VTBODC,CD Shadow® VLX IMPORTANT SAFETY NOTICE Indicates a strung puxsibimy a/ mere perxunul injury or death ifinslmctiuns m rm! [Ulla wed. cnunou: [ridicules a possibility of eqiupmenl damage ifinxlrucliari: are no! followed. NOTE: 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 or could 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 by 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 thorough/y that neither personal safety nor vehicle safety will be ieopardixed by the service methods or tools selected. HOW TO USE THIS MANUAL Follow the Maintenance Schedule (Section 3) recommendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the US. Environmental Protection Agency and Califor- nia Air Resources Board. Performing the first scheduled maintenance is very important. It compensates for the initial wear that occurs during the break-in period. Sections 1 through 3 apply to the whole motorcycle, while sections 4 through 19 describe parts of the motorcycle, grouped ac- cording to location. Find the section you want on this page, then turn to the table of contents on the first page of that section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section, The subse— quent pages give detailed procedures. If you don’t know the source of the trouble, go to section 20. TROUBLESHOOTING. ALL INFORMATION, ILLUSTRATIONS. DI- RECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR C0., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI- GATION WHATEVER. N0 PART OF THIS PUBLI— CATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE CONTENTS GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM COOLING SYSTEM - I I I I ENGINE REMOVAL/INSTALLATION '5 E CLUTCH/GEARSHIFT LINKAGE n % ALTERNATOR/STARTER CLUTCH a CYLINDER HEAD/VALVE E CYLINDER/PISTON m CRANKSHAFT/TRANSMISSION w FRONT WHEEL/SUSPENSION/STEERING g REAR WHEEL/BRAKEISUSPENSION 8 HYDRAULIC DISC BRAKE m BATTERY/CHARGING SYSTEM E 2' IGNITION SYSTEM E ELECTRIC STARTER a LlGHTS/METER/SWITCHES WIRING DIAGRAM TROUBLESHOOTING m INDEX Date of Issue: June, 1994 © HONDA MOTOR (30., LTD. 1. GENERAL INFORMATION GENERAL SAFETV 1-1 SERVICE RULES 1-1 MODEL IDENTIFICATION 1-2 SPECIFICATIONS 1-3 TORQUE VALUES 1»5 TOOLS 1-8 CABLE & HARNESS ROUTING 1-10 EMISSION CONTROL SVSTEMS 1 >21 EMISSION CONTROL INFORMATION LABELS 1-22 GENERAL SAFETY If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed area. The exhaust contains posisonous carbon monoxide gas that may cause loss of consciousness and lead to death. AWAHNINI; The battery generates hydrogen gas which can be high] y explo- sive. Do not smoke or allow flames or sparks near the battery, especially while charging it. w w Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA -approved vacuum cleaner or alternate method approved by OSHA designed to minimize the hazard caused by airborne asbestos fibers. SERVICE RULES A mwt . Gasoline is extremely flammable and is explosive under certain conditions Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the work area or where gasoline is stored. AWARMNG The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. In case of contact, flush thoroughly with water and call a doctor if electrolyte gets in your eyes. CAUTION: Used engine oil may cause skin cancer ifrepeatedly left in con» tact with the skin for pro/onged periods. Although this is unlikely unless you hand/e used oil on a daily basis, it is still adviseable to thorough/y wash your hands with soap and water as soon as possible after handling used OH. 1. Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Farts that don't meet HONDA's design specifications may damage to the vehicle. ton tenets. . Use the special tools designed for this product to avoid damage and incorrect assembly. . Use only metric tools when servicing the vehicle. Metric bolts, nuts, and screws are not interchangeable with English fas- 4. Install new gaskets, O-rings. cotter pins. and lock plates when reassembling. 5. When tightening bolts or nuts, begin with the larger-diameter or inner bolts first. Then tighten to the specified torque diag- onally in 1-5 steps, unless a particular sequence is specified. 6. Clean parts '71 non-flammable or high flash point solvent upon disassembly. 7. Lubricate any sliding surfaces before reassembly. B. After reassembly, check all parts forproper installation and operation. 1-1 GENERAL INFORMATION MODEL IDENTIFICATION // // Q I‘I) VEHICLE IDENTIFICATION NUMBER The vehicle idemifica‘ion number (VIN) is attached on the left side of ‘he steering head. The frame serial numberis s‘amped onthe right side ohhe The engine serial number is stamped on ‘he righ‘ crank- steering head. case below the rear cylinder. I5) COLOR LABEL (4) CARBURETOR lDENTlFléATION NUMBER The carbure‘or identifica‘ion numbers are on ‘he carbure- The color label is anached on ‘he frame undenhe seat. (or body imake side. When ordering a color coded pan, always specify i‘s desig- na‘ed color code. 1-2 GENERAL INFORMATION SPECIFICATIONS ITEM SPECIFICATIONS DIMENSIONS Overall length 2,310mml90.9 in) Overall width '88,’89"91-'94: 760mm(29.9 in) Aiter'94: 890mm(35V0 in) Overall height 1,125mml44.3 in) Wheelbase 1‘605mml63.2 in) Seat height 590mm(27.2 in) Footpeg height 285mml11v2 in) Ground clearance 140mml5v5 in) Dry weight '88.'89.'91—93: 196kg(432 lb) '94: 199kg(439 lb) After'94(Standard type): 199kg(439 lb) After'94 (Delux type): 202kg (445 lb) Curb weight '88"89,'91—93: 207kg (455 lb) '94: 213kgl470 lb) After'94 (Standard type): 213kg(470 lb) After'94(Deluxe type): 216kg(476 lb) After'94 (Standard/California type): 214kg(472 lb) After'94 (Deluxe/California type): 217kgl478 lb) FRAME Type Double cradle Front suspension,travel Telescopic iork,146.5mm(5,77 in) Rear suspension,trave| Swingarm,90mm(3 5 in) Front tire size 100/90—19 578 Rear tire sile 170/80—15 M/C 778 Cold me Up to maximum Front 200 kPaIZ 00 kg/cm2,29 psi) pressure vehicle capacity Rear 250 kPaIZVSO kg/cm2,36 psi) up w 90 kg Front 200 kPaI2.00 kg/cm2,29 psi) (200 'bSIIOad Rear 200 kPaI2,00 kg/cm1,29 psi) Front brake Hydraulic single disc Swept area ’88,’89"91-'93: 448cm1(59.4 sq in) Aher'93: 482.3cm2(74.8 sq in) Rear brake Mechanical leading 54 trailing Swept area 201cm2(31v2 sq in) Fuel capacity '88"89"91—'93: 9,0 liters(2,4 US gal,2.0 Imp gal) Aiter'93: 11.0 liters(2 9 US gal,2 4 Imp gal) Fuel reserve capacity '88,’89"91-'93: 1V9 litersIOVS US gal,0v42 Imp gal) After'93 3.4 liters(0.9 US gal,0v74 Imp gal) Caster angle 35° Trail 164mm(5. 5 in) Fork leg oil capacity '88"89: 453cc(15.7 US oz,13.0 Imp oz) '91—'9 : 468cc(15_8 US oz,13_2|mp ox) After'93: 449cc(16_9 US oz,15_8 Imp oz) ENGINE Type Water cooled 4—stroke SOHC Cylinder arrangement Bore and stroke Displacement Compression ratio Valve train Oil capacity Lubrication system Air filtration Cylinder compression 52° V2 cylinders 75.0X66 0mml2.95><2,60 in) 583cc(35,5 cu—in) 9,2:1 Silent,multi-|ink chain drive and OHC with rocker arms 2,8 lit(2.94 US qt,2v46 Imp qt)after disassemny 2,1 lit(2,21 US qt,1,85 Imp qt)after draining Forced pressure and wet sump Paper filter 1‘324 kPa(13.5kg/cm2‘192 psi) GENERAL INFORMATION ITEM SPECIFICATIONS Intake valve Opens 10' (ETDC) at 1 mm lift Closes 30' (ABDC) Exhaust valve Opens 30' (BBDC) ENGINE Closes 10’ (ATDC) Valve clearance(cold) intake 0‘15:0V02mm(0.006:0,0008 in) exhaust 0.20:0V02mm(0.008:0.0008 in) Engine dry weight '88.’89"91-’93: 51kg(134 lb) Alter'93: 62kg(135.7 lb) After'94(standard type): 61kg(134 lo) After'94(Deluxe type): 64kg(‘|41 |b) CARBURETOR Type Piston valve,dual carburetor I.D.number See page 471 Main jet FRONTMI 15 REAFHII 15 Pilot screw opening See page 4715 Float level 7.0 mml0.28 in) Idle speed 1,200t100 rpm DRIVE TRAIN Clutch Wet,multi—plate Transmission 4—speed constant mesh Primary reduction 1.888(68/35) Final reduction 2.7 50(44/1 5) Gear ratio I 2.571(35/14) Gear ratio || 1.700(34/20) Gear ratio I|I 1.227(27/22) Gear ratio IV 0.931(27/29) Gear shift pattern Left loot operated return svstem,1—N-2-3-4 ELECTRICAL Ignition Battery ignitioanuIl transistor) Ignition timing Initial ’88,'89,'91J93: 6.2” BTDC at idle After '93: 6,5' BTDC at idle Full advance 30‘ BTDC at 6,000 rpm Alternator (MSW/5,000 rpm Battery capacity 12V 8AH 593'“ P'UQ NGK NIFPONDENSO Standard DPRBEArQ X24EPR-U9 For cold climate (Below 5. C141. F) DPR7EA-9 X22EPR-U9 Ezi'nzx‘eme" "'9“ 59”“ DPRQEA-Q X27EPR7U9 Spark plug gap Fuse Main Sub Starting system Headlight Turn signal light Front Rear Brake £4 taillight Meter light Indicator light Neutral High beam Turn signal Licence light Firing order 0.8-0.9 mm(0.031—0.035 in) 30 A 10 AX3,15 AX1 Electrical starter 12 V 60/55 W 12 V 32/3 CF(23/8 WIXZ SAE No.1034 12 V 32 CPI23 WIXZ SAE No.1073 12 V 32/3 CF(23/8 W)X2 SAE No.1034 12 V 3.4 W 12 V 1.7 W 12 V 1.7 W 12 V 1.7 W 12 V 4 CP Frontl2)-Rear(1)308‘ 1-4 GENERAL INFORMATION TORQUE VALUES ENGINE , Thread dia. Torque ITEM Oty (mm) m (kgqurfmb) Remark Cylinder head cover bolt 4 6 10(1.0‘7.2) Special bolt Camshaft holder bolt 6 8 23(2.3,17) nut 2 8 23(2_3.17) bolt 4 5 10(1,0.7.2) Cylinder head nut 8 1O 48(4,8,35) bolt 2 B 23(2,3,17) nut 4 B 23(2,3.17) bolt 2 6 10(1,0.7.2) Camshaft sprocket bolt 4 7 23(2,3,17) Apply locking agent Primary drive gear bolt 1 12 90(9,0,65) UBS bolt Flywheel bolt 1 12 130(13,0,94) UBS bolt left hand threads Connecting rod bearing cap nut 4 8 34 (3,4,25) Apply oil to the threads Clutch lock nut 1 18 130(13,0,94) Oil pressure switch 1 - 12(1.2‘9) Apply sealant Spark plug 4 12 14(1,5,10) Oil drain bolt 1 14 35(3.5,25) Starter clutch torx bolt 6 8 30(3.0.22) Apply locking agent 0“ pump driven Sprocket 1 6 15(1.5‘11) flange socket bolt.App|y lockr Ing agent, Oil pass pipe bolt 2 7 10(1.0,7.2) 1 8 23 (2.3‘ 1 7) Valve adjusting screw lock nut 6 7 23 (2.3‘ 1 7) Apply oil Gearshift return spring pin 1 8 26(2_6‘19) Starter motor cable nut 1 6 10(1_0‘7.2) Clutch lifter plate bolt 4 6 10(1_0‘7,2) Flange bolt Cam chain tensioner bolt 4 6 10(1.0‘7.2) Flange bolt Oil filter 1 20 100.012) Drive sprocket bolt 2 6 10(1_0‘7_2) Timing hole cap 1 22 3.5(0.35‘2.5) Apply grease to the threads Crankshaft hole cap 1 30 15(1 _5‘ 1 1) Apply grease to the threads Cylinder stud bolt ’88,’89,'91—'95: 8 10 30—50(3.0-5.0, 22—36) 2 8 20-30(2.0—3.0. 14-22) Drum stopper plate bolt 1 — 12(1 .23) Apply locking agent_ Stator bolt 4 6 12(1.2‘9) Apply locking agent_ Stator wire clamp bolt 2 6 12(1_2‘9) Apply locking agent. Right crankcase cover bolt 13 6 12(1.2‘9) Left crankcase cover bolt 10 6 12(1_2‘9) 1-5 GENERAL INFORMATION FRAME , Thread dia. Torque “EM 0 w (mm) N‘m(Kg—m,ft—lb) Remark Steering stem nut 1 24 105(10.5,75) Steering bearing adjustment nut 1 26 25l2.5,18) See page 12-23 Fork top pinch bolt 2 7 11(1.1,8) Fork bottom pinch bolt 2 10 506.036) Apply oil to the threads Front axle 1 18 7505,54) Front axle pinch bolt 2 7 22l2.2,16) Rear axle nut 1 16 90l9.0,65) Brake torque rod nut 8 27l2.7,20) '88,'89,'91—'93, AftEr '94: 2 8 22(2.2,16) '94: 2 8 27l2.7,20) Middle brake arm 1 8 27l2.7,20) Middle rod Joint nut After '94: 2 6 9(0.9,6.5) Caliper mounting bolt '88,'89, 1-'93: 2 8 27(2.7,20) After 93: 2 8 31(3.1,22) Brake hose oil bolt '88,’89,'91—'93: 2 1O 30(3.0,22) After '93: 2 1O 35(3.5,25) Bleed valve 1 B 5.5(0.55,4) Brake master cylinder holder bolt 2 6 12(1.2,9) Brake master cylinder cover screw 2 4 1.5l0.15,1.1) Brake lever pivot bolt 1 6 1(0.1,0.7) nut 1 6 6(0.5,43) Brake disc mounting bolt 5 8 40(4.0,29) Apply locking agent Caliper pin bolt 1 8 22(2.2,16) Apply locking agent Caliper bracket pin bolt 1 8 12l1.2,9) Apply locking agent Pad pin 1 10 18(1.B,13) Pad pin plug 1 10 2.5l0.25,1.8) Shock absorber upper mounting bolt 1 10 45l4,5,33) Socket bolt Shock absorber lower mounting bolt 1 10 45l4.5,33) Gearshift arm bolt 1 6 12(1.2,9) Foot peg bracket bolt 4 10 40(4.0,29) Swingarm pivot bolt 1 14 90(9.0,65) Front upper engine mounting bolt 1 10 55(5.5,40) Front upper engine bracket bolt 2 8 27(2.7,20) Front lower engine mounting bolt 1 1O 55(5.5,40) Rear upper engine mounting bolt 1 1O 55(5.5,40) Rear upper engine bracket bolt 2 8 27(2.7,20) Exhaust pipe Joint nut 4 8 25(2.5,18) Flange nut Fuel tank mounting bolt 1 8 19(1.9,13.7) Flange bolt Ignition switch mounting bolt 2 6 11(1.1,8) Shear bolt Exhaust pipe cover bolt 3 6 12(1.2,9) Exhaust muffler bracket bolt/nut 'ss/agggp'ga; 1/1 8 27(2.7,20) After '93 1/4 8 20(2.0,14) Helmet holder mounting bolt 2 6 13l1.3,9) Shear bolt Side stand pivot bolt 1 10 10l1.0,7.2) Socket bolt nut 1 10 30l3.0,22) Driven sprocket nut 5 10 55l5.5,47) Fork tube cap 2 34 22(2.2,16) Front socket bolt 2 10 30(3.0,22) Apply locking agent Damper rod lock nut '88,’89,’91,’92: 1 14 70(7.0,51) Spokes 108 4 4(0.4,2.9) Handlebar mounting nut 2 8 25(2.5,18) Handlebar upper holder bolt After '94: 2 a 30(3.o,22‘) Handlebar lower holder nut After '94: 2 B 23(2.3,16) Fuel valve body 1 22 23l2.3,15) Throttle link cover stay screw 2 4 2.1(0.21,1.5) Rear ignition coil stay bolt 2 6 9(0.9,6.5) Battery cover mounting bolt 2 6 9(0.9,6.5) Fuel pump stay mounting nut 1 6 9(0.9,6.5) 1-6 GENERAL INFORMATION Torque specifications listed above are for specific tightening points If a specification is not listed, follow the standard torque values below‘ STANDARD TORQUE VALUES TYPE TORQUE N-m (kg-m, ft-lb] TVFE TORQUE N-m (kg-m, ft-lb] 5 mm bolt, nut 5 (050, 3.6] 5 mm screw 4 (040, 2,9) 6 mm bolt, nut 10 (1.0, 7,2) 6 mm screw, 6 mm 8 mm bolt, nut 22 (2.2, 16) bolt with 8 mm head 9 (0.9, 65) 10 mm bolt, nut 35 (3‘5, 25) 6 mm flange bolt, nut 12 (1.2, 9) 12 mm bolt, nut 55 (5.5, 40) 8 mm flange bolt, nut 27 (2.7, 20) 10 mm flange bolt, nut 40 (4‘0, 29) GENERAL INFORMATION TOOLS SPECIAL Description Tool number Alternate tool Tool number “mi ‘° section on pressure gauge 07505—3000000 Equivalent 2 Oil pressure gauge attachment 07510—4220100 commercially 2 Oil filter wrench 07HAA—PJ70100 available 2 in U.S.A. Vacuum gauge 07404—0030000 Vacuum gauge 07LMJ—001000A 3 Valve adjusting wrench 07908—KE90000 Not available 07908—KE90100 in USA. 4 Vacuum/Pressure pump A937X—041—XXXXX —[Vacuum pump s'r_AH_2eo_Mc7 4 Snap ring pliers Pressure pump ST_AH_255_M07 Z, 13, 07914—3230001 Equivalent 14 commercially available Steering stem socket 07916—3710100 '" U‘S'A‘ 12 Clutch center holder 07923—KE10000 07HGB—001000A 7 Bottom holder pipe 07930—KA50000 Not available 12 —holder attachment 07930—KA50100 in USA. —holder handle 07930—KA40200 Bearing remover set 07936—3710001 11 —remover handle 07936—3710100 —bearing remover set 07936—3710600 —remover weight 07741—0010201 Remover weight 07936—3710200 Valve guide driver attachment llNl 07943—MF50100 9 Valve guide driver attachment (EX) 07943—MF50200 9 Bearing race remover 07945—3710500 12 Steering stem driver 07946—M300000 12 Driver shaft 07945—MJ00100 13 Fork seal driver, 39 mm 07947—4630100 12 Ball race remover 07953—MJ10000 Attachment 07953—MJ1000Ar 12 —driver attachment 07953—MJ10100 Driver 07953—MJ1000E5 0' —driver handle 07953—MJ10200 Driver handle 07949—3710001 and Attachment, 32x35mm 07745—0010100 Main bearing driver attachment 07HMF—MM90400 11 Valve guide reamer, 5.510 mm (IN) 07984—2000001 9 Valve guide reamer, 6.612 mm 07984—2000000 (EX) 07984—ZE20001 07984—ZE2000D 9 Attachment, 28 x 30 mm 07745—1870100 'Drive chain cutter 07HMH—MH10103 Not available 07HMH—MR101OB 'Shock absorber compressor at- 07JME—MH10100 in USA. 13 tachment ‘: New for this model. 1-8 GENERAL INFORMATION COMMON Description Tool number Alternate tool Tool number He'er to section Float level gauge 07401 —0010000 4 Lock nut wrench, 17 x 27 mm 07715—002030!) Equivalent 7 Gear holder 07724—0010100 commercially 7 Flywheel holder 07725—004000!) available 8 Torx bit 07703—0010100 in U.S.A B Rotor puller 07733—0020001 0793373290001 3 Valve guide remover, 5.5 mm 07742—0010100 9 Valve guide remover, 616 mm 07742—0010200 7 Not available 0794276570100 9 in U.S.A. Attachment, 32 x 35 mm 07746—0010100 13 Attachment, 42 x 47 mm 07746—0010300 11. 12, 13 Attachment, 52 x 55 mm 07746—0010400 11, 12 Pilot, 15 mm 07746—0040300 13 Pilot, 17 mm 07746—0040400 13 Pilot, 20 mm 07746—0040500 11, 12 Pilot, 22 mm 07746—0041000 11. 13 Pilot, 25 mm 07746—0040600 11 Bearing remover head, 17 mm 07746—0050500 Equwalent 13 Bearing remover shaft 07746—0050100 Ecommercially 13 Bearing remover head, 20 mm 07746—0050600 available 12 in U.S.A. Driver 07749—0010000 11. 12, 13 Valve spring compressor 07757—0010000 Valve spring 07957—3290001 9 compressor Shock absorber compressor 07GME—0010000 —compressor screw 07GME—0010100 13 Spoke wrench 07JMA—MR60100 H Not available in U,S.A. VALVE SEAT CUTTERS (NOT AVAILABLE IN U.S.A.1 Description Tool number Remarks Valve seat cutter, 275 mm 07780—0010200 45° IN Valve seat cutter, 35 mm 07780—0010400 45° EX Valve seat cutter, 28 mm 07780—0012100 32° |N Valve seat cutter, 35 mm 07780—0012300 32° EX Valve seat cutter, 30 mm 07780—0014000 60° IN Valve seat cutter, 37.5 mm 0778070014100 60° EX Cutter holder, 55 mm 07781—0010101 Valve guide IN Cutter holder, 6.6 mm 07781—0010201 Valve guide EX GENERAL INFORMATION CABLE & HARNESS ROUTING Note the following when routing cables and wire harnesses: o A loose wire, harness or cable can be a safety hazard. After clamping, check each wire to be sure it is secure. 0 Do not squeeze wires against welds or clamps. 0 Secure wires and wire harnesses to the frame with their re- spective wire bands at the designated locations. Tighten the bands so that only the insulated surfaces contact the wires or wire harnesses. 0 Route harnesses so they are neither pulled taut nor have ex- cessive slack. 0 Protect wires and harnesses with electrical tape or a tube if they contact a sharp edge or corner, Clean the attaching surface thoroughly before applying tape. 0 Do not use a wire or harness with broken insulation. Repair by wrapping them with protective tape or replace them. 0 Route wire harnesses to avoid sharp edges or corners. Also avoid the projected ends of bolts and screws. 0 Keep wire harnesses away from the exhaust pipes and other hot parts. 0 Be sure grommets are seated '71 their grooves properly. 0 After clamping, check each harness to be certain that it does not interfere with any moving or sliding parts. 0 After routing. check that the wire harnesses are not twisted or kinked. 0 Wire harnesses routed along the handlebars should not be pulled taut. have excessive slack. be pinched by or interfere with adjacent or surrounding parts in all steering positions. 0 Do not bend or twist the control cables, Damaged control cables will not operate smoothly and may stick or bind, >< fi §A® O: CORRECT x : INCORRECT 1-10 GENERAL INFORMATION '88-'89 ; ’91 : (1) THHO'I'rLE CABLES (2) CLUTCH CABLE [3] LEFT HANDLEBAR SWITCH WIRE (4) SPEEDOMETER CABLE (9) FRONT BRAKE HOSE N (a) RIGHT HANDLEBAR co NECTOR SWITCH WIRE (6) HORN (7) HORN WIRE ’92—'93: (2) CLUTCH CABLE (1) THROTTLE CABLES (3) LEFT HANDLEBAR /\ SWITCH WIRE (4) SFEEDOMETER @l; r CABLE \ , (9) FRONT BRAKE HOSE / ” (5) HEADLIGHT CONNECTOR (a) RIGHT HANDLEBAR SWITCH WIRE (7) HORN WIRE < —]—(5) HORN 1-11 GENERAL INFORMATION '94: (1) THROTTLE CABLES (2) CLUTCH CABLE (3) LEFT HANDLEBAR SWITCH WIRE (4) SPEEDOMETER / CABLE (5) HEADLIGHT / CONNECTOR I9) FRONT BRAKE HOSE (a) RIGHT HANDLEBAR SWITCH WIRE \ 16) HORN (7) HORN WIRE I Aflu ’94: III THROTTLE CABLES ‘ (Z) CLUTCH CABLE I3] LEFT HANDLEBAR SWITCH WIRE 1/39}. {'0} _I4) SPEEDOMETER CABLE CABLES (9) RIGHT HANDLEBAR [2] CLUTCH CABLE SWITCH WIRE \(5) FRONT BRAKE HOSE I9) RIGHT HANDLEEAR SWITCH WIRE [SI HORN WIRE (6] HEADLiGHT CONNECTOR (7) HORN 1-12 GENERAL INFORMATION '33—'39, '91; (2) HANOLEBAR SWITCH WIRE BANOS (13) CRANKCASE BREATHER ‘ TUBE (12) WATER HOSE ‘_ 7 l1 ENGINE BREATHER '— -~ ‘ )TUBE (1) EVAPORATIVE < EMISSION _ PURGE CONTROL ‘ C7 “ E , VAL_VE (California -3m I]. 3‘ y, » ‘ mdlonlv I I O R“ a} ‘ ‘ ,, v! (10) STARTER 3% alak’ifii? 1’ 13) CRANKCASE r BREATHER ' ' SEPARATOR MOTOR 554‘ VI—'-\ x; Elwyxk },J,\ ‘l “3" (9) STARTER - MOTOR « CABLE , / I 7x/ w (4) (8) GROUND/\2r/ A SUBAIR CABLE \ I CLEANER (5) AIR CLEANER (6) IGNITION PULSE HOUS'NG GENERATOR I7) CLUTCH CABLE WIRE 92:93: (1) HANDLEBAR SWITCH WIRE BANDS 113) CRANKCASE BREATHER TUBE ‘. ., «‘1! (2) CRANKCASE I11) ENGINE BREATHER p—S BREATHER \ 4?€§% \E. JE— c a. k‘ 6“ 1‘ W 9‘"’>“‘ ‘ I.) r (IO) STARTER Wk“ ‘ . MOTOR :51)» 7‘5 , - I3) L" A g J' g‘. EVAPORATIVE (in: y EMISSION ‘. I .' PURGE CONTROL A- (9) STARTER Q I MOTOR a” VALVE (California CABLE 1;] 1E model only) / x S V I. ‘1 (4) SUB-AIR (I f CLEANER 1" A / { ,8 IB) GROUND / / I CABLE (5) AIR CLEANER I6) IGNITION PULSE HOUSING (7) CLUTCH CABLE GENERATOR WIRE 1-13 GENERAL INFORMATION ’54: (13) CRANKCASE BREATHER (1) HANDLEBAR SWITCH TUBE WIRE BANDS (11) ENGINE BREATHER TUBE I12) WATER HOSE I2) CRANKCASE 7'" BREATHER (w) sTARTER (k1 MOTOR ' I” q SEPARATOR (o ’ E“ ~/ (3) I 1 l7 ' (9) STARTER 9 I Emgggfinw -’ ' MOTOR ’ff) 5". PURGE CONTROL CABLE 44 \ VALVE (California model only) ‘ a (4) SUB»AIR CLEANER Is) GROUND CABLE (6) IGNITION PULSE ‘5) fig‘UCSIFE‘ENER I7) CLUTCH CABLE GENERATOR WIRE “‘9' '9‘ (13) CRANKCASE I1) HANDLEBAR SWITCH BREATHER TUBE WIRE BANDS (11) ENGINE BREATHER (2) CRANKCASE TUBE BREATHER SEPARATOR I1) HANDLEBAR ' 7 /‘~ f SWITCH WIRE I \ , ‘ BANDS I10) STARTER U at [V MOTOR manm‘a“\‘ ‘ ‘_ . l)..- .\ ‘1‘ F’i’Rw “N v- Im‘wz- I3) EVAPORATIVE ;/flflw’ (3.6.x \‘_A)‘r EMISSION ’ V A ‘ PUFIGE CONTROL [9) STARTER VALVE(CaIifomia MOTOR model only) CABLE I4] SUB-AIR (8) EXgIE'END CLEANER I7) CLUTCH CABLE L__ (6) IGNITION PULSE I5) AIR CLEANER GENERATOR WIRE HOUSING 1-14 GENERAL INFORMATION (1 ) THROTTLE CABLES (2) FRONT IGNITION COIL (3) FUEL TANK BREATHER TUBE (California model only) (4) FUEL TUBE INLET LINE (5) ALTERNATOR WIRE (6) NEUTRAL SWITCH WIRE (7) RIGHT CHOKE CABLE (10) SPEEDOMETER (9) Am CLEANER HOUSING (e) THERMOSTATIC SWITCH CABLE HOLDER BREATHER TUBE ’88—'89,'91-'93: (11) IGNITION PULSE GENERATOR 4P WHITE CONNECTOR (12) HORN/FAN MOTOR 2P BLACK CONNECTOR (17) FRONT BRAKE HOSE (I8) CLAMP TURN SIGNAL 9P WHITE CONNECTOR (14) INDICATOR PANEL 6P GREEN CONNECTOR (15) SPEEDOMETER 6? BLACK CONNECTOR I16) RIGHT HANDLEBAR SWITCH _/ 9F RED CONNECTOR 1-15 GENERAL INFORMATION '94: (2) FRONT BRAKE HOSE (1) CLAMP (3) IGNITION PULSE GENERATOR 4F WHITE CONNECTOR (4) HORN/FAN MOTOR 2P BLACK CONNECTOR " I“ EJ§** hi \I ‘ fiN) ' Is, ‘ I Ix (5) TURN SIGNAL 9F WHITE CONNECTOR (6) INDICATOR PANEL 6P GREEN CONNECTOR (7) SPEEDOMETER 6P BLACK CONNECTOR (3) RIGHT HANDLEBAR SWITCH 9P RED CONNECTOR Aher '94: (9) CRANKCASE BREATHER DRAIN TUBE (10) MAIN WIRE HARNESS (11) FAN MOTOR WIRE (12) EVAPORATIVE EMISSION PURGE CONTROL VALVE (California model only) 1-16 GENERAL INFORMATION m TURN S'GNALSELF‘L‘JIL (a) REAR IGNITION COIL (11) FUEL PUMP FILTER (9) COOLANT RESERVE (25) REAR SUSPENSION (7, SUEFUS‘ES’BgQTTERY TANK OVERFLOW TUBE DRA'N TUBE [8) REAR BRAKE LIGHT SWITCH I10) BRAKE/ TAILLIGHT, (23) SIDE STAND (1) TURN SIGNAL RELAY FUEL PUMP, REAR RIGHT / 2F GREEN CONNECTOR TURN SIGNAL CONNECTORS __ v (11) FUEL \(24) IGNITION SWITCH 4" PUMP - x I “I? \ ‘ “ ‘4‘ . l‘ fl 1‘ I w :3 /(12) :IélfkaT ‘ C N .1 /é% 7% , j,“ ‘ “3’ $323 LsEIELAL, — ‘ /"~: I‘ ‘ LICENCE LIGHT CONNECTORS (22) NEUTRAL 14) IGNITION COTROL MODULE SWITCH 15) REGULATOR/RECTIFIER VTIS 4? BLACK CONNECTOR 5?— J \ . / > ‘ I16) NEUTRAL SWITCH 2P BLACK CONNECTOR ’ I/ \ L ‘ at l ' I7)«REGULAT0R/ RECTIFIER . I (15) ALTERNATOR 3P WHITE CONNECTOR ‘__ (19) IGNITION SWITCH 4PKWSITE CONNECTOR 20) OIL PRESSURE SWITCH (21] SIDE STAND SWITCH 1-17 GENERAL INFORMATION (9) GROUND [1) STATOR COIL [2) CLAMPS POINT (4) LEFT CRANKCASE COVER (3) GROMMETS (B) CLAMPS (7) THERMOSTATIC SWITCH WIRE (5) IGNITION PULSE [1' I6) RIGHT GENERATOR CRANKCASE (11) BRAKE/TAILLIGHT (10) TAILLIGHT WIRE (12) TURN SIGNAL LIGHT WIRE (13) LICENCE LIGHT WIRE 1-18 GENERAL INFORMATION (1] ALTERNATOR WIRE After '93: (2) NEUTRAL SWITCH 13) OIL PRESSURE SWITCH (4) SIDE STAND SWITCH 1-19 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) NOTE - The hoses shown below are numbered as they appear on The Vacuum Hose Routing Diagram Label. (1) @TUBE (1) @TUBE (7) EVAPORATIVE EMISSION PURGE CONTROL VALVE (5) @TUBE (2) ©TuaE (7) EVAPORATIVE EMISSION PURGE CONTROL VALVE 3-»T0 AIR CLEANER HOUSING (1) TUBE (2) ©TUBE (15) ENGINE BREATHER TUBE (FROM REAR (4) IBTUBE CYLINDER 0 HEAD] (6) EVAPORATIVE EMISSION CARBURETOR ‘3‘ TUBE AIR VENT CONTROL VALVE [5) @TUBE CARBURETOR AIR VENT 15 To AIR 0 EA ING CONTROL I I L NER Hous VALVE (I4) COOLANT RESERVE TANK DRAIN TUBE [10) T0 EVAPORATIVE EMISSION CANISTER [9) AIR CHAMBER DUCT (12) EVAPORATIVE EMISSION 8:951“ (11) EVAPORATIVE EMISSION CANISTER AIR TUBE (13) REAR SHOCK ABSORBER TUBE 1 -20 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The US. Environmental Protection Agency and California Air Resources Board [CARE] require manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their uselul Iile, when operated and maintained according to the instructions provided, and that motorcycles built after January 1, 1983 comply with applicable noise emis- sion standards for one year or 6,000 km (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control System is necessary in order to keep the emissions system warranty in ellect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. Control of hydrocarbons is very important because, under certain conditions, they react to lorm photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro- carbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission control system. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the combustion chamber. (1) CRANKCASE EHEATHER (2] AIR CLEANER HOUSING SEPARATOR =9 FRESH AIR -> BLOW-BY GAS 1-21 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) This model complies with California Air Resources Board evaporative emission requirements. Fuel vapor from the fuel tank and carburetor is directed into the evaporative emission canister where it is adsorbed and stored while the engine is stopped.When the engine is running and the evaporative emission purge control diaphragm valve is open, fuel vapor in the evaporative emission canister is drawn into the engine through the carburetor. f (3) DRAIN I4) EVAPORATIVE EMISSION CANISTER (SIEVAPOHATIVE EMISSION CARBUHETOR AIR VENT CONTROLVALVE r J [7] T6 OPEN _' ‘ (6] EVAPORATIVE EMISSION AIR CARBUHETOR AIR VENT CONTROL VALVE (ENGINE STOP] NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person, other than for purposes of maintenance, repair, or replace— ment, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. 2. Removal of, or puncturing of any part of the intake system. 3. Lack of proper maintenance. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the inside of the left side cover as shown. It contains basic tune-up speci- fications. % J (I) VEHICLE EMISSION CONTROL INFORMATION LABEL 1-22 GENERAL INFORMATION VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) The Vacuum Hose Routing Diagram iabel is on the inside of ‘he left side covet Route the vacuum hoses as shown on this labei. VAClIlII IlflSE RUIITIIIG DIASRAM ENGINE FAMILY- |:I EVAMATIVE FAIIlV- :l BALIFIIIIIIIA VEHICLE FUEL TANK stP CAV CONTROL VALVE ('10 on» All? EvAP PUIGE CDNYROL VALVE 1-23 LUBRICATION '88, '89: (1) ROCKER ARM (13) CAMSHAFT (2] OIL PIPE (12) PISTON (11)O|L JET (10) CRANK SHAFT 3) MAINSHAFT (9) COUNTER- SHAFT (8) OIL PRESSURE SWITCH T (4) OIL PUMP 3/ l)\ ‘ r“) (5) OIL STRAINER (6] PRESSURE (7) OIL FILTER RELIEF VALVE 2-0 2. LUBRICATION After '89: [1) ROCKER ARM [12) CAMSHAFT [11) PISTON (10)0|LJET (9) CRANKSHAFT [2) MAINSHAFT (8) COUNTERSHAFT (7) OIL PRESSURE /. T ML; (6) OIL FILTER (5) PRESSURE RELIEF VALVE (3) OIL PUMP (4] OIL STRAINER LUBRICATION SERVICE INFORMATION TROUBLESHOOTING ENGINE OIL LEVEL ENGINE OIL CHANGE OIL FILTER CHANGE 2-2 OIL PRESSURE CHECK 2-5 2-3 OIL PUMP 2-6 2-4 CONTROL CABLE LUBRICATION 2-12 2-4 LUBRICATION POINTS 2-12 2-5 SERVICE INFORMATION MARNIN , - tfthe engine must be running to do 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. CAUTION - Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis. it is still advisable to thoroughly wash your hands with soap and water as soon as possi- ble after handling used oil. GENERAL 0 The oil pump can be serviced after removing the engine from the frame. SPECIFICATIONS Engine oil oil capacity 2.5 lit (2.94 US qt, 2.46 Imp Cm aftet disassemny. 2.25 iit (2.36 us qt, 1.95 imp on at oil filter and OH change. 