'clmch switch Faulty starter switch - Loose or poor contenot at connector Open circuit in wire harness. Faulty ignition switch 0 Broken starter switch wire - Loose or poor contct at connector - Open circuit in wire harness. Loose or poor contact at starter relay switch connector - ‘Fafiiiy—staiiEr'relay switch Starter Motor Turns. but Engine Does Not Tum - Starter motor is runnign backwards — Brushes assembled improperly — Case assembled Improperly 7 Terminals connected improperly - Faulty starter clutch - Damaged idler gear or reduction gear 1 7-3 I Elemric Starter/Starter Clutch Starter Clutch/Primary Drive Gear Removal/Installation Remove through the recessed portion of the clutch outer, , 7, Ar installaiton, align the wide groove with the wide tooth, Requisite Service Right crankcase cover removal/installation (page 9-2) Electric Starter/Starter Clutch Procedure O’ry Remarks Remuval Order Installation is the reverse order of removal. (1) Pulse generator mounting bolt 2 Remove the pulse generamrsr l2) Starla idle gear/shaft 1/1 (3) Primary drive gear bolt 1 Use the gear holder (00724—001010) as shown. (4) Staner Clutch 1 Disassemblylassembly (page 17-5) NOTE ' - Remove the clutch through the recessed portion of the clutch outerr - Ar installation, align the wide groove with the wide tooth of the crankshaft. (5) Spacer 2 (6) Primary drive gear 1 ‘ 17-5 Electric Starter/Starter Clutch Starter Clutch Disassembly/Assembly , ~» 3 - ~ J Requisite Service , 7 , - Starter clutch removal/installation (page 17-4) , , ,7 , _ A“. . o__ 7,... . __ .. ,_ :3 Procedure Q'ty Remarks . _ 7 ii a Remaval Order Assembly is in the reverse order of disassembly. (1) Starter driven gear 1 NOTE - A1 installation. install the gear into the clutch while (urn- ing it clockwise. (2) Needle bearing 1 (3) Clutch saver bolt 3 (4) Clutch cover 1 NOTE - At installat‘lon, align the hole with the locating pin, (5) Roller 3 (S) Fldnger 3 [7) Spring 3 (3) Starter clutch body 1 7 Electric Starter/Starter Clutch Starter Motor Removal/Installation (4) ' With the ignition switch OFFI remove the negative cable from the battery before servxcrng the starter molar. Requisite Service - Lower fairing remavalfinstallation (page 274) Remarks Procedure Q'ty Removal Order (1) Lower radiator mounting bolt 2 (2) Starter motor cable 1 (3) Starter motor mounting bolt 2 Starter motor/O-ring 1/1 Installation is in the reverse order of removal. NOTE ' Remove the bolts and move the lower radiator forward. CAUTION - Cover the radiator fins to prevent them from damage when servicing Disconnect the cable. NOTE ' Install the rubber cap securely after installing. Disassembly/assembly (page 17-8) 17—7 Electric Starter/Starter Clutch Starter Motor Disassembly/Assembly __‘. - _ p: » (1) (9) a ., ‘50 $2 " (2) V 7 A _ u _ ,- r .9 <2 2,,- 1: NOTE 7 7 , 7 mum—”‘77 .7 >9v..: A ,7.- 3:- ; ’ - NatJrhe location and number of the shims when disassembw. ,7 ‘ ~——-u--+ - -g» s -? w ‘ aw Requisite Service - Starter,motor removalfinsrallation (page 17.7) _ ....., k- 4.2 are? - 2 Procedure Q’ty Remarks 5 Removal Order Assembly is in the reverse order of disassembly. (1) Case bolt 2 (2) Front caver 1 (3) Dust sew/Thrust plare 1/1 (4) Shim V_ , (5) Rear never 1 (5D Shim _ (7) Armature 1 (B) O-ring 1 (9’ Brush holder assembly 1 ‘1‘: ‘— ‘ "" 1 7—8 18. Lights/Meters/Switches Service Information 18-17 Turn Signal Light Bulb System Location 18-2 hepalcement 185 Oil Pressure Switch Inspection 18-3 Ijieadllght Bulb Replacement 18'6 . . Ignition Switch Fan Motor Swrtch lnspectron 18-3 Removal/Installation 1&7 azaleagtignemperature Gauge 