2.1 lit (2.21 us gt, 1.85 imp an alter draining. Oil iecommendation HONDA GN4 4—stmke oil or equivalent API service classification: SF or 56 VISCOSITY: SAE 10W—40 Other viscosities shown In the chart may be used when the average temperature in voul riding area IS within the indicated range. OIL VISCOSITIES Oil pump ITEM STANDARD SERVICE LIMIT Rotor tip clearance 0.15 mm (0.006 in) 0.20 mm (0.008 inI Pump body clearance 0.15—0.22 mm I0.006—0.009 in) 0.35 mm (0.014 inI Pump end clearance 0.02—0.07 mm (0.001 —0.003 in) 0.10 mm (0.004 inI OII pressure 441 kPa (4.5 kg/cmz, 64 psi) at 6,000 rpm TORQUE VALUES OII pressure switch Engine oil drain bolt DII filter 12 N‘m (1.2 kg-m, 9 fI-lbI 35 N‘m (3.5 kg-m, 25 fl-lb) 10 N-m (1.0 kg-m, 7.2 fl-lb) 2-2 LUBRICATION TOOLS Special Oil filter wrench Oil pressure gauge Oil pressure gauge attachment Snap ring pliers TROUBLESHOOTING OII level too low Normal oil consumption External oil leaks Worn piston rings Oil contamination Oil not changed often enough Faulty head gasket Worn piston rings Low oil pressure Faulty oil pump Clogged oil strainer Low oil level Faulty pressure relief valve Oil leaks High oil pressure - Faulty pressure relief valve - Clogged oil filter or oil orifice No oil pressure Oil level too low Broken oil pump drive or driven sprockets Broken oil pump drive chain Faulty oil pump Oil leaks 07HAA—PJ70100 07506—3000000 07510—4220100 07914—3230001—or equivalent commercially available in USA Tor equivalent commercially available '71 USA LUBRICATION ENGINE OIL LEVEL Support the motorcycle in an upright and level position using a hoist or a jack under me engine. Start the engine and let it idle for a few minutes. Stop the engine, remove the oil filler cap/dipstick and wipe it clean, Check the oil level with the oil filler cap/dipstick by inserting it without screwing it in, NOTE - Do not screw the cap in when making this check. If the oil level is below the lower level mark on the dipstick, fill to the upper level mark with the recommended oil. Check the O-ring for damage. ENGINE OIL CHANGE NOTE - Change the engine oil with the engine warm and the motor- cycle on its side stand to assure complete and rapid drain- ing, « Remove the oil filler cap/dipstick and drain bolt, With the engine stop switch OFF, push the starter button for a few seconds to drain any oil which may be left in the engine. NOTE - Do not operate the motor for more than few seconds. After the oil has drained, check that the drain bolt sealing washer is in good condition, and install the bolt. TORQUE: 35 Man (3.5 kg-m. 25 tt-Ibl Fill the crankcase with the correct quantity of the recommend— ed oil. OIL CAPACITY: 2.8 lit (2.94 US qt, 2.46 Imp qt) after disassemny 2.25 lit (2.36 us at. 1.98 Imp at) at oil filter and oil change 2.1 lit [2.21 US qt, 1.85 Imp qt) alter draining RECOMMENDED OIL: Honda 6N4 4-stroke oil or equivalent API service classification: SF or 56 VISCOSITY: SAE 10W—40 Install the oil filler cap/dipstick. Start the engine and let it idle for 2 or 3 minutes. Stop the engine and wait a few minutes, then check that the oil level is at the upper level mark with the motorcycle upright. Check that there ae no oil leaks. (1) DRAIN BOLT l1) DRAIN BOLT l2) SEALING WASHER 2-4 LUBRICATION OIL FILTER CHANGE Drain the engine oil (page 274). CAUTION « Do not replace the oilfilter when the exhaust system ix hm. Remove the oil lilter with a filter wrench. TOOL: Oil filter wrench 07HAA—PJ70100 [2) OIL FILTER WREECH Apply oil to the new oil filter O—ring and install the new oil filter. ‘1 I OIL FILTER Tighten the oil filter with a filter wrenchr TORQUE: 1O N-m (1.0 kg-m, 7.2 It-lb) Fill the engine with recommended oil (page 274). OIL PRESSURE CHECK Remove the following: — drive sprocket cover (page 13—14} — drive sprocket cover bracket (2’ O_R|NG — switch cover and switch screw Disconnect the wire from the oil pressure switch, remove the jun-M n. W ._(___._—' switch and connect an oil pressure gauge to the switch hole (1) COVER BRACKET ‘ (2) IL PRESSURE SWITCH TOOLS: Oil pressure gauge 07506—07506—3000000 Attachment 07510—4220100 or equivalent commercially available in U,S.A, Check the oil leveL Start the engine and allow it to warm-up to operating tempera- ture Check the oil pressure at 6,000 rpm STANDARD OIL PRESSURE: 441 kPa [4.5 kg/cm’, 64 psi) Stop the engine. Apply sealant to the pressure switch threads and install it. TORQUE: 12 Nvm (1.2 kg-m, 8.7 tt-Ibi Connect the oil pressure switch wire and pull the dust cover over the switch body securely‘ Start the engine and checkthat the oil pressure warning light goes out alter one or two seconds NOTE PRESSURE - Floute the oil pressure switch wire properly (page 1715] ' GAUGE LUBRICATION OIL PUMP PRESSURE RELIEF VALVE REMOVAL Separate the crankcase (Section 1 1). Remove the bolt and pressure relieI valve cover. Remove the pressure relief valve Irom the oil pump. PRESSURE RELIEF VALVE DISASSEMBLY Remove the snap ring and disassemble the relieI valve. TOOL: Snap ring pliers 07914—3230001 or equivalent commercially available in U.S.A, INSPECTION Check the spring, O—ring and valve for fatigue, wear or dam- age. Check the body for clogging or damage. Replace the relieI valve as an assembly. Clean all the parts and assemble them in the reverse order of disassembly. OIL PUMP REMOVAL/DISASSEMBLY Remove the oil pump by removing two mounting bolts. Remove the dowel pins and O—rings. (II PRESSURE RELIEF VALVE COVER. I2) BOLT l3) PRESSURE RELIEF VALVE (1) SNAP RING (I) O-RING I2) BODY I3) VALVE (4) SPRING em (5) SNAP RING [II BOLTS 2-6 LUBRICATION Remove the oil strainer and oil pipe from the oil pump. Check the O—rings and oil seal for fatigue or damage‘ Ciean the oil strainer and oil pipe with non-flammable or high flash point solvent Remove the three cover baits, Disassembled parts and clean them with non—flammable or high flash point solvent. OIL PUMP INSPECTION Instail the outer and inner voters to the pump bodv‘ Measure the outer rotor—to-pump body clearance‘ SERVICE LIMIT: 0.35 mm (01314 in) (1] OIL STRAINEH (2) OIL PIPE (1] OIL SEAL I2) OIL STRAINER (3) O—RINGS (1] COVER BOLTS I2) INNER ROTOR ‘ I3) OUTER ROTOR 'L 2-7 LUBRICATION Remove the oil pump shaft from the on pump and measure the pump end cIearance. SERVICE LIMIT: 010 mm (0.004 in) Temporarily install rhe shaft in the pump body. Measure the inner rmor tip clearance‘ SERVICE LIMIT: 020 "In (0008 in) Replace the oil pump, if necessary as an assemny‘ W (2) INNER RoT R OIL PUMP ASSEMBLY 'ss,'as.'s1-93: (1) PUMP BODY (4) PRESSURE RELIEF VALVE BODY (6) SNAP RING (a) INNER ROTOR ‘5’ VALVE (7) RELIEF VALVE COVER ' S) I Iv (14) DRIVE PIN (2) OUTER ROTOR (13) PUMP SHAFT 110) O—RING (11] OIL STRAINEH LUBRICATION Aher '93: [HPUMP BODY (“PRESSURE RELIEF VALVE BODY (GISNAP RING (“VALVE (7)RELIEF VALVE COVER (2)0UTER ROTOR (14IDRIVE PIN (12)SPACER (13]PUMP SHAFT ‘I‘IJOIL STRAINER Install the outer rotor 'n the pump body with the punch mark (1) OUTER ROTOR (3) SPACER facing the cover, then install the inner rotor. (4) Install the drive pin and spacer on the shaft. (2) PUNCH MARK PUMP SHAFT Install the shaft in the body, aligning the drive pin with the inner rotor groove (6) (5) INNER ROTOR DRIVE PIN '88.'89.'51-'53: (1] OIL PUMP BODY Install the dowel pin and a new gasket on the pump body, then install the covert (4) GASKET I3) DOWEL FIN [21 OIL PUMP COVER 2-9 LABRICATION After ’93: Install the dowel pins on the pump coventhen install the pump body. Tighten the cover bolts securely. Install the O-rings, oil seal, oil strainer and oil pipe on the oil pump. CAUTION ' Install the Orrings on [he oil pipe with the tapered side facing aw as shown. ar [he engine will be damaged. After ’93: Install the oil seal on the oil pump. Align the edge of oil strainer with the groove of the pump coventhen install the oil strainer as shown. (1 IOIL PUMP BODY (2)DOWEL PINS (3)O|L PUMP COVER (1) COVER BOLTS l5) 0~RINGS I._ (HOIL SEAL (4)0IL STRAlNEH [ZIEDGE (3)6FIOOVE 2-10 LUBRICATION OIL PUMP INSTALLATION install rhe dowel pins and new O-rings. Install the oil pump as an assembly. lns‘all ‘he pressure relief valve 'n ‘he oil pump. Install me pressure relief valve cover with rhe bolt Assemble rhe crankcase (Sec‘ion 1 1). (1) O-RTBES/DBWEI; PINS ; (1) PRESSURE RELIEF VALVE (1) PRESSURE HELlEF VALVE COVER \ (2) BOLT 2-11 LUBRICATION CONTROL CABLE LUBRICATION Periodically disconnect the throttle and choke cable at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil. LUBRICATION POINTS Use general purpose grease when not otherwise specified here. Apply oil or grease to the other sliding surfaces and cables not shown here. [I] CLUTCH AND BRAKE 3% LEVER PIVOTS (2] THROTTLE GRIP .&1 (11) STEERING HEAD BEARINGS— (10) FORK (3) FOOT PEG PIVOTS I7) BRAKE PEDAL I5I SWINGARM (a) SPEEDOMETER P'VOT :‘XSLEé‘s-E DRIVE GEAR ,fii (8) BEARINGS I4) DHIVE CHAIN PRO HONDA CHAIN LUBE BRAKE a. CHANGE r—fifl I I CALIPER PIVOTS I5I SIDE STAND (SILICON GREASE) PIVOT 2-12 3. MAINTENANCE SERVICE INFORMATION 3-1 CVLINDER COMPRESSION 3-12 MA'NTENANCE SCHEDULE ‘88: 3»3 EVAPORATIVE EMISSION MAINTENANCE SCHEDULE '89,'91-'93: 3.4 CONTROL SYSTEM 3-13 MAINTENANCE SCHEDULE After 93; 3-5 DRIVE CHAIN 3.13 FUEL LINE 3_6 BRAKE FLUID 3.15 THROTTLE OPERATION 3’6 BRAKE SHOE/PAD WEAR 3-16 CARBURETOR CHOKE 3_7 BRAKE SVSTEM 3-16 AIR CLEANER 3,7 BRAKE LIGHT SWITCH 3.17 CRANKCASE BREATHER 3_3 HEADLIGHT AIM 3.1 s SPARK PLUGS 3_3 CLUTCH SYSTEM 3.1 a VALVE CLEARANCE 13 SIDE STAND 3.19 CARBURETOR SYNCHRONIZATION 3.10 susPENSION 3.19 CARBURETOR IDLE SPEED 3,1 1 NUTS, BOLTS, FASTENERS 3-20 RADIATOR COOLANT 3-11 WHEELS/TIRES 3.20 COOLING SYSTEM 34 2 STEERING HEAD BEARINGS 3.21 SERVICE INFORMATION m ' If the engine must be running m 110 some wark, make sure the area is well-ventilated. Never run the engine in an enclased area. The exhaust canmr'n: paimnau: carbon monaxide gas that may cause loss afconsciausness and lead (0 death - Gizmline is extremely flammable and is explosive under certain candiu'ons. Wark in a well ventilated area wirh the engine stopped. Do not smake or allaw flame: or spark: in the wark area or where gasaline is stored. GENERAL ' Engine Oil See page 2-4 ' Engine oil filter change See page 2-5 SPECIFICATIONS «ENGINE» IgniIiOn Iiming Initial ’88,'89,‘91-’93; 6.2D BTDC at idle After ’93; 6‘5” BTDC at idle Full advance 30" BTDC 3‘ 6,000 rpm 593'“ “"9 NGK NIPPONDENSO SIandard DPH8EA-9 X24EFR-U9 For Cold Climate (below 5°C/41°F) DPR7EA-9 X22EPR-U9 For extended high speed driving DPR9EA-9 X27EFR-U9 Spark plug gap 03—09 mm i0.031—0.035 in) Valve Clearance IN 015 : 002 mm (0.006 t 00008 in] (COLD) EX 020 i 0.02 mm (0.008 t 00008 in) Idle speed 1,200 x 100 rpm Cylinder compression 1,324 3 98 kPa (13.5 x 1.0 kg/le, 192 i 14 psi) Throule grip free play 2—6 mm (1/16—1/4in] MAINTENANCE Rear brake lree play 20—30 mm (3/4—1—3/16in) Brake pedal height 43 mm (117 in) Clutch lever lree play 10—20 mm (3/8—3/4 in) Drive chain slack 20—30 mm l3/4—1—3/16in) Tires Front Rear Tire size 100/90-19 57S 170/80-15 778 Cold tire pressures Up to vehicle capacity load 20012.00, 29) 250 [2150, 35) kPa «kg/cmZ, psn up to 90 kg (200 lbs) load 20012.00, 29) 20012.00, 29) Maximum weight capacity 161 kg (355 lbs) Tire brand Bridgestone L309 G 546 Dunlcp F24 K555 TORQUE VALUES Rear axle nut 90 N-m (9.0 kg-m, 65 ft-lb) Valve adjusting screw lock nut 23 N-m (2.3 kg-m, 17 ft-lb) Spokes llront/rear) 4 N-m (0.4 kg-m, 2.9 ft-lb) Timing hole cap 35 NM [0.35 kg-m, 2.'5 ft-lb) Crankshaslt hole cap 15 N-ml1.5 kg—m, 11 ft—lb) TOOLS Special Valve adjusting wrench 07908*KE90000 Not available in U.S.A. 079087KE90100 U.S.A. Only vacuum gauge 0740470030000 01 Not available i'l U.S.A. 07LMJ7001000A U.S.A. Only Drive chain cutter 07HMH7MR10100 or 07HMH7MR‘IO‘IOB UVSVAV Only Spoke wrench 07JMA7MR50100 Not available in U.S.A. 3-2 MAINTENANCE MAINTENANCE SCHEDULE ’88; Perform the PRE—RIDE INSPECTION in the Owner’s Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN R: REPLACE L: LUBRICATE FHEOUENCV SSA/ESEVEH _. ODOMETER READING (NOTE 1) FIRST N x 1,000 mi 0.6 4 a 12 15 20 24 REFER To 'TEM EVERY x 100 km 10 64 125 192 255 320 384 | PAGE ' FUEL LINE | | I 3-6 - THROTTLE OPERATION I I I 3—6 ' CARBURETOR CHOKE I I I 3—7 | AIR CLEANER (NOTE 2) R R 3-7 I w CRANKCASE BREATHER (NOTE 3) c C c c 378 E SPARK PLUG R R R R R R 3-8 g - VALVE CLEARANCE I I I I I 3-8 E ENGINE OIL R R R 2-4 d ENGINE OIL FILTER R R R R 2-5 E - CARBURETOR- I I I I 3710 g SYNCHRONIZATION Q ' CARBURETOR-IDLE SPEED I I I I I I I 3-11 3 RADIATOR COOLANT 2 YEARS 'R I I *R 3—11 ' COOLING SYSTEM I I I 3712 :II:%2I2I:IIIISS'°N 4» I I DRIVE CHAIN EVERY 500 mi [1,000 km) I. L 3—1 3 m BRAKE FLUID 2 YEARS -R I I *R I I 'H 3—15 E BRAKE SHOE/PAD WEAR I I I I I I 3715 o BRAKE SYSTEM I I I I 3715 E - BRAKE LIGHT SWITCH I I I 3-17 g ' HEADLIGHT AIM I I I 3—18 g CLUTCH SYSTEM I I I I I I I 3—18 g SIDE STAND I I I 3-19 E ' SUSPENSION I I I 3—19 (2‘) ' NUTS, BOLTS, FASTENERS I I I I 3-20 2 ' * WHEELS/TIRES I I I I I I I 3720 H STEERING HEAD BEARINGS I I I I 3721 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 these items be serviced only by m authorized Honda dealer. NOTES: 1. At higher Odometer readings, repeat at the frequency interval established here. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Service more frequently when riding in rain or at full throttle. 4. California model only. 3-3 MAINTENANCE MAINTENANCE SCHEDULE ’89,’91-’93; Perform the PRE-RIDE INSPECTION 'n the Owner’s Manual at each scheduled maintenance period. I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN R: REPLACE I.‘ LUBRICATE The following items require some mechanical knowledget Certain items (particularly those marked * and t It) may require more technical information and tools. Consult their authorized Honda dealert FREQUENCY I ODOMETER READING (NOTE 1] ITEM x 1,000 m. 0.6 4 e 12 16 20 24 REFER To NOTE x 1,000 km 1 54 128 19,2 25.5 32.0 38.4 PAGE ' FUEL L|NE I I I 3—6 ‘ THROTTLE OPERATION I I I 3-6 ' CAREURETOR CHOKE I I I 3—7 m AIR CLEANER (NoTE 2] R R 3—7 5 CRANKCASE BREATHER INOTE 3) C C C C C C 3-8 E SPARK PLUG R R R R R R 3-8 E "VALVE CLEARANCE I I I I 3~8 d ENGINE OIL R R R H 2-4 giENGINE OIL FILTER R R R R 2-5 5 ‘ CARBURETOR SVNCHRONIZATION I I I I 3-1 0 g ' CARBURETOR IDLE SPEED I I I I I I I 3-11 m RADIATOR COOLANT (NOTE 5I I I 'R 3-11 - COOLING SYSTEM I I I 3—1 2 ' Eggfgzgygg EMISSION CON- mom. . . 3.13 DRIVE CHAIN I,L EVERY 500 mi (1,000 km) 3-1 3 U) BRAKE FLUID (NOTE 5] I I ’R I I 'R 3-1 5 EV BRAKE SHOES/PADS WEAR I I I I I I 3-16 I: BRAKE SYSTEM I I l l 3—1 6 E ‘ BRAKE LIGHT SWITCH I I I 3-1 7 g * HEADLIGHT AIM I I I 3-18 g CLUTCH SYSTEM I | I I I I I 3—1 8 g SIDE STAND I I I 3—19 E ' SUSPENSION I .I I 3-19 3 ' NUTS, BOLTS, FASTENERS I I I I 3—20 2 H WHEELS/TIRES I I I I | I I 3—20 ' ' STEERING HEAD BEARING I I I | 3—21 ' SHOULD BE SERVICED BY AN AUTHORIZED HONDA DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SER- VICE DATA AND IS MECHANICALLY QUALIFIEDt " IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED HONDA DEALER. NOTES: 1. At higher odometer readings, repeat at the frequency interval established here. t Service more frequently when riding in unusually wet or dusty areas. t Service more frequently when riding in rain or at full throttle. t California type only t Replace every 2 years, Or at indicated odometer interval, whichever comes first. Replacement requires me— chanical skill. (nwa MAINTENANCE MAINTENANCE SCHEDULE After ’93; Perform the PRE-RIDE INSPECTION .n the Owneranual at each scheduled malntenance perlod. |:INSPECT AND CLENA,ADJUST,LUBRICATE on REPLACE IF NECESSARY. CchEAN R:REPLACE L:LUBRICATE The following items require mechanical knowiedgeCenam items(partlcularly thOse marked Hand: -)may require more technlcal informatron and tools,Consult their authorized Honda dealer. FREQUENCY ODOMETER READING(NOTE1) x1.ooomi 0.6 4 s 12 15 20 24 REFERTO ITEM NOTE x IOOkm 10 64 128 192 255 320 384 PAGE x FUEL LINE l l I I 3-5 x THROTTLE OPERATION I I I 3—6 x CAREURETOR CHOKE | | | 377 U) AIR CLEANER (NOTEZ) R R 3—7 E CRANKCASE BREATHER (NOTES) C C C c C C 3—8 a SPARK PLUG R R R R R R 3-8 E x VALVE CLEARANCE I I I I 3-8 a ENGINE OIL R R R R 2—4 : ENGINE OIL FILTER R R R R 2-5 3 e CARBURETOR SYNCHRONIZATION I I I I 3—10 9 x CARBURETOR IDLE SPEED | | l l | I | 3-11 3 RADIATOR COOLANT(NOTE5) l | R 3-11 x COOLING SYSTEM I I I 3-12 x Eggigzg'gfi EMISSION CON' (NOTE4) I I 3-13 DRIVE CHAIN |,L EVERY 500mi(800km) 3-13 g BRAKE FLUID (NOTES) | | R | I R 3-15 “,1 BRAKE SHOES/PADS WEAR | | l | | | 3-15 ‘ é BRAKE SYSTEM I I I I 3-16 3 '5 v BRAKE LIGHT SWITCH | | | 3-17 g v HEADLIGHT AIM | | | 3-18 2 CLUTCH SYSTEM | | | | | l | 3-18 8 SIDE STAND I I I 3-19 ‘é’ v SUSPENSION I I I 3-19 us e NuTs,EOLTS,EASTENERS I I I I 3-20 CZ) wt WHEELS/TIRES | l | | | l | 3-20 2 v‘ STEERING HEAD BEARING | | | | 3—21 t SHOULD BE SERVICED BY YOUR AUTHORIZED HONDA DEALER,UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE DATA AND IS MECHANICALLY QUALIFIED. x‘ IN THE INTEREST OF SAFETY,WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY YOUR AUTHORIZED HONDA DEALER. NOTES: 1 . At higher Odometer readings,repeat at the frequency interval established here. . Service more frequently when riding it unusually wet or dusty areas. . Service more frequently when riding it rain Or at full throttle. _ California type only. _ Replace every 2 years,or at indicated odometer interval,whichever Comes first.ReplaCement requires me- chanical skill. mew» 3-5 MAINTENANCE FUEL LINE Remove the seat. Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines fl necessary. FUEL FILTER Pull the fuel filter out, clip the inlet line closed and remove the filter. Replace the fuel finer with new one, if necessary (page 4-3]. THROTTLE OPERATION Check for smooth throttle grip lull opening and automatic lull closing in all steering positions. Check the throttle cables and replace them if they are deterio- rated, kinked or damaged. Lubricate the throttle cables, fl throttle operation is not smooth. Measure the free play at the throttle grip flange. FREE PLAV: 2—6 "In (1/16—1/4inl Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper ad- juster. Major adjustments are mode with the lower adjuster. Adjust the free play by loosening the lock nut and turning the adjusting nut. Tighten the lock nuts. Recheck throttle operation. Replace any damaged parts, if necessary. 3-6 MAINTENANCE CARBURETOR CHOKE NOTE {3) ADJUSTER ~ Choke knob operating friction can be adjusted by turning the adjuster. Check (or smooth operation of the choke knob. Lubricate the choke cable and/or adjust the choke knob operat- ing friction ii operation is not smooth. To adjust the iriction, pull the rubber cover away andturn the adjuster. Direction Friction A Increase B Decrease Loosen the choke valve nut and remove the choke valve from the carburetor. Pull the choke knob all the way out to fully open position and recheck (or smooth operation oi the choke knob. There should be no iree play. Check the valve seat on the choke valve for damage. Reinstall » the choke valve in the reverse order of removalt AIR CLEANER Remove the air cleaner housing cover bolt and cover. Remove the holder bolts and the air cleaner element. Replace the element in accordance with the maintenance schedule. Also, replace the element any time it is excessively dirty or damaged. MAINTENANCE CRANKCASE BREATHER The crankcase breather drain tube is behind the left frame pipe J J 7( and front cylinder head. (1) DRAIN PLUG Pull the drain tube out of the frame clampt / Remove the drain plug from the tube to empty any deposits. Reinstall the drain plug NOTE / - Service more frequently when ridden it rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the transparent section of the drain tubet (1) PLUG GAP ‘lZl SIDE ELECTRODE 08—03 mm SPARK PLUGS (0031—0035 in) Disconnect the spark plug cap and remove the spark plugs. . l3) CENTER RECOMMENDED SPARK PLUG, ELECTRODE NGK NlPFONDENSO Standard DFHBEA-9 X24EFR-U9 For cold climate lbelow 5°C/4‘I °F) For extended high speed driving DFH7EA-9 X22EPR-U9 DPHQEA-Q X27EPH-U9 Measure the spark plug gap with a wire-type feeler gauge. SPARK PLUG GAP: 03—03 mm l0.031—0.035 in) Adjust by bending the side electrode carefullyt With the plug washer attached, thread each spark plug in by hand to prevent crossthreading. Continue tightening by hand until the spark plug bottomst Then, tighten the spark plugs another 1/2 turn with a spark plug wrench to compress the plug washert Connect the spark plug caps. (1) INTAKE DUCT VALVE CLEARANCE NOTE ' Inspect and adjust valve clearance while the engine is cold lbelow 35°C/95°F]. Remove the following parts: — fuel tank {page 4-3] — air cleaner housing (page 4-4) — air cleaner chamber and intake duct. 3-8 Remove the crankshaft and timing hole caps. Remove the valve adjusting covers from the cylinder head cov- ers. NOTE ' Adjust the front cylinder valves first. FRONT CYLINDER HEAD Rotate the flywheel counterclockwise to align the "FT" mark with the index notch on the left crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. Inspect the clearance of all three valves by inserting a feelev gauge between the adjusting screw and the valve. VALVE CLEARANCES: Intake: 0.15 z 0.02 mm (0.006 t 0.0008 in) Exhaust: 0.20 z 0.02 mm (0.008 t 0.0008 in) Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. Hold the adjusting screw and tighten the lock nut. TOOL: Valve adjusting wrench 07908—KE90000 Not available in U.S.A. 07908—KE90100 TORQUE: 23 N~m (2.3 kg-m, 17 ft-Ib) Apply oil to the nut and bolt threads. MAINTENANCE HICRANKSHKFfEOLECAF' " x‘\5) (ilFEELEH GAUGE ». (1) VALVE ADJUSTING WRENCH MAINTENANCE REAR CYLINDER HEAD Flotate the flywheel counterclockwise to align the "RT" mark with the index notch on the left crankcase cover. Make sure the piston is at TDC on the compression stroke. Check the O-rings of the valve adjusting covers llN/EX) for damage and replace if necessary. Install the front and rear valve adjusting covers. Apply grease to the timing and crankcase hole caps, then install and tighten them. TORQUE Timing hole cap: 3.5 N~m (0.35 kg-m, 2.5 fl-Ib) Crankshaft hole cap: 15 "mt (1.5 kg-m, 11 ft-Ib) CARBURETOR SYNCHRONIZATION NOTE ' Perform this maintenance with the engine at normal operat- ing temperature. Hemove the.fuel tank mounting bolt. Carefully raise the tank and support it in the frame using a suitable base (see page 3- 9]. ‘ Remove the air cleaner case lpage 4-4).Remove the plugs from the cylinder intake ports and install the vacuum gauge adaptors as shown. Connect the vacuum gauge. TOOL: Vacuum gauge 07404—0030000 Not available in U.S.A. 07LMJ—001000A Warm up the engine and adjust the idle speed with the throttle stop screw. IDLE SPEED: 1.200 t 100 rpm 3-10 MAINTENANCE Check that the difference 'n vacuum readings is 40 mm (1.6 in) Hg or less. NOTE ~ The rear cylinder carburetor is the base carburetor. If necessary, synchronize to the specification by turning the synchronization adjusting screw. Recheck the idle speed and synchronization. Disconnect the gauge and adaptors and install the removed parts. CARBURETOR IDLE SPEED NOTE O Inspect and adjust idle speed after all other engine adjust- ments are within specifications. ~ The engine must be warm for accurate adjustment. Ten minutes of stopvand-go riding is sufficient‘ Warm up the engine, shift to NEUTRAL, and place the motor- cycle on its side stand. Turn the throttle stop screw as required to obtain the specified idle speed. IDLE SPEED: 1,200 x 100 rpm RADIATOR COOLANT Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the "UP" and "LOW" level lines. If necessary, remove the right side cover and then remove the reserve tank cap. Fill up to the upper level line with 50/50 mixture of distilled water and antifreeze. Reinstall the reserve tank cap and right sider cover. MAINTENANCE COOLING SYSTEM Remove the radiator shroud and check the radiator air pas- sages for clogging or damage. Straighten bent fins or collapsed core tubes with a small flat blade screwdriver as shown and remove insects, mud or any obstructions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over more than 20 % of the radiated surface. For radiator replacement, refer to page 5-5. Make sure the hoses are in good condition. Replace any hose that shows any sign of deterioration. Check that all hose clamps are tight. CYLINDER COMPRESSION Warm up the engine. Stop the engine and remove the spark plug. Connect a compression gauge. Turn the engine stop switch OFF. Open the throttle grip fully. Crank the engine with the starter motor until the gauge stops rising. Check the gauge reading. NOTE ' Check that there is no leakage at the gauge connection. ' The maximum reading is usually reached within 4-7 sec- onds. COMPRESSION: 1.324 i 98 kPa [13.5 : 1.0 kglcmz. 192 :14 psi) Low compression can be caused by: ' Improper valve clearance adjustment - Valve leakage ~ Leaking cylinder head gasket ' Worn piston rings or cylinder High compression can be caused by: - Carbon deposits in the combustion chamber or on the piston head. 3-12 MAINTENANCE EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) Check the hoses between the fuel tank,evaporative emissron canrster,evaporative emission purge control valvelEVAP PURGE CONTROL VALVE),evaporative emission carburetor air vent control valve(EVAF CAV CONTROL VALVE),and carburetor for deterioratron,damage or loose connections. Also check the tubes for clogging due to bending or twisting. Check the evaporative emission canister for cracks deterio- ration,or other damage. Refer to the vacuum hose routing diagram label for hose connections. DRIVE CHAIN CHAIN SLACK INSPECTION M— - Never inspect or adjust the drive chain while the engine is run- ning. Turn the ignition switch off, support the motorcycle on its side stand, and shift the transmission into neutral. Check slack in the drive chain lower run midway between the sprockets‘ SLACK: 20—30 mm [3/4—1-3/16inl CHAIN ADJUSTMENT Loosen the axle nut. Loosen both lock nuts and turn both adjusting bolts as neces— sary, Make sure the index marks on both the adjuster collars are aligned with the corresponding scale graduations on both sides of the swingarm. Tighten both lock nuts, then tighten the rear axle nut‘ TORQUE: 50 N-m (9.0 kg-m. 65 ft-lbl (liEVAF CANISTEH VAEllll llllSE lllllllli mama [MINE uni-1:: (vimrlvt rAInH:, ' CALIVIIIIIA mum FUEL um union: mum: -m w. u. l1] SCALE (3) LOCK NUT (4) ADJUSTER BOLT MAINTENANCE Recheck chain slack and free wheel rotation. Lubricate the drive chain with Pro Honda Chain Lube or equiv- alent chain lubricant designed specifically for use on O—ring chains. Check the chain wear label. If the red zone on the label aligns with the arrow mark of the chain adjuster alter the chain has been adjusted, the chain must be replaced. REPLACEMENT CHAIN: RK525 SM5 DID525 V8 LUBRICATION AND CLEANING When the drive chain becomes extremely dirty, it should be cleaned prior to lubrication. Clean the drive chain with a non—flammable or_high flash point and wipe dry. The drive chain on this motorcycle is equipped with small 0— rings between the link plates. The O—rings can be damaged by steam cleaners, high pressure washers and certain solvents. Lubricate the drive chain with Pro Honda Chain Lube or equiv- alent chain lubricant designed specifically for use on 0-ring chains. CHAIN REPLACEMENT The VTBOOC uses a drive chain (120 pins] with a staked master link. Loosen the drive chain (page 3-13). Locate the crimped pin ends of the master link from the out- side of the chain and remove the link with the chain cutter. TOOL: Drive chain cutter 07HMH—MR10103 Not available in U.S.A. 07HMH—MR101OB NOTE - When using the special tool. follow the manufacturer's op- erating instructions. CAUTION - Never reuse the old drive chain, master link, master link plate and Grings. REPLACEMENT CHAIN: RK525 5M5 DID525 V8 Install the new drive chain through the swingarm as shown. (1) WEAR LABEL (1) CRIMPED ENDS (3) MASTER LINK I1) SWINGARM [2) DRIVE CHAIN 3-14 Assemble the new master link. O-rings and plate. CAUTION - Insert the master linkfrom the inside ofthe drive chain and in- stall the plate with the identification mark facing the outside. MAINTENANCE lZl O-RINGS Make sure that the master link pins are installed properly. Measuring the master link pin length projected from the plate. Standard length: RK: 1.2-1.4 mm (0.05-0.06 in) DID: 1.15-1.55 mm (0.05-0.06 in) Stake the master link pins using the special tool. Make sure that the pins are staked properly by measuring the diameter of the staked area using a slide calipers. DIAMETER OF THE STAKED AREA: 5.50-5.80 mm (0217-0228 in) After staking, check the staked area of the master link for cracks. If there is any cracking, replace the master link, O—rings and plate. CAUTION - Drive chain with Clip-type master link must not be used. DRIVE AND DRIVEN SPROCKET lnspect the sprocket teeth for excessive wear or damage. Fle- place if necessary. NOTE - Never install a new drive chain on worn sprockets or a worn chain on new sprockets. Both chain and sprockets must be in good condition, or the new replacement chain or sprock- ets will wear repidly. BRAKE FLUID Check the front brake fluid through the sight glass; if the level is visible, remove the cover, set plate and diaphragm. Fill the reservoir to the upper level with DOT 4 fluid from a sealed con- tainer. Check the system for leaks. CAUTION - Do not remove the reservoir cover until the handlebar has been turned so that the reservoir is level. - Do not mix different types offluid, as they are not compatible with each other. - Do not allow foreign material to enter the system when filling the reservoir. - Avoid spilling the fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. Refer to section 14 for brake bleeding procedures. (ll MASTER LINK (4| DRIVE CHAIN CUTTER (5| STANDARD LENGTH Ill SLIDE CALIFER (2) GOOD (3| NO GOOD (4) CRACKED (1) WEAR» \ (2) NORMAL (3) DAMAGE . . i (1) COVER (2) SET (31 UPPER I PLATE Law'- (S) DIAPHRAGM 4) SIG T GLASS 3-15 MAINTENANCE BRAKE SHOE/PAD WEAR BRAKE PAD WEAR '88,'89,'9‘l -93: Check the brake pads for wear by looking through the slot indi- cated by the arrow cast on the caliper assembly. Replace the brake pads if the wear grooves in the pads are visi- ble (page 14-5]. CAUTION - Always replace the brake pads a: a set to assure even disc pres sure. After ’93: Inspect the pads visually from under the caliper to determine the pad wear. Replace the brake pads if the wear grooves in the pads are visi- ble lpage 1475!. CAUTION - Always rep/ace [he brake pad: as a set in assure even disc pres sure. BRAKE SHOE INSPECTION Replace the brake shoes if the arrow on the brake arm aligns with the reference mark "A" on full application of the rear brake pedal. BRAKE SYSTEM Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage Tighten any loose fittings. Replace hoses and fittings as required. BRAKE PEDAL HEIGHT Adjust the brake pedal so that the pedal height is 43 mm (1.7 in) above the top of the footpeg. 3-16 MAINTENANCE To Adjust: Loosen the stopper bolt lock nut and turn the stopper bolt. Fletighten the lock nut. NOTE ~ After adjusting the brake pedal height, check the rear brake light switch and brake pedal free play and adjust if neces— sary. BRAKE PEDAL FREE PLAY NOTE - Perform brake pedal free play adjustment after adjusting brake pedal height‘ 20—30 mm Check the brake pedal free play. [3/4 1 1/4_ ) — - “1 FREE PLAV: 20—30 mm (3/4- 1-1/4 in) If adjustment is necessary, use the rear brake adjusting nut. NOTE ' After adjusting the brake pedal free play, check the rear brake light switch operation and adjust if necessary. BRAKE LIGHT SWITCH NOTE ' Perform rear brake light switch adjustment after adjusting the brake pedal play and height. ' The front brake light switch does not require adjustment. Adjust the brake light switch so that the brake light will come on when the brake pedal is depressed 20 mm [3/4 in], and brake engagement begins. Hold the switch body and turn the ‘ adjusting nut. Do not turn the switch body. ' W ’ (1) BRAKE LIGHT SWITCH ‘ 3-17 MAINTENANCE HEADLIGHT AIM Adjust vertically by turning the vertical adjustment screw Adjust horizontally by turning the horizontal adjusting screwt (1) HomiofiTAL ADJUSTlNG NOTE ' Adjust the headlight beam as specified by local laws and regulations. @— - Arr improperly adjusted headlight may blind oncaming drivers, ar it may fail to light the rand/or a safe distance. (2) VERTICAL zDJUSTIN SCREW CLUTCH SYSTEM Measure the clutch lever free play at the lever end. FREE PLAV: 10—20 mm (3/8—3/4 in) (1) 10—20 mm 1 (3/8—3/4 in) Minor adjustments are made with the upper adjustert H) UPPER ADJUSTER Pull the lever cover back, loosen the lock nut and turn the ad- juster to obtain the specified free play. Tighten the lock nut and install the cover. Check clutch operation. Major adjustments are made with the lower adjuster. Loosen the lock nut and turn the adjusting nut to obtain the specified free play. Tighten the lock nut and check the clutch operation. i1) LOWER ADJUSTER 3-18 MAINTENANCE SIDE STAND Check the spring for damage or loss of tension. Check the side stand assembly for freedom of movement. Lubricate the pivot bolt and the side stand pivot area if neces- sary. Tighten the pivot bolt and nut. TORQUE: BOLT: 10 N-m (1.0 kg-m. 7.2 "-Ib) NUT: 30 mm (3.0 kg-m, 22 lt-lb) I. 5 ll) PIVOT BOLT Check the side stand ignition cut-off system: — Sit astride the motorcycle and raise the side stand. — Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch lever squeexed. — Move the side stand full down. — The engine should stop as the side stand is lowered. If there is a problem with the system, check the side stand switch (section 16). G, SUSPENSION FRONT Check the suspension action by compressing it several times. Check the entire fork leg assembly for signs of leaks or dam- age. Replace any components which are unrepairable. Tighten all nuts and bolts to the specified torque value. m“ - Do not ride a vehicle with faulty suspenxion. Loose, worn, or damaged .tuspenxiarr part: may affect .rlabiiiry and rider can- Iml. REAR Check the action of the rear suspension components by com- pressing them several times. Check the entire suspension assembly, being sure it is securely mounted and not damaged or distored. Tighten all nuts and bolts to the specified torque value. MAINTENANCE NUTS, BOLTS, FASTENERS Tighten the bolts, nuts and fasteners at the intervals shown in the Maintenance Schedule (page 373). Check that all chassis nuts and bolts are tightened to their cor- rect torque values [page 1-5, 6 and 7]. Check all cotter pins and safety clips. WHEELS/TIRES TIRE PRESSURE NOTE - Tire pressure should be checked when the tires are COLD. Front Rear Tire sue 100/90-19 57S 170/80-15 778 Cold tire Up to “assures “9””? 20mm, 29) 250 (250, 36] kPa capacity lkg/cmfi load psll Up to 90 kg l1) SPOKE (200 lbs] 20012.00, 29) 200 (2.00, 29) (2) SPOKE WRENCH load Maximum weight capacity 161 kg (355 lbs) Tlre Brldgestone L309 G 546 brand Dunlop F24 K555 Check the tires for cuts, imbedded nails, or other sharp ob- iects. Check the front and rear wheels for trueness lSectIon 12 and 1 3L Measure the tread depth at the center of the tires. Replace the tires if the tread depth reaches the following limit: MINIMUM TREAD DEPTH: Front: 15 mm (0.06 in) Rear: 20 mm (0.08 in) Tighten the wheel spokes periodicallyt TORQUE (front/rear): 4 N-m (0,4 kg-m, 2.9 ft-Ib) TOOL: Spoke wrench 07JMA— MRSO‘l 00 Not available in U.S.At 3-20 MAINTENANCE STEERING HEAD BEARINGS ‘ r , , m STEERING HEAD BEARINGS NOTE ' Check that the control cables do not interfere with handle- bar rotation. Raise the front wheel off the ground. Check that the fork pivots freely from side to side. If the fork pivots unevenly, binds, or has vertical movement, inspect the steering head bearings [Section 12]. 3-21 FUEL SVSTEM 19 N-m (1.9 kg-m, 13.7 lt-lb] 4-0 4. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING FUEL TANK AIR CLEANER HOUSING CARBURETOR REMOVAL CARBURETOR ASSEMBLY CARBURETOR SEPARATION/ASSEMBLY CARBURETOR DISASSEMBLY 4-1 CARBURETOR INSTALLATION 4-15 42 PILOT SCREW ADJUSTMENT 4-15 4-3 HIGH ALTITUDE ADJUSTMENT 44 (USA ONLY) 446 46 EVAPORATIVE EMISSION PURGE CONTROL VALVE INSPECTION 4-6 (California model only) M 6 440 EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE 443 INSPECTION (California model only) 4-17 SERVICE INFORMATION - Gasoline is extremely flammable and is explosive under certain conditions work in a well ventilated area a with the engine stopped. Work in a well ventilated area, - If the engine must be running to do 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. GENERAL Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments. When disassembling fuel system parts, note the locations of the O-rings; replace them with new ones on reassembly. The carburetor float chambers have drain screws that can be loosened to drain residual gasoline. For fuel pump refer to section 18. All hoses used 'n the evaporative emission control system are numbered for identification. When connecting one of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4-16 (California model only], for its routing. CAUTION - Do not bend or twist contra! cables. Damaged control cables will not operate smoothly and may stick or bind. NOTE ' If vehicle is to be stored for more that one month. drain the float bowls. Fuel left '11 the float blowls will cause clogged jets resulting in starting and drivability complaints. SPECIFICATIONS Item 49 St. model California model Type Constant Vacuum dual carburetor Throttle bore 34 trim [1.4 inl 34 mm [1.4 in] Identification No. VDFDA VDFEA Float level 7.0 mm 10.28 in) 7.0 mm 10.28 in] Main jet Front: #115, Rear: #115 Front: #115, Rear: #115 Slow jet #40 #40 Idle speed 1,200 1 100 rpm 1200 : 100 rpm Throttle grip free play 2—6 mm 11/8—1/4inl 2—6 mm (1/8—1/4 in) Pilot screw initial opening See page 4-15. FUEL SVSTEM TORQUE VALUE Fuel tank mounting bolt TOOLS Special Vacuum/Pressure pump Pressure pump Vacuum pump Valve guide driver, 7 mm Common Float level gauge TROUBLESHOOTING Engine cranks but won’t start ' No fuel in tank ~ No fuel to carburetor ~ Engine flooded with fuel ~ No spark at plug [ignition system faulty) ~ Clogged air cleaner - Intake air leak - Improper choke operation ~ Improper throttle operation Hard starting or stalling after starting - Improper choke operation - Ignition malfunction - Faulty carburetor - Fuel contaminated - Intake air leak - Incorrect idle speed - Incorrect valve clearance (Section 3) - Incorrect carburetor synchronization (Section 3) - Improper choke valve operation. Rough idle - Faulty ignition system ' Incorrect idle speed ' Incorrect valve clearance (Section 3) ' Incorrect carburetor synchronization ' Faulty carburetor ~ Fuel contaminated ' Faulty air cut off valve (California model only:) : Faulty evaporative emission purge control valve : Faulty evaporative emission carburetor air vent control valve : Worn/damaged emission system hoses Afterburni g during deceleration - Faulty ignition system ' Faulty air cut off valve ' Lean mixture (California model only:) : Worn/damaged emission system hoses 07401 —0010000 19 NA!“ [1.9 kg-m, 13.7 ft-lb] A937X—04‘I —XXXXX or ST—AH—ZSS—MC7 IU.S.A. only) ST—AH—ZBO—MC7 (USA. only) 07942—8230000 [USA only) Misfiring during acceleration ' Faulty ignition system Backfiring ' Faulty ignition system - faulty carburetor Poor performance (driveability) and poor fuel economy ~ Clogged fuel system - Faulty ignition system ~ Dirty air cleaner (California model only:) : Faulty evaporative emission carburetor air vent control valve : Warn/damaged emission system hoses Lean mixture . Clogged fuel jets . Stuck vacuum piston . Faulty float valve . Low float level . Clogged fuel tank breather . Clogged fuel strainer . Restricted fuel line - Intake air leak ' Restricted or faulty fuel pump Rich mixture ' Clogged air jets - Faulty float valve ~ Float level too high - Dirty air cleaner 4-2 FUEL SYSTEM FUEL TANK REMOVAL @— Gaso ne is extremely flammable and is explosive under certain conditians. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or Spark: in the work area or where gasoline is stored. (2) FUEL TANK MOUNTING BOLT Remove the seat and turn the fuel valve off. Remove the fuel valve knob mounting bolt and fuel valve knob from the fuel tank body. Remove the fuel tank mounting bolt. Disconnect the fuel tube from the fuel tank and fuel breather tube (to canister: California model only]. Check that fuel flows out of the fuel valve freelyt If flow is restricted, clean the fuel strainer. Remove the fuel tank from the frame. INSTALLATION Install the fuel tank in the reverse order of removal. Install the fuel valve knob onto the fuel valve as shown and tighten the bolt.. (1) FUEL VALVE I ‘ (2) BREATHER TUBE [5) ALIGN (4i KNOB Tighten the fuel tank mounting bolt securely. (1) FUEL TANK Q (3) FUEL STRAINER SCREEN g (5) FUEL FILTER N OTE ~ The fuel filter with its narrow pointing toward the outside (4) O-RINGM (6) FUEL VALVE BODY k (7) FUEL VALVE KNOB I (8] TO FUEL Q“ n ‘ g. PUMP / v SM» 411 (2) FUEL PIPE JOINT L91 T0 CARBURETOR NOTE ' The fuel pipe mm with its nar- row end toward outside. FUEL SYSTEM AIR CLEANER HOUSING l1lA|Fl CLEANMSTN‘G ‘ MOUNTING BOLTS REMOVAL Remove the fuel tank mounting, and lift the tank and remove the air cleaner housrng mounting bolts. Loosenthe aircleaner hOUSIng-to-air cleaner chamber band. Disconnect the crankcase breather tube from the air cleaner housing. INSTALLATION Wipe clean the mating surfaces shown and apply a cemment Ior equivalentlt Install the removed parts in the reverse order of removal. [II APPLY A CEMENT SUB-AIR CLEANER ELEMENT .l—1Il'SB-AIR CLEAER” Remove the following: — seat (page 13-18] and fuel tank Ipage 4-3) — air cleaner I’IOLISIHQ Disconnect the air hoses lcarburetors~to~sub-air cleaner cov- erl. Remove the sub-air cleaner mounting bolt and cover and remove the element. 4-4 FUEL SYSTEM Wash the element in non—flammable or high flash point sol- vent. squeeze out the solvent thoroughly, and allow the ele— @ I ment to dry. Soak the element in gear oil (SAE #80—90] and squeeze out the excess. Reinstall the element and cover, and tighten the bolt. Reconnect the air tubes from the carburetors. I1) (2) l4] (5) WASH w SQUEEZE our GEAR OIL souzzzz our SOLVENT SOLVENT ISAE #80790) EXCESS OIL THOROUGHLY AIR CLEANER CHAMBER (1) INTAKE DUCT , REMOVAL/INSTALLATION J HOSE ANDS Remove the air cleaner housing and sub-air cleaner element lpage 4-4). Loosen the intake duct hose bands at the carburetors and unhook the air cleaner chamber drain tube from the frame. Remove the air cleaner chamber from the frame. To reinstall the chamber: position it in the frame, and connect the intake ducts to the carburetors and tighten the band screws. Install the sub-element and cover (page 4-4). Install the air cleaner housing (page 4-4). I10) INTAKE DUCT HOSES l7) DRAIN TUBE a“my/’43) PLUG (2) BRACKET [3] AIR CLEANER HOUSING (9) ELEMENT (1) AIR CLEANER CHAMBER (5) HOUSING COVER (4) AIR CLEANER ELEMENT (6] HOLDER FUEL SVSTEM CARBURETOR REMOVAL KWHOTTE CABLES . , ' Gaxalme is extremely flammable and i: exploxive under certain conditions. Work in a well ventilated area with the engine flopped. Do not .rmoke or allow flamex or mark in the work area or where gaxolirre i: stored. Loosen the drain screws and drain the fuel into a containert Remove the sub-air cleaner chamber (page 4-4]. Remove the throttle cable cover and disconnect the throttle cables from the carburetor. Remove the left choke valve from the carburetor and loosen the carburetor insulator bands. Disconnect the evaporative emission purge control valve No.5 tubes and evaporatrve emission carburetor air vent control valve No.6 and 10 tubes from the carburetor [California model only). Pull the carburetors the upward and out of the engine. CARBURETOR DISASSEMBLY NOTE ‘(2) CHOKE CABLE LOCK l NUT ' The carburetors can be disassembled without being sepa- rated Remove the airtubes lcarburetors-to-sub-air cleaner), and fuel tube from the carburetor. Remove the choke cable and right choke valve from the carbu- retor by loosening each lock nut. (3) AIR TUBES ; VACUUM CHAMBER (1) VACUUM CHAMBER COVER Remove the four screws and vacuum chamber cover. Remove the spring, and diaphragm/vacumm piston, Inspect the vacuum piston for wear, nicks, scratches or other damage, Make sure the piston moves L9 and down freely in the cham- bert Push the needle jet holder 'n and turn it 'n 90 degrees counter— clockwise Then remove the needle holder, spring, jet needle and washer from the piston Inspect the needle for excessive wear at the tip, bending or other damget Inspect the diaphragm for damage, fatigue or pin holes. Inspect the vacuum piston for wear or damage FLOAT CHAMBER. FLOAT AND JETS Remove the four screws and float chamber. (1) DIAPHRAGM/PISTON (1 ) WASHER FUEL SYSTEM (2) SPRING (3) PISTON (1) NEEDLE JET HOLDER (2) JET NEEDLE (4] SPRING (1) FLOAT CHAMBER (3) HOLDEH FUEL SYSTEM Remove the float pin, float and float valves. Check the float valve and valve seat for scratches. clogging or damage. Inspect the operation of the float valve. Remove the main jet, needle jet holder, slow jet and valve seat/ filter. Check each part for wear or damage. Blow open all jets with compressed air. Clean eachjet with non—flammable or high flash point solvent. Inspect the float valve seat and filter for grooves, nicks or de— posits. Clean the filter with low-pressure compressed air. PILOT SCREW NOTE - The pilot screws are factory pre-set and should not be re- moved unless the carburetors are overhauled. - The pilot screw plugs are factory installed to prevent pilot screw misadjustment. Do not remove the plugs unless the pilot screws are being removed. I ' Cover all openings with tape to keep metal particles out when the plugs are drilled. (1) FLOAT VALVE (2) PIN (ZIILQAT VALVE (5] FILTER (4) VALVE SEAT (1 lTlEEDLE ‘ HOLDER JET [2] MAIN JET 4-8 FUEL SYSTEM Center punch the pilot screw plug to center the drill point, Dri|| through the plug with a 4 mm (5/32 in) dri|l bit. Attach a drill stop to the bit 3 mm (1/8 in) from the end to prevent drilling into the pilot screw. CAUTION - Be careful rm! to drill into the pilot screw. - Bath pilot screws must be replaced even if only one requires it, for proper pilot screw ad juxtrriertt (page 445). Force a self-tapping 4 mm screw, P/N 93903—35410) into the drilled plug and continue turning the screwdriver until the plug rotates with the screw. Pull on the screw head with pliers to remove the plug. Use compressed air to clean the pilot screw area and remove metal shavings. turns until it seats lightly. Make a note of this to use as a refer— Turn each pilot screw in and carefully count the number of ence when reinstalling the pilot screws. < (1) claims CAUTION (2) SPRING - Damage to the pilot screw seat will occur if the pilot screw is tightened agm'rnl the seat. Remove the pilot screws and inspect them. Replace them if they are worn or damaged. (4) WASHER (3) PILOT SCREW/'7 AIR CUT OFF VALVE 5(1) AIR our on: VALVE covsn « \ Remove the two screws. the set plate and the air out off valve cover. NOTE - The air out off valve cover is under spring pressure. Do not loose the spring and screws. FUEL SYSTEM Visually check the following: ‘ ‘ ‘ (2) O-RING — diaphragm for deterioration, pin hole or other damage. \ ' — spring for deterioration or other damage. — diaphragm needle for excessive wear at the tip or other damage. — orifice of air vent for clogging. — O-ring for damage. V . ’/(3) DIAPHRAGM Replace the air cut off valve as an assembly, if necessary. 0 fl"; .v a (4) SPRING Separate the carburetors [page 4713). Blow open all passages with compressed air before installing jets and valves. CARBURETOR ASSEMBLY (7) VACUUM CHAMBER COVER (5) HOLDER F (4) SPRING (a) JET NEEDLE\ (2) WASHER (6) SPRING (1a) SYNCHRONIZATION " ADJUSTING SCREW (17) NEEDLE JET HOLDER (16) MAIN JET (15) FLOAT (14) PISTON (8) O-RING (13) FLOAT CHAMBER \ SCREW (12) VALVE [10) SLOW JET SEAT 4-10 PILOT SCREW Install the pilot screws and return them to their original posi— tion as noted during removal. Perform pilot screw adjustment if new pilot screws are in- stalled. NOTE - Do not install new plugs on new pilot screw holes until after adjustment has been made. - if you replace the pilot screw in one carburetor, you must replace the pilot screw in the other carburetor for proper pilot screw adjustment. FLOAT CHAMBER, FLOAT AND JETS Install the pilot screw and turn it in until it seats lightly. Turn the pilot screw out the number of turns recorded during removalt CAUTION - Damage to the pilot Screw seat will occur if the pilot screw is tightened againxt the seat. Install the valve seat. slow jet, needle jet holder and main jet. Install the float with float valve in the carburetor body, then in- stall the float arm pin through the body and the float. FLOAT LEVEL Measure the float level with the float tang just contacting the float valve. TOOL: Float level gauge 07401 —0010000 FLOAT LEVEL: 7 m (0.28 in) Adjust the float level by carefully bending the float tangt FUEL SYSTEM l4) PILOT SCREW (3) SPRING (3) NEEDLE JET HOLDER 4-11 FUEL SYSTEM Install the O-ring on the float chamber groove. Install the float chamber and tighten the screws securelyt NOTE ' Install the fuel tube clamp. VACUUM CHAMBER Install the washer, jet needle, spring and needle holder to the vacuum piston. Push the jet needle holder in and turn it in 90 degrees cloc— kwise. Hold vacuum piston up to almost full open to avoid pinching the diaphragm with the chamber covert The vacuum piston with the tab of the diaphragm aligned with the groove of the carburetort Install the chamber cover with the spring, aligning the cover cavity with the hole in the carburetor, and secure with at least two screws before releasing the vacuum piston. (3) ALIGN m o RING\ 11) JET NEEDLE HOLDER (2) CAV|TY (2) DIAPHRAGM ‘ l3) PISTON / l4) FINGER 4-12 Install the right choke valve and choke knob, Install the fuel and air tubes as shown‘ CARBURETOR SEPARATION/ASSEMBLY SEPARATION Loosen the synchronization adiusting screw. NOTE ' When separating the carburetors, be take careful not to lose the thrust spring and synchronization adjusting spring, Separate the carburetors by removing two attaching screws‘ Remove the synchronization spring. FUEL SYSTEM (1) RIGHT CHOKE VALVI; ’— (2) CHOKE KNOB (I) FUEL TUBIEI \ (3) SYNCHONI SPRING m scgew \ S ZATION (2) AIR TUBES _ (1) THRUST SPRING (2) SYNCHRONIZATION ADJUAS'ILIEGECREW ‘ .,, )2 (2) SVNCHRONIZATION SPRING 4-13 FUEL SYSTEM ASSEMBLY Loosen the synchronization adjusting screw until there is no spring tension‘ Install the thrust spring between the throttle linkst Secure the carburetors together with the two screws‘ Install the synchronization spring and synchronization adjust- ing screw‘ Inspect throttle operation as descrlbed below: - Open the throttle slightly by rotating the throttle valve, then release the throttle‘ Make sure that there is no drag when opening and closing the throttle. Turn the throttle stop screw to align the rear cylinder carbure- tor throttle valve with the edge of the by-pass hole, Align the front cylinder carburetor throttle valve with the by— pass hoIe edge by turning the synchronization adjusting screw‘ Make sure the throttle returns smoothly. (1) THHUST SPRING m (2) SVNCHHONIZATION ' ADJUSTING SCREW A (1) SYNCHHONIZATION SPRJ'lG. ' ‘(fiFP‘AES—H'oe (1) SVNCHHONIZATION ADJUSTING 4-14 CARBURETOR INSTALLATION Install the carburetors onto the cylinder heads and tighten the insulator bands securely. Install the following parts — air cleaner chamber — air cleaner housing — fuel tank — throttle cables Adjust as follows: — pilot screw (page 4-15) — carburetor synchronization (page 3710]. — throttle grip free play (page 376). — carburetor idle speed (page 3711]. — carburetor choke (page 377]. PILOT SCREW ADJUSTMENT IDLE DROP PROCEDURE (U.S.A. ONLY) NOTE - The pilot screws are factory pre-set and no adjustment is necessary unless the pilot screws are replaced. - Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change. 1, Remove the pilot screw plugs(page 4-8). 2. Turn each pilot screw clockwise until it seats lightly and back it out to the specification givent CAUTION - Damage to the pilot screw seal will occur if the pile! screw is lightened against the seal. This is an initial setting prior to the final pilot screw adiust- ment. INITIAL OPENING: 1-1/4 turns out 3. Warm up the engine to operating temperature Stop and go driving for 10 minutes is sufficient. 4‘ Attach a tachometer according to the manufacturer's in- structions. 5. Adjust the idle speed to the specified rpm with the throttle stop screw. IDLE SPEED 2 1.200:100rpm 6. Turn each pilot screw 1/2 turn out from the initial setting. 7. If the engine speed increase by 5 0 rpm o r more, turn each pilot screw out by successive 1/2 turn increments until engine speed does not increase. 8. Adiust the idle speed with the throttle stop screw. 9. 'Turn the rear cylinder carburetor pilot screw in until the engine speed drops 50 rpm. 10. Turn the rear cylinder carburetor pilot screw 1 turn out from the position obtained in step 9. 11. Adiust the idle speed with the throttle' stop screw. 12. Perform steps 9, 10 and 11 for the front cylinder carbu— retor pilot screw. 13. Drive new pilot screw plugs into the pilot screw bores with a 7 mm valve guide driver lP/N 07942—8230000). When fully seated the plug surfaces will be recessed 1 mm FUEL SYSTEM (TI PLUG FUEL SYSTEM HIGH ALTITUDE ADJUSTMENT (U.S.A. only) When the vehicle is to be operated continuously above 2,000 m (6,500 feet) the carburetors must be readjusted as follows to improve driveability and decrease exhaust emissions Remove each pilot screw plug (page 4—8). Warm up the engine to operating temperature. Stop and go driving for 10 minutes is sufficient. Turn each pilot screw to the specification below. HIGH ALTITUDE SETTING: 1/2 Tums in Adjust the idle speed to 1,200:100 rpm, with the throttle stop screw. Drive new pilot screw plugs into the pilot screw bores (page 4- 1 5). NOTE - This adjustment must be made at high altitude to ensure proper high altitude operation. Attach a Vehicle Emission Control information up date label onto the inside of the left side cover as shown.See SLIM 32 for information on obtaining the label. NOTE - Do not attach the label to any part that can be easily re- moved lrom the vehicle. m— ' Sustained operation at an altitude lower than 1,500m (5,000 feet) with the carburetor: adjusted for high alti- tude may cause the engine to idle roughly and engine My Mail in traflic and my cause engine damage due to overheating. When the vehicle '5 to be operated continuously below 1,500m(5,000 feet),turn each pilot screw to the specification below, its original position. LOW ALTITUDE SETTING : 1/2 turn out Adjust the idle speed to 1.2001100 rpm with the throttle stop screw. Drive new pilot screw plugs into the pilot screw bores(page 4 *1 5). Be sure to make these adjustments at low altitude, Remove the Vehicle Emission Control Update Label that attached to the inside of the left side cover after adjusting for the low altitude. EVAPORATIVE EMISSION PURGE CONTROL VALVE INSPECTION (California model only) NOTE -The evaporative emission purge control valve should be inspected if hot restart is difficult. Check all fuel tank,Evaporative Emission Purge Control Valve (EVAP PURGE CONTROL VALVEI,and evaporative emission canister hoses to be sure they are not kinked and are securely connected.Replace any hose that shows signs of damage or deterioration. NOTE ~ The EVAP PURGE CONTROL VALVE is located under the fuel tank. (1) VEHICLE EMISSION CONTROL INFORMATION UP DATE LABEL VENICLE EMIssIou comnoL INFORMATION uman - HONDA MDYM couuo ms vamE ms IEEN ADJUSTED ro MOVE EMISSION otnnot rEnroancE WHEN ernArEn Ar man ALTITUDE ALmuoE rEnioancE AnJuerEur wsrmicnous ARE AVAILABLE Ar voun Aunmzzo MNDA oEALEn, VAClIlllA lllJSE lllJlITlllG DIAGRAM ENGINE mam: EVAPORATIVE FAMILH:I CALIFORNIA VEHICLE FuEL rmx EVAF CAV CONTROL VALVE ‘1 <— 10 OPEN AI R 0 a I CONTROL VALVE / DRAIN EVAP CANISTER 4-16 FUEL SYSTEM Disconnect the EVAP PURGE CONTROL VALVE hoses from their connections and remove the EVAP PURGE CONTROL VALVE from its mount.Referto the routing label on the inside of the left side cover for hose connections. Connect a vacuum pump to the 8 mm(0.31 in.l|.D.hose No.5 that goesto the 3—way Joint.Apply the specified vacuum to the EVAP PURGE CONTROL VALVE. SPECIFIED VACUUM: 250 mm (5,8 in) H9 The specified vacuum should be maintained. Replace the EVAP PURGE CONTROL VALVE if vacuum is not maintained. TOOL: Vacuum/Pressure pump Vacuum pump A937X—041—XXXXX or ST—AH—ZGO—MC7 (U.S.A. only) Remove the vacuum pump and connect it to the vacuum hose No.11 that goes to the left carburetor body. Apply the specified vacuum to the EVAP PURGE CONTROL VALVE. SPECIFIED VACUUM: 250 mm [9.8 in) H9 The specified vacuum should be maintained. Replace the EVAP PURGE CONTROL VALVE if vacuum is not maintained. TOOL: Vacuum/Pressure pump Vacuum pump A937X—041—XXXXX or ST—AH—ZGO— MC7 (USA. only) Connect a pressure pump to the 8 mm(0.31 in.ll.D.hose No.4 that goes to the evaporative emission canister.While applying the specified vacuum to the EVAP PURGE CONTROL VALVE hose that goes to the 3—way joint pump air through the evaporative emission canister hose.Air shoud flow through the EVAP PURGE CONTROL VALVE and out the hose that goes to the 3-way joint. Replace the EVAP PURGE CONTROL VALVE if air does not flow out. CAUTION . To prevem damage to the evaporative emission purge tantra! valve, do '10! use high air pressure sources. Use a hand operated air pump only. TOOL: Vacuum/Pressure pump Vacuum pump Pressure pump A937X—04‘I —XXXXX or ST—AH—ZGO—MC7 ST—AH—ZSS—MC7 (U.S.A. only) Remove the pumps, install the EVAP PURGE CONTROL VALVE on its mount, route and reconnect the house accord- ing to the routing label. EVAPORATIVE EMISSION CARBURETOR AIR VENT CONTROL VALVE INSPECTION (California model only) Disconnect the Evaporative Emission Carburetor Air Vent Control ValvelEVAP CAV CONTROL VALVEihoses from their connections and remove the EVAP CAV CONTROL VALVE from its mount.Refer to the routing label on left side cover for hose connections. (1| EVAPORATIVE EMISSION PURGE CONTROL VALVE (3) TO 3-WAV / (5| T0 EVAPORATIVE EMISSION CANISTER (4) TO CAHBURETOH BODY (2) VACUUM PUMP 4-17 FUEL SYSTEM Connect a vacuum pump to the No.10 hose that goes to the right carburetor body. Apply the specified vacuum to the EVAP CAV CONTROL VALVE. SPECIFIED VACUUM: 250 mm (9,8 in) H9 TOOL: Vacuum/Pressure pump Vacuum pump A937X—041—XXXXX or ST—AH—ZGO—MC7 IU.S.A. only) The specified vacuum should be maintained. Replace the EVAP CAV CONTROL VALVE if vacuum is not maintained. CAUTION . To prevent damage to [he evaporaiive emission carburetor air ven! comm! valvedo no! use high air pressure sources.U.ve a hand operated air pump only. Connect the vacuum pump to the air vent port of the EVAP CAV CONTROL VALVE. Apply vacuum to the EVAP CAV CONTROL VALVE.The vacuum should hold steady. Replace the EVAP CAV CONTROL VALVE if vacuum leaks. room Vacuum/Pressure pump Vacuum pump A537X—041 —XXXXX or ST—AH—ZGO—MC7 (USA. only) Connect the vacuum pump to the No.10 hose that goes to the right carburetor body. Connect the pressure pump to the air vent port of the EVAP CAV CONTROL VALVE. While applying the vacuum to the EVAP CAV CONTROL VALVE No.10 hose that goes to the right carburetor body. pump air through the air vent pon. Air should flow through the EVAP CAV CONTROL VALVE and out the hose that goes to the carburetor air joint pipe. TOOL: Vacuum/Pressure pump Vacuum pump Pressure pump A937X—041—XXXXX or ST—AH—ZSO—MC7 ST—AH—255—MC7 (u.s.A. only) Plug the hose that goes to the carburetor air joint pipe. While applying vacuum to the EVAP CAV CONTROL VALVE No.10 hose that goes to the right carburetor body,apply air pressure. It should hold steady. Replace the EVAP CAV CONTROL VALVE if pressure is not retained. Remove the pumps,install the EVAP CAV CONTROL VALVE on its mount,route and reconnect the hoses according to the routing label. TOOL: Vacuum/Pressure pump Vacuum pump Pressure pump A937X—041—XXXXX or ST—AH—ZGO— MC7 ST—AH—ZSS—MC7 (U.S.A. only) (2) TO OPEN AIR (1) TO AIR JOINT PIPE l3] EVAPORATIVE EMISSION No. 6 HOSE CARBURETOR AIR VENT CONTROL VALVE l4l T0 EVAPORATIVE v’ EMISSION CANISTER No. 4 HOSE <51 T0 RIGHT / CARBURETOR BODV No. 10 HOSE [5) VACUUM FUMF (1 ) BLOCKED TUBE VACUUM PUMP 4-18 MEMO COOLING SVSTEM 5-0 5. COOLING SYSTEM SERVICE INFORMATION TROUBLESHOOTING SVSTEM TESTING COOLANT REPLACEMENT 5-1 THERMOSTAT 5-1 RADIATOR/COOLING FAN 5-2 WATER PUMP 5-3 COOLANT/RESERVE TANK 53 5-5 5-7 5-9 SERVICE INFORMATION GENERAL WARNING ' Do not remove the radiator cap when the engine is hot, The coolant is under pressure and severe scalding could result. The engine must be cool before servicing the cooling system. ' I/ the engine must be running to do 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 o / consciousness and lead to death. C Use only distilled water and ethylene glycol 'n the cooling system. A 50—50 mixture is recommended for maximum corro— sion protection. Do not use alcohol-based antifreeze. 0 Add coolant at the reserve tank. Do not remove the radiator cap except to refill, coolant mixture testing or drain the sys- tem, or to test the coolant mixture. 0 Avoid spilling coolant on painted surfaces. 0 After servicing the system, check for leaks with a cooling system tester. o For thermosensor and thermostatic switch removal and inspection, refer to section 15. 0 To service the water pump, the engine must be removed from the frame. SPECIFICATIONS ITEM SPECIFICATIONS Fladiator cap relief pressure 88—127 kPa (0.9—1.3 kg/cm2,13—18 psi) Freezing point [Hydrometer test): 55% Distilled water + 45% ethylene glyc l-25°F) 50% Distilled water + 50% ethylene glyc l-34°F) 45% Distilled water + 55% ethylene glycol: 445°C l-4B°Fl Coolant capacity: Total system: Coolant change: 1.45 lit (1.37 US qt, 1.28 Imp qt) 1.6 lit 11.51 us qt, 1.41 Imp qt) Thermostat Begins to open: 80° to 84°C [176° to 153°F) Valve lift: Minimum of 8 mm at 95°C (0.3 in at 203°Fl Boiling point (with 50—50 mixture]: Unpressurized: 107.7“C (226°Fl Cap on, pressurized: 125.6°C (258°F) TROUBLESHOOTING Engine temperature too high t Faulty thermosensor bulb or sensor - Thermostat stuck closed - Faulty radiator cap ~ Insufficient coolant or coolant level too low Engine temperature too low - Faulty thermosensor bulb or sensor - Thermostat stuck open Coolant leaks - Passages blocked in radiator, hoses or water jacket - Faulty pump mechanical seal - Cooling fan motor does not turn — Burned or loose sub fuse — Faulty fan motor — Faulty thermostatic switch - Deteriorated O-rings — Poor connector contact or open circuit in harness ~ Faulty water pump COOLING SVSTEM SYSTEM TESTING COOLANT MIXTURE Remove the fuel tank [page 4-3). Remove the steering covers by removing the bolt. Remove the radiator cap. m— - He sure the engine is cool before removing the cap or you may be .teverel y .tcalded. Test the coolant mixture with an antifreeze tester. For maximum corrosion protection, a 50—50% solution of ethylene glycol and distilled water is recommended. RADIATOR CAP Wet the radiator cap sealing surface, install the cap on the tester, and apply pressure. Replace the radiator cap if it does not hold pressure, or if it's relief pressure is too high or too low. It must hold specified pressure for at least six seconds. RADIATOR CAP RELIEF PRESSURE: 88— 127 kPa (0.9—1.3 kg/cmi. 13— 18 psi) SYSTEM PRESSURE TEST Remove the steering covers and radiator cap. Attach the tester to the radiator and apply enough pressure to test the radiator, engine and hoses. Check for leaks. CAUTION ~ Excessive pressure can damage the radiator. Do not exceed [25 kPa (1.25 kg/cml, [8 psi) Repair or replace components if the system will not hold speci- fied pressure for at least six seconds. My STEERING covan (1) RADIATOR c'AP [1 I RADIATOR CAP 5-2 COOLING SVSTEM COOLANT REPLACEMENT _ (2» am cumogn » DRAIN BOLT m— - The engine must be cool before replacing the coolant or severe melding ma y result, Remove the radiator cap (page 5-2]. Drain the coolant from the system by removing the drain bolt on the water pump cover. Remove the rear cylinder coolant drain bolt and drain the collant using a vinyl as shown. Reinstall the drain bolt. (1] DRAIN BOLT l3) VINYL Fill the system with 50—50 mixture oi distilled water and eth- vlene glycol. Bleed air from the cooling system. - Lower the side stand and shift the transmission into neutral. ~ Stan the engine and snap the throttle grip, 3—4 times at 4,000—5,000 rpm. Then add coolant up to the radiator filler neck. - Reinstall the radiator cap. - Check the level of coolant in the reserve tank and fill to the correct level if the level is low. THERMOSTAT 7 ——mm (2] FILLER MOUNTING BOLTS, REMOVAL Remove the following: — fuel tank [page 4-3] — air cleaner hOUSIng (page 4-4) — steering covers (page 5—2) — radiator cap Drain the coolant. Remove the thermostat housing and radiator filler mounting bolts. Disconnect the siphon tube from the radiator filler. Disconnect the upper radiator hose at the radiator and remove filler and the radiator hose from the frame. Remove the thermostat housing cover. COOLING SYSTEM Remove the thermostat from the housing. INSPECTION Inspect the thermostat visually for damage. Suspend the thermostat 'n heated water to check its opera- tion. NOTE - If the thermostat or thermometer touches the pan, you'll get a false reading. Replace thermostat if valve stays open at room temperature, or if it responds at temperatures other than those specified. Data: Start to open 80" to 84°C1176—183°F) Valve lift 8 mm (0.3 inl minimum when heated to 95°C [203°F) for five minutes. INSTALLATION Install the thermostat into the housing. Install a new O—ring on the housing cover and install the hous— ing cover onto the housing, (1 fiT—ufiAOSTAT l1] THERMOSTAT COOLING SYSTEM Tighten the thermostat housing cover mounting bolts. NOTE - Be sure to secure the thermostat ground wire with the cover mounting bolt shown. Install a new O—ring on the radiator filler, and connect the upper radiator hose to the radiator. Install the radiator iiller onto the thermostat housing. Tighten the filler and thermostat housing mounting bolts. Install the remaining removed parts it the reverse order of re- moval. Fill the system with coolant. RADIATOR/COOLING FAN REMOVAL NOTE - For fan motor inspection, reier to section 18. Remove the steering cover and disconnect the (an motor con- nector (2P BLACK) Remove the horn mounting bolt and horn, then disconnect the horn wires. Remove the radiator mounting bolt and disconnect the lower radiator hose from the radiator by loosening the hose band. (1) Gnourfi'wms AND BOLT ‘FTZI HOUSING MOUNTING BOLT (3) FILLER ATTACHING \ “JEL— ‘ l [1) RADIATOR MOUNTING BOLT COOLING SYSTEM Unhock the radiator mounts from the grommets from in frame‘ Unclamp the upper radiatorhose and disconnect the hose from the radiator. I \\\ n ) MOUNTS \ DISASSEMBLY Disconnect the thermostatic switch wire connector from the switch and remove the wire from the clamp. Remove the ground wire terminal bolt. Remove the fan motor shroud mounting bolts, and remove the fan motor shroud and fan motor as an assembly. [2) WIRE CONNECTOR Remove the nut to separate the fan from the shroud. l1) NUT Remove the fan motor mounting nuts and fan motor from the (1) FAN MOTOR OUNTING NUTS shroud. " I (2) SHROUD COOLING SYSTEM ASSEMBLY Inspect the radiator soldered joints and seams for leaks Blow dirt out from between core fins with compressed airt If insects, etc‘. are clogging the radiator, wash them off with low pressure water. Carefully straighten any bent fins. Install the motor on the shroud and tighten the nuts. Install the fan to the fan motor shaft, aligning the boss of the shaft with the groove of the fan. Assemble the remained components 'n the reverse order of the disassembly. If removed the thermostatic switch from the radiator, refer to page 15—8. NOTE ~ Do not overtighten the thermostatic switch, when reinstall it. TORQUE: IBN-ml1.8kg-m,13ft—lbl. WATER PUMP MECHANICAL SEAL INSPECTION NOTE - The water pump cover and O-ring can be removed with engine in the frame. Inspect the telltale hole for signs of mechanical seal coolant leakage. Replace the water pump as an assembly if the mechanical seal is leaking‘ REMOVAL Remove the engine from the frame [section 6]. Remove the water pump cover mounting bolts and cover‘ Remove the O-ring and dowel pins from the water pump as- sembly and disconnect the water hose. Remove the water pump from the crankcase. (1 I ALIGN COOLING SYSTEM INSPECTION m 0-HING (2) WATER PUMP ASSEMBLY Check the water pump for mechanical seal leakage and bear- ing deterioration. Replace the water pump as an assembly if necessary. [3) WATER PUMP (4) O-RING INSTALLATION Apply a coat of clean engine oil to a new O—ring and install it in the water pump shaft housing groove. Align the water pump shaft groove with the oil pump shaft and insert the water pump into the crankcase. Apply a coat of engine oil to a new O-ring and install it around the impeller housing. Install the two dowel pins. Connect the water hose with the clamp. Install the water pump cover and tighten the cover mounting bolts. Connect the water hose with the clamp. Install the engine in the frame (section 6]. Fill the system with coolant (page 5—3]. Fill the engine with the recommended engine oil [page 2-4). Check the cooling system for leakage. COOLING SYSTEM COOLANT/ RESERVE TANK REMOVAL/INSTALLATION Raise and support the motorcycle rear frame using a hoist or jack under the engine Remove the evaporative emission canister(California model only). Place a clean container under the reserve tankt Disconnect the radiator siphon tube at the reserve tank‘ Remove the reserve tank mounting bolt, filler mounting nut and the reserve tank‘ Hold the overflow tube upright and remove the reserve tank from the frame Empty the tank, it necessary. Install the reserve tank in the reverse order of removal. Fill the tank with coolant, if necessary CAUTION ' The tab of the reserve tank should be aligned with the grommet in the/tame. (1) GROMMET (4) SIPHON TUBE (2) TAB [3) RESERVE TANK ENGINE REMOVAL/INSTALLATION mm K; ‘ 90 N~m (9.0 kg-m, es lt-lb) 55 N-m [5.5 kg-m, 40 lt-lb)\.