18-4 Instruments, Headlight Unit p Removal/Installation 1 8-8 Headlight Relay Inspection , 18—5 7 Service Information 7 A WARNING - A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for a whle after it is turned OFF. Be sure to let it cool down before servicing, - Use a heat element to heat water/coolant mixture for thermosensar inspection. Keep all flammable materials away from the burner Wear protective clothing, gloves and eye protection, - Note the ruuwing when replacing the halogen headlight bulb. — Wear clean gloves while replacing the bulb Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break a If vaumuch the bulb with your bare hands. clean It with a cloth mistened with alcohol to prevent its early failure. — Be sure to install the dust cover after replacing the bulb ' Check the battery condition before performing any Inspection that requires proper battery voltage - A continity test can be made with the switches installed on the motorcycle 18—1 Lights/MeterslSwitches System Location (3) IGNITION SWITCH ’ (2} INSTRUMENTS (4) FRONT BRAKE LlGH‘/l' SWITCH (1) LEFT HANDLEBAR / / SWITCH / (5) RIGHT HANDLEBAR SWITCH (6) THERMOSENSOR (7) HEADLIGHT HIGH BEAM RELAY (8) CLUTCH DIODE (9) BRAKE/TAILLIGHT (13) FAN MOTOR SWITCH I (12) OIL PRESSURE SWITCH /: // , o, (1 1) NEUTRAL SWITCH (10) TURN SIGNAL RELAY 1 8—2 n. Wm..-“ w. ”.4“ Oil Pressure Switch Inspection Remove the lower fairing (page 2-4lt If the oil pressure warning light does not come on with the ignltion swltch turned ON: 1 . Disconnect the oil pressure switch wire from the switch and ground it. 2. Turn the ignitiion switch 0N and check that the oil pressure warning light comes one 7 lf the light comes an, the oil pressure switch is faulty. Replace the switch. — it the light does not comes on, the bulb is buwn or wire harness has an Open circuit. Check them. If the oil pressure warning light stays on while the engine is running. 1 . Check the engine oil level and addrthe recommenged oil if the level is low. 7 2. Disconnect the oil pressure switch wire from the switch and check that the oil pressure warning light does not come on with the ignition switch turned ON, 7 If the light comes on, the wire haness between the light and switch is shorted to the ground, — If the light does not come on, measure the oil pres- sure. If the pressure is normal, replace the oil pres» sure switch. Fan Motor Switch Inspection NOTE ’ ~ Perform this inspection while the engine is culdv Tim the I'Qnition switch OFF. Remove the lower rairing (page 2-4), It the tan motor does not stop: 1 , Disconnect the fan motor switch connector immrthe switch and turn the ignition switch ON.” 7 — If the starter motor does not start. the fan motor switch is faulty Replace the switch — If the fan motor starts, the wire between the mgtor ' and switch is shorted to the groundt Lights/Meters/Switches (1) OIL PRESSURE WARNING LIGHT w l2) on. PRESuhE SWITCH _(1) SWITCH WIRE 1: Lights/MetersISwitches If the fan motor does not start: 7 1 , Disconnect the fan motor switch connector from the switch and ground it with a jumper wire, 2. Turn the ignition switch ON, and check the fan motor. — If the motor turns, the fan motor switch is faulty or switch connector is loose or poorly connected. — If the motor does not turn, check for voltage be- tween the connector and ground. 