® 27 N-m (2‘7 kg-m, 20 ft-lb)\~$W/l 40 N-m (4‘0 kg-m, 29 h-Ib) 27 N4m,(2‘7 kg-m, 20 lt-lb] 6-0 6. ENGINE REMOVAL/ INSTALLATION SERVICE INFORMATION 6-2 ENGINE INSTALLATION 6-5 ENGINE REMOVAL 6-3 55 N-m (5.5 kg—m, 40 ft-Ib) 27 N‘m (2.7 kg-m, ZOIt-Ib) 6-1 ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL 0 Support the motorcycle using a hoist, a floor jack or other adjustable support. 0 The following parts can be serviced with the engine installed in the frame: - Clutch ' Gearshift linkage - Camshafts - Front cylinder head/cylinder 0 To service the water pump body, oil pump, and rear cylinder head/cylinder the engine must be removed from the frame SPECIFICATIONS Engine dry weight Oil capacity Coolant capacity TORQUE VALU ES Rear axle Shook absorber lower mounting bolt Gearshift arm bolt Foot peg bracket bolt Swingarm pivot bolt Front upper engine mounting bolt Front upper engine bracket bolt Front lower engine mounting bolt Hear upper engine mounting bolt Hear upper engine bracket bolt Exhaust pipe joint nut Fuel tank mounting bolt Exhaust muffler bracket bolt ' Alternator - Starter motor ' Carburetors 51 kg (134 lb] 28 lit (2.94 US qt, 2‘46 lmp qt) at disassemny 1‘6 Iit (1.51 US ot,1.41 lmp qt) total 90 N-m [9.0 kg-m, 65 lt-Ib) 45 N4“ [4.5 kg-m, 33 It-lb) ‘IZ N-m [1‘2 kg-m, 9 ft-Ib) 40 N4“ [40 kg-m, 29 It-Ib) 90 N-m [9.0 kg-m, 65 ft-lb) 55 N-m [5‘5 kg-m, 40 ft-lb) 27 N-m (2‘7 kg-m, 20 ft-Ib) 55 N-m (5.5 kg-m, 40 ft-Ib) 55 N4“ [55 kg—m, 40 ft-Ib) 27 N4“ (27 kg-m, 20 ft-Ib) 25 N-m (2.5 kg-m,18 ft-Ib) 19 N-m (1‘9 kg-m,13.7lt-lb) 27 Wm [27 kg-m, 20 ft-Ib) ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Support the motorcycle using a hoist or a jack. CAUTION - Do no! jack up the engine 11! [he oi/ filler. Drain the engine oil (page 2—4) and the radiator coolant (page 5-3]. Disconnect the battery negative cable from the battery termi- nal. (2i EXHAUST PIPE AND MUFFLERS Remove the following: — fuel tank (page 4-3] — air cleaner housing (page 4-4) . , _. ~— — air cleaner chamber (page 4-4) (1) NEUTRAL ‘ (2) DRIVE SPROCKET — carburetor (page 4-6] » SWITCH — exhaust pipe protectors — exhaust pipe and mufflers Loosen the drive chain (page 3—13). Remove the drive sprocket cover (page 13-14], then remove the sprocket from the drive chain by removing the two sprock- et bolts. Disconnect the oil pressure and neutral switch wires irom the switch terminals and tree the switch wire harness from the engine and frame Remove the gearshift arm from the gearshift spindle. Disconnect the starter motor cable and ground cable from the starter motor. Disconnect the clutch cable from the clutch lifter arm by re- (2) 50'- moving the holder bolt. .1\ fix Remove the right foot peg and rear brake pedal by removing the two bracket mounting bolts. A. - (3) BRACKET MOUNTING BOLTS 6-3 ENGINE REMOVAL/INSTALLATION Disconncet the ignition pulse generator wire connectorl4P WHITEL Remove the lower radiator hose lradiator-to-water pump). Disconnect the water hoses (thermostat housing-to-cylinder heads] from the cylinder heads (page 9-3]. (1| LOWER RADIATOR HOSE I FRONT FER ’ BOLT , ...v__, 4 Place a floor jack or other adjustable support under the engine. (1) REAR UPPE BOLT rwu‘TZ) NOTE - The jack height must be continually adjusted to relieve stress for ease of bolt removal. Remove the following: — rear wheel (page 13-3) — swingarm [page 13-14] — front upper engine bracket [two 8 mm bolts, 10 mm bolt and collar) — front lower engine bracket [8 mm bolts and 10 mm bolt) (4) Sg'NGARM P'VOT 3 « O O O — rear engine bracket [two 8 mm bolts and 10 mm bolt) B LT _— i ) FR NT '- WER 3 LT NOTE ~ Do not damage the radiator fin. ENGINE REMOVAL/INSTALLATION ENGINE INSTALLATION - “ n) coma Engine installation is essentially the reverse order of removal. Use a floor jack or other adjustable support to carefully manuever the engine into place. CAUTION - Carefully align mounting points wilh lhe jack lo prevenl damage to mounting ball threads and wire harness and cables. NOTE - Be sure to install the mounting collars and swingarm dust seals in their correct positions. [1) SWINGAHM LEFT SIDE COLLAR Tighten all the fasteners to the specified torque given on page I 7 5-0, 1 and 2. NOTE - Route the wires and cables properly (section 1). - Fill the crankcase to the proper level with the recommended oil (page 274). - Fill the cooling system (page 5—3). - Perform the following inspection and adjustments: Throttle operation [page 3—6) Clutch (page 3718), CLUTCH/GEARSHIFT LINKAGE 12N-m(1_2kgim, 9mm 130N~m(13A0kg-m. 23N.m(2 .3kgim,17hilb) 7. CLUTCH/GEARSHIFI' LINKAGE SERVICE INFORMATION 74 PRIMARY DRIVE GEAR 7-1 1 TROUBLESHOOTING 7-2 CLUTCH INSTALLATION 7-12 RIGHT CRANKCASE COVER REMOVAL 7-3 RIGHT CRANKCASE COVER CLUTCH REMOVAL 7_4 INSTALLATION 7-14 GEARSHIFT LINKAGE 7-8 SERVICE INFORMATION GENERAL 0 This secTion covers The removal and installaTion of the clutch, oil pump drive chain, gearshift linkage and primary drive gear. All These operations can be done with the engine insTalled in The frame. 0 If The shifT fork, drum and Transmission require servicing, remove The engine and separaTe The crankcase [section 11]. - O Coat The new clutch discs with clean engine oil before reassembly. SPECIFICATIONS UniT: mn (in) ITEM STANDARD SERVICE LIMIT Clutch Spring free lengTh 887 39.0 (1.54) 37.4 (1 ‘47) After 88; 43.2 (1‘70) 41.5 (164) Spring preload/IengTh 25.25—27.25/25.2 kg/mm — Disc Thickness 2.52—2.78 [0.103—0.107) 2.30 (0.090) B 2.92—3.08 [0.115—0t121) 2.60 (0.102) PlaTe warpage 7 030 (0.012) Outer guide LU. 21.991—22.016[0.8658—03668] 22.09 (0.870) OTD. 31959—31025 [1.2582—12559] 31.98 (1.259) Outer |.D. 32000—32025 [12598—12508] 32.10 (1264) Oil pump drive sprocket l.D. 32000—32025 (12598—12508) 32.10 (1264) MainshalT CD. at cluTch ouTer guide 21.967—21380 (03648—03554) 21.92 (0.863) TORQUE VALUES Drum sTopper plaTe bolT Primary drive gear bolT Oil pump driven sprockeT MIT 12 N-m (1.2 kg-m, 9 fT-lb] Apply locking agenT 90 N-m (9.0 kg-m, 65 ft-lb] 15 N-m (1.5 kg-m, 11 fT-Ib) Apply locking agent CluTch lock nut Oil pass pipe bolT [8 mm) (7 mm) TOOLS Special CluTch cenTer holder Gear holder Common Luck nut wrench, 17 x 27 mm 130 Nam (13.0 kg-m, 94 it-lb) 23 N-m [2.3 kg-m, 17 ft-lb) 10 N-m (1.0 kg-m, 7.2 ft-lb] 07923—KE10000 or 07HGB—001000AIU.S.A.on|y) 07724—0010100 07716—0020300 EquivalenT commercially available in U.S.A. 7-1 CLUTCH/GEARSHIFT LINKAGE TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch lever free play. Clutch slips when accelerating - No free play - Discs worn - Springs weak Clutch will not disengage - Too much free play - Plates warped Motorcycle creeps with clutch disengaged - Too much free play - Plates warped Excessive lever pressure ' Clutch cable kinked, damaged or dirty ' Lifter mechanism damaged Clutch operation veels rough - Clutch outer slots rough ' Dirty clutch cable 7-2 CLUTCH/GEARSHIFT LINKAGE RIGHT CRANKCASE COVER REMOVAL '88, '89: Drain the engine oil [page 274iv Remove the clutch cable holder and disconnect the clutch cable from the clutch lilter arm. Loosen the oil pipe holder and remove the oil pipe bolt and seal- ing washers from the right crankcase cover. Remove the right crankcase cover bolts and cover. After '89: Drain the engine oil (page 274). Remove the clutch cable holder and disconnect the clutch cable from the clutch lifter armt 1’] Remove the right crankcase cover bolts and cover. #12ng , / Remove the dowel pins and gasket. A. '88, '89: Remove the oil orificet CLUTCH LIFTER SHAFT ’ -' ' . (ii'urrn mac's? Remove the clutch lifter piece, and remove the snap ring and return spring from the right crankcase cover. Remove the clutch lifter shaft. Check the clutch lifter piece and shaft for damage or excessive scratchingt Check the return spring for fatigue or damage. (2) LIFTER , ,SHAFT 7-3 CLUTCH/GEARSHIFT LINKAGE Check the needle bearing for wear or damage or a loose fit in the cover. Check the dust seal for fatigue or damage. Apply grease to the dust seal and needle bearing‘ (2) NEEDLE - ” ’1 (1i DUST SEAL BEARINGS ‘ Install the clutch lifter shaft. snap ring and return spring. Hack the spring end in the cover tab securely, and turn the shaft. Install the clutch lifter piece, aligning the piece end with the groove in the clutch lifter shaft. a: swarm N6 - - - .fi 0 (9(1) CLUTCl-lvlFTEVR PLATE CLUTCH REMOVAL Remove the following: — clutch bolts — clutch lifter plate — springs ‘u Unstake the clutch lock nut with a drill or grindert NOTE - Be careful not to damage the shaft threadst CLUTCH/GEARSHIFT LINKAGE Hold the clutch center with the special tool and loosen the clutch lock nut. Remove the tools and the lock nut. TOOLS: Clutch center holder 07923-KE10000 or 07HGB-001000A (U.S.A. only) Lock nut wrench, 17 x 27 mm 07716—0020300 Equivalent commercially available in U.S.A. Remove the following: ispring washer (After’95 only) iwasher iclutch center,judder spring and spring seat 7discs and plates ipressure plate l V ‘5 (3) PRESSURE PLATE , Remove the thrust washer and clutch outer. Remove the oil pump driven sprocket mounting bolt, driven sprocket and oil pump drive chain. CLUTCH/GEARSHIFT LINKAGE Remove the drive sprocket and clutch outer guide from the mainshaft. INSPECTION Check the lifter plate bearing for damage. Turn the bearing inner race with your finger. The bearing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the clutch lifter plate. Replace the hearing if necessary. Measure the spring free length. SERVICE LIMIT: 88; 88; 37.4 mm (1.47 in) After 89: 41,6 mm (1.65 in) Replace the clutch discs if they show signs of scoring or dis- coloration. Measure the thickness of discs A and E. SERVICE LIMIT: (A) 2.30 mm (0.090 in) (B) 2.60 mm (0.102 in) NOTE ' Replace the discs and plates as a set it any one is beyond the service limit. (2] CLUTCH L|FTEH PLATE 7-6 Check the plate wavpage on a surface plate using a thickness gauge. SERVICE LIMIT: 0.30 mm (0.012 In) Check the clutch center for nicks or indentations made by the clutch plates. Check the spring seat and iudder spring for distortion, wear or damage. Replace them it necessary. Check the slots in the clutch outer for nicks or indentations made by the clutch discs. Measure the I. D. of the clutch outer and the 0.0. oI the clutch outer guide. SERVICE LIMITS: Clutch outer I.D. 32.10 mm (1.264 In) Clutch outavgulda 0.D. 31.58 mm (1.255 In) CLUTCH/GEARSHIFT LINKAGE (1) PLATE (1] CLUTCH CENTER l1) JUDDER SPRING (2) SPRING SEAT (1) CLUTCH OUTER CLUTCH/GEARSHIFT LINKAGE Check the oil pump drive sprocket for damage. Measure ID of the drive sprocket and the OD. of the outer guide. SERVICE LIMITS: OI pump the sprocket I.D. 32.10 mm (1.264 in) Clutch outer gulde CD. 31.93 mm (1.259 In) Measure the mainshaIt CD. at the clutch outer guide SERVICE LIMIT: 21.92 mm (0,863 In) GEARSHIFI' LINKAGE " m GEARSHII—‘I’ SPINDLE y,‘ REMOVAL » ‘ Remove the following: — drive sprocket cover {page 13—14) gearshift pedal arm from the gearshift spindle right crankcase cover (page 7—3) clutch assembly (page 74] oil pump drive chain (page 7—5) Loosen thetwo oil pipe stay mounting bolts and remove the oil pipe mounting bolt‘ Pull the oil pipe out of the stay and oil pump. Remove the following: — gearshift spindle — drum stopper arm bolt, stopper arm, collar and spring — drum stopper plate bolt and stopper plate/drum INSPECTION Check the gearshift spindle for bending or damage. Check the return spring for fatigue or damage. Inspect the gearshift pedal shaft for damage or loose lock nuts. Replace the shaft if necessary, Inspect the dust seals and pivot collar for wear or damage. Replace if necessary, Apply grease to the dust seal lips and pivot collar and install them into the pedal shaft. CLUTCH/GEARSHIFT LINKAGE (1) GEARSfilFT SPINDLE (2) DUM STdPPER-XRM g . , %~~ . / ‘ i r (4) st)ng PLNE . g) BOLT (1) SPINDLE / $3 [2) RETURN SPRING [1) GEARSHIFT PEDAL SHAFT (1i DUST SEALS 7-9 CLUTCH/GEARSHIFT LINKAGE INSTALLATION (1) DOWEITPIN ('2) s’TOPPEn A Install the collar, spring, stopper arm, washer and stopper arm 7 ' bolt and tighten the bolt. ' , r Install the dowel pins into the holes of the gearshift drum. Lift up the drum stopper arm and install the drum stopper plate. Apply locking agent to the threads of the stopper plate bolt and tighten the bolt. TORQUE: 12 N-m (1‘2 kg-rn, 9 ft—lb) Install the gearshift spindle, aligning the return spring ends with the pin in the case. Install the oil pipe with a new O-ring onto the oil pipe stay and oil pump Tighten the bolts securely. Install the removed parts in the reverse order of removalt Install the gearshift arm to the gearshift spindlet Align the punch mark on the arm with the punch mark on the spindle Tighten the gearshift arm mounting bolt. V / \‘, ‘ r (_4)EARSH|FT seiNDLE .‘ it! (a G_EAHSHIFT ARM 7-10 CLUTCH/GEARSHIFT LINKAGE Install the gearshift pedal mounting bolt and tighten the bolt securely. Install the drive sprocket cover (page 13-17). [1) GEARSHIFT PEDAL MOUNTING BOLT PRIMARY DRIVE GEAR i . ‘lll IGNITION P—ULSE REMOVAL Remove the following: — right crankcase cover (page 7-3] — clutch assembly [page 7-4) Remove the ignition pulse generator mounting bolts and lgnltion pulse generators. Temporarily install the clutch outer, (page 7-13) then install (1) lofilTTON PULSE GENERQTOR‘ MOUNTl-Nfs BOLT V _ ‘ ‘,, , g the gear holder as shown. ‘ , TOOL: Gear holder 07724—0010100 Remove the followmg: — ignltion pulse generator rotor bolt and rotor — clutch outer and gear holder — prlmary drive gear INSTALLATION I1) PRIMARY g DRIVE Install the primary drive gear with the "OUT" mark facing out. ' GEAHx NOTE i 0’ - The primary drive gear and ignltion pulse generator rotor will only go on in one position because of the extra wide alignlng spline. Install the ignition pulse generator rotort 14> IGNITION pULs€\\' GENERATORfiOTOH . CLUTCH/GEARSHIFT LINKAGE Temporarily install the clutch outer and install the gear holder as shown. TOOL: Gear holder 07724—0010100 Install the washer and bolt and tighten the bolt. TORQUE: 90 Nvm (9.0 kg-m. 65 ft-lbl Remove the gear holder and clutch outer. Install the following: — ignition pulse generators — clutch(page 742) NOTE ' If removed the ignition pulse generator WIre grommets were removed from the case groove,reInstaI| them securely. . , 7 \I " (A (2) IGNITION PULsgostrgAlofir CLUTCH INSTALLATION Apply M052 paste grease to the outside of the clutch outer guide and install the oil pump drive sprocket over the outer guide. Install the oil pump drive chain on the drive sprocket. Ill OIL PUMP DRIVEN SPROCKET Install the oil pump driven sprocket with the "IN" mark facing inside. Guide the drive chain over the sprocket. Apply locking agent to the threads of the driven sprocket mounting bolt and tighten it with the washer to the specified torque. TORQUE: 15 N-m (1.5 kg-m. 11 ft-Ib) 7-12 Align the grooves '11 the clutch outer with the bosses on the oil pump drive sprocket while turning the sprocket with the chain and pushing the clutch outer onto the shaft Install the thrust washer onto the mainshaftt Install the spring seat, iudder spring and clutch disc 8 on the clutch center. NOTE - Note the positions of the seat, spring and disc B. Install clutch discs, clutch plates, clutch disc A, the plates, discs, and pressure plate on the clutch center and install them in the clutch outer as an assembly. Align the tabs in the disc 8 with the slots on the clutch outert NOTE ' Stack the discs and plates alternately as shown‘ ' Coat the new clutch discs with clean engine oil. Install the washer on the mainshaft. After'95: Install the spring washer on the mainshaft with the “OUT SIDE" mark facing outside. CLUTCH/GEARSHIFT LINKAGE [2) JUDDER SPRING (3) DISC B [1) SPRING SEAT m»! ( > (1) WASHER 12) SPRING WASHER 7-13 CLUTCH/GEARSHIFT LINKAGE Hold the clutch center with the clutch center holder, and tight- en the lock nut to the specified torque. TORQUE: 130 N-m (13.0 kg-m, 94 ft-lb) TOOLS: Clutch center holder 07923-KE10000 or 07HGB-DO1DDOA (USA. only) Lock nut wrench. 17 x 27 mm 07716-0020300 Equivalent commercially available in U.S.A. Stake the lock nut with the center punch. Install the clutch springs, lifter plate and bolts. Tighten the bolts '71 a crisscross pattern in 2 or 3 steps. NOTE ' Make sure the pressure plate firmly pushes the discs and plates. Install the bearing into the lifter plate. RIGHT CRANKCASE COVER INSTALLATION '88, '89: Install a new O-ring on the oil orifice. Install the oil orifice with its smaller hole facing in. (3) INSIDE _. m 7-14 CLUTCH/GEARSHIFT LINKAGE . .._._ Install the dowel pins and new gasket. (1) DOWEL PIN ‘ "‘4 s {,4} '88, '89: Tighten the right crankcase cover mounting bolts 'n a crisscross pattern 'n 2 or 3 steps and install the clutch cable holder and oil pipe holder at the same time. Connect the clutch cable to the clutch lifter arm. Tighten the oil pipe bolt with the sealing washers. TORQUE: 2.3 N-m (L3 kg-m. 17 ft-Ib) Fill the crankcase with engine oil (page 274! Adjust the clutch lever free play (page 3718! a (3] OIL BOLT After ’39: Tighten the right crankcase cover mounting bolts in a crisscross pattern 'n 2 or 3 steps and install the clutch cable holder and oil pipe holder at the same time‘ Connect the clutch cable to the clutch lifter arm. Fill the crankcase with engine oil [page 274) Adiust the clutch lever free play (page 3718! 7-15 ALTERNATOR/STARTER CLUTCH 130 N-m (13,0 kg-m, 94 fI-Ib) 30 N'm (3.0 kg-m, 22 ft»|b) 8-0 8. ALTERNATOR/ STARTER CLUTCH SERVICE INFORMATION 8-1 FLVWHEEL INSTALLATION 85 LEFT CRANKCASE COVER REMOVAL 8-2 LEFT CRANKCASE COVER FLYWHEEL REMOVAL 8-3 INSTALLATION 8’6 STARTER CLUTCH 8-4 GENERAL 0 This sec‘ion covers Ihe removal and installa‘ion of the alIernator, s‘arter clumh and sIaner gears. These opera‘ion can be done with Ihe engine ins‘alled in the frame 0 Refer to sec‘ion 15 for troubleshoming and inspemion of me alternamr. SPECIFICATIONS mm (in) ITEM STANDARD SERVICE LIMIT a SIaner driven gear 0.0T 57.749—57.768 [22736—21743] 5715012268) TORQUE VALUES Flywheel belt 130 N-m [13I0 kg-m, 94 fi-Ib) Len-hand thread SIaner clutch (orx bolts 30 N-m (3.0 kg-m, 22 ft-lb) Apply locking agem TOOLS Common Romr puller 07733—0020001 or 07933—3290001 [U.S.A only) Flywheel holder 07725—0040000 Equivalem commercially available In USA. Torx bi: 07703—0010100 Equwalent commercrally available In U.S,A. 8-1 ALTERNATOR/STARTER CLUTCH LEFI CRANKCASE COVER REMOVAL Remove the left side cover and disconnect the alternator wire 3? connector (WHITE). Remove the drive sprocket cover (page 13-14). Place a container under the left crankcase cover to catch the engine oiL Remove the eleven left crankcase cover bolts and the cover. Remove the dowel pins and gasket. (2) GROMMETS STATOR REPLACEMENT , 3 STAT R Remove the wire clamp bolts and the clamps. [ ) 0 Remove the stator mounting bolts and stator. Position the new stator and the grommets in the covert Apply a locking agent to the threads of the stator mounting bolts and wnre clamp bolts. Tighten the stator mounting bolts and the clamp bolts. ALTERNATOR/STARTER CLUTCH FLYWHEEL REMOVAL V, (1) IDRMMR * (2 RIVE GEAR Remove the starter drive and idle/reduction gears by removan the shafts. Hold the flywheel with the flywheel holder and remove the ilv- wheel bolt and washer. TOOL: Flywheel holder 07725—0040000 Equivalent commercially available in U.S.A. NOTE The flywheel bolt has leit-hand threads. Remove the flywheel with the rotor puller. TOOL: Rotor puller 07733—0020001 or 07933—3290001 (USA. only) Remove the starter driven gear, washer and needle bearing irorn the crankshaft, Remove the wooorurt key. it. (a) WOODRUliF KEY\ ALTERNATOR/STARTER CLUTCH STARTER CLUTCH DISASSEMBLY Reinstall the starter driven gear into the flywheelt Inspect the starter clutch by turning the starter driven gear. The gear should turn counterclockwise freely and should not turn clockwise: if it turns incorrectly, replace the starter clutch‘ Hold the flywheel with the flywheel holder and remove the torx bolts using a torx bitt Remove the starter clutch outer and oneway clutcht TOOLS: Flywheel holder 07725-0040000 Equivalent commercially available in USA. Torx blt 07703-0010100 Equivalent commercially available in USA, INSPECTION Measure the CD. of the starter driven geart SERVICE LIMIT: 57.60 mm (2.268 In) Inspect the oneway clutch for wear or damage and replace if necessary. l‘ll STARTER DRIVEN GEAR l1) FLYWHEEL HOLDER ll] ONEWAV CLUTCH (2) FLVWHEEL 8-4 ALTERNATOR/STARTER CLUTCH ASSEMBLY Install the oneway clutch into the clutch outer with the flange side facing inside. Hold the flywheel with the flywheel holder‘ Apply locking agent to the trox bolt threads and tighten the bolts. TORQUE: 30 N-m (3‘0 kg-m, 22 ft-lb) TOOLS: Flywheel holder 07725-0040000 Equivalent commercially available in USA. Torx bit 07703-001010!) Equivalent commercially available in U,S.A. FLYWHEEL INSTALLATION Clean the crankshaft and install the woodruff key‘ Install the needle bearing onto the crankshaftt Install the starter driven gear and washer onto the crankshaft. (1) CLUTCH OUTER (2) FLANGE l3) ONEWAY CLUTCH (1 l TORX BIT ALTERNATOR/STARTER CLUTCH _ ,‘r’ Install the flywheel, aligning the woodruff key on the crank- ‘(1) FLVWHEEL HOLDER shaft with the flywheel keyway. Hold the flywheel with the flywheel holder, install the washer and flywheel bolt and tighten the bolt. TORQUE: 130 N>m [13.0 kg-m, 94 Tt-Ib) TOOL: Flywheel holder 07725-0040000 Equivalent commercially available in USA. NOTE ' The flywheel bolt has left hand threads. Install the starter idle/reduction gear with the longer shaft. (1) lDLE/REDUCTION (2) STFRTER DRTVE GEAR K “ \1 ' Install the starter drive gear with the "OUT" mark facing out ‘ and the shorter shaft. Install the dowel pins and new gaskett LEFT CRANKCASE COVER INSTALLATION Install the left crankcase cover and tighten the cover belts with the neutral and oil pressure switch wire harness clamps as shown. Floute the alternator wire and connect the alternator 3P con- nectar. Install the drive sprocket cover and the left side cover. Check the oil level and add oil if necessary. 8-6 MEMO CVLINDER HEAD/VALVE 1O N-m (1.0 kg-m, 7 2 h-lb) 23 N-m (2‘3 kg-m, 17 ftrlb) 23 Nom (2.3 kg-m, 17 ft-lbD 9 23 N-m [2.3 mink 17 h-Ib) 23 N.m (2.3 Wm, 48 N>m14.8 kg-m, 35 mm) 17 ft-lb) mg 9 23 N‘m (2.3 kg-m, O 17 mm 10 N-m (1V0 kg-m, 7.2 fK-lb) 10 N‘m (1.0 kg-m, 7.2 h-lb) 23 N-m12.3 kg-m, 17 (Mb) 9-0 9. CYLINDER HEAD/VALVE SERVICE INFORMATION 9.1 VALVE SEAT lNSPECTlON/REFACING 9.12 TROUBLESHOOTING 9»2 cVLINDER HEAD ASSEMBLV 9-15 CYLINDER HEAD cOVER REMOVAL 9»: CYLINDER HEAD INSTALLATION 9-16 CAMSHAFT REMOVAL 9»4 CAMSHAFT INSTALLATION 9-18 CVLINDER HEAD 9-8 CVLINDER HEAD COVER VALVE GUIDE REPLACEMENT 941 '"STALU‘T'O" 9'21 SERVICE INFORMATION GENERAL 0 The from cylinder head can be removed without removing the engine. 0 To service the rear cylinder head, the engine must be removed from the frame. (See section 6 for engine removal and in- stallation.) However, the rear cylinder head cover can be removed to service the camshaft, rocker arms, cam chain and cam chain tensioner. O Camshaft lubricating oil is fed through an oil pass pipe. Be sure the holes in the Oil pass bolts are not clogged. 0 During assembly apply molybdenum disulfide Oil [a 50/50 mixture of engine oil and molybdenum disulfide grease) to E the camshaft holders, camshaft journals of the cylinder head, rocker arm shafts, rocker arm slipper faces and valve stems to provide initial lubrication. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Compression pressure 1,324 kPa _ (13.5 2 1.0 kg/cmz, 192 z 14 psi] Camshaft Cam lobe height IN 37930 (1.4933) 37.730 (1.4854) Ex 37.950 (1.4941) 37.750 (1.4862) Journal O.D. 21859—21680 [0.5645—0.8654) 21.90 [0.562) Hunout 0.030 (0.0012) 0.05 (0.002) Oil clearance 0050—0111 (00020—00044) 0.130 (0.0051) Rocker aim Rocker aim |.D. lN/EX 12000-1201 8 (04724—04731) 12.05 (0.474) Rocker arm shaft IN/Ex 11366—11384 (04711—04718) 11.83 (0.465) 0.0. Valves and Valve stem CD. IN 5475—5490 (02156—02161) 5.45 (0.215) “We guides Ex 6555—6570 (02580—02587) 6.55 (0.255) | Valve guide |.D. IN 5500—5512 (02165—02170) 5.55 (0.219) | Ex 6.600—6.615(02598—02604) 6.65 (0.262) Stem-tO-guide IN 0.010—0037 (00004—00015) 0.10 (0.004) “93'3"” EX 0030—0060 (00014—00024) 0.11 (0.004) Valve seat width 0.9—1.1 (0035—0043) 1.5 (0.06) Valve guide pro- IN 19.4—19.5 (0.76—0.77) 7 19mm “Eigh‘ EX 17.9—18.1 (0.70—0.71) 7 Valve springs Free length OUTER IN 42.14 (1.559) 40.58 (1.595) EX 42.53 (1.686) 41.25 (1.624) INNER IN 38.11 (1.500) 36.47 (1.435) EX 38.81 (1.765) 37.51 (1.477) Cylinder head warpage 7 0.10 (0.004) 9-1 CVLINDER HEAD/VALVE TORQUE VALUES Cylinder head cover bolt Camshaft holder 8 mm bolt 8 mm nut 6 mm bolt Cylinder head 10 mm nut 8 mm bolt 8 mm nut 6 mm bolt Camshaft sprocket bolt Cam chain tensioner bolt Oil pass pipe 7 mm bolt 8 mm boIt TOOLS Special Valve guide reamer (IN) Valve guide reamer (EX) Valve guide driver attachment (IN) Valve guide driver attachment (EX) Common Valve guide driver, 5.5 mm (IN) Valve guide driver, 6.6 mm (EX) Valve spring compressor Valve seat cutter [Not available in USA.) Cutter holder IN 55 mm EX 6.6 mm IN 28 mm [32°] EX 35 mm (32°) Interior cutter IN 30 mm (60°) EX 37.5 mm (60°) IN 27.5 mm (45°) EX 35 mm (45°) TROUBLESHOOTING Flat cutter Seat cutter 1O N-m [1,0 kg—m, 7.2 “413) 23 N-m (2.3 kg—m, 17 ft-lb] 23 N‘m (2,3 kg—m, 17 ft-lb] 10 N‘m (1.0 kg-m, 7.261-lb) 48 N‘m (4.8 kg-m, 35 ft-lb] 23 N-m (2,3 kg-m, 17 “413) 23 N-m (2.3 kg-m, 17 “413) 10 N-m (1.0 kg-m, 7.261-lb) 23 N-m (2.3 kg-m, 17 ft-lb) 10 N-m (1.0 kg-m, 7.2 It-lb) 10 N-m (1.0 kg-m, 7.21t-lb) 23 N-m (2.3 kg-m, 17 ft-lb) 07984—2000001 or 07984—200000D 07984—ZE20001 or 07984—ZEZOOOD 07943—MF50100 07943— MF50200 07742—001010!) 07742—001020!) Not available in U.S.A. 07942—557010!) 07757—0010000 or 07957—3290001 07781—0010101 07781—0010201 07780—0012100 07780—0012300 07780—0014000 07780—0014100 07780—0010200 07780—0010400 Engine top-end problems are usually perIormance-related and can usually be diagonosed by a compression test. Engine noises can usually be traced to the top-end with a sounding rod or stethoscope. Uneven or low compression - Valves — Incorrect valve adjustment — Burned or bent valves — Incorrect valve timing — Broken valve spring - Cylinder head — Leaking or damaged head gasket — Warped or cracked cylinder head - Cylinder and piston (Refer to Section 10) High compression Excessive noise - Incorrect valve adjustment - Sticking valve or broken valve spring - Damaged or worn rocker arm or camshaft - Loose or worn cam chain ' Worn or damaged cam chain tensioner ' Worn cam sprocket teeth Poor idling ' Compression too low ' Excessive carbon buiId-up on piston crown or combus- tion chamber 9-2 CYLINDER HEAD/VALVE CYLINDER HEAD COVER REMOVAL ‘ j " WATER HOSES Remove the following parts: — steering covers — fuel tank lpage 4-3) — air cleaner housing lpage 4-4) — carburetors [page 4-6) Drain the coolant (page 5-3). Front: Disconnect the spark plug caps and the water hose Remove the water pipe mounting bolt, front water pipe and 0- ring. NOTE - If coolant drips on the engine, wipe it off immediatelyt Remove the cylinder head cover bolts and cover. Rear: BREATHER '887'89. '917'942 TUBE Disconnect the spark plug caps, crankcase breather tube and ‘ M water hose Remove the water pipe mounting bolt, rear water pipe and 0- ring. Remove the cylinder head cover bolts and cover. Unclarnp the wire harness from the frame After '94: Disconnect the spark plug caps,crankcase breather tube and water hose. Remove the water pipe mounting bolt, rear water pipe and O-nng. (1) SOCKEI’ BOLTS Remove the socket bolt and valve adjusting cover. (Zl VALVE ADJUSTING COVER 9-3 CYLINDER HEAD/VALVE Remove the cylinder head cover bolts, washers and rubber. Align the wire harness with the valve adjusting hole. then re— move the rear cylinder head cover forward. CAUTION ~ Be careful not to damage the the wire harness. CAMSHAFI REMOVAL Remove the cylinder head covers. Remove the timing hole cap and crankshaft hole cap from the left crankcase cover. Align the FT mark (rear: RT mark) on the flywheel with the index mark on the left crankcase cover timing hole by turning the crankshaft counterclockwise Make sure the piston is at TDC [TOP DEAD CENTER) on the compression stroke. If the piston is not at TDC, turn the crankshaft 360° counter— clockwise, and re-align the mark and index mark. Measure the amount of the cam chain tensioner projection as shown. Replace the cam chain with the new one if the projec— tion exceeds 6.0 mm (0.24 in]. To replace the cam chain, drain the oil from the engine and remove the following parts: FRONT CYLINDER HEAD Left crankcase cover Right crankcase cover Front camshaft Rear camshaft Flywheel Primary drive gear REAR CYLINDER HEAD I1) WEDGE E 6.0 mm (0.24 in) [2] CAM CHAIN TENSIONEH 9-4 CVLINDER HEAD/VALVE Pull wedge A straight Lp while holding wedge B down. Secure wedge A with a 2 mm pin as shown. Remove the camshaft holder on the cam sprocket side by re- moving the two mounting bolts Remove the cam sprocket bolt, rotate the crankshaft counter- clockwise one turn [360°] and remove the other cam sprocket bolt. NOTE ' Be careful not to let the cam sprocket bolts fall into the crankcase. ’83, '89: Remove the three camshaft holder mounting bolts and the nut, the oil plate and the holder. Aller'89: Remove the three camshaft holder mounting bolts, nuts, _ v oil plate and the holdert OCKET BOLT .. - -» A Remove the dowel pins. Hang the cam chain on the camshaft behind the camshaft flange and remove the cam sprocket while lifting the camshaft out. Attach a piece of wire to the cam chain to prevent it from being dropped into the crankcase. CYLINDER HEAD/VALVE INSPECTION Cylinder head Inspect the camshaft holder and cylinder head journal surfaces for scoring or evidence of insufficient lubrication. Camshaft runout Support both ends of the camshaft with V-blocks and check the camshaft runout with a dial indicator. SERVICE LIMIT: 0.05 mm [0.002 in) Using a micrometer, measure the height of each cam lobe. (1) IN SERVICE LIMIT: IN: 37.730 mm (1.4854 in) EX: 37.750 mm (1.4862 in) \ (2) EX Check the camshaft journals for wear or damage. Measure the 0.0. of each journal. SERVICE LIMIT: 21.90 mm (0.862 in) (3) CAM 7 HEIGHT Camshaft bearing oil clearance 11) PEASTIGAUGE Wipe any oil from the journals. Lav a strip of plastigauge . A w ‘ 7’ lengthwise on top of each camshaft journal. NOTE ~ Avoid placing plastigauge over the oil hole. Install the camshaft holders and tighten the mounting bolts in a crisscross pattern in 2 or 3 steps NOTE ' Do not rotate the camshaft when using plastigauge. TORQUE: 6 mm flange bolt: 12 N>m (1.2 kg-m, 9 ft-lb) 8 mm flange bolt: 23 Mai (2.3 kg-m, 17 ft-lb) 8 mm flange nut: 23 N-m (2.3 kg-m. 17 ft-Ib) Remove the camshaft holder and measure the width of each plastigauge. The widest thickness determines the oil clear— ance SERVICE LIMIT: 023 mm (0.009 in) When the service limit exceeded, replace the camshaft and re— check the oil clearancet Replace the cylinder head and camshaft holder if the clearance still exceeds the service limit. Camshaft holder/Rocker arm shaft/Rocker arm Remove the rocker arm shafts by tapping the holder with a soft hammer. CVLINDER HEAD/VALVE '88, '89: , m 8 mm FLANGE BOLTS (3| 3 mm f FLANGE " NUT lZl 6 mm FLANGE BOLTS After '39: (1) 8 mm FLANGE BOLTS (3)8 mm FLANGE NUTS (2)6 mm FLANGE BOLTS . m PLASTIGAUGEm (‘Il ROCKER ARM SHAFTS CYLINDER HEAD/VALVE Remove the rocker arms and wave washers from the shafts. (1) ROCKER ARMS (2) WAVE WASHERS Inspect the rocker arm shafts and rocker arms for wear or damage. Check the rocker arms for clogged oil holes. Measure the 0.0. of each rocker arm shaft. SERVICE LIMIT: lN/EX: 11.83 mm (0.466 in) Measure the ID. of each rocker arm. SERVICE LIMI : 12.05 mm (0.474 in) CYLINDER HEAD REMOVAL NOTE - The front cylinder head can be removed with the engine installed. The engine must be removed to service the rear cylinder head. Drain the coolant (page 5—3) and remove the following: — front camshaft lpage 9—3) — the cam chain tensioner mounting bolts and washers from the cylinder head and cylinder — cam chain tensioner A [(3) CAM CHAIN TENSIONER .w_UNTILIG.BOL15.§ l) IL IrfE Remove the exhaust pipes as an assembly (Section 6] by re- moving the heat protector and exhaust pipe joint nuts. Disconnect the clutch cable from the clutch lifter arm by re— moving the clutch cable holder bolt. Remove the oil pipe from the engine. NOTE ' Do not bend the oil pipe during removal. Loosen the 6 mm bolt, 8 mm bolts, 8 mm nut and 10 mm nuts/ washers in a criss-cross pattern in 2 or 3 steps. Remove the bolts and nuts. 9-8 CYLINDER HEAD/VALVE Remove the upper radiator hose and the radiator mounting bolts (page 5-5}. Release the radiator from the frame grommets and suspend it with a piece of rope or something suitable Remove the front cylinder head. Remove the gasket, dowel pins and cam chain guide from the cylinder. Rear cylinder head: Remove the following: —engine (section 6) NOTE - Make sure the piston is at TDC on the rear cylinder com- pression stroke. ‘7 oil pass pipe ('88, '89), cylinder head cover, and cam chain tensioner — head bolts and nuts, as described for front cylinder head re— moval — cylinder head, head gasket, dowel pins, and cam chain guide DISASSEMBLY/IN SPECTION Cylinder head Clean the cylinder head surfaces of any gasket material. CAUTION ' Avoid damaging the gasket surfaces. ' Gaskets will come off easier if soaked in solvent. Check the spark plug hole and valve areas for cracks. Check the cylinder head for warpage with the straight edge and thickness gauge. SERVICE LlMl'I: 0.10 mm [0,004 In) (2 FEELERAU Remove the valve spring cotters, retainers, springs, and valves using a Valve Spring Compressor. [1i VALVE SPRING mm; COMPRESSOR ‘ Valve spring compressor 07757—0010000 or r . 07957—3290001 CAUTION - To prevent loss of tension, do not compress the valve springs more than necessary to remove the callers. NOTE “'7 - Mark all parts during disassemny so they can be placed back in their original locations. CVLINDER HEAD/VALVE Remove the valve stem seals and valve spring seats. Remove carbon deposits from the combustion chamber, Valve springs Measure the free length of the inner and outer valve springs. SERVICE LIMITS: INNER (IN): 36.47 mm (1.436 In) (EX): 37.51 mm (1.477 In) OUTER (IN): 4058 mm (1,598 In) (EX): 41.25 mm (1,624 In) Replace the springs as a set if they are shorterthan the service limit. Valve stem-to-gulde clearance [1 ) VALVE STEM Inspect each valve for bending, burning, scratches or abnormal stem wear. Check valve movement in the guide and measure and record each valve stem 0D. SERVICE LIMITS: IN‘ 5.45 mm (0.215 In) EX: 6.55 mm (0.258 In) Measure and record each valve guide |.D. NOTE - Ream the guides to remove any carbon deposits before checking clearances. SERVICE LIMIT: IN: 5.56 mm (0.219 In) EX: 6.65 mm (0.262 In) Subtract each valve stem CD. from the corresponding guide ID, to obtain the stem to guide clearance. N: 0.10 mm (0,004 In) EX: 0.11 mm (0.004 In) CYLINDER HEAD/VALVE if the stem-to—guide clearance exceeds the service limits, de- (1) VALVE GU‘DE REAMER termine if a new guide with standard dimensions would bring the clearance within tolerance. If so, replace any guides as necessary and ream to fit. TOOLS: Velve guide reemer IN: 07984-2000001 or 07984-200000D EX; 07984-ZE20001 or 07984-ZEZOOOD NOTE ~ It is important that the reamer always be rotated '71 the same direction when it is inserted or removed. If the stem-to-guide clearance exceeds the service limits with new guides, also, replace the valves. NOTE - Relace the valve seats whenever the valve guides are re- placed. VALVE GUIDE REPLACEMENT Chill the valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 212°F (100°C) with a hot plate or oven. Maximum allowable temperature is 300°F (150°C). m___—_ - To avoid burns, wear heavy glaves when handling he heated cylinder head. CAUTION ' Do not use a torch to heal the cylinder head; it may cause warping. Support the cylinder head and drive out the old guides from the combustion chamber side of the cylinder head. TOOL: Velve guide drlver (IN): 07742—0010100 (EX): 07742-0010200 Not available in U.S.A. 07942-6570100 NOTE (1) VALVE GUIDE DRIVER (2) ATTACHMENT - Avoid damaging the cylinder head. Make note of the valve guide proiection specifications (follow- ing), then drive in new guides from camshaft side of the cylin- der head. TOOLS: Velve gulde driver 5.5 mm (IN): 07742—0010100 6,6 mm (EX): 07742—0010200 Atmchment 5.5 mm (IN): 07943—MF50100 6.6 mm (EX): 07943—MF50200 9-11 CVLINDER HEAD/VALVE VALVE GUIDE PROJECTION HEIGHT: IN: 19.4—19.6 mm (0.76—0.77 in) EX: 173—18] mm (070—071 in) Ream the new valve guides after installation: NOTE - Use cutting oil on the reamer during this operation - It is important that the reamer always be rotated in the same direction when it is inserted or removed Cleanthe head thoroughly after reaming the valve guidest TOOLS: Valve guide reamer IN: 07984-2000001 or 07584-2000000 EX: 07584-ZE20001 or 07584-ZE2000D VALVE SEAT INSPECTION/REFACING Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply alight coating of Prussian Blue to each valve seat: Lap each valve and seat using a rubber hose or other hand—lapping toolt Remove and inspect each valvet CAUTION - The valve cannot be ground. lflhe valve face is burned or badly worn or if it contacts the sea! unevenly, replace the valve: Inspect the width of each valve seat. STANDARD: 03—11 mm (moss—0.043 In) SERVICE LIMIT: 1.5 mm [0.06 In) If the seat is too wide, too narrow or has low spots, the seat must be ground. (I) VALVE GUIDE (2) GUIDE PROJECTION HEIGHT [1) VALVE GUIDE REAMER 9-12 VALVE SEAT CUTTERS Honda Valve Seat Cutters, grinder or equivalent valve seat refacing equipment are recommended to correct a worn valve seat. NOTE - Follow the refacer manufacturer's operating instructions. VALVE SEAT REFACING Use a 45 degree cutterto remove any roughness or irregulari— ties from the seat. NOTE ~ Reface the seat with a 45 degree cutter when a valve guide is replaced. Use a 32 degree cutter to remove the top 1/4 of the existing valve seat materialt Use a 50 degree cutter to remove the bottom 1/4 of the old seatt Remove the cutter and inspect the area you have refaced. CVLINDER HEAD/VALVE a 80 32° IN: 07780—0012100 [28 cal EX: 07780—0012300 [35 él IN: 07780—0014000 [30 vbl EX: 07780—001410!) (37.5 é] 45" IN: 07780—0010200 (27.5 r15) EX: 07780--0010400 (35 at) 11] ROUGHNESS/IRREGULARITIES 45° (21 VALVE SEAT (HOLD SEAT WIDTH [1) OLD SEAT WIDTH 60° 9-13 CYLINDER HEAD/VALVE Install a 45 degree finish cutter and cut the seat to the proper width. Make sure that all pitting and irregularities are removed‘ Refinish if necessary Apply a thin coating of Prussian Blue to the valve seat. Press the valve through the valve guide and onto the seat to make a clear pattern. NOTE - The location of the valve seat in relation to the valve lace is very important for good sealingt If the contact area is too high on the valve, the seat must be lowered using a 32 degree llat cutter‘ ll the contact area is too low on the valve, the seat must be raised using a 60 degree inner cuttert Refinish the seat to specifications, using a 45 degree linish cutteri After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pressure. After lapping, wash all residual compound off the cylinder head and valve. NOTE ' Do not allow lapping compound to enter the guides. 0.9—1.1 mm [0.035—0‘043 in) (1) CONTACT T00 HIGH f j 12) OLD SEAT WIDTH 2 (1) CONTACT T00 LOW (21 OLD SEAT WIDTH 9-14 CVLINDER HEAD/VALVE ~ -‘, fiéfsfia'm gm: (1) VALVE (4) RETAINER f}?! . Install the valve spring seats and new stem seals, ‘ ‘ Lubricate each valve stem with molybdenum disulfide oil and I v (3) OUTER insert the valve into the valve guide. Turn the valve slowly V ’/ SPH'NG while inserting to avoid damaging the seals. A /°. §% (7) SPRING (6] INNER / " SEAT SPFllNG (5) con-535% Move the valves up and down to check for smooth operation. Install the valve springs with the tightly wound coils facing the combustion chamber‘ Install the spring retainers, Compress the springs and install the valve cotters. CAUTION - To prevent loss of tension, do not compress the valve springs more than necessary to install the valve cotter: TOOL: Valve spring compressor 07757—0010000 or 07957 — 3290001 CYLINDER HEAD/VALVE Tap the valve stems gently with a soft hammer to firmly seat the cotters. NOTE - Support the cylinder head above the work bench surface to prevent possible valve damage. Apply locking agent to the threads of the sealing bolts and tighten them, if removed. CYLINDER HEAD INSTALLATION Install the cam chain guide into the cylinder. Make sure that the cam chain guide bosses are in the grooves of cylinder. Clean the cylinder head surface of any gasket material. Install the dowel pins and a new head gasket. . , [y A“) 9A$KEIT t» 9-16 CVLINDER HEAD/VALVE all 4 i1) BOSS i2) SLOT Install the carburetor insulator on the cylinder head, aligning the boss on the cylinder head with the slot in the insulator. After '91 (California model only) : Install the insulator bands aligning the pins on the insulator bands with the slots on the insulators as shown. Tighten the band screws securely‘ Install the cylinder headt Install the 10 mm nut/washer, 5 mm nut/washer, 5 mm bolt/ washer and 6 mm bolt and tighten them in a crisscross pattern in 2 or 3 steps. TORQUE: 10 mm nut: 48 Mai (4,8 kg-m, 35 It-lb) 8 mm bolt: 23 Mai (2.3 kg-m, 17 ft-lbl 8 mm nut: 23 N-m [2‘3 kg-m, 17 ft-lb) 6 mm bolt: 10 N-m (1,0 kg-m, 7.2 It-lb) '88, '89: Check the oil pass pipe bolts and oil pass pipe for clogging or bending. Install the oil pass pipe, new sealing washers, oil pass pipe bolts and the pipe holder bolt‘ Tighten the bolts. TORQUE: Oil pass pipe bolt: 7 mm: 10 N-m (1‘0 kg-m, 7.2 ft-Ib) 8 mm: 23 N‘m (2.3 kg-m, 17 ft-Ib) (3) OIL PIPE 12) HOLDER CVLINDER HEAD/VALVE Install the following: — cam chain tensioner with washers and bolts. TORQUE: 10 Nan (1.0 kg-m, 7.2 ft-Ib) — camshaft (page 9—13) — camshaft holders (page 9-19) — cylinder head cover (page 9—21) CAMSHAFI' INSTALLATION Apply molybdenum disulfide oil to the rocker arm shafts. Install the *ocker arms, rocker arm shafts and wave washers in the camshaft holders. NOTE ~ Install the wave washers in the proper position as shown‘ Position the grooves in the rocker arm shafts vertically, align— ing the bolt holes of the holder with the holes of the shafts. Apply molybdenum disulfide oil to the rocker arm slipper faces. FRONT CYLINDER NOTE ‘ If the rear cylinder head has not been serviced, remove the rear cylinder head cover and check the camshaft position as follows: Turn the crankshaft counterclockwise and align the "HT" mark on the flywheel with the index mark on the timing hole, then look for the identification mark on the camshaft flange. If the notch mark '5 facing up, turn the crankshaft counter- clockwise approximately 171/3 turn (412°) and begin Installation of the front camshaft. If the notch mark faces down (cannot be seen), turn the crankshaft counterclockwise approximately 1/3 turn (52°) and begin installation. ' (1) CHAIN TENSIONEH WASHEBSI'BOJJS (1) WAVE WASHERS (5) AFIMS (IN) 7% MoSz (4) SHAFT (IN) ‘(ZI ARM (EX) (3) SHAFT (EX) (1 I GHOOVES 3(1) mosx ‘ (2) “RI”MAI1I< 9-18 Align the "FT" mark on the flywheel with the index mark on the timing hole. N OTE - if the front and rear cylinder camshafts were removed, do not confuse them. Check the identification mark on the neck of the camshaft flange. lnstallthe camshaft in the cylinder head through the cam chain and install the cam sprocket on the camshaft with the IN mark facing inside. With the notch mark on the camshaft flange facing up. align the timing marks (index lines) on the cam sprocket with the top of the cylinder head. Place the cam chain on the sprocket. Install the cam sprocket on the camshaft flange and recheck that the timing marks (index lines) align with the top of the cyl- inder head. Align the cam sprocket bolt holes 'n the cam sprocket and camshaft, install and tighten the cam sprocket bolt. IOROUE: 23 Man (23 kg-m. 17 ft-Ibl Turn the crankshaft counterclockwise one full turn (360°) and install the other sprocket bolt. Turn the crankshaft counterclockwise one full turn (360°), aligning the "FT" mark with the index mark, then check that the timing marks on the cam sprocket align with the top of the cylinder head. CVLINDER HEAD/VALVE [1 ) NOTCH (1 ) CAM SPROC KET BOLT (2] HOLDER (3) FLAT 9-19 CYLINDER HEAD/VALVE '88, '89: Install the dowel pins into the cylinder head. Install the holders. oil plate, 5 mm bolts, 5 mm nut and 6 mm bolts. After '89: Install the dowel pins into the cylinder head. Install the holders, oil pipe 3 mm bolts, 3 mm nuts and 6 mm bolts. TORQUE: 8 mm bolt: 23 Nam (2.3 kg-m, 17 It-lb) 8 mm nut: 23 Nam (23 kg-m, 17 ft-lbl 6 mm bolt: 10 N-m (1.0 kg-m, 7.2 "-Ib) CAUTION - Note the direction of the camshaft end holder, install the flat Am" '59: surflu‘e on the holder fitting in. (1)8 mm BOLTS (2) OIL PLATE After installing the front cylinder camshaft, turn the crank- shaft counterclockwise approximately 7/3 turn (308°) and align the RT mark with the index on the timing hole, then install the rear cylinder camshaft. “I A ' / Lubricate the cam lobes with fresh engine oil. If the cylinder head was removed from the engine in theframe, install the following: — radiator with upper radiator hose — exhaust pipe REAR CYLINDER NOTE (3] NOTCH ' If the front cylinder head was not serviced, remove the front cylinder head cover and check the camshaft position as follows: Turn the crankshaft counterclockwise and align the "FT" mark on the flywheel with the index mark on the timing hole, then look for the identification mark on the camshaft flange. If the notch mark is facing up, turn the crankshaft counterclockwise approximately 7/3 turn (303°) and begin installation of the tear camshaft, If the camshaft notch mark faces down (cannot be seen). turn the crankshaft counterclockwise approximately 1-7/3 turn (668°) and begin installation. 9-20 CVLINDER HEAD/VALVE Make sure that the "RT" mark on the flywheel aligns with the index mark on the timing hole. Place the camshaft into the correct position with the notch mark on the camshaft flange facing up and install the cam sprocket and camshaft holders using the same procedure as for the front cylinder. Remove the 2 mm pin holding cam chain tensionev wedge A. NOTE - Be careful not to let the 2 mm pin fall into the crankcase. - Do not forget to remove the 2 mm pin before installing the cylinder head cover. sew; £52 mm PIN CYLINDER HEAD COVER INSTALLATION Clean the gasket and apply contact cement to the gasket groove. Apply sealant around the gasket. (2) GASKET Install the cylinder head cover, rubber washer, washer cover and cylinder head cover bolts. Tighten the cover bolts. . TORQUE: 10 Na" (1.0 kg-m, 7.2 ft-lb) (II RUBBER ,. __ \ WASHER " . (ZI WASHER a \ COVER . (3) BOLT 9-2‘1 CYLINDER HEAD/VALVE Install the O—ring on the water pipe with the tapered side facing out and install the water pipe into the cylinder head (1) WATER PIPE Connect the water hose to the water pipe and install the spark plug caps. Install the following parts: — carburetors (page 4-15] — air cleaner housing (page 4-4) — fuel tank (page 4-3) — steering covers Fill the cooling system [page 5-3] 9- 22 MEMO CYLINDER/PISTON 10-0 10. CYLINDER/ PISTON SERVICE INFORMATION 10-1 PISTON RING INSTALLATION 10-5 TROUBLESHOOTING 10-1 PISTON INSTALLATION 10»5 CYLINDER 10-2 CYLINDER INSTALLATION 10»6 PISTON 10-3 SERVICE INFORMATION GENERAL O This section covers service of the cylinder and piston. U The front cylinder/piston can be serviced with the engine installed in the frame. U The engine must be removed to service to rear cylinder/piston. 0 To service the crankcase stud bolts, refer to page 11-15. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT I Cylinder |.D. 75000—75015(23528—28533) 751012.957) I Warpage across top 7 0.10 10.004l I Taper 7 0.06 10002) E Out-oI-round 7 0.06 10.002) Piston, Piston ring-to-ring TOP 0.015—0045 I0.0006—0.00IBI 0.10 l0.004l $2?“ 9'°°Ve “93'3"” SECOND 0015—0045 10.0006— 0.001 8) 0.10 I0.004I and mm“ Fling end gap TOP 0.10—0.30 10004—0012) 0.50 l0.020l pin SECOND 0.10—0.30 10004—0012) 0.50 10.0201 OIL 0.20—0.7010000—0028l 0.90 10.0351 Piston 0.D. 74365—74990128514—2352“ 74.90 12.9491 Piston pin bore 18002—1800810.7087—0.7090l 18.05 10.7111 Connecting rod small end I.D. 18016—18034 l0.7093—0.7iool 18.07 10.7111 Piston pin 0.0. 17094—18000 I0.7054—0.7057l 17.98 [0.708) Piston-to-piston pin clearance 0002—0014l0.0001—0.0006l 0.040 l0.0016l Cylinder-to—piston clearance 0.010—0.05010.0004—000201 0.10 10.0041 Eminezyégfiflzcmg M 0016—0040 10.0006—0.0016l 0.060 10.0024l TROUBLESHOOTING Low or uneven compression Piston noise - Worn cylinder or piston rings. - Worn cylinder and piston. ' Leaking head gasket. - Excessive carbon deposits. ' Incorrect valve timing. Excessive smoke ' Worn cylinder and piston rings. ' Improperly installed piston rings. ' Damaged piston or cylinder. Overheating - Excessive carbon deposits on piston or combustion chamber. ' Faulty water pump. 10-1 CYLINDER/PISTON CYLINDER REMOVAL (1) WATER H'Sse NOTE To service the rear cylinder/piston, first remove the engine and then proceed with the common removal steps below. Remove the following: — cylinder head cover (page 9-3) — cylinder head (page 9-8] — gaskets, dowel pins, and cam chain guides. Disconnect the water hose from the coolant connector. Remove the clip and slide the cylinder joint collar toward eigther the front or rear cylinder. Remove the cylinder to be serviced. Remove the cylinder gasket and dowel pins from the crank- case. INSPECTION Clean the top of each cylinder thoroughly. Inspect the cylinder walls for scratches and wear. Measure and record the cylinder ID. at three levels in both an X and Y axis. Take the maximum reading to determine the cyl- inder wear. SERVICE LIMIT: 75.10 mm (2.957 in) Calculate the piston-to-cylinder clearance. Take the maximum reading to determine the clearance. SERVICE LIMIT: 0.10 mm (0.004 in) Calculate the cylinder for taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.06 mm (0.002 in) tdoIAfiT ’ it CONNECTOR Calculate the cylinder for out-ol-round at three levels in an X and Y axis. Take the maximum reading to determine the out- of—round. SERVICE LIMIT: 0.06 mm (0.002 in) I3I TOP The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded. I4) MIDDLE 'lhe following oversize piston are available: 0.25 mm (0.010 in) and 0.50 mm (0.020 in) (5) BOTTOM The cylinder must be rebored so that the clearance to an over- size piston is 0010—0050 mm (00004—00020 in]. I1)lN c( 10-2 CVLINDER/PISTON Inspect the cylinders for transverse warpage across the top. NOTE - Measure warpage using a straight edge and teeler gauge as shown. SERVICE LIMIT: 0.10 mm (0.004 in) PISTON REMOVAL Place a shop towel into the crankcase and remove the piston pin clips. NOTE - Do not let the clips fall into the crankcase. Push the piston pin out and remove the piston. (1) PIN CLIP INSPECTION Clean the piston domes, ring lands and skirts. Measure the piston ring-to-groove clearance. SERVICE LIMIT: Top: 0.10 mm (0.004 in) Second: 0.10 mm (0.004 in) It clearance is excessive, replace the piston ring. Remove the piston rings and mark them to indicate the correct cylinder and piston position for reassembly. NOTE - Do not damage the piston rings when removing them. CYLINDER/PISTON Insert the old piston ring into the proper ring groove and clean the groove by rolling the ring around the pistons circumference. Inspect the piston for cracks or other damage. Measure the piston 0.D. NOTE - Take measurements 10 mm (0.4 in) from the bottom, and 90" to the piston pin hole. SERVICE LIMIT: 74:90 mm [2.949 in) Calculate the piston-to-cvlinder clearance by subtracting the piston CD. from the cylinder I‘D: (page 10-2). SERVICE LIMIT: 0.32 mm (0.013 in) Measure the top and second piston ring end gaps: using a pis- ton, push the ring into the cylinder squarer and make the mea- surement. SERVICE LIMIT: Top/Second: 0.50 mm (0,020 in) Oil: 0:90 mm (0,035 in) Measure each piston pin bore. SERVICE LIMIT: 1805 mm (0,711 in) Measure each piston pin 0.Dt SERVICE LIMIT: 17:98 mm (0,708 in) Calculate the piston pin-to-piston clearance. SERVICE LIMIT: 0:40 mm (0.0016 in) 1 0-4 Measure the ID. of the connecting rod small end. SERVICE LIMIT: 18.07 mm (0.711 in) Calculate the piston pin—to-connecting rod clearance. SERVICE LIMIT: 0060 um [0.0024 in) Refer to section 11 for connecting rod replacement. PISTON RING INSTALLATION NOTE ~ Insert the outside surface of the ring into the proper ring groove and roll around in the groove to make sure that the ring has a free fit around the piston's circumference. Carefully install the piston rings onto the piston with the mark- ings facing up. NOTE - Be careful not to damage the piston and piston rings during assembly. Stagger the ring end gaps 120° apart from each other as shown. NOTE ~ To install the oil ring, install the spacer first, then install the side rails. After installing the rings, check that they rotate freely without sticking. PISTON INSTALLATION Place a shop towel into the crankcase. Coat the rod small end with molybdenum disulfide grease. As- semble the piston and connecting rod with the piston and piston pin clips as shown. NOTE - install the pistons with the mark "lN" facing towards the intake side. ' After installing the piston pin clips, make sure that they are seated properly and the end gaps are not aligned with the cut-out in the piston. - Do not let the piston pin clips fall into the crankcase. CYLINDER/PISTON <—l1) TOP RING ‘— <—(2) SECOND RING (4) SIDE RAIL (5i SPACER (3) on. RING (6) SIDE RAIL (7) (7) 20 mm DH 20 mm OR MORE MORE (11 “IN” 1 MARK ’/ 0/ (2) PISTON PIN CLIP I4) END GAP (3) CUT-OUT 10-5 CYLINDER/PISTON CYLINDER INSTALLATION Clean the cylinder gasket surface being careful notto drop any gasket material into the crankcase. Install the dowel pins and new gaskett Coat the cylinders piston rings/grooves and piston with oil. Install the piston assembly into the cylinder from the top of the crankcase while compressing the piston rings with your fin- gers. Be sure each assembly is returned to its original position as noted during removal. NOTE ' Be careful not to damage the piston rings during assembly. ' When the cylinder is halfway over the piston, route the cam chain through the cylinder. “’5 '(1 )‘PlSTON‘ Install a new O-ring onto the cylinder joint and install the cylin- ‘ ’ \ ' ‘ ‘2‘ UPS \ der joint collar by sliding the collar toward eigther cylindert ~ Install the clip securely. ' Clean the cylinder gasket surface being careful nottodrop any gasket material. NOTE ' Avoid damaging the gasket surfacet Install the cam chain guide. NOTE ' Align the guide boss with the groove in the cylindert ~ Make sure that the end of the guide is inserted into place in the crankcase. 1 0-6 CVLINDER/PISTON Install a new O-ring into the connecting pipe and install and "I, ' (1) O-RlNG tighten the connecting pipe mounting bolts, if the connecting "“ pipe was removed If only the water hose was removed, connect the hose with clamp. Install the dowel pins and a new gasket. Install the cylinder heads and covers (Section 9). ,. A “ 1(2) GASKET t... 10-7 CRANKSHAFT/TRANSMISSION '88»'89,'91»'95: 20—30 N-m (2.0—3.0 kg-m, 14—22 fl-Ib) '887'89fl917’95: 30—50 N-m (3,0750 kg-m, 22—36 ft-Ib! ‘88»‘39591295: 20—30 N-m (2.0—3.0 kgm, / 14—22 mm) '887'89f917’95: 30750N~m(3_075_0kgim,22736h4b) 11-0 ll. CRANKSHAFI/TRANSMISSION S ERVICE INFORMATION TROUBLESHOOTING CRANKCASE SEPARATION TRANSMISSION CRANKSHAFT/CONNECTING ROD 11-1 11-3 114 115 11-11 CRANKCASE TRANSMISSION ASSEMBLY/ INSTALLATION CRANKCASE ASSEMBLY 1143 11-17 11-19 SERVICE INFORMATION GENERAL 0 To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame (Sec- tion 6i. 0 All bearing inserts are select fitted and are identified by color code. Select replacement bearings from the code tables. After installing new bearings, recheck them with plastigauge to verify clearance. 0 Apply molybdenum disulfide grease to the main journals and crankpins during assembly. 0 Before separating the crankcase, the following parts must be removed. NOTE Section 9 Section 9 Cylinder head cover Water pipe Camshaft Camshaft holder Cam chain and drive sproket Section 10 Section 9 Oil pass pipe Cylinder joint collar . Cylinder head Water hose connecting pipe Cam chain tensioner Section 9, 10 Section 10 Cam chain guide Cyl'm‘" Piston Crankshaft CRANKCASE Connecting rod SEPARATION Transmission Oil pump Starter motor lSection 17) Right crankcase cover (Section 7) —Clutch —Gearshift —Primary drive gear foil pipe Left crankcase cover (Section 8i —F|ywheel —Starter gears hnkage - The front cylinder camshaft and cylinder head service can be performed without removing the engine from the frame. 11-1 CRANKSHAFT/TRANSMISSION SPECIFICATIONS mm (in) ITEM STANDARD SERVICE LIMIT Cyankshafi/ Connecting rod big end side clearance 0.05—0.20l0.002—0.008) 0.30(0.001) connec‘mg md Crankpin oil clearance 0.028—0.052[0.0011-0.0020) 0.07(0.003) Main Journal oil clearance 0.02 5—0.041l0.0010—0.0016) 0.06 (0.002) Crankshaft runout 7 0.05(0.002) Transmission Gear LU. C1 24.000—24.021l0.9449—0.9457) 23.94(0.943) M4,M2,C3 28.000—28.021(1.1024-1.1032) 28.04(0.104) Gear bushing 0.D. C1 23.959—23.980l0.9433-0.9441) 24.94(0.982) M4,M2,C3 27.959—27.980[1.1007-1.1016) 27.94(1.100) Gear bushing l.D. C1 20.016—20.037I0.7880—0.7889) 20.06(0.790) M2 25000—25021(03843-09851) 25.04(0.986) Bushing—m. C1 0.023—0.057l0.0009-0.022) 0.10(0.004) Shaft Clearance M2 0.020—0.062(0.0008—0.0024) 0.10(0.004) Gear-to— M4,M2 0.002-0.062(0.0008—0.0024) 0.10(0.004) bushing clearance 01,03 Countershaft 0.D. c1 bushing 19.980—19.993(0.7866-0.7871) 19.96(0.786) Mainshaft 0.D. M2 bushing 24.959-24.980(0.9835-0.9826) 24.94(0.982) Backlash 1st,2nd,3rd 1.021—0.110(0.0008—0.0043) 4th 1.023—O.117(0.0009—0.0046) Shift fork/ Claw thickness 5.93—6.00l0.233-0.235) 5.63(0.222) fork—shaft Min and |eft sh", 'sa.'89.'91-'95: 13.000—13.01B(0.5118-05125) 13.04(0.513) forkI-D- Aiter'95: 13.000—13.021(0.5118-05126) 13.04(0.513) Shaft 0.D. '88.'89.'91-'95: 12.966—12.984l0.5105-0.5112) 12.90l0.508) Aiter'95: 12.966—12.984l0.5105-0.5112) 12.95(0.509) Shift drum 0.D. (at the left side Journal) 11 .966—11.984(0.4711—0.4718) 11.94(0.470) TORQUE VALUES Connecting rod bearing cap nut Crankcase 5 mm stud bolt 10 mm stud bolt TOOLS Special Main bearing driver attachment Bearing remover set — remover handle — bearing remover set — remover weight Common Driver Attachment, 42 x 47 mm Pilot, 20 mm Attachment, 52 x 55 mm Pilot, 22 mm Pilot, 25 mm 34 N-m (3.4 kg-m, 20—30 N-m (2.0— 30—50 N-m (3.0— 25 it-lb) 3.0 kg-m, 14—22 it-lb) 5.0 kg-m, 22—35 it-lb) 07HMF— MM90400 07936—3710001 07936—3710100 07936—3710600 07741—0010201 0793673710200 07749— 0010000 07746— 0010300 07746— 0040500 07745—0010400 07 746 — 0041000 07745—0040600 Not available in U.S.A. or U.S.A. Only 11-2 TROUBLESHOOTING Excessive noise - Crankshan — Worn main bearing — Worn crankpin bearing - conneciing rod — Worn rod small end — Worn crankpin bearing Hard m shin ' Shin forks bent ' Shin fork shan bent ' Shin spindle claw bem - Shin drum cam grooves damaged ' Shin fork guide pin damaged Transmission jumps out oi gear ' Gear dogs worn - Shin shan bent - Shin forks bem CRANKSHAFT/TRANSMISSION 11-3 CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION (1) OlL PIPE C Remove the engine from the frame (Section 6]. Refer tothe service information (page 11-1] forthe parts that must be removed before the separating the crankcase Remove the oil pipe stay and cam chain tensioner set plate by removing the bolts Remove the rear cam chain and cam chain drive sprockett Remove the bolt and cam chain tensioner set platet Remove the front cam chain from the crankshaftt Remove the 8 mm bolts and 6 mm bolts from the left crank- case. NOTE - Remove the bolts in a crisscross pattern '71 2 or 3 steps - Loosen the 6 mn bolts first, then loosen the 8 mm bolts. Remove the 8 mm bolts and 6 mn bolts from the right crank— case. NOTE ' Remove the bolts 'n a crisscross pattern in 2 or 3 steps. ' Loosen the 6 mm bolts first, then loosen the 5 mm bolts. 