0 if the battery voltage exists, the fan motor is faulty. a If no voltage, the wire harness has an open circuit, (2) CONNECTOR When installing a new fan motor switch, apply sealant to the ‘ threads and tighten it to the specified torquet (1) FAN MOTOR SWITCH Torque: 18 N‘m (1.8 kg-rn, 13 ft-Ib) Connect the fanmotor switch connector. : , install the lower fairing (page 2-4). \ Coolant Temperature Gauge Inspection Remove the lower fairing (page 2-4) and the fuel tank (page 2-5L Disconnect the thermcsensor wire connector from the sen- ’ soy and ground it with a jumper wire, Turn the ignition switch ON and check the coolant tempera- ture gauge. Disconnect the thermosensor wire lrorn the ground immediately when the gauge needle moves iuliy to H, CAUTION , A ,, a ‘ 7,. - Do not ground the thermosenor wire longer trhan 5 se- conds to prevent damage to the gauge if the needle does not move to H, check the wire harness be- tween the switch and gauge. if the wire harness is normal, replace the coolant temperature gauge. Install the removed parts in the reverse order of removal. 18—4 Lights/Meters/Switches Headlight Relay lnspection High Beam Relay Remove the lower fairing (page 241), Turn the ignition switch 0N and the headlight switch to "H‘C Turn the dimmer switch to ”HI" and check for a "click" sound from the high beam realy. — lf the relay click, measure the voltage between the BI/R wire [+) and ground with the ignition switch 0N. - It the battery voltage exists, replace the relay. ‘ if no voltage, check the wire harness. — If the relay does not click, measure the voltage between the Eu/W (+) and G (—i wire terminals at the relay con- nectar. The binary voltage should be registered when the head- light switch is turned to ”H" and the dimmer switch is turned to "HI". - If the battery voltage exists, replace the relay, ' If no voltage, check the wire harness, lighting switch andnimmer switch. Low Beam Relay Remove the upper fairing (page 2-2i, Turn the ign on switch 0N and the headlight switch to H Tum'thfi’immefiwircfi to “LO’réfiEl‘éfie'tTt—‘or a "oak" soufi' from the high beam relayt A If the relay CllEkSy measure the voltage between the Elm wire (+) and ground with the ignition switch 0N. ' If the battery voltage eixsts, replace the relay - If no voltage, chick the wire harmess — If the relay does not click, measure the voltage between the W/Bu (+) and G l—) wire terminals at the relay con- nectar. The battery voltage should be registered when the head; light switch is turned to "H" and the dimmer switch is turned to “L0". . If the battery voltage exists, replace the relay. ’ If no voltagecheck the wire harness, lighting switch and dimmer switch. Turn Signal Light Bulb Replacement Remove the screw and the turn signal light from the case. Remove the bulb socket from the light by turning it counter- clockwise. Removtrthe bulb from the socket by pushing it in and turning it counterclockwise Install the new bulb in the reverse order otremcgal, NOTE H - Align the tab oi the turn signl light with the hole in t e case properly, (1) CASE l7} SCREW (6) SOCKET l5) BULB 18-5 Lights/MetersISwitches Headlight Bulb Replacement (2) ' A halogen headlight bulb becomes very hot while the headlight is ON. andrremain hot for awhile after it is turned OFF. Be sure to let it cool down before servicing. CAUTION - a 1 , fin . 7-7 _, , ' If you touch the bulb with yuur bare hands, clean it wth a cloth moistened with alcohol to prevent early failure. s" v '7 ' , 4 "fl, ,_ u _, ._ V- is . Requisite Service - Upper fairing removal/installation (page 2-2! - Instruments removal/installation (page 18-8) Procedure Q’ty Remarks Removal Order Installation is in the reverse order of removal. (1) Headlight connector 1 (2) Rubber cap 1 NOTE install the cap securely with the ”TOP" mark facing up (3) Headlight bulb , 1 (4) Headlight unit mounting screw 3 (5) Position light socket (6) Position light bulb 1 1 8—6 ignition Switch Removal/installation Ligh‘slMeters/Switches NOTE . w i._ .. u. . ~ - Route the ignition switch wire harness properly (see page 1721). Procedure finiarké (1) (2) (3) Removal Order ignition switch wire connector ignition switch mounting boil Ignition switch ' Instaiiaaonis In the reverée order or removalr Disconnect at right connector bracket (page 1-24). 