11-4 CRANKSHAFT/TRANSMISSION Place the left crankcase side down and separate the right crankcase from the left crankcase while prying where indicat- ed at the point shown and tapping the cases at several loca- tions with a soft hammert Remove the dowel pins and clean the crankcase halves of any sealant materialt CRANKSHAFT/CONNECTING ROD CRANKSHAFT REMOVAL Remove the crankshaft from the left crankcase. CRANKSHAFT SIDE CLEARANCE INSPECTION Check the connecting rod side clearance with feeler gauge. SERVICE LIMIT: 0.30 mm (0,001 in) If either side clearance exceeds the service limit, replace the connecting rod and recheck. If still beyond the limit, replace the crankshaftt Inspect the crankshaft for rough spots or damage (I) DdWEL PINS (1) CRANKSHgFT 11-5 CRANKSHAFT/TRANSMISSION CONNECTING ROD DISASSEMBLY Remove the connecting rod bearing caps noting their loca- tions. NOTE - Tap the side of the cap lightly if it is hard to remove. CAUTION - Do not interchange the Nan/(pin bearings. They must be my stat/ed in their original pnsitt'ons or the correct bearing oi/ clear mice may rm! be obtained resulting in engine damage. CRANKSHAFT RUNOUT INSPECTION Place the crankshaft on a stand or V blocks. Set a dial indicator on the main journals. Rotate the crankshaft two revolutions and read the runout. Actual runont is 1/2 the total indicator reading. SERVICE LIMIT: 0.05 mm (0002 in) NOTE - The crankshaft cannot be repaired. Replace it if the journals or crankpins are burnt, cracked, or if the runout is beyond limits. [1) BEARING CAPS (1 I V-BLOCK CONNECTING ROD BEARING INSPECTION Inspect the bearing inserts for damage or separation. Clean all oil from the bearing inserts and crankpins. OIL CLEARANCE INSPECTION Put a piece of plastigauge on each crankpin avcuding the oil hole. Install the bearing caps and rods on the correct crankpins, and tighten them evenly. TORQUE: 34 N-m (3,4 kg-m. 25 ft-lb) NOTE - Do not rotate the crankshaft during inspection. (2] SEPARATION iii DAMAGE [1] PLASTIGAUGE 11-6 CRANKSHAFT/TRANSMISSION Remove the caps and measure the compressed plastigauge at its widest point on each crankpin to determine the oil clear- ance. SERVICE LIMIT: 0.07 mm (0.003 in) If the rod bearing clearance is beyond tolerance, select re- placement bearings, CONNECTING ROD BEARING SELECTION Determine the connecting rod LDt code number, The code will be either a number 1 or 2 located on the rod in the area shownt Determine the corresponding crankpin O‘Dt code (or measure the crankpin 0.D‘lt The code will be either a letter A or B on the crank weight. Cross reference the crankpin and connecting rod codes to de- termine the replacement bearing colort A a CHANKPIN OtD. CODE 39982- 39374- 39.990 mm 39‘981 mm CONNECT'NG (15741 — (1.5738— HOD “3- CODE 15744 in) 1.5741 in) 1 noon—43.007 mm c a [16929—15932 in) (BROWN) (BLACK) 2 43008—41016 mm a A I1,6932—1,6935 in) (BLACK) (BLUE) BEARING INSERT THICKNESS A (BLUE): 1‘495—1‘499 mm (0.0589—0‘0590 in) B (BLACK): 1‘491—1t495 mm (0‘0587—0‘0589 in) C lEHOWN):1I4B7—1‘491 mm (0.0585—0‘0587 in) (1) PLASTIGAUGE I‘ll 0.D. CODE LETTERS [1] CRANKPIN BEARINGS 11-7 CRANKSHAFT/TRANSMISSION MAIN BEARING INSPECTION Measure the main journal OD. and record it. Measure the main journal bearing ID. and record it. Calculate the clearance between the main journal and the main bearing. SERVICE LIMIT: 006 um [0.002 in) If the oil clearance is beyond the service limit, select a replace- ment bearings as follows: MAIN BEARING SELECTION Determine the crankshaft main journal O.D. code. The code will be either a number 1 or 2 on the crank weight. Determine the replacement main bearing. Determine the corresponding main bearing LD. code. The code will be either a letter A or B on the crankcase 11-8 CRANKSHAFT/TRANSMISSION Choss replacement main bearings in accordance with the table below MAIN JOURNAL 1 2 000‘ CODE 44.992— 44984— 450% mm 44.991 mm (1‘7713— (1.7710— CASE We CODE 1.7717 in) 1‘7713 in) A 48.990—49.000 mm c a (19287—19291 in) [BROWN] (BLACK) E 49000—49010 mm B A (1.9291 —1.9295 in] (BLACK) (BLUE) BEARING INSERT THICKNESS A (BLUE): 2.003—2.013 mm (00789—00793 in) E {BLACK}: Lees—2.008 mm (00787—00791 in) C [BROWN):1.993—Z.003 mm (00785—00789 in) MAIN BEARING REPLACEMENT Press the main bearing out ol the crankcase using a hydraulic press and special tools. NOTE - Always use a press to remove the main bearing. TOOLS: Driver 07749—0010000 Main bearing remover attachment 07HMF— MM90400 Mark a vertical line below each side ol the bearing tab. Apply molybdenum disulfide grease to the outer surface of the main bearing‘ Align the marks on the bearing with the groove in the bearing hole, and press the main bearing into the crankcase CAUTION - Be careful not to damage the bearing; (l) DRIVER H H (IITAB (3) GROOVE TOOLS: Driver Main hearing driver attachment 07749—0010000 07HMF—MM90400 (I) DRIVER (2) ATTACHMENT (3] MAIN BEARING 11-9 CRANKSHAFT/TRANSMISSION CONNECTING ROD/CRANKSHAFT SELECTION If a connecting rod requires replacement, you should select a rod with the same weight code as the original. But if that is unavailable, you may use one of the others specified in the fol- lowing chartt NOTE - The "0“ mark in the table indicates that the matching is possible in the crossed codest SELECTION TABLE Front rod code A B C Rear rod code A ' O O B O O O C O 0 v . CAUTION For selecting crankshaft weight: - Select "L" crankshaft weight, if the front rod and rear road have code A (t). ' Select “H” crankshaft weight, I] the front rod and rear rod have code C («A ' Select crankshaft weight with no code, other than the above two casest CONNECTING ROD ASSEMBLY Install the bearing inserts on the rods and caps. NOTE - Align the boss on the bearing with the groove 'n the rod or cap. ' Apply molbdenum disulfide grease to the bearing Install the connecting rods and caps on the crankpin. Be sure each part is installed in its original position, as noted during re- movaL Tighten the bearing cap nutst NOTE - Align the LD code on the cap and rod. - Tighten the nuts it two or more steps After tightening, check that the rods move freely without binding. TonouE: 34 N-m (3.4 kg-m, 25 lt-lb) CRANKSHAFT INSTALLATION Install the crankshaft in the left crankcaset Install the dowel pins and assemble the crankcase (1) CONNECTING ROD WEIGHT CODE (2) CHANKSHAFT WEIGHT CODE l“L" or "H" or no mark) [1) Apply molybdenum disulfide grease l1) CRANKSHAFT , ? 11-10 TRANSMISSION REMOVAL ’88,’89,'91-'95: Remove the mainshaft,countershaft,shift fork shaft and shift drum as an assembly. After’95: Remove the shift fork shaft then remove the shIft drum and shift forks. Remove the mainshaft and countershaft as an assembly. '8B.'89"917’95: Separate the shift fork/shaft,mainshaft and countershaft assemblies from each other. After'95: Separate the mainshaft and countershaft assemblies from each other. DISASSEMBLY/INSPECTION Temporarily install the mainshaft and countershaft to the left crankcase. Measure the backlash of each gear. STANDARD: 1st, 2nd. 37d 1.021 —0.1‘IO mm (00008—00043 in) 4th 1.023—0.‘I17 mm [00009—00046 in) 'B8.'89.’917'95: Bend down the lock washer tabs and remove the bolt and lock washer from the left shift fork. Remove the shift fork shaft. Disassemble the mainshaft and countershaft. Remove the C4 gear by removing the stop ring. CRANKSHAFT/TRANSMISSION {1] MAIN- SHAFT l2) COUNTER- mfl T EOSHED - (1) MAlNSHAFT ASSEMBLY (2) SHIFT FORK! l3) COUNTERSHAFT ASSEMBLV (3) C4 GEAR l1) LOCK WASHER (2) BOLT RING 11-11 CRANKSHAFT/TRANSMISSION Inspect the shift drum end for scoring, scratches, or evidence of insufficient lubrication. Check the shift drum grooves for damage‘ Measure the shift drum shaft CD. at the left side journalt SERVICE LIMIT: 1134 mm (0‘470 in) Check the bearing inner and outer races for damage‘ The bearing should turn smoothly and quietly Check the shift fork shaft for scratches, scoring or evidence of insufficient lubricationt Measure the shift fork shaft O.Dt SERVICE LIMIT: '88,'89,'9‘l-'95:12.90mm(0v508 in) After'95:12.95mm(0.509 In) Measure the shift fork I. Q (right and |efl)and the shift fork claw thickness. SERVICE LIMIT: LD.: 1104 mm (0.513 in) CLAW THICKNESS: 5.63 mm (0.222 in) Inspect the shift drum and shift fork shaft journals for exessive wear or damage. Check the gear dogs, holes and teeth for excessive or abnormal wear, or evidence of insufficient lubrication‘ Measure the LD‘ of the following mainshaft countershaft at CS, C1 gearst SERVICE LIMITS: C1 gear: 24.04 mm (0.947 in) M2, M4, 03 gear: 28.04 mm (1.104 in) / / [2) SHIFT DRUM (1) BEARING ‘. 11-12 Measure the 0.0. of the mainshaft following bushings: SERVICE LIMITS: M4 gear bushing: 27.94 mm (1.100 in) C3 gear bushin 27.94 mm [1.100 in) M2 gear bushing: 27,94 mm (1.100 in) C1 gear bushing: 24.94 mm [0.982 in) Calculate the clearance between each bushing and gear. SERVICE LIMIT: 0.10 mm (0.004 in) Measure the ID, of the M2 and C1 bushings: SERVICE LIMITS: M2 gear bushing: LD, 25.04 mm (0.986 in) c1 gear bushing: I.D. 24.06 mm (0.790 in) Measure the 0D. of the mainshaft and countershaft at the M2 and Cl bushings. SERVICE LIMITS: Mainshaft (at M2 gear bushing) 24.90 mm (0.980 in) Countershaft (at C1 gear bushing) 19.92 mm (0.784 in) Calculate the clearance between each bushing and shaft. SERVICE LIMIT: 0.06 mm (0.0024 in) Check the each shaft grooves for damage. Replace if necessary. BEARING REPLACEMENT Turn the inner race of each bearing with your finger. The bear- ings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the crankcase. Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the crankcase. CRANKSHAFT/TRANSMISSION (1) M4 or C3 BUSHING (2) M2 or C1 BUSHING (2] C1 [1) SNAP RING GROOVES (2) LOCK AND STOP WASHER GROOVES (3) SNAP RING GROOVE (4) STOP RING GROOVE 11-13 CRANKSHAFT/TRANSMISSION Left crankcase (I) BEARING REMOVER Remove the left mainshaft bearing using the special tools. SET TOOLS: Bearing remover set 07936—3710001 Not available in USA. — remover handle 07936—3710100 — bearing remover set 07936—3710600 — remover weight 07741—0010201 or 07936—3710200 Drive the countershaft bearing and oil seal out of the crank- case. (I ) BEARING SET PLATE Install the new mainshaft bearing set plate on the left crank— case, NOTE (1) DRIVER ' Apply fresh engine oil to the new crankcase bearings before installation. Install the new bearings with the following tools TOOLS: Left mainshaft bearing Driver 07749 — 0010000 Attachment, 42 x 47 mm 07746—0010300 /2 Left countershaft bearing Driver 07749—0010000 .‘ ’ ' Attachment. 52 x 55 mm 07746—0010400 . (2’ ATTACHMENT Pilot, 25 mm 07746—0040600 m DUST SEALS \ ‘ ~55 1") r" 0-. Install a new countershaft oil seal. Check the gearshift spindle oil seal for wear or damage, re- place if necessaryt 11-14 CRANKSHAFT/TRANSMISSION Right crankcase I ‘ (1) DRIVER Remove the mainshalt bearing set plate and drive the counter- ~ ’ ' shalt bearing, mainshalt bearing and shift drum bearing out of the crankcase TOOLS: Right malnshaft bearing Driver 07765—0010000 Attachment, 52 x 55 mm 07746—0010400 Pilot, 22 mm 07746—0041000 Right countershaft bearing Driver 07749—0010000 Attachment, 42 x 47 mm 07746—0010300 Pilot, 20 mm 07746—0040500 (1 ) RIGHT CRANKCASE Apply a locking agent to the threads of the mainshaft bearing set plate attaching boltt Install the set plate and tighten the bolt securely. INSPECTION (1) 10 mm STUD BOLT HOLES Crankcase studs '88"89,'91-’95: 0 Check that the studs are tighttlf any are loose,remove them, clean their threads with contact cleaner,then reinstall them using Honda Anaerobic Thread Lock,or equivalent. O (2) 8 mm STUD BOLT HOLE After installing, be sure to measure the distance from the top (1) 8 mm srup BOLT (2) 10 mm STUD BOLT of each stud to the crankcase surfacet Tighten the stud bolts to the specified torque. TORQUE: 8 mm stud bolt: 20—30 N-m (2.0—3‘0 kg-m, 14—22 tt-lbl 178_180 mm 10 mm stud b0": (7008—7087 in) 30—50 N-m [3.0—5‘0 kg-m, 22—36 ft-lbl 158—170 mm [6514—5593 in] 1(3) CRANKCASE CRAN KSHAFT/TRANSMISSION After’95: Check that the studs are tight,lf any are loose,remove them, clean their threads with contact cleaner,then reinstall them apply engine oil to the threads. (1) FLAT SIDE I H «x - Install the studs with the flat side into the crankcase. (2) BOSS SIDE After installing.be sure to measure the distance from the top of each stud to the crankcase surface as shown. ‘1) 8 mm STUD BOLT (2) 10 m'“ STUD BOLT 185—187 mm (7283—7362 in) 168—170 mm (6‘614—6,693 in) OIL JET (1 ) OIL—J-ET Remove the oil jets from the front cylinder bore of the right and left crankcase. Check the O-ring for latique and damage. 11-16 CRANKSHAFT/TRANSMISSION TRANSMISSION ASSEMBLY/ INSTALLATION Apply molybdenum disulfide grease to the following — shift fork gvooves — inside and outside of the bushings — outside of the spline bushings (5) C1 (SST) (4) C2 (GMT) (3) C3 I27Tl (9) M3 (22T) (10] M4 (29T) (2) COUNTERSHAFT C4 C3 CZ C1 Install the stopper ring and C4 gear onto the countershasft. (1) C4 GEAR (2) STOP RING 11-17 CRANKSHAFT/TRANSMISSION Install the lock washer and stop washer, aligning bigger tabs of the lock washer with bigger grooves of the stop washer in the countershaft groove. Turn the washers as shown to lock them on the nearest spline. Install the stop washer first, and then the lock washer for the CS gear. Align and lock the washers using the procedure above. Assemble the countershaft and mainshaft, Check the gears for freedom of movement or rotation on the shaft. Check that the snap rings are seated 'n the grooves and align their end gaps with the lands of the splines. '58"89,'91-'95: Install the left shift fork on the shaft with MR1 mark facing the groove on the shaft end and the bolt hole aligned with the shaft hole. '58"59,'91-'95: Tighten the bolt with the lock washer and bend up the tabs of the lock washer. 5‘ (1) LOCK WASHER (2) STOP WASHER (1) STOP WASHER [2) LOCK WASHER (1) MR1 MARK l2) GROOVE l1) BOLT 11-18 CRANKSHAFT/TRANSMISSION '88,'89,'91-'95: Install the right shift fork with the "R" mark on the fork facing (1) RIGHT SHIFT up. FORK Assemble the mainshaft, countershaft, shift fork shaft and shift drum. Install them into the left crankcase as an assembly. After'95: (1) “R” SHIFT F0 Assemble the maInshaft and countershaft. Install them into the left cankcase as an assembly. Install the shIft forks into the shifter gear 'grooves with the markings facing up(right crankcase side). Install the shift drum by aligning the shift fork guide pins wiht the shift drum guide grooves. Insert the shift fork shaft through the shift forks into the left crankcase with the stepped end facing up. STEPPED ‘2’ END CRANKCASE ASSEMBLY Apply sealant to the crankcase mating surfacesi Install the dowel pinsi Assemble the right and left crankcases being careful to align the dowel pins and shafts. CAUTION - Do not force the crankcase halves together; if there is exessive force required, something is wrong. Remove the right crank- easa and check for misaligned parts. CRANKSHAFT/TRANSMISSION Apply oil to all crankcase boltst Install and tighten the right crankcase belts in a crisscross pat- tern in 2 or 3 steps. NOTE - Tighten the 8 mm bolts first, then tighten the 6 mm bolts. Install and tighten the left crankcase bolts '71 a crisscross pat- tern in 2 or 3 steps NOTE - Tighten the 8 mm bolts first, then tighten the 6 mm boltsi Install the rear cam chain drive sprocket over the crankshaft, aligning the extra-wide splines in the sprocket and crankshaftt Install the rear cam chain over the drive sprocket. Install the oil pipe stay and cam chain tensioner set plate. Tighten the bolt sercurely. (1) CAM CHAIN DRIVE SPROCKET IE) FIEAFI cgiw CHAer a "W 3 x O o 11-20 CRANKSHAFT/TRANSMISSION Ins‘all ‘he front cam chain over the from cam chain drive i‘ sprocke‘. w. lns‘alI the cam chain ‘ensioner set pla‘e and tigmen the ban securelvr lns‘all ‘he remaining pans in the reverse order of removal (page 11-1). 11-21 FRONT WHEEL/SUSPENSION/STEERING 30 N-m(3.0 Kg—m, 22 fl-lb) After '94: 105 N-m(l0.5 Kg—m, 76 fl—lb) Alter '93: 50 N'm(5.0 Kg~m, 75 N'm(7.5 Kg-m, 54 ft-Ib) 36 ft-Ib) 22 N-ml2.2 Kg-m,16fl-Ibl ’88,’59,'91~’93:27 N-m(2.7 Kg-m, 20 h-lb) Aher '93231 N-m(3.1 Kg-m, 22 ft—|b) 1 2-0 12. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION TROUBLESHOOTING HANDLEBAR 12-1 FRONT WHEEL 12-2 FORK 12-3 STEERING STEM 12-6 12-12 12-19 SERVICE INFORMATION - 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 clean brake assemblies. Use an OSHAapproved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by air borne asbestos fibers. 0 This section covers maintenance of the front wheel, fork and steering stemt Reler to section 14 for front [hydraulic] brake service. 0 Support the motorcycle using a hoist or a jack under the engine 0 The VTSODC uses leaf valve to the left SPECIFICATIONS ITEM STANDARD SERVICE LIMIT Axle runout — 0.2 mml0.008 in) Front wheel rim runout Radial — 2‘0 mm(0.08 inI Axial — 2‘0 mmI0.08 irII _ f '88,'89,'91-'93: 305 mml12.0 in] 299 mm(11.8 inI Fm 5"""g r“ “3"” After'93: 333.9 mm(13.1 in] 327.2 mmI12.9 in) Fork tube runout — 0.2 mmiOtOOB in) 88/89: 453 CCI15.7 US oz,13.0 Imp oz] — Fork fluid capacity '91-'93: 468 cc(15.8 US oz,13.2 Imp ozl — After'93: 449 CC(16.9 US 01,153 Imp oz] — Right 950 mm(3t74 in) — 88/89 _ Left 93.0 mm(3.66 In) — Fork fluid level ’91 '93 Right 8&0 mml3.50 in) — Left 87.0 mm(3.43 in) — After'93: 111 mm(4.4 in] — TORQUE VALUES Handlebar mounting bolt 23 N.m (2.3 kg“, 17 mm) Handlebar upper holder bolt After '94: 30 N-m (3‘0 kg-m, 22 ft—Ibl Clutch lever holder bolt 12 N.m (1‘2 kg“, 9 (HD) Brake mastercylinder holder bolt 12 N.m [1.2 kg.m' 9 (Mb) Spokes 4 N-m (0‘4 kg-m, 2.9 ft—lb) Brake disc mounting bolt 40 Mn] [40 kg,“ 29 [Mb] Fm"! axle 75 N-m (7‘5 kg-m, 54 lt—lb) Fork axle pinch bolt 22 Man (2.2 kg-m, 16 ft—lb) Fork socket bolt 30 NAm (3.0 kg—m, zz ft-Ib) Fork top pinch bolt 11 Nsm (1.1 kg-m, a lt-lb] Fork bottom pinch bolt 50 Ntm (5‘0 kgqnl 36 be) Brake caliper mounting bolt ’88,'89,’91-'93: 27 Nm [2‘7 kg_m' 20 mm) After ’93: Steering bearing adjustment nut Steering stem nut 31 N~m (3.1 kg—m,22 lt-lbl 25 N-m [2.5 kg-m,186t—|b) 105 Man (10.5 kg-m, 75 It-Ib) 12-1 FRONT WHEEL/SUSPENSION/STEERING TOOLS Special Spoke wrench Bottom holder pipe — holder attachment — holder handle Ball race remover —driver attachment —driver handle Fork seal driver ,39mm Steering stem socket Steering stem driver Bearing race remover Common Driver Attachment, 42 x 47 mm Pilot, 20 mm Bearing remover shaft Bearing remover head, 20 mm Attachment, 52 x 55 mm TROUBLESHOOTING Hard Steering - Steering bearing adjustment nut too tight - Faulty steering stem bearings - Insufficient air in front tire 07JMA—MR60100 or equivalent commercially available in USA 07930—KA50000 Not available in USA. 07930—KA501003— 07930— KA40200 07953—MJ10000 Not available 'n U.S.A O7953—MJ10‘IOO 07953—MJ1000A, 07953—MJIOOOB or 07953—MJ10200 07949—3710001 and 07746—0010100 07947—4630100 07915—3710100 07946— MBOOOOO 07946— 3710500 07749 — 0010000 07746 — 0010300 07746—0040500 07746~0050100:l—Equlvalent commercially available in USA, 07746—0050600 07746—0010400 Soft Suspension ' Weak fork springs ' Insufficient fluid in fork legs Hard Suspension Steers to One Side or Does Not 'frack Straight - Fork oil level too high - Bent fork legs - Fork tubelsl bent or fork sliderls) damaged - Bent front axle, wheel installed incorrectly - Unequal oil quantity in each fork tube Front Wheel Wobbling - Distorted rim ' Worn front wheel bearings - Loose or broken spokes ' Faulty tire Front Suspension Noise - Slider binding - Insufficient fluid 'n fork legs - Loose fork leg fasteners ' Axle or axle holder not tightened properly 1 2-2 HANDLEBAR GRIP REPLACEMENT Remove the right handlebar switch screws and disconnect the throttle cables from the throttle pipe. Remove the grip end cap and right handlebar grip. Remove the grip from the throttle pipe. Apply Honda Bond A or Honda Grip Cemment (U.S.A. only) to the inside surface of the throttle grip to the clean surface of the throttle pipe. Wait 3 — 5 minutes and install the grip. Rotate the grip for even application of the adhesive. Connect the throttle cables to the throttle pipe and install the right handlebar switch. install the grip end cap. Remove the grip end cap and pull the grip off of the left handle- bar. Apply Honda Bond A or Honda Grip Cemment (USA. only] to inside surface of the left grip to the clean surface of the handlebar. Wait 3—5 minutes and install the grip. Rotate the grip for even application of the adhesive. NOTE - Allow the adhesive to dry for an hour before using. Check for smooth throttle operation after the right grip is installed. Install the grip end cap. REMOVAL Disconnect the clutch switch wires from the switch terminals. Remove the following: — rear view mirror from the clutch lever holder — clutch lever holder mounting bolts and holder — left handlebar switch wire bands. — left handlebar switch screws and switch FRONT WHEEL/SUSPENSIGN/STEERING ( 1 ) TH HOTTLE CABLE S (3) THROTTLE PIPE (2) GP“? END CAP (1) CEMMENT (4) LEFT HANDLEBAR SWITCH (2] CLUTCH SWITCH (3) HOLDER FRONT WHEEL/SUSPENSION/STEERING Disconnect the front brake light switch wires from the switch. Remove the following: — rear view mirror from the master cylinder — master cylinder holder mounting bolts and holder — right handlebar switch wire bands — right handlebar switch screws and switch Loosen the throttle cable lower adjusting nuts at the carbure— tors and disconnect the throttle cables from the throttle pipet Remove the handlebar mounting nuts, handlebar and rubber seat from the fork bridget After ’94: Remove the handlebar upper holder bolts caps. Remove the socket bolts, upper holders and handlebar. Remove the nuts and handlebar lower holders. m BARKE LIGHT SWITCH (2) REAHVIEMT WIRE MIRS‘OFI ( i HANDR (2) SOCKET BOLTS l2) LOWER HOLDERS 1 2-4 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION '88, '89, '91—'94: Install the rubber seat into the fork bridge. Install the washers and handlebar mounting nuts. Tighten the nuts. TORQUE: 23 N-rn (2.3 kg-m, 17 ft-lb) After '94: Install the handlebar lower holders and temporarily tighten the nuts. Install the handlebar and upper holders With their punch marks lacing forward. Temporarily trghten the socket bolts. Tighten the lower holder nuts to the specified torque. TORQUE: 23 N~m(2.3 kg-m, 16 ft-Ib) Loosen the upper holder socket bolts and align the punch marks on the handlebar With the spins of the handlebar holders. Tighten the forward bolts first, then tighten the rear bolts. TORQUE: 30 N-m(3.0 kg-m. ZZIt-Ib) Install the upper holder bolt caps. Install the left handlebar switch set collar on the upper switch housing. Align the locating pin in the lower switch housing with the hole in the handlebar. Install the left handlebar switch attaching screws, and tighten the forward screw first, then tighten the rear screw. (1) SEAT RUBBE I ..- ———— (I HANDLEBAR MOUNTING NU§ (1| LOWER HOLDER NUTS (3) CAPS (2) SOCKET BOLTS (1) PUNCH MARKS [4) PIN FRONT WHEEL/SUSPENSION/STEERING Install the clutch holder/lever and with the "UP" mark facing up. Align the end of the holder with the punch mark on the handle- bar and tighten the upper bolt first then tighten the lower bolt. TORQUE: 12 N~m (1.2 kg-m, 9 "-lb) Connect the clutch switch wires. Install the right rear view mirror in the holder. Secure the wires with wire bands. Apply grease to the throttle cable ends and connect the cables to the throttle pipe. Install the right handlebar switch onto the handlebar, aligning the locating pin with the hole in the handlebar. Install the right handlebar switch screws and tighten the for- ward screw first. then tighten the rear screw. Install the front brake master cylinder/holder with the "UP" mark facing up. Align the end of the holder with the punch mark on the handle- bar and tighten the upper bolt first, then tighten the lower bolt. TORQUE: 12 N>m (1,2 kg-m. 9 ft-lb) Connect the front brake light switch wires. Install the right rear-view mirror into the master cylinder/ holder. Secure the wire with wire bands. Adjust the following: — throttle operation and free play lpage 375), — clutch lever free play (page 3718!. [1) HOLE ('1) PUNCH MARK 12) UP MARK (2] THROTTLE 12-6 FRONT WHEEL/SUSPENSIGN/STEERING FRONT WHEEL REMOVAL Raise and support the motorcycle using a hoist or a jack under the engine. Remove the set screw and pull the speedometer cable out of the speedometer gearbox. Remove the axle pinch bolt caps, and bolts from the right front fork legt Remove the axle and the front wheel. NOTE - Do not operate the front brake lever after removing the front wheeL To do so will cause difficulty in fitting the brake disc between the brake pads. Remove the side collar. Remove the speedometer gearbox. {1) SPEEDOMETER P (3) AXLE PINCH BOLhTS (Z) CAPS \ 11) SIDE COLLAFL ELF; (1) SPEEDOMETE‘R GEARBOX FRONT WHEEL/SUSPENSION/STEERING INSPECTION I AXLE Set the axle in V blocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.2 mm (0.01 in) O WHEEL Check the spokes and tighten any that are loose. TORQUE: 4 N-m (0.4 kg-m, 2.9 It-Ib) Check the rim vunout by placing the wheel on a truing stand. Then spin the wheel with hand, and read the runout using a dial indicator. SERVICE LIMITS: RADIAL: 2.0 mm [0.08 in) AXIAL: 2.0 mm [0.08 in) CAUTION - Wheel balance directly affec/s the stability, handling and every al/ safe/y of [he motorcycle. Always check balance when the tire has been removed from the rim. NOTE ' For optimum balance, the tire balance mark la paint dot on the sidewall) must be located next to the valve stem. ' Hemount the tire if necessary. Mount the lront wheel in a inspection stand. Spin the wheel, allow it to stop, and mark the lowest [heaviest] part ol the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position. in FRONT AXLE / l'll VALVE 12) BALANCE MARK 1 2-8 To balance the wheel, install wheel weights on the highest side of the rim, the side opposite to the chalk marks, Add just enough weight so the wheel will no longer stop in the same po- sition when it is sound Do not add more than 70 grams 0 WHEEL BEARING Turn the inner race of each bearing with your fingert The bearings should turn smoothly and quietly. Also check that the bearing outer race lits tightly in the hub, Remove and discard the bearings if the races do not turn smoothly, quietly, or if they loosely in the hub‘ BEARING REPLACEMENT Remove the front wheel (page 12-7). Remove the dust seal and retainer from the left side of the wheel hub, Remove the dust seal from the right side of the hub, Remove the brake disc mounting bolts and disc, FRONT WHEELISUSPENSION/STEERING (1) WHEEL WEIGHT [1) WHEEL BEARING 52;, (1) Bus? SEALS {£9 FRONT WHEEL/SUSPENSION/STEERING Drive out the wheel bearings and distance collart CAUTION ~ Never reuse old bearings. TOOLS: Bearing remover shaft 07746-0050100 Equivalent commercially available in USA. Bearing remover head, 20 mm 07746-0050600 Equivalent commercially available in U‘S,A‘ Drive in the new left bearing first until it seats. ' 1V (1] DRIVER Install the distance collar and drive in the right bearing‘ ' NOTE ' install the bearings with the vendor markings facing the outside Be sure to drive the hearings in squarely. ' Always replace wheel hearings in pairs. TOOLS: Driver 07749 — 0010000 Attachment, 42 x 47 mm 07746—0010300 Pilot, 20 mm 07746—0040500 ‘ , (2) ATTAQHMENI ASSEMBLY m_‘ ~ Do not get get grease an the brake disc 07 stopping power will be reduced. El 11) DISTANCE COLLAR [11)SIDE /CD COLLAR / (10) DUST SEAL (2) BEARING (3) DUST SEAL Ml SPEEDOMETER GEARBOX l8) RETAINER l7) DISC (5) SPEEDO- METER (5) WASHERS GEAR 12-10 FRONT WHEEL/SUSPENSION/STEERING To replace the wheel; Remove the tire and tube from the rim. Place the rim and hub on the work bench and begin lacing with new spokes from inside the hub. Install the spokes with a space of six holes in between. Measure the distance (B), and make a calculation. (A) : 70.8 mm (2.787 in] - (B) + 2 Adjust the hub position so that the distance from the hub sur- face where the brake disc mounts to the side of rim is (Al. Tighten the spokes 'n 2 or 3 progreassive steps. TOOLS: Spoke wrench: 07JMA—MR60100 or equivalent commercially available in U.S.A. TORQUE: 4 Wm (0.4 kg-m, 2,9 ft-Ib) Check the wheel runout [page 12-8). Install the tube and tire. Coat the speedometer gear retainer with grease and install the retainer into the wheel hub, aligning the tangs with the slots in the hubt Apply grease to the oil seal lip and install the oil seal over the gear retainer. Install the brake disc onto the wheel hub. Apply a thread locking agent to the bolt threads and install and tighten the bolts. NOTE - Tighten the belts in a crisscross pattern 'n 2 or 3 steps. TORQUE: 40 Man (4.0 kg-m, 29 ft-Ib) m— - Do not get grease an the brake disc 07 Slapping power will be reduced. \ l I, _ 70.8 mm (2.787 In) (2) DUST §EAL «v. [1) SLOTS AND TANGS Apply grease to the dust seal lips and install the seal on the right side of the hub. FRONT WHEEL/5USPENSION/STEERING Apply grease to the speedometer gearbox and geart ll) GEAR BOX (2) WASHER Install the speedometer gear and washers into the gearbox l3) SPEEDO- METER GEAR Install the speedometer gearbox into the wheel hub, aligning the tangs with the slots. Clean the brake discs with a high quality degreasing agent. Install the right side collart INSTALLATION Place the front wheel between the front fork legst Fit the caliper over the brake disc, taking care notto damage the brake pads Clean the axle and holder. Install the axle through fork leg, the side collar, wheel hub and speedometer gear box Set the speedometer gearbox tab under the tang on the left fork slider. Tighten the front axle. TORQUE: 75 N~m (7.5 kg-m, 54 ft-Ib) Tighten the fork pinch boltst TORQUE: 22 N-m (2.2 kg-m, 16 ft-Ibl Install the speedometer cable and set screw securelyt (3) FORK PINCH BOLTS (2] LCAPS 12-12 FORK REMOVAL Remove the front wheel lpage 1277) Remove the brake caliper mounting bolts and brake caliper. Unhook the brake hose from the hook on the lender. Tie the caliper to the handlebar so its weight does not pull on the brake hose. Pull the speedometer cable out of the cable holder on the fend- er. Remove the front fender mounting bolts from the fork legs. If the fork legs will be disassembled, loosen the fork cap bolts, but do not remove them yet. Loosen the following bolts: — turn signal mounting bolt — fork top pinch bolt — fork bottom pinch bolt Pull the fork tubes out of the top bridge and steering stem. FRONT WHEEL/SUSPENSION/STEERING l1) BRAKE CALIPEFl MOUNTING eons (2) anififiHosE'aAMP ~ l2) TUN SIGNAL LIGHT / t, > 13) FORK BOTTOM PINCH BOLT_ MOUNTING BOLT 12-13 FRONT WHEEL/SUSPENSIGN/STEERING DISASSEMBLY l1] FORK CAP Remove the fork cap bolt. m— . The cap bolts are under spring prexsure. Take care when re- moving, and wear eye and face pmlecn'on. Remove the fork spring, seat washer and spacert wk [1) WASHER (2] SPRING Four out the fork fluid by pumping the fork up and down sever- al times. (3) SPACER Hold the fork slider in a Vise with soft jaws or a shop towel. l‘l) HOLDER HANDLE “x CAUTION - Do not distort the fork S/ider in the vise. Install the special tool into the fork tube and hold the piston, then remove the socket boltt TOOLS: Bottom holder pipe 07930-KA50000 Not available in USA. —holdev attachment 07930-KA501 00 Not available in USA. —bottom holder handle 07930-KA40200 Not available in USA. Remove the dust seal and stop ringt i A, m DUST SEAL CAUTION - Be careful rm! to damage thefark tube. (2) STOP RING X ‘12-14 In quick successive motions, pull the fork tube out or the slid— er. NOTE - The slider bushing that is pressed into the slider, and the fork tube bushing on the end or the fork tube, must be forced out Remove the oil lock piece from the fork slider. Remove the piston and rebound spring from the fork tube. Remove the oil seal, back-up ring and slider bushing from the fork tubet Do not remove the fork tube bushing until inspection determines it is necessary (page 12-15). INSPECTION Fork spring Measure the fork spring free length SERVICE LIMIT: '88.'89,'91-'93: 299 mm (11,8 in) Afler'93: 333.9 mmI13.1 inI Replace the spring if it is shorter than the service limit. Fork tube/sliderlpiston Check the fork tube, fork slider and piston for score marks, ex- cessive or abnormal wear. Replace any components which are worn or damaged Check the rebound spring for fatigue or damage. FRONT WHEEL/SUSPENSION/STEERING (1) OIL SEAL (2i SLIDER BUSHING [4] BACK-UP RING (3) TUBE BUSHING (I) FORK SPRING Li (H J‘I‘JJt/ ’L,’ H’s/JJJJWVJI’I’M’I (1) FORK SLIDEH (2) FORK Tuéz I5l REBOUND SPRING (4) PISTON (3) OIL LOCK PIECE 12-15 FRONT WHEEL/SUSPENSION/STEERING Set the fork tube in V blocks and read the runout. Actual runout is 1/2 the total indicator readingt SERVICE LIMIT: 010 mm (0‘008 in) Bushings Visually inspect the slider and fork tube bushings, l1) BUSHING 12) BACK-UP RING Replace the bushings iI there is excessive scoring or scratch- ing, or if the teIIon is worn so that the copper surface appears on more than 3/4 of the entire surface Check the back-up ring; replace it it there is any distortion at the points shownt @ (3) CHECK POINTS (4) COPPER SURFACES ASSEMBLY (2) DUST SEAL l1] FORK TUBE CAP '88.’89.’91-’93 ONLY \‘é g (3) STOP RING [19) O-RING QA/(M OIL SEAL (1) LEFT FORK TUBE (2) RIGHT FORK TUBE \ I15) SPACER (5) BACK-UP RING (6) SLIDER BUSHING (17) SPRING SEAT HS) FORK SPRING (15) PISTON RING :- \ an 17) FORK suoen a {W PIST0N\‘/¢ ., P110) SOCKET BOLT 'N‘ 111) FORK TUBE “3’ gm?” [J a BUSHING CAUTION [12) OIL LOCK PIECE - Thefork tube cannot be disassembled - Do not interchange the right and left fork tube when inv .rtalling the fork tube in the fork .rlx'aer. I3) LEAF (8) FORK TUBE VALVE “(9) DRAIN BOLT (Except after’95) 12-16 FRONT WHEEL/SUSPENSION/STEERING Install the rebound spring into the fork tube. Install a new postion ring into the piston groove. Place the oil lock piece on the end of the piston and insert the fork tube into the slider. Install the special tools into the fork tube to hold the pis- ton,and install and tighten the socket bolt. TOOLS: Bottom holder pipe 07930-KA50000 Not available in U.S,A. 07930-KA50100 Not available in U.S.A. 07930-KA40200 Not available in U.S.A. — holder attachment —bottom holder handle Place the fork slider in a vise with soft jaws or use a shop towel. Apply a locking agent to the socket bolt and thread it into the piston. Tighten with a 6 mm hex wrench. NOTE ~ Temporarily install the fork spring and fork cap bolt to tight- en the socket bolt. TORQUE: 30 N-m (3,0 kg-m, 22 ft-lb) Place the slider bushing over the fork tube until it rests on the slider. NOTE - Tape the upper edge of the fork tube to avoid damaging the oil seal lip, while installing the oil seal. Using a fork seal driver , drive the bushing into place. Install the back-up ring with the chamfered side facing the slider bushing. Coat the oil seal lip with the recommended fork oil. Drive the oil seal into place using a fork seal driver. Install the oil seal stop ring and the dust seal. w TOOL: Fork seal driver. 39mm 07947—4630100 (1i 0|L SEAL (2) BACK-UP HlNG ’// l3) PISTON a. I (6) SLIDEH BUSHING IS) TUBE BUSHING (4) LOCK PIECE (1) HOLDER ATTACHMENT [2) BOTTOM HOLDER i HAliDLE [1] SOCKET BOLT \ (2) DUST SEAL 11) FORK SEAL DRIVER (3) STOP RING \l L I g \«y (4) on. SEAL “I LT‘— 15) BACK-UP I RING i 12-17 FRONT WHEEL/SUSPENSION/STEERING Compress the fork leg and pour Honda Suspension Fluid $878 or equivalent into the fork tube. SPECIFIED LEVEL: '88, '89: Right fork: 95.0 mm (3.74 in) Le" fork: 93.0 mm (3.36 inl '91-'93: Right fork: 89.0 mm (3.50 in) Le" fork: 87.0 mm (3.43 in) After '93: Right and left forks: 111mml4.4 in) CAPACITV: '88, '8 : 463cc (15.7 US 01,13,0lmp oz) '91- 93: 468 0c (15.8 US 01, 13.2 Imp 01) After '93: 449 ccl16.9 US 02.15.8lmp oz) l‘li OIL LEVEL Install the fork spring, washer and spacer into the fork tube. (1)116 HTLV WOUND COILS ’88,’89,'91—’93: OT ItIII I""_..\_ N e t. , 1-]. l. l _. H'JNJJNJll ~ Note the direction: the tightly wound coils should be at bot- tom, AFtet '93: NOTE Note the direction:the tightly wound coils should be at top. Loosely install the forktube cap with a new O-ring. l1l 0-HING (2) FORK TUBE CAP venoer INSTALLATION l1) ALIGN Install the fork tube, aligining its top end with the upper sur» face of the top bridge as shown. Temporarily install and tighten the fork top pinch bolts and turn signal mounting bolts. (3) TURN SIGNAL MOUTING BOLT 12-18 Install and tighten the bottom pinch bolt. TORQUE: 50 N~m (5‘0 kg-m, 36 ft-Ib) Tighten the top pinch bolt. TORQUE: 11 N-m (1.1 kg-m, 8 ft-Ib) Install the front lender and tighten the mounting bolts secure- ly. Hook the brake hose onto the hose clip. Install the brake caliper with the mounting bolts. Tighten the bolts to the specified torque. TORQUE: '88,‘89,'91r'93; 27 WM (2.7 kg-m, 20 ft-Ib] After ’93: 31N>m(3.1kg-m, 22 fl-Ib) Insert the speedometer cable through the fender holder. FRONT WHEEL/SUSPENSION/STEERING m HOSE-CLAMP // F71 Ho/LB'E'R z (2) BRAKE CALIPER MO_UNTING BOLTS 12-19 FRONT WHEEL/SUSPENSION/STEERING STEERING STEM REMOVAL Remove the fork legs and handlebar. Disconnect the speedometer cable from the speedometer, and the 6? black connector (see page 1713) Remove the following: — speedometer from the fork bridge — headlight from the headlight case — headlight stay and mounting nuts, headlight stay and case Remove the steering stem nut and washer. Remove the top bridge. Remove the indicator panel and lights by removing the two screws. Straighten the lock washer tabs and remove the lock nut and lock washer. [1) SPEEDOMETER /’ ,, l2) SPEEDO- t N h )1 Mi STAY MOUNTJN9_NUTS (3] CONNECTOR n l STEEWNG STEM NUT \ fl 1 (1) INDICATOR PANEL y 2 (v.82 m [1)LOCK NUT (2) LOCK WASHER 1 2-20 FRONT WHEEL/SUSPENSION/STEERING I'II STEERING STEM SOCKET Loosen the steering head bearing adjustment nut. TOOL: Steering stem socket 07916—371010!) Hold the steering stem by hand and remove the adjustment III QBHIUSTMENT nut, dust seal, upper bearing inner race and upper bearing. Remove the steering stem from the steering head. Check the bearings and outer race for wear or damage. Replace if necessary. BEARING REPLACEMENT [I] LOCK NUT [2) LOCK WASHER I3) BEARING ADJUSTMENT NUT (4) DUST SEAL (5i UPPER BEARING INNER RACE 16) UPPER BEARING I7) UPPER BEARING OUTER RACE (8) LOWER BEARING OUTER RACE 19] LOWER BEARING I10) LOWER BEARING INNER RACE MIMI DUST SEAL 12-21 FRONT WHEEL/SUSPENSION/STEERING NOTE (ll DUST SEAL (2i STEM NUT - Always replace the bearing and race as a set. Install the steering stem nut on the top end of the steering stem to protect the threads from damage. Remove the lower inner race and dust seal using a punch or driver. Replace the dust seal with a new one whenever it is removed. Remove the lower outer race using the special tools and a suit- [1) BEARING RACE able shaft. REMOVER 'lOOLS: Bearing race remover: 07946—3710500 Remove the upper bearing outer race using the special tools. TOOLS: Ball race remover 07953—MJ1000 Not available —attachment 07953—MJ101023’ in U-S-A- —driver handle 07953— MJ10200 or Attachment 07953—MJ1000A, 07953—MJ‘IOOOB or Driver 07949—3710001 and Attachment, 32 X 35 mm 07746—001 0100 (1i STEERING ' STEM DRIVER Install a new dust seal over the steering stem. Press a new lower bearing inner race onto the stem. TOOL: Steering stem driver 07946—M300000 Drive new upper and lower bearing outer races into the steer- ing head pipe. TOOLS: Upper bearing outer race: Drive 07749—0010000 Attachment, 42 x 47 mm 07746—0010300 Lower bearing outer race: Driver 07749—0010000 Attachment, 52 x 55 mm 07746—0010400 1 2-22 FRONT WHEEL/SUSPENSION/STEERING (3) BEARINGS INSTALLATION Pack the bearing cavities with grease. Install the lower bearing onto the stern. Insert the stem into the steering head pipe and install the upper bearing, inner race, dust seal and steering bearing adjustment nut. NUT I1] INNER RACE *IZ] STEERING BEARING ADJUSTMENT ‘ Apply englne on to the adjustment nut threads I“ SEE/Wm Tighten the steering bearing adjustment nut to the specified SOCKET torque. TOOL: Steering stern socket 07916—3710100 TORQUE: 25 N-m [2,5 kg-m, 18 ft-Ib) Turn the steering stem back and iorth five times to seat the bearings. Retighten the adjustment nut to the same torque. Turn the steering stem to seat the bearings. Install a new look washer and bend the two opposite tabs I“ LOCK WASHER IZI LOCK NUT down into the grooves in the adjustment nut. Install and finger tighten the lock nut all the way. Hold the bearing adjustment nut and further tighten the lock nut, within 90 degrees, to align its grooves with the tabs at the lock washer. Bend up the lock washer tabs into the grooves of the lock nut. FRONT WHEEL/SUSPENSION/STEERING Install the indicator panel with two screws. Install the fork bridge then temporarily install the fork legs. Tighten the steering stem nut. TORQUE: 105 N‘m (10.5 kg-m, 76 "-lb) Install the following parts: —lork legs lpage 12718) —lront wheel (page 12712) Check the steering head bearing preload. STEERING HEAD BEARING PRELOAD Place a stand under the engine and raise the front wheel off the ground. Position the steering stem to the straight ahead position. Hook a spring balance to the fork tube and measure the steer- ing head bearing preload. NOTE ' Make sure that there is no cable and wire harness interfer— ence. The preload should be within 1.0—1.5 kg {2.20—3.31 lb] for right and left turns. If the readings do not fall within the limits, lower the front wheel on the ground and adjust the bearing adjustment nut. After making sure the bearing preload, install the removed parts in the reverse order of removal. 12-24 MEMO REAR WHEEL/BRAKE/SUSPENSION 90 N-m (9.0 kg-m, 65 le) 27 N~m (2.7 kg-m. 20 ft-Ib) ‘ so N~m (9,0 kg-m. 1 3-0 l3. REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 13-1 BRAKE PEDAL 13-10 TROUBLESHOOTING 13-2 SHOCK ABSORBER 13-11 REAR WHEEL 13-3 SWINGARM 13-14 REAR BRAKE 13-7 SEAT/REAR FENDER/SUB-FRAME 13-18 SERVICE INFORMATION GENERAL 0 Support the motorcycle using a hoist or a jack under the engine. CAUTION - Do not jack up the motorcycle using the all filler. C Use only genuine Honda replacement fasteners for the rear suspension. 0 Note the installation direction of the bolts. AwaRNINo ' Any attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with enough explosive flzrce to cause serious injury or death. . The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Use only nirro gen to pressurize the shock absorber. The use of an unstable gas can cause a tire or explosion resulting in serious energy. ' Before disposal of the shock absorber, release the nitrogen by pressing the valve core. Then remove the valve from the shock ab— sorber. - Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner or alternate morhod approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers. SPECIFICATION Unit: mm (in) ITEM STANDARD SERVICE LIMIT Rear wheel runout Radial 7 20 mm [0.08 in) Axial 7 20 mm [0‘08 in) Rear axle runout 7 0.2 mm [0.01 in) Rear brake drum LU. 160 mm (5.3 in] 151 mm (6.3 in) Rear brake lining thickness 5 mm (0.2 in) 2 mm [0.08 in) Shock absorber spring free length 1375 mm (5.41 in) 135.0 mm [5.31 in) Rear suspension damper compression 13.4—17.4 k9129.54—38o36|bl 13.3 kg (29.32 lb) TORQUE VALUES Spokes 4 N-m (0.4 kg-m, 2.9 ft-lb] Sprocket nut 65 N-m (6.5 kg-m, 47 lt-Ib) Shock absorber mounting bolt 45 N-rn [4.5 kg-m, 33 lt-lb) Swingarm pivot bolt 90 Man [9.0 kg-m, 65 lt-lb) Hear axle 90 Man [9.0 kg-m, 65 lt-Ib) Damper rod lock nut 70 N-m [7.0 kg-m, 51 It-Ib) Brake torque rod nut 27 N‘m (2.7 kg-rn, 20 lt-Ib) 13-1 REAR WHEEL/BRAKE/SUSPENSION TOOLS Special Driver shaft Attachment, 28 x 30 mm Spoke wrench Shock absorber compressor Attachment Compressor screw Snap ring pliers Common Bearing remover shaft Bearing remover head, 17 mm Driver Attachment, 42 x 47 mm Pilot, 17 mm Attachment, 32 x 35 mm Pilot, 15 mm Pilot, 22 mm TROUBLESHOOTING Wobble or vibration in motorcycle ~ Bent rim - Loose wheel bearing(s) ‘ Loose or bent spokes ‘ Damaged tire - Axle not tightened properly - Swingarm pivot bearing worn c Chain adjusters not adjusted equally ‘ Bent frame or swingarm Soft suspension ' Weak spring ' improper shock absorber spring preload Hard suspension - Improper shock absorber spring preload ~ Bent shock absorber rod ~ Swingarm pivot bearings damaged - Bent frame or swingarm Suspension noise - Faulty rear damper - Loose fasteners Poor brake performance ' Improper brake adjustment - Worn brake shoes ' Brake linings oily, greasy or dirty ' Worn brake cam ~ Worn brake drum ~ Brake arm serrations improperly engaged ~ Brake shoes worn at cam contact area 07946— MJ00100 07745—1570100 07JMA—MR60100 or equivalent commercially available in USA. O7GME—0010000 O7JME—MR10‘IOO 07GME—0010100 07914— 3230001 07746—0050100 or equivalent commercially 0[available in USA. 07746—005050 07749770010000 07746—0010300 07746—0040400 07745—0010100 07745—0040300 07745 — 0041000 "1 3-2 REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL Support the motorcycle using a hoist or a jack under the en- gine. CAUTION ~ Do not jack up the oilfilter. Loosen the drive chain adjusters on both sides of the swing- arm. Remove the following parts: — brake rod — cotter pin, nut, seat washers and bolt from the torque rod on the brake panel. — Axle nut, adjuster collars, side collar and rear axle. — drive chain from the drive sprocket — rear wheel — brake panel from the brake drum INSPECTION I AXLE Set the axle on V blocks and measure the runout. SERVICE LIMIT: 0.2 mm (0,01 In) 0 WHEEL Check the spokes and tighten any that are loose. TORQUE: 4 Mom (0.4 kg-m. 2.9 ft-lb) TOOL: Spoke wrench 07JMA—MR60100 or equivalent commercially available in U.S,A. Check the rim runout by placing the wheel on a truing stand. Spin the wheel hand and read the runout using a dial indicator. SERVICE LIMITS: RADIAL: 2.0 mm (0.08 In) AXIAL: 2.0 mm [0.08 In) 0 WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smootth and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. NOTE - Replace wheel bearings in pairs. For bearing replacement, see page 13-4. 0 WHEEL BALANCING Refer to page 12—7. NOTE - Do not add more than 70 grams of balancing weight to the rear wheel K (3) TORQUE u ROD NUT (5’ AXLE (5) BRAKE/Ami! (4) BREKE non (1 ) WHEEL BEARING 1 3-3 REAR WHEEL/BRAKE/SUSPENSION SPROCKET/DRIVEN FLANGE DISASSEM ELY/INSPECTION Remove the wheel (page 13-3). Remove the mounting nuts and separate the sprocket from the flange. Check the condition of the sprocket teeth. Replace a worn or damaged sprocket. NOTE - The drive chain and drive sprocket must also be inspected if the driven sprocket is worn a damaged. Never install a new drive chain on worn sprockets or a worn chain on new sprockets. Both chain and sprocket must be in good condi- tion or the new replacement chain or sprockets will wear rapidly. If driven flange the hub, drive it out by tapping it at several lo— cations with wood block. Remove the dampers from the flange in the hub. Remove the collar and dust seal from the flange. Drive out the driven flange hearing, if necessary. Inspect the dampers for deterioration. Turn the inner race of the bearing with your finger. The bearing should turn smoothly and quietly. Also check that the outer race fits tightly in the flange. Remove and discard the bearing if it does not turn smoothly and quietly, or if the outer race fits loosely in the flange. BEARING REPLACEMENT Wheel beating Drive out the wheel bearings and the distance collar. NOTE - If the bearings are removed, they must replaced. TOOLS: Bearing remover shalt 07746 —0050 100 Bearing remover head. 17 mm 07746—0050500 or equivalent commercially av able in U.S.A, (1) GOOD (2) REPLACE A _ _ a « l1) DRIVEN FLANGE‘ Y l2) COLLAR ‘ m BEAfitTG' REMovén (1) BEARING LL . x y (2) BEARING REMOVER SHAFT 13-4 REAR WHEEL/BRAKE/SUSPENSION First, drive in a new left wheel bearing until it is fully seated, in- > ‘ ' ’ ' (1) DRIVER stall the distance collar, then drive in a new right bearingt ' TOOLS: Driver 07749—0010000 Attachment, 42 x 47 mm 07746—0010300 Pilot, 17 mm 07746 —0040400 NOTE ' Drive the wheel hearings in with the vendor mark facing outt Flange bearing Drive out the bearing using a suitable molt Drive the new bearing in with its vendor mark facing outt TOOLS: Driver 07749—0010000 Attachment. 42 x 47 mm 07746—0010300 Pilot, 17 mm 07746—004040!) a A. ‘(21 DRIVEN [3) ATTACHMENT ‘5" FRANGE ASSEMBLY (2] DISTANCE COLLAR m BEARING ' l. E [3) O-RING [4) DRIVEN SFROCKET l9] COLLAR (8) FLANGE (5) DUST SEAL (7) NOISE ARRESTEH (6) BEARING 'fi. 13-5 REAR WHEEL/BRAKEISUSPENSION Placethe rim and hub on the work bench and begin lacing with a new spoke from the hole of inside in the hub. Install the spoke with a space of two holes in between. Measure the distance (B), and make a calculation (A) : 79 mm (3.110in) - (B) + 2 Adjust the hub position so that the distance from the hub right end surface to the side of rim is (Alt Tighten the spokes in 2 or 3 progressive steps. TOOL: Spoke wrench 07JMA—MH60100 or equivalent commercially available in USA TORQUE: 4 N-m [0‘4 kg—m, 2,9 ft-Ibl Check the wheel runout (page 13-3]. Install the tube and tire. Install the collar in the driven flange bearingt Install the damper rubbers on theflange and place flange in the hub. Apply grease to a new O—ring and install it onto the flange groove. Apply grease to the dust seal lip and install it Install the driven sprocket, it removed, and a new sealt Tighten the driven sprocket mounting nutst TORQUE: 65 N~m [6.5 kg-m. 47 fl-Ibl (A) j , (1) 79 mm [3.110jn) W (2) DRIVEN FLANGE BEARING r, (2) O-RING I (1) DRIVV’EN SPROCKET MOUNTING NUT ax 1 3-6 REAR WHEEL/BRAKE/SUSPENSION Install the axle collar. INSTALLATION Install the brake panel on the wheel hub. Position the rear wheel between in swingarm and install the drive chain over the driven sprocket. Install the left side adjuster collar onto the rear axle and insert the axle (from the left side] through the swingarm, wheel hub and right side collar. Install the adjuster collar and axle nut. Tighten the axle nut lightly. Adjust the drive chain (page 3713) Tighten the axle nut. TORQUE: 90 N-m [9.0 kg-m, 65 "-Ib) Connect the brake torque rod to the brake panel with belt, seat washer, washer and nut. (page 13-8). Tighten the nut. TORQUE: Z7 Nam (2.7 kg-m, 20 "-lb) Install the cotter pin and bend back it securely. Connect the brake rod to the brake arm and adjust the rear brake pedal free play (page 3716) INSPECTION Remove the rear wheel (page 13-3) Remove the brake panel and measure the rear brake drum LU. SERVICE LIMIT: 161 mm (6.3 in) Measure the rear brake lining thickness. SERVICE LIMIT: 2 mm (0.08 in) Replace the brake shoes if either one is thinner than the service limit. J (1i $1532 COLLAR (2) ADJUSTER COLLAR REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY m SETPLAT“ kw. \ Remove the cotter pins and set plate. Remove the brake shoes and springs from the brake panel. NOTE - Mark the shoes to indicate their original positions before re- moving them. Remove the following parts form the brake panel: — bolt and brake arm — indicator plate — brake cam — lelt seal ASSEMBLY [1] BOLT (2) INDICATOR PLATE (4) BRAKE SHOES l5) BRAKE CAM (10] BRAKE ARM 0 (6) COTTER PINS 0 . (7) SET PLATE [9) BRAKE (8] SPRINGS PANEL 1 3-8 REAR WHEEL/BRAKEISUSPENSION Apply grease to the brake anchor pins and brake cam. Install the brake cam into the brake paneL |ns |ns tall the felt sea|. tall the indicator plate on the brake cam aligning its tab with cut—out on the brake came Ins tall the brake arm by aligning the punch marks on the arm and cam, Ins 1“ Po tall and 'tighten the bolt sition the brake shoes in their original locations and install the springs. m— Grem an the brake linings will reduce stopping power. Keep grease off n f the brake linings. Wipe excess grease a] f the cam and anchor pin. Install the set plate and cotter pins, then bend back the pins. Install the brake panel onto the wheel hub and install the rear wheel [page 13-7]. (1) BRAKE CAM (2) ANCHOR A (3) FELT SEAIL (2) BRAKE CAM I ('1) PUNCH MARKS (3i BRAKE ARM (1) BRAKE SHOES (4) SET PLATE (3) COTTER FIN§X (2) SPRINGS ' 1 3-9 REAR WHEEL/BRAKE/SUSPENSION BRAKE PEDAL REMOVAL Remove the foot peg bracket mounting bolts and washerst Remove the brake pedal by removing the cutter pin, washer and bolt. (1) FOOT PEG BRACKET BOLTS INSTALLATION Install the brake pedal in the reverse order of removalt NOTE (1] WASHER 4 Note the locations of the washerst \/ $90 MI BRAKE SHAFT ARM (5) PUNCH MARK (1) BRAKE PEDAL ADJUSTER BOLT (3| MIDDLE BRAKE ROD l2) DUST SEALS 16) BRAKE ROD l9] BRAKE PEDAL I5) PUNCH MARK l8) PIVOT COLLAR l7) MIDDLE BRAKE ARM NOTE - Align the punch mark on the brake shaft arm end with the punch mark on the middle brake arm. 13-10 REAR WHEEL/BRAKE/SUSPENSION REAR SHOCK ABSORBER [2) FUEL pow REMOVAL l1) STAY m—__7 MOUNTING ~ The rear shock absorber contains nitrogen under high pressure. 32” 7\ Na Do not allow fire or heal near the shock absorber. fir SYQL Support the motorcycle using a hoist, or a jack under the en- gine. Remove the following: — seat, right and left side cover — rear ignition coil mounting bolts (page 1675) — rear ignition coil stay mounting bolt Disconnect the fuel pump, fuel pump relay and turn signal relay from the fuel pump stay. Remove the fuel pump stay mounting bolt, nut and fuel pump stay. Remove the upper and lower shock absorber mounting bolts and nuts then remove the shock absorber. DISASSEMBLY ‘ (2) ATTACHMENT Set the spring preload adjuster to No. 1 position. t Compress the shock absorber with the compressor and attach- ’ ment. CAUTION - Be sure the base is adjusted correctlyfor the shock spring sea! and (he Elevis pin is all the way in. TOOLS: Shock absorber compressor O7GME—0010000 (31 SHOCK ABSORBER Attachment 07.1 ME—MH10100 “' N°' 1 POS'T'ON COMPRESSOR V Compressor screw 07GME—0010100 (1) LOWER JOINT Loosen the lock nut and remove the lower joint and nut. Remove the compressor and disassemble the shock absorber. (2) LOCK NUT 13-11 REAR WHEEL/BRAKEISUSPENSION SPRING FREE LENGTH Measure the shock absorber spring free length. SERVICE LIMIT: 135.0 mm (531 in) Mark the damper rod at 10 mm below the case as shown. Place the damper rod on a scale and measure the force re- quired to compress the damper to the 10 mm (0.4 in) mark. COMPRESSION FORCE: 13.4—17‘4 kg (2954—3836 lb) If the force required is less than 13.3 kg (2932 lb), gas is leak- ing. Examine the damper rod and replace the damper unit if it is bent or scored. Check the damper unit for oil leaks or other damage and the damper rod for trueness. Check the upper mount bushing for wear or damage. SHOCK ABSORBER DISPOSAL PROCEDURE Center punch the damper case to mark a drilling point, approxi- mately 45 mm (1 .B in] from the mount top surface. Wrap the damper unit inside a plastic bag and support the damper unit upright in a vise as shown. Through the open end of the bag, insert a power drill with a sharp 2 or 3 mm (5/64—1/8 in] drill bit. m— - Do nat usea dull drill bit which could cause a build-up a/exces— sive heat and pressure inside the damper, leading to explosion and severe personal in jur y. e The shock absorber cantains nitrogen gas and oil under high pressure. Do nat drill any farther down the damper case than the measurement given abave, ar you may drill into the ail chamber; ail escaping under high pressure may cause serious personal injury. - Always wear eye protection ta avaid getting metal shavings in yaur eyes when the gas pressure is released. The plastic bag is anly intended to shield you [mm the escaping gas. Hold the bag around the drill motor and briefly run the drill motor insidethe bag; this will inflate the bag with air ltomthe motor and help keep the bag from getting caught in the bit when you start. (1) PLASTIC BAG i (2) DRILL LINE (3] DAMPER UNIT W’ 45 mm (1.8 in) L I 13-12 ASSEMBLY (1) DAMPER [3) UPPER SPRING SEAT I10) STOPPER RUBBER Install the Iollowing: — stop rubber onto the damper rod — spring adjuster seat and spring adjuster onto the damper so that it rests in the softest position — upper spring seat, spring (with the tightly wound end upward and lower spring seat), — lock nut Compress the spring with the compressor (O7GME— 0010000) and attachment l07JME—MH10100]. Screw the lower joint onto the damper rod fully, hold it, and tighten the lock nutt TORQUE: 70 N~m (7‘0 kg-m. 51 ft-Ib) INSTALLATION Install the rear shock absorber with the drain tube pointing down. Install and tighten the upper and lower mounting bolts and nuts TORQUE: 45 N-m (4.5kg-m, 33 ft-lbi Route the drain tube into the tube guide in the swingarm. Install the removed parts it the reverse order of removal. Adjust the shock absorber spring preload by turning the spring adjuster, if necessary. [12) ADJUSTER @ (11) SPRING GUIDE (8) PLUG I9) LOCK NUT REAR WHEEL/BRAKE/SUSPENSION .61 (2) SPRING ADJUSTER (4] SPRING I5) LOWER SPRING SEAT I7] LOWER JOINT (6) DRAIN TUBE I1) LOCK NUT \ /\ (2) LOWER MOUNTING BOLT 13-13 REAR WHEEL/BRAKE/SUSPENSION SWINGARM REMOVAL Remove the rear wheel (page 13-3) Remove the gearshift pedal mounting bolt from the foot peg. (1i PEDAL MOUNTING BOLT Remove the drive sprocket cover. i i DRIVE SPROCKET Remove the drive sprocket bolts, set plate and drive sprocket, CQyER Disconnect the gearshift arm from the gearshift spindle. ‘ t w. Remove the reserve tank from the frame (page 5-9) (1) SHOCK ABSORBER Remove the shock absorber lower mounting bolt and nut. LOWER MOUNTING BOLT Remove the swingarm pivot bolt caps, pivotbolt and nut then ‘ " ‘ . remove the swingarm from the frame. DISASSEMBLY m CHAIN COVER Inspect the drive chain slider for wear or damage. Replace it if necessary. Inspect the drive chain for dirt or damage. Clean or replace it if necessary (page 3714) Remove the following: — drive chain slider and chain cover — dust seals and pivot collars ;'(2) CHAIN SLIDER 13-14 REAR WHEEL/BRAKE/SUSPENSION INSPECTION Inspect the swingarm for deformation or cracks. Check the pivot bearings, collars and dust seals for wear or damage. Disassemble the drive chain cover and inspect the chain pro- tector for wear or damage, Replace if necessary. PIVOT BEARING REPLACEMENT Remove the dust seals from the right and left swingarm pivots. Remove the snap ring from the right pivot. TOOL: Snap ring pliers 07914—3230001 Drive the right pivot ball bearing out of the swingarm using a hydraulic press and driver shaft. TOOL: Driver shaft: 07946—MJ00100 (1) COLLARslziTafiRING (3) DUS , If “ I3) DUST SEALS I5) COLLAR (1) CHAIN COVER l2) PROTECTOR (1) SNAP RING l1) DRIVER SHAFT (2) RIGHT PIVOT T says \ l4) BEARINGS REAR WHEEL/BRAKE/SUSPENSION Drive the left needle bearing out of the swingarm. (1) DRIVER SHAFT TOOL: Driver shaft 07946— MJOO‘I 00 Carefully press new bearings into the swingarm pivots. NOTE ' Install the bearings with the marks lacing outt Right side ball bearing: TOOLS: Driver 07749—0010000 Attachment, 32 x 35 mm 07746—0010100 Pilot, 15 mm 07746—0040300 (21 ATTACHMENTS w P|LOT$_ Left side needle hearing: TOOLS: Driver 07749—0010000 Attachment, 28 x 30 mm 07746— 1870100 Pilot, 22 mm 07746—0041000 Snap ring pliers 07914—3230001 Install the snap ring into the right pivot. Apply grease to the new dust seal lips and install them , and the callers in the correct positions. (2] PIVOT COLLARS 13-16 REAR WHEEL/BRAKE/SUSPENSION ASSEMBLY/INSTALLATION I I1) CHAIN COVER Install the chain slider and chain cover with protectort Install the swingarm in the frame. Install the swingarm pivot bolt and nut, and tighten the nut to the specified torque. TORQUE: 90 N-m (9.0 kg-m, 65 ft-Ib) Install tne shock absorber lower mounting bolt and nut TUnidE: 45 N-m (4.5 kg-m. 33 ft-lb) Install the following: — swingarm pivot caps — reserve tank (page 5-9) — evaporative eml55(0n canister (California model only] — drive sprocket with the drive chain — gearshift arm Install the drive sprocket cover and tighten the mounting bolt. Install the gearshift pedal mounting bolt. Apply grease to the gearshift pedal pivot collar refer to page 7-9. Adjust the drive chain (page $13) and rear brake pedal free play (page 3716) — rear wheel [page 13-7I (1] DRIVE SPROCET (2) PEDAL MOUNTING COVER BOLT 13-17 REAR WHEEL/BRAKE/SUSPENSION SEAT/ REAR FENDER/SUB-FRAME REMOVAL/INSTALLATION Remove the seat mounting socket bolts and unhook the seat hooks lrom the frame, then remove the seat. Remove the right and left side covers, pull out the prongs then pull the cover down slowly to the release tabs. Remove the luel tank (page 4-3) and the rear lender mounting bolts and Remove the tallight case mounting nuts. Disconnect the right and left turn signal wire connectors, and the rear brake light and licence light connectors. Remove the rear fender lrom the main frame and sub—frame Remove the two sub-frame mounting bolts and two nuts, then remove the sub-lrame. Install the removed parts in the reverse order ol removalt (2] SEAT (1) FENDER MOUNTING [3) RIGHT SIDE (4) FENDER COVER MOUNTING .3 sons (5) SUB~FRAME [9) REAR MOUNTING : FENDER a) (6) TAILLIGHT CASE MOUNTING NUTS ‘51 LEFT 5'05 [7) SUB-FRAME COVER MOUNTING NUTS 13-18 MEMO HYDRAULIC DISC BRAKE 'BB,’89,'91-'53: bur. N-m (0‘15 kg-m,1‘1ft—lb) 12 N-m 11.2 amen—m) 27 N-m (2.7 kg-m, & 20 be) 5‘5 N-m (0.55 kgm, 4 (HM 27 N‘m (2‘7 kg-m, 20 fl-lb) 14-0 l4. HYDRAULIC DISC BRAKE Aher '53: 1.5 N‘rn(0.15 Kg-m,1.1 fl-lbl 12 N-ml1.2 Kg-m,9 h-Ib) 31 N-m(3V1 Kg—m,22 flilb) 2.5 N-m(0.25 Kg-m,1.8 fl—Ib) 14-1 HYDRAULIC DISK BRAKE SERVICE INFORMATION 14- 2 BRAKE PAD/DISC 14»5 TROUBLESHOOTING 14-3 MASTER CYLINDER 14-8 BRAKE FLUID REPLACEMENT/ BRAKE CALIPER 14-11 AIR BLEEDING 14-4 SERVICE INFORMATION GENERAL m e A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high qualit y brake degreasing agent. ' Use only DOT 4 brake fluid. ' The brake caliper can be removed without disconnecting the hydraulic system. - Once the hydraulic system has been disassembled, or ifthe brakes feel spongy, the system must be bled. ' Do not allow foreign material to enter the system when filling the reservoir. ' Brake fluid will damage painted, plastic, and rubber parts. Whenever handling brake fluid, protect the painted, plastic and rubber parts by covering them with a shop towel. If fluid does get on these parts, wipe it of] immediately with a clean cloth. ' Always check brake operation before riding the motorcycle. - Inhaled asbestos fibers have been found to cause respiratory disease and cancer. Never use an air hose or dry brush to clean brake assemblies. Use an OSHA~approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by airborne asbestos fibers. SPECIFICATIONS Unit:mm(in) ITEM STANDARD ERVICE LIMIT Disc thickness 5.0(0.2l 4.0(0.16l Disc runout — 0.30l0.012l 38589, ID. 12.700-12.743(0.5000-0.5017l 12.76(0.502l Mam, '91-'93= plston 0.0. 12.657-1Z.684l0.4983-0.4994) 12.55lo.498l cWilder A“ ’93 LB. 11.0—11.043IO.4331-0.4348) 11.05(O.435I e : r plston 0.D. 10.957—10.984(0.4314—0.4324) 10.945(O.4309) r8339, cylinder LU. 30230-30250“.1902—1.1921) 30.29l1.193l Brake ’91-’93= piston 0.0. 