1 8—7 iii Lights/Meters/Switches Instruments, Headlight Unit Removal/Installation “4a; NOTE Lig hts/Meters/Switches . Instruments can be removed with the upper lairirlg installed. - the right and left mounting brackets are different. When replacing the bracket, install the headlight aim adjusting screws in the marked locations as shown. a? , -_ - . i , :7 Requisite Service - Upper fairing removal/installation (page 2-2) Procedure Q’ty Remarks Insrrumem Removal Order 7 Installation is in the reverse order or removal. (1) Speedometer cable 1 (2) Instrument mounting bolt 2 {3) Instrument wire connector 3 Disconnect the connectors. (4i Instrument unit 1 Headlight Removal Order lnstallation is in the reverse order of removal. (3) Oil Cooler mounting bolt 1 (b) Headlight wire connector 2 Disconnect the connectors. (c) Headlight stay mounting bolt 2 (dl Head lght mounting screw 3 Headlight Disassemhly Otder Assembly is in the reverse order of disassembly. (e) Headlight aim adju 9 Screw 2 (f) Headlight aim adju ng springlnut 2/2 (g) Headlight pivot holder screw 1 Remove the screw and open the holder covert (hi Headlight 1 18—9 25w- was. .22: :5 a a... . 2.3.... xx . a. . is 25 a as . a a: S: . a u... a y E? n say . I E.- . 52 . a; 1i i...§.i§él._§.ia§. Q i, 512:: :55... wine... @ E59 E9920 96:5 .9. use- was. :Nam—E at a E. _. 5.. . e. K Eu .5: a 5: as E: a u:- a as: o 5! . .3: .. a: . ESE. .x :3 r a: 4 ._ . 15.3: 33:. . n . :55 .5158. sin: .5... :15 3.5. .u m 20. Technical Feature ,‘ "-7._-:" P _ 7 Cylinder Head 20-1 Newly Designed Spark Plug 20-2 Shim Direct Push Mechanism With Rocker Arm 20-2 , Cylinder Head (5) SPARK PLUG The new design does not require the rocker armiwhich isipos'nioned thru the rocker arm shaft and the thrust spring, the camshaft which is located on the same shaft as the valve stem, and the valve lifter. This achieves a larger valve dismeter and higher valve lift amount for the newly designed cylinder head‘ The part supporting the valve litter is not required, because a mechanism directly pushes the shim and the newly desinged special spark plug (details are described on the next page) is used The resulting compact cylinder head yields a higher performance, Compared with conventional models, the installa- tion position of the new engine can be shifted further toward the front. Thus, the new design contributes to an improved rotation performance, driving safety and load balance of the front and rear wheels by shifting load to the front wheels, and simultaneously decreasing he required wheel base. 20-1 iii Technical Feature Shim Direct Push Mechanism With Rocker Arm ‘4) CAMSHAFI’ 12) ROCKER ARM SHAFT (3) ROCKER ARM (5i SHlM l1) THRUST SPRING (6) SHIM The newdesign is a compact cylinder head, using a shim direct push mechanism with mcker arm for easier maintenance, without any valve lifter. in conventional designs, the direct push type shim is located inside the valvelif‘lert Therefore, the valve lifter including the camshaft must he removed/installed when the shim is replaced. The new direct shin push mechanism used in the VFR4004R facilitates easier maintenance than with the valve adjuster method, however. without requiring any valve adjusterr The decreased operating mass Thanks to the reduced weight cf the rocker arm, the decreased operating mass results in better valve perfor- mance during high speed, as well as in enhanced durability and reliabilitvr Newly Designed Spark Plug [Conventional Type] [Screw Diameter: 8 mm] i1) SPARK PULG The newly designed dedicated spark plugs (diameter: 3 mm) maintain a balancedecombustion and use a valve with larger diameter. Greater charging efficiency and higher gas speed are attained, resulting in a better acceleration response. 20—2 721. Trou bleshooting _-‘ “‘ e Lv—eei; 7:7 ,7 EnSine Does Not Start or is Hard Poor Performance at High Speed 21'3 m 5‘3“ 21" Poor Handling 214 Engine Lacks Power 21-2 Poor Performance at Low and Idle Speeds Engine Does Not Start or is Hard to Start 1. Checkjuel flow to carburetor Reaching Carburetor 2. Perform a spark test Good Spark Not Reaching Carhuretor —>; Weak or No Spark —>-* 3. Test cylinder compression Low Compression ——>-* Compression Normal , - 4. Start by following normal Engine Starts But Stops 4v» procedure '- Engine Does Not Fire - 5. Remove and inspect spark plug —— Wet Plug fi—M Possible Cause Clogged fuel tube or fuel strainer Sticking float valve Clogged fuel tank breather Disconnected or faulty auto fuel valve vacuum tube Faulty spark plugs Fouled spark plugs Faulty spark unit Broken or shorted spark plug wires Broken or shorted ignition coil Faulty ignition switch Faulty pulse generator Faulty engine stop switch Loose or disconnected ignition system wires improper valve clearance [shim too thick) Valve stuck open wdrn cylinder and piston rings Damaged cylinder head gasket Seized Valve lmprdper valve timing Improper valve and seat contact Improper chock operation Carburetor incorrectly adjusted Intake pipe leaking Improper ignition timing (Faulty spark unit or pulse generator] Fuel contaminated Carburetor flooded Choke closed Throttle valve open Air cleaner dirty 21-1 Troubleshooting Engine Lacks Power 1. Raise wheels off ground and spin by hand Wheel Spins Freely 2. Check tire pressure Pressure Normal 3 . Accelerate rapidly from low to second . Engine Speed Increases Clutch is Released 4. Accelerate Lightly Engine Speed Increases v 5‘ Check ignition timing Correc? 6‘ Check valve clearance Correct 7. Test cylinder compression Normal 8. Check'carburetor for clogging Not clogged 9. Remove spark plug Not Fouled or Discolored 10.Check oil level and condition Correct 11. Remove cylinder head cover and inspect lubrication Valve Traln Lubricated Properly Wheels Do Not Spin Freely ——>. Pressure Low _——>- Engine Speed Not Changed When —>' Clutch is Released ' Engine Speed Does Not Increase —>- lncorrect __,,, Incorrect *- Too Low #- Clogged TW‘ Fouled or Discolored ——->' Incorrect fi‘ Valve Train NC! Lubricated —>‘ Properly ' Possible Cause Eraks dragging Warn or damaged axle bearings Axle bearing needs lubrication Drive chain too tight Axle nut excessively tight Faulty tire valve Faulty clutch lifter system Worn clutch disc/plate Warped clutch disc/plate Weak clutch spring Carburetor choke closed Clogged air cleaner Restricted fuel flow Clogged muffler Pinched fuel tank breather Faulty spark unit , Faulty pulse generator Improper valve adjustment Worn valve seat Valve stuck open Worn cylinder and piston rings Leaking head gasket Improper valve timing Seized valve Improper valve and seat contancr Carburetor not serviced frequently enough Plugs not serviced frequently enough Spark plugs are incorrect heat rang oil level tau high Oil level too low Contaminated oil Clogged oil passage Clogged oil control orifice Contaminated oil Faulty oil pump 21-2 our 12 Check for engine overheating Not Overheating 13. Accelerate or run at high speed Engine Does Not Knock Overheating me‘ Engine Knocks E» Poor Performance at Low and idle Speeds 1. Check ignition timing and hydraulic teppet condition Correct 2. Check carburetor pilot screw adiustrnent Correct 3. Check for leaking intake pipe No Leak 4. Perform spark test Good Spark incorrect w» A" —— , Troubleshooting Possible Cause Coolant level low Fan motor not working {Faulty fan motor switch) Thermostat stuck closed Excessive carbon buildup in com- bustion chamber Use of poor quality fuel Clutch slipping Lean Iuel mixture Worn piston and cylinder Wrong type of fuel Excessive carbon buildup in com- bustiun chamber Ignition timing too advanced (Faulty spark unit) Lean fuel mixture Possible Cause Improper valve clearance improper ignition timing — Faulty spark unit — Faulty pulse generator Incorrect fflprfiee Fuel System (Section 5) ol the Leaking ‘7‘; Weak or intermittent Spark *rt Common Service Manual Loose insulator clamps Damaged insulator Faulty, carbon or wet fouled spark plug Faulty spark unit Faulty ignition coil Broken or shorted spark plug wires Faulty engine stop switch Faulty pulse generator Fautly ignition switch Loose or disconnected ignition sys- tem Wires 21-3 Troubleshooting , Poor Performance at High Speed Possible Cause 1. Check ignition timing and Incorrect ww- improper valve clearance hydraulic tappet condiiion - Improper ignition timing — Faulty spark unit Ccrrec‘ — Faulty pulse generator 2. Disconnect fuel tube at car- Fuel Flow Restricred a" Fuel tank empty buremr ‘ Clogged fuel line ' Clogged fuel cap vent hole Fuel Flows Freely - Clogged fuel valve ’ Fautly fuel valve - Clogged fuel filter 3. Remove carburetor and check Clogged fl Clean for clogged jers Nor Clogged ' 4. Check valve timing Incorrect —*—> Cam sprocket not installed properly Correct, 5. Check valve spring Weak HFFaulty spring Not Weakened Poor Handling —>Check the pressure Possible Cause 1‘ If steering is heavy " i — " Starfigstfi adjustment nut too right - Damaged steering head bearings 2. If either wheel is wobbling wfimxswe wheel bearing play - Bent rim - Improperly installed wheel hub - Swingarm pivm bearing excessive- ly warn - Bent frame - Swingarm pivot adjusting bolt too tight 3‘ If the motorcycle pulls to one side w'fir‘aulty shock absorber - Incorrect drive chain adjustment ' Front and rear wheels not aligned - Bent fork legs - Bent swingan-n - Bent frame .r ”a..." Air Cleaner Removal/Installation Alternator Inspection Removal/installation Battery ReTnvaI/Installation Bearing Holder Removal/Installation 13-4 Holder, Axle Disassemblv/Assembly 13-6 Selection .. 11-10 Brake System ,, 14-1 Cable 3. Harness Routing . 1-21 Cam Gear Case Installation . 8-10 Camshaft Installation 8-11 Camshaft, Carri Get-Jr Case Installation . 8-8 Camshaft/Cam Gear Case Removal .. 8-2 Carburetor Combination Disassemny/Assembly 6-14 Removal/Installation 6-8 Separation .1 6-10 Synchronization Charging System/Alternator Installation 9-6 Removal 9-4 Coolant Draining 5-: Temperature Gauge Inspection 18-4 Cooling System 5-1 Countershaft Disassemny/Assemblv Crankcase Assembly .. Separation Crankshaft/Pisten/Transmission 11-1 Cylinder Head/Valves 1 8-1 Head .1 20-1 Cylinder Head Disassemny/Assernbly 8-5 Removal/Installation . 8-4 Drive Chain 3-1 1 Sprocket Cover Removal/Installation . Electric SJarter/Starter Clutch Engine Removal/Installation 7-1 Installation 1 7-4 Removal .. 7-2 Exhaust Pipe Removal/Installation . 2—10 Fan Motor Switch Inspection Fork Assembly . Disassembly .. Removallinstallation . a 12710 Frame/Body Panels/Exhaust System 21 Front Wheel/Suspension/steering r. 12-1 Front Brake Caliper Disassemny/Assembly . 14-6 Pad Replacement .1 14-2 Front Master Cylinder Disassembly/Assembly 14-4 Front Wheel Disassembly/Assembly 12-3 Removal/Installation 12-6 Fuel System 6-1 Fuel Tank Disassemny/Assembly . Removal/Installation Fuel Valve Disassembly/Assembly Gearshift Linkage . Gearshift Linkage, Shil! Drum Installation Removal General Information 10-6 10-4 1.1 22. Index Safety ...... 1-1 Headlight Bull: Replacement . 18-6 Relay Inspection . 18-5 Ignition System 15-1 Coil Inspection 16-6 Switch Removal/Installation 18-7 System Inspection 16—4 Timing 16-7 instruments, Headlight Unit Removal! Installation .. 13-8 Left Handlebar Disassembly/Assembly 12-2 Lights/Meters/Switches 18-1 Lower Fairing Removal/installation .. 2-4 Lubrication System 4-1 Lubrication & SeaIiPoints 1-19 System Diagram 4-2 Mainshaft Disassembly/Assembly 1 1-5 Malntenance . 3-1 Schedule 3-4 Model ldentificat n 1-3 Muffler Removal/Installation , 2-8 Newly Designed Spark Plug 20—2 Oil Cooler Removal/Installation .. 4-3 Pressure Switch Inspection . 18-3 Oil Pump Disassemny/Assembly . 4-6 Removal/Installation 4-4 Piston Disassemth/Assembly 1 1-8 Pulse Generator Inspection 16-6 Removal/Installation 16-8 Radiator Disassembly/Assembly 5-8 Removal/Installation 5-6 Rear Wheel/Suspension . t 13-1 Rear Brake Caliper DisassemblylAssembly . 14-10 Pad Replacement 14-3 Pedal Removal/installation . 1412 Rear Master Cylinder Disassembly/Assembly 14-8 Wheel, Driven Sprocket Removal/ Installat‘ 13-2 Regulator/Rectifier Inspection . 15-6 Right Crankcase Cover Removal/Installation . 9-2 Handlebar Disassembly/Assembly . 12-4 Seat Cowling Removal/Installation 2-2 Service Access Guide . 3-2 Service Information Brake System 14-1 Charging System/Alternator , 15-1 Clutch 9-1 Cooling System 5-1 Crankshaft/PiStan/Transmission t 11-1 Cylinder Head/Valves 8-1 Electric Starter/Starter Clutch 17-1 Engine Removal/Installation M 7-1 Frame/Body Panels/Exhaust System 2—1 Front Wheel}Suspension/steering 12-1 Fuel System 6-1 Gearshift Linkage 10-1 ignition System 16-1 Lights/MetersISwitohes 18-1 Lubrication System 4-1 Maintenance 3-1 Rear Wheel/Suspension 13-1 22-1 Index Shin Fork Installafion Shim Direct Push Mechanism With Rocker Arm Shock Absorber Disassemhiy/Assembly Absorber, Linkage Hemoval/lns‘allauon Linkage DisassemblylAssembly ,. Side Fairing fiemQVal/lnstallalion 2-3 7 Stand. 3-12 Spark Plug , 3-5 7 Specificafions 1-4 Starter Clumh Disassemny/Assemblv 17-6 Clutch, Primary Drive Gear Removal/Installation ...... 17-4 Starter Motor Disassembly/Assembly . 1743 Removal/Installation . S‘sering Stern Installation .. Removal Sub-frame Removal/Installation Swingarm Disassemny/Assembly . Removal/installation . System Flow Panem Location .. 152, 1&2, 17-2, 18-2 7 Technical'Feature . 20-1 Thermostat Removal/Installation 5—4 Tools », 1-17 7 Torque Values 11 4 Troubleslfcoling , Brake Sysxem 14-1 Charging System/Alternator 15-3 Clutch .i 9-1 Cooling System 5-1 Crankshaft/Piston! ransmissian 11-1 : Cyllnder Head/Valves 8-1 Electric Starter/Starter Clutch 17-3 From Wheel/Suspension/sleenng . 124 Fuel System ................ 6-2 Gearshifi Linkage 10-1 Ignition System i. 15-3 Lubrication System ReaLWheeleuspension . Turn Signal Light Bulb Replacement . Uppei Fairing Removal/Installation Valve Clearance .. Water Pump Disassembly/Assemblv ‘ Windshield Remuval/Installatiun . 22-2 (238) mi rum". .Lmim.‘.m.... w 3 4 I 2 “n 1.1. i 3