30.165-30.198l1.1876—1.1889l 30.16l1.1a7l caliper Aha ,9? cylinder |.D. 27.000—27.050l10630—10650) Z7.06(1.065l r . piston 0.D. 26335—26358“ .604-1 .061 7) 26.93l1.060l TORQUE VALUES Caliper mounting bolt 27 N~m (2.7 kg-m, 20 ft-lb) Brake hose oil bolt 30 N‘m (3.0 kg—m, 22 ft-lb) Bleed valve 5.5 N-m (0.55 kg-m, 4 ft-IIJ) Master cylinder holder bolt 12 N-m (1.2 kg—m, 9 it-lb) Master cylinder cover screw 1.5 N-m (0.15 kg-m, 1.1 ft-lb) TOOL Special Snap ring pliers 07914—3230001 or equivalent commercially available in U.S.A. 14-2 HYDRAULIC DISC BRAKE TROUBLESHOOTING Brake lever soft or spongy . All bubbles i'l hydraulic sysrem. ' Low fluid level. . Hydraulic system leaklng. . Faully dust seal or pislon seal. Brake lever (00 hard - Sticking pislonlsl. . Clogged hydraulic syslem. - Pads glazed or worn excessively. Brake drag ~ Hydraulic system slicking. . Slicking plstonlsl. Brake grab or pull to one side ' Pads contaminated. I Disc of wheel misaligned. Brake chaner or squeal ' Pad Contaminated. ' Excessive disc runout. - Caliper inslalled incorrectly. I Disc 0! wheel misaligned. 14-3 HVDRAULIC DISC BRAKE BRAKE FLUID REPLACEMENT/ m RESERVOIR coven AIR BLEEDING CAUTION - Ee careful not to allow dust or water to enter the brake system when filling the reservoir. ' USE 0NLYDOT4 BRAKE FLUID - Do not mix different types of fluid since they are not compatible. - Avoid spi/Iing fluid on painted surfaces. P/tzce t1 mg over the fuel tank whenever the system is serviced. Check the fluid level with the fluid reservoir parallel to the ground Remove the reservoir cover, set plate and diaphragm. BRAKE FLUID DRAINING Connect a bleed hose to the bleed valve. Loosen the caliper bleed valve and pump the brake lever. Stop operating the lever when fluid stops flowing out of the bleed valve. BRAKE FLUID FILLING/AIR BLEEDING Close the bleed valve, fill the master cylinder with DOT 4 brake fluid to the casting ledge level {brake fluid upper level]. CAUTION ~ Do not mix different types of fluid since they are not compatible. Connect the commercially available brake bleeder to the bleeder valve. Pump the brake bleeder and loosen the bleed valve BLEEDER Add fluid when the fluid level in the reservoir is low. Repeat above procedures until no air bubbles appear in the plastic hose. NOTE - lf air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. If a brake bleeder is not available, fill the system as follows: Pump up the system pressure with the lever or pedal until there are no air bubbles in the fluid flowing out of the reservoir hole and lever or pedal resistance is felt. 1 4-4 HYDRAULIC DISC BRAKE 1) Squeeze the brake lever, then open the bleed valve 1/2 turn and close the valve. NOTE - Do not release the brake lever lor pedal) until the bleed valve has been closed. 2] Release the brake lever slowly and wait several seconds after it reaches the end of its travel. Repeat steps 1 and 2 until bubbles cease to appear in the fluid at the end of the hose. Tighten the bleed valve. TORQUE: 5.5 N‘m (0.55 kg-m, 4 ft-Ib) Close the bleed valve, fill the reservoir with the specified brake fluid to the casting ledge level. Reinstall the diaphragm, set plate and cover. m—_ ~ A contaminated brake dixc or pad reduce: slapping po wer. Dix» card contaminated padx and clean a contaminated disc with a high quality brake degreasing agent. BRAKE PAD/ DISC FRONT BRAKE PAD REPLACEMENT ME; ~ A contaminated brake dirt or pad reduce: flapping power. Dis- card contaminated pad: and clean a contaminated din with a high quality brake degreasing agent. NOTE - Always replace the brake pads in pairs to assure even disc pressure, '88.'89.'9‘l -'93: Remove the pad pin plugs and loosen the pad pins. Remove the caliper mounting bolts, then remove the brake cal— iper and bracket. Pry one old pad against the caliper with a screwdriver to push the pistons into the caliper. 14-5 HYDRAULIC DISC BRAKE '17) PAD PIN Pull the pad pins out of the caliper and remove the brake pads. Position the pad spring in the caliper as shown. Install new pads in the caliper. NOTE ' Always replace the brake pads in pairs to assure even disc pressure. Install the pad pins, first one pin, then the other, by pushing the pads against the caliper to depress the pad spring. Position the retainer spring in the bracket. Apply silicone grease to the caliper and bracket pin bolts. Install the bracket. (4) BRACKET m 14-6 HYDRAULIC DISC BRAKE ‘ (‘Zl‘PA Ple V 2 Install the brake caliper over the disc, being careful not to i1i'cALIP‘EH M‘6UTING damage the pads, then tighten the caliper mounting bolt. BOLTS TORQUE: Z7 N-m (2.7 kg-m, 20 ft-Ib) Tighten the pad pins and tighten the pad pin plugs securely. NOTE ' Operate the brake lever to seat the caliper pistons against the pads. After '93: Remove the pad pin plug and loosen the pad pin. Pull the pad pin out of the caliper. Remove the brake pads. Insert new outside pad and push the caliper piston in allow clearance for installation of the new inside pad. Install new inside pad. Install the pad pin by pushing the pads against the caliper to depress the pad spring. Tighten the pad pin to the specified torque. TOROUE:18 N -m(‘l ,8 Kg-m,13 h-Ib) Install and tighten the pad pin plug to the specified torque. TOROUE:2.5 N~m(0.25 Kg-m,1,8 fl-Ib) 1) PAD PIN 14-7 HYDRAULIC DISC BRAKE DISC THICKNESS Measure the thickness of the disc. SERVICE LIMIT: 4.0 mm (0.16 in) BRAKE DISC WARPAGE Measure the brake disc for wavpage with a dial indicator as shown. SERVICE LIMIT: 0.30 mm (0.012 in) MASTER CYLINDER REMOVAL Drain brake fluid from the hydraulic system. Remove the rear view mirror from the master cylinder and dis- connect the brake light switch wires. Disconnect the brake hose by removing the oil bolt and sealing washers. l1) OIL BOLT (2) REAR VIEW CAUTION MIRROR - Avoid spilling brake/714M on painted surfaces. Place a rug over the fuel rank whenever the brake system is serviced. NOTE - When removing the oil hose bolt, cover the end of the hose » » to prevent contamination. Secure the hose to prevent fluid a from leaking out. Remove the master cylinder holder bolts and holder, then remove the master cylinder from the handlebar. DISASSEMBLY ("BRAKE LEVER Remove the brake lever and brake light switch. “M “~— [2) BRAKE LIGHT swnc 14-8 HYDRAULIC DISC BRAKE Remove the boot. (1) SNAP RING Remove the piston and spring by removing the snap ring. TOOL: Snap ring pliers 07914—3230001 or equivalent commercially available in U, S, A, (2) BOOT Clean the inside of the master cylinder, reservoir, spring and (1)5PRING piston with clean brake fluid. (2) PISTON INSPECTION Measure the master cylinder LDt SERVICE LIMIT: ’88.’89,’91-’93: 12.76 mm (0.502 in) Ahet'93: 1105 mm (0.435 in) Check the master cylinder for scores, scratches or nickst Measure the master piston CD. at the shown positiont SERVICE LIMIT: '88,'89,’91-’93: 12.65 mm (0‘498 in) Aher'93: 10,945 mm (Q4309 in) Check the primary and secondary cups for damage before as- sembly. ASSEMBLY CAUTION ’ - Handle the masler cylinder pixlon, cylinder and Spring a: a xet. Coat all parts with clean brake fluid before assemblyt V If the spring and seat were disassembled, assemble the wide end of the spring on the seat. Install the spring '71 the master cylinder with its seat facing in- side. Install the piston ‘ CAUTION - When ins/ailing the pismn, do not allow [he cup lips In turn {side nut. 14-9 HYDRAULIC DISC BRAKE Install the snap ring using a snap ring pliers. Install the boot. (1) SNAP RING CAUTION - Be certain that the snap ring is sealed firmly in the groove TOOL: Snap ring pliers 07914—3230001 or equivalent commercially available in Ur S, A g e- (2] BOOT Install the brake lever and brake light switch. (WAKE LEVER My / (2) BRAKE LIGHT’ L ,.,' 3 SWITCH ’ INSTALLATION Set the master cylinder onto the handlebar with the holder (1) pUNCH MARK "UP" mark facing up Temporarily install the holder bolts. Align the slit of the master cylinder with the punch mark on the handlebart Tighten the upper bolt first, then the lower bolt. Connect the brake light switch wires to the switch terminals. Install the rear view mirror. Connect the brake hose with the oil bolt and two sealing wash— ers and tighten the oil bolt. TORQUE: 30 N~m (3.0 kg-m, 22 lt-lbl Fill the reservoir with DOT 4 brake fluid to the casting ledge and bleed the brake system (page 14-4]. [2) “UP” MARK 14-10 HVDRAULIC DISC BRAKE BRAKE CALI PER » ’ , [1I-OIL-B‘OET ‘ REMOVAL Place a clean container under the caliper and disconnect the I) 6 brake hose from the caliper by removing the oil bolt and sealing washers. CAUTION ' Avoid :pi/Iing brake fluid on painted surfaces. Remove the brake pads (page 14-5). DISASSEMBLY Remove the following: — pad spring and pin bolt boot from the caliper — retainer spring and pin boltboot from the bracket If necessary, apply compressed air to the caliper fluid inlet to get the piston out. Place a shop rag under the caliper to cush- ion the piston when it is expelled. Use the air in short spurts. CAUTION - Do not bring the nozz/e (on close m (h inlet. Push the dust seals and piston seals in, lift them out and dis- card them. NOTE - The seals must be replaced whenever they are removed. Clean the seal grooves with clean brake fluid. CAUTION - Be mrefu/ not to damage the piston sliding xurfaces. INSPECTION Check the pistons for scoring, scratches or other faults. Measure the piston O.D. SERVICE LIMIT: '38.’89.'91-'93: 30.16 mm (1.187 in) After'93: 26.93 mm (1.060 in) Check the caliper cylinder for scoring, scratches or other faults. Measure the caliper cylinder I.D. SERVICE LIMIT: ’88,’89.’91-'93: 30.29 mm (1.193 in) After 93: 27.06 mm (1.065 in) 14-11 HYDRAULIC DISC BRAKE ASSEMBLY Coat new piston seals and dust seals with clean brake fluid and install them in the caliperi Install the pistons and install them with the open ends toward the pads Install the pad spring on the caliper as shown. Apply silicone grease to the inside of the boot, and install it. Install the retainer spring as shown Apply silicone grease to the inside of the boot and install it. Install the following: — pads and pad pins to the caliper — bracket to the caliper Install the caliper assembly over the brake disc so thatthe disc is positioned between the pads. CAUTION - Be Barefu/ no; to damage [he padx. Install and tighten the caliper mounting bolts TORQUE: ’88,'89.’9‘l-’93: 27 N-m (2.7 Kg-m,20 h-lbI After’93: 31 N-m (3.1 Kg-m.22 h-lbI Tighten the pad pins and install and tighten the pad pin plugs. Connect the brake hose to the caliper with the hose bolt and two new sealing washerst TORQUE: 30 N-m (3.0 kg-m. 22 ft-lb) Bleed the air from the brake system [page 1474I. )“ (1) PISTON SEALS [2) DUST SEALS ‘ (I) BOOT (3) SILICONE —> \ rfil (2) PAD SPRING l‘l) RETAINER SPRING 1‘ ‘—I2) SILICONE ‘ ,6». (2) BOOT _‘ (1i CA'LIIDER Mé’iu'isiTING B-QLTS >.. 72) on. aou’ . ,(3) SEALING WASHERS 14-12 MEMO BATTERV CHARGING SYSTEM (1) REGULATOR! RECTIFIER / ~\ ;. h\ (4) ALTERNATOR [3) STARTER RELAY (2) BATTERY SWITCH MAIN FUSE 30A 1 5-0 15. BAUERY/CHARGING SYSTEM '887'89, '91 : Y Y (3| MAIN FUSE 30A v G ® 9 IzvaAH BUG (2) BA‘I'I'ERY Bl Bl BI BI/R I REGULATOR RECTIFIER Vi Ve"°W (4) ALTERNATOR ( I / BI: Black G : Green R: Heel w: White Af‘er ’91 : v : (3| MAIN FUSE 30A G R/W (-9 e 12V8AH (Z) BATTERY Y: YeIlow ‘4) ALTERNATOR (1) REGULATOR/RECT|F|ER Sf 39'?" W: whiIe 15-1 BATTERY/CHARGING SYSTEM SERVICE INFORMATION 15-2 CHARGING SVSTEM 15-7 TROUBLESHOOTING 15»3 REGULATOR/RECTIFIER 15-8 BATTERV 15-4 ALTERNATOR 15-9 SERVICE INFORMATION GENERAL WARNIN ‘ The battery generate: hydorogen gas which can be highly explosive, Do not smoke or allow flame: or spark: near the battery, expeciall y while charging it. - I/ the engine must be running in do some work, make sure the area is well-ventilated. Never run the engine in an enclosed. The ex- haust contain: posisarmu: carbon monoxide gas that may cause loss of consciousness and, lead to death. O The following color codes are used throughout the electrical sections. Bu = Blue G = Green Lg = Light Green Fl = Red Bl = Black Gr = Gray 0 Orange W = White Br = Brown Lb = Light Blue P = Pink V = Yellow 0 Slow charge the battery whenever possible, quick charging should be an emergency procedure only. C Remove the battery from the motorcycle for charging O The battery on this motorcycle is a sealed type. Do not remove the filler hole caps even during charging. Do not use a non» maintenance free battery as a replacement. 0 All charging system components can be checked on the motorcycle 0 When inspecting the charging system,check the system components and circuits step-by-step according to the trouble- shooting chart on the next page. 0 Alternator removal is described in Section B. SPECIFICATIONS ITEM STANDARD Battery Capacity 12 V—5 AH Voltage at 20°C (68°F) Fully cahrged 130—132 V Needs charging 12.3 V Charging current 0.8 amperes Charging time 10 Hr Regulator/rectifier Type Three-phase/lulI—wave Regulated voltage 14— 1 5 V/4,000 rpm Alternator Charging coil resistance at 20°C (68°F) 0.1 —1.0 (2 Output 0.345 kw/5,000 rpm Charging start rpm 1,000 1 100 rpm TOOLS Digital multitester (KOWA) 07411 —0020000 or KS-AHM-32-003 (USA. only) or Circuit tester (SANWA) 07308—0020001 or Circuit tester (KOWAI TH-SH 1 5-2 BATTERY/ CHARGING SYSTEM TROUBLESHOOTING ABNORMAL Measure the battery leakage (page 15-7). }—-. Check the regulator/rectifier resistances be- tween each regulator/rectifier terminals (page 15‘s) NORMAL NORMAL ‘ Short circuit in wire harness Faulty ignition switch ABNORMAL —>. —| ABNORMAL Check for an overcharged battery [page 154mg NOT OVERCHARGED REGULATED , , Measure the voltage between the WW (+) and G No VOLTAGE with terminals (a) of the regulator/rectifier 4P —-——->- Black connector. (wire harness side) [page 15-8) ' BATTERY VOL'TAGE COMES Disconnect the 3P connector of the regulator/ rectifier, check the alternator stator coil resitances (page 15-8) NORMAL —_—._.. Check the regulator/recrifier resistances be- ABNORMAL tween each regulator/rectifier terminal (page 15-5). | NORMAL I___—__.. ' Faulty regulator/ rectifier Faulty battery Open or short circuit in wire harness Loose connecotor STANDARD |—->~ Loose 3P connector ABNORMAL Faulty stator coil Faulty regulator/ rectifier Faulty battery 1 5-3 BATI'ERY/CHARG | N G SYSTEM BATTERY REMOVAL CAUTION - Do not remove the [11111er while exhaust pipe is hot. Remove the right side cover. Unhook the fuse box from the battery case cover. Remove the battery case cover by removing the bolts. Remove the left side cover. Disconnect the battery negative terminal lead from the battery first, then disconnect the positive terminal lead. Pull the battery out of the battery case. INSTALLATION Place the battery into the case and connect the battery posiv tive cable to the battery first from the right side, then connect the negative cable from the left side. Coat the battery terminal with clean grease. Install the battery case cover by hooking the tab on the cover to the hook on the case. Install and tighten the cover mounting bolts. Install the fuse box onto the battery case cover. Install the rubber covers '71 the sequence as shown. Install the right and left side covers. Route the battery cables as shown on the battery caution label. (‘I ) NEGATIVE TERMINAL l2) POSITIVE * TEFIMINAL CAUTION mum; As SIIDWI 9(th 1 5-4 VOLTAGE |N SPECTION Remove the right and left side covers. Remove the battery case cover. Measure the battery voltage using a digital multimeter. VOLTAGE : Fully charged : 13,0713.2V Under charged : Below 12.3V TOOL : Digital multimeter 0741 1 70020000 (KOWA) KS‘AHM’GZ’OOMU. S. A. only) BATTERY TESTING NOTE - Always clear the work area of flammable materials such as gasoline, brake fluid, electrolyte, or cloth towels when operating the tester, the heat generated by the tester may cause a fire. BA'I'I'ERY/CHARG IN G SYSTEM (1i BATTERY Remove the battery(page 1574). Securely connect the tester's positive(+)cable first, then connect the negative(-)cable. NOTE - For accurate test result, he sure the tester's cables and clamps are in good working condition and that a secure connection can be made at the battery. Set the temperature switch to "HIGH" or "LOW" depending on the ambient temperature. Push it the appropriate test button for three second and read the condition of the battery on the meter. NOTE ' Be sure you've selected the test button of 5.5 Ah-9Ah. For the first check, DO NOT charge the battery before testing—test it is an "as is” condition. HIGH: 60°F (15°C) or higher LOW: 60°F (15°C) or lower l Test Buttons OOOOO© ©0 15-5 BA'I'I'ERY/CHARG ING SYSTEM CAUT|ON - To avoid damaging the tester, only test betteries with an amperage rating of less than 30A. - Tester damage can result from overheating when: —The test button in pushed in for more than three seconds. —The tester is used without being allowed to coal for at least one minute when testing more than one battery. —Move than ten consecutive tests are performed without allowing at least a 30-minute cool-dawn period. NOTE - The result of a test on the meter scale is relative to the amp. hour rating of the battery. Any BATTERY READING IN THE GREEN ZONE IS 0K. Batteries should only be char- ged if they register '71 the VELLOW or RED zone. BAWEHV CHARGING NOTE - Be sure the area around the charger is well ventilated, clear of flammable materials, and free from heat, humidity, water and dust. - Clean the battery terminals and position the battery as far away from the charger as the leads will permit - Do not place batteries below the charger—gases from the battery may corrode and damage the charger. - Do not place batteries on top of the charger. Be sure the air vents are not blocked. 1. Turn the Power Switch to the OFF position. Set the battery Amp. Hrt Selector Switch for the size of the battery being charged. 3. Set the Timer to theposition indicated by the Honda Battery Tester ; RED-3, RED‘Z or VELLOW‘l. If you are charging a new battery, set the switch to the NEW BATT position. 4. Attach the clamps to the battery terminals-RED to Posi- tive, BLACK to Negative. Connect the battery cables only when the Power Switch is OFF. Connect the battery cables only when the Power Switch is OFF. ' Connecting the cables with the Power Switch can pro~ duce a spark which could ignite or explode the battery. YELLOW RED (-1, GREEN (-3, -2) (+1, +2, +3) _\ BATTERY AMP HR. SELECTOR SWITCH m.“ m.“ u... M,” m.» Set the appropriate amp. hour rating. 15-6 5. Turn the Power Switch to the ON position. 6. When the timer reaches the "Trickle" position, the charg- ing cycle is complete. Turn the Power Switch OFF and disconnect the clamps. NOTE - The charger will automatically switch to the Trickle mode after the set charging time has elapsed. 7. Retest the battery using the Honda Battery Tester and recharge if necessary using the above steps. NOTE - For accurate test results. let the battery cool for at least ten minutes or until gassing subsides after charging. CHARGING SYSTEM NOTE - When inspecting the charging system, check the system components and lines stepibyistep according to the troubleshooting on page 1542. - Measuring circuits with a large capacity that exceeds the capacity of the tester may cause damage to the tester. Before starting each test, setthetesteratthe high capacity range first, then gradually down to low capacity ranges in order that you have the correct range and do not damage the tester. - When measuring small capacity circuits, keep the ignition switch off. If the switch is suddenly turned on during a test, the tester fuse may blow. LEAKAGE INSPECTION Check the battery ampere leakage before making the regulat— ed ampere inspection. Turn the ignition switch off and disconnect the battery nega- tive cable from the battery. Connect the tester between the negative cable and the nega- tive battery terminal. The voltage should indicate less than 0.1 mA with the ignition switch off. LEAKAGE AMPERES: 0.1mA max. BA'I'I'E RY/CHARG ING SYSTEM NEW TIMER BATT "3“ \ YELLOW -—’V, 7 RED (I) BATTERY NEGATIVE TERMINAL (Z) BATTERY NEGATIVE CABLE 15-7 BATTERY/CHARGING SYSTEM REGULATED VOLTAGE INSPECTION N OTE - Be sure the battery is in good condition before performing this test. Warm up the engine to normal operating temperature Stop the engine, and connect the voltmeter as shown. Start the engine and allow it to idle, then increase the engine speed gradually. The voltage should be controlled to 14.3—15.1 V at 5,000 rpm CAUTION - Be careful no! to let the battery positive cable contact thefrume while testing. INSPECTION Remove the left side cover. Disconnectthe 3F (WHITE) and AP (BLACK) regulator/rectifier connectors Check the connectors for loose or corroded terminals. If the regulated voltage reading was out of specification, check the circuits between the connector terminals (wire harness side and alternator side] following the chart below. ITEM TERMINALS STANDARDS Battery charging line Red/White (+) and Green (*1 Battery voltage should come Alternator coil line Yellow and Yellow 0.1 —1.0 n (20°C/68°F) Check the resistances between the leads with an ohmmeter. If ’88-’89, ’91 ; Unit: Kn the resistance '5 out of the specifications, replace the regulator + Probe rECfiIieh Red/White Green Yellow Yellow Yellow - Probe NOTE Red/While w w u: w - Use a SANWA [SP-100] or [TH-5H] tester or KOWA DIGI- 6”" 5 N 3° ‘ N 2° ‘ "V 2° ‘ N 2° TAL VOLTOMETER [07411—0020000L “"W ‘ 2 "" m m ' The regulator/rectifier has a semi»conductor. If a different "How ‘1 "° N W tester IS used, the results will be out of specification. Yellow 4.2 w w w ' You'll get a false reading if your finger touches the tester probe. Aftev ’91 : Unit: Kn - If the pointer of the tester fails to swing to zero when the +Probe adjusting knob is turned fully clockwise or counter- “Gd/WW“ Ve'k’W Yellow Yellnw 0’99" clockwise, replace the battery in the testert 'th‘ Red/White cu m m m Vollnw o 5» ID a: m m Tester Range Vollnw o 5» IO cu m m SP-l OD K n Vollnw o 5» lo a: on u. TH_5H Rxmo Green 0.7»15 O.5~l0 05»io o5»Io 15-8 BATTERY/CHARGING SYSTEM ALTERNATOR INSPECTION NOTE - It is not necessary to remove the stator coil to make this test Remove the left side cover. Disconnect the alternator 3P (WHITE) connectort Measure the resistance between the yellow wire terminals and check for no continuity between each terminal and ground. STANDARD: 0‘1 —1t0 (1 Replace the stator if the resistance is out of specification or if there is continuity between each yellow wire terminal and ground (page 15-8) mg ’ ‘ r—/ a (1] ALTERNATOR 3P (WHITE) CONNECTOR 15-9 IGNITION SYSTEM (1) ENGINE STOP SWITCH (4) MAIN FUSE (2) SUB FUSE (5) IGNITION (3) BATTERY SWITCH V (71 FRONT ~ IGNITION COIL (1 3) SIDE STAND SWITCH (11) NEUTRAL (6] REAR IGNITION V SWITCH COIL (12) IGNITION CONTROL MODULE , (14) SIDE STAND SWITCH 1 6-0 16. IGNITION SYSTEM '88,'89 —B|IW——o\o—Bl /BI-: I" $ng I2) SUE I5) IGNITION I4) MAIN FUSE SWITCH FUSE DOWN SWITCH .0 A 30 A 0 6 —o II3) SIDE STAND SWITCH IaITo UP I3) BATTERY METER 12 v BAH T ‘ G/W we G BI: Black v» Yellow G III) NEUTRAL BU: Blue SWITCH G: Glee" I12) TO R: Red w» WhIle m Lg: LIgm Green I: E) z a 5 V q“: G/W 5v; u; a) UN BI/W v ' ' ' ' m In II2) IGNITION M M CONTROL ' ' ‘ ‘ MODULE I9) FRONT IIOI REAR 1 1 1 1 I9) FRONT IIOI REAR T T T T (14) IGNITION PULSE GENERATOR I7) IGNITION COIL AFTER '89: —BllW——o\o—el RISI< I2! SUB I5) IGNITION I4) MAIN II) ENGINE STOP FUSE SWITCH FUSE 8 DOWN SWITCH IO A 30 A 9 '° II3) SIDE STAND IaITo UP 4 SWITCH I3) BATTERY _ METER I GM, I2 v BAH f “3 Bl: Black v: VeIlOw IIIINEUTRAL Bu BIue G i 7 SWITCH G Gveen II2) TO R Red FUEL CUT w: WMe “EL” Lg: LIgm Green A L :2: 3‘ z E > a: G/W I ¥$su 3 BMW Eu/V Bl/W v m M II2) IGNITION W W CONTROL MODULE T IIO R R (9| FRON EA 1 1 1 1 I9) FRONT I10) REAR T T E f (14) IGNITION PULSE GENERATOR I7) IGNITION COIL 16-1 IGNITION SYSTEM SERVICEINFORMATION 16»2 IGNITION PULSE GENERATOR 16»6 TROUBLESHOOTING 1&3 SIDE STAND SWITCH 16»7 IGNITION CONTROL MODULE INSPECTION 16-4 IGNITION TIMING 16-8 IGNITION COIL 16-5 SERVICE INFORMATION ' I/ the engine must be running to do 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, GENERAL Olgnition timing cannot be adjusted since the ignition control module is non-adlustabletli ignition timing is incorrect,check the system inspection and replace any faulty parts (For spark plug gap inspection and adjustment procedure,see page 378. OFor alternator removal and installation,see section 8. OFor ignition pulse generator removal and installation,see page 7711‘ OWhen inspecting the ignition system,check the system components and lines step~by~step according to the trouble- shooting on next page. u Each pair of the spark plugsIFrom and Rear)has its own ignition circuit. UTo test the neutral switch,refer to section 18‘ SPECIFICATIONS ITEM STANDARDS (20°C/68°Fl Spark plug NGK NlPPONDENSO DPHSEA-S X24EPH-U9 Spark plug 08—03 mm loos—0‘04 inI Ignition timing Initial (F markl 6.2 BTDC/idle Ignition coil Primary 1.89—2.32 I1 “55‘3"” Secondary With plug ere 23.55—30.45 kn Without plug wire 19.8—24.2 kn Ignition pulse generator Coil resistance 450—550 9 Firing order Fl2)—Rlll 308° TOOLS Tester Digital niuititester [KOWA] 07411—0020000 or KS-AHM-32-003 (USA. only) or circliit tester [SANWA] 07308—0020000]Not available in USA or circuit tester IKOWAI TH-5H 16-2 IGNITION SYSTEM TROUBLESHOOTING “mm - When performing a spark lest, keep open flame: or sparks away from the work area. we No spark at one spark plug ' Faulty spark plug - Faulty spark plug wire No spark at all plugs it Check the ignition control module connec— ABNORMAL ' Loose connectorst tors for loose contact. Faulty NORMAL - Fuel cut relay (page 18-9) 2 Measure voltage between the Bl(+)and GH/ - Fuel pump (page 18-10) between the Bu/Yl+)and Gl-l/between Y - Open circuit in wire harness l+)and G(-)of the Ignition control module 6P ABNORMAL NORMAL . (page 20.1] connector.Eattery voltage should appear with the ignition switch 0N and engine stop Faulty switch at RUN. - Side stand switch (page 16—6) - Neutral switch (page 18-11) ‘ NORMAL 3—1.Check the ignition pulse generator resist- ABNORMAL 3‘2' Che“ "‘9 '9"'"°" 9“"9 9°"e'a‘m‘page ances at the ignition control module 4P 15'5)‘ connector(page 15-4l. NORMAL l lABNORMAL - Open or short circuit - Faulty pulse gener- in wire harness ator - Loose connectors No spark at either spark group (Front or Rear) —(CHECK WRONG SPARK GROUP) it Check the ignition secondary coil resistance ABNORMAL ~ Faulty ignition coil (page 16-4]. - Faulty spark plug wire NORMAL 2-1.Check the ignition primary coil resistance at the ignition control module 6P connector ABNORMAL 2-2. Check the ignition coil [page16-4)t (page 15-4). NORMAL ABNORMAL - Loose connectors ' Faulty ignition coil NORMAL - Open or short circuit ' Open circuit 'n wire 'n wire harness harness 3—1.Check the ignition pulse generator resistr ABNORMAL 3-2. Egeck the Ignltlon DUISE genera‘orIDaQE ances at the ignition control module 4P con- '6)' nector(page 16- 4). NORMAL l ABNORMAL - Open or short circuit - Faulty ignition pulse NORMAL in wire harness generator ' Loose connectorst 4. Exchange the ignition coil and try the spark GOOD JUMP test. . Faulty ignition coil 16-3 IGNITION SYSTEM IGNITION CONTROL MODULE INSPECTION Remove the left side cover and connector plate. NOTE ' Check the system components and lines step-by-step ac- cording to the troubleshooting chart on page 1673. Disconnect the ignrtion control module connectors and check them for loose or corroded terminals. Measure the resistance between connector terminals using the following chart. <6F CONNECTOR> ITEM TERMINALS STANDARD (20°C/68°F) Ignition primary coil Y and BI (Rear) Eu/V and BI (Front) 1.89—232 9 DC power supply circuit line Bl H) and G 1—), Eu/Y 1+) and G (a), V 1+) and G Battery voltage should come. (—I with the ignition switch "0N" and engine stop switch "RUN" <4P CONNECTOR) h ITEM TERMINALS STANDARD (20°C/68°F) Ignition pulse generator coil W/V and Y (Front) W/Bu and Bu (Rear) 450—550 ll Each terminal and body ground NO CONTINUITV IGNITION COIL INSPECTION Remove the fuel tank (page 4-3) and crankcase breather tank. Measure the primary coil resistance of the front ignition coil in the frame. Remove the right side cover and rear ignition coil and measure the primary coil resistance) Checking for continuity between the primary terminalst STANDARD: 1‘89 — 2.32 n l20°Cl68°F) Disconnect the spark plug caps from the plugs and measure the secondary coil resistance with the spark plug caps in place. STANDARD: 23.55—30.45 kfl (20°C/58°FI 1 6-4 IGNITION SYSTEM It the resistance is out of range, remove the spark plug wires and measure the resistance between the secondary coil termi- nals. STANDARD: 19.8—24.2 k0 (20°C/GBDF) REPLACEMENT Rear ignition coil Remove the right side cover. Disconnect the (use connectors and starter relay switch from the case. III CRANKCASE BREATHER TANK Front ignition coil Remove the iuel tank [page 4—3). Remove the crankcase breather tank irom the irame. Remove the ignition coil mounting bolts and disconnect the (1) FRONT IGNITION primary terminals from the coils. COIL Remove the spark plug caps from the spark plugs. Install the new ignition coil in the reverse order of the removal. NOTE - Connect the primary wire terminals properly. Front coil: black terminal—black/white wire green terminal—yellow/blue wire Rear coil: black terminal—black/white wire green terminal—blue/yellow wire IGNITION SYSTEM IGNITION PULSE GENERATOR III IGNITION PULSE GE NEHATOH CON NECTOR INSPECTION NOTE ' It is not necessary to remove the ignition pulse generator to make this inspection. Remove the left steering cover. Disconnect the ignition pulse generator 4P connector IWHITEI. Measure the resistances between the white/yellow and yellow wireslfront ignition pulse generatorland white/blue and blue wireslrear ignition pulse generator) STANDARD: 450—550 I2 (20°C/68°FI ' For ignition pulse generator replacement, refer to section 8. V SIDE STAND SWITCH I INSPECTION I ’88,’89,’9‘l»’93: Remove the seat and left side cover. Disconnect the 2? (Green) connector and the Green/White wire. Check the continuity between each terminal of the side stand switch. SIDE STAND DOWN (RELEASED) SIDE STAND UP IFUSHEDI Side stand V Tester , Termlnals . posmon Reading Sidestand up . . . (pushed) _ Green/White to Green No continuity ’Ignmon C'Icu“ Yellow/Black to Green Continuity “’5” ll) TO H To Side stand down V _ WARNING I (released) ‘ Green/White to Green Continuity LIGHT WARNING Q flaring” CIIcuIt Yellow/Black to Green No continuity WEI LIGHT l case in To ‘ [2) TO ‘WB' SPARK UNIT SPARK UNIT AG/W 7 46M G G 16-6 After '93: Remove the left side cover. IGNITION SYSTEM Disconnect the side stand 3P green connector and check for continuity between each terminals as shown below. E There should be continuity between the 070 positions on the IQ continuity chart. 6 :9 ® Green/White Yellow/Black Green IZI UP Side stand down Side stand (1) DOWN up REMOVAL/INSTALLATION Remove the left Disconnect the side stand 3P green connector. side cover. Remove the side stand switch mounting bolt,setting plate, washer and side Install the switch in the reverse order of removal. . NOTE stand switch. (3) WASHER - Align the switch pin with the side stand hole.Align the switch groove with the setting plate tang and align the setting plate solt with the side stand return spring holding pin. TORQUE: Side stand switch mounting bolt: 9 N-m (0.9 kg-rn,7 h-lb) Route the side stand switch wire properly. IGNITION TIMING NOTE < The ignition control module system is factory preiset and cannot be adjustengnition timing inspection procedures are given to inspect the function of the ignition control module components. - Connect the timing light to the other spark plug wire if 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. Remove the timing inspection hole cap on the right crankcase cover. Connect the timing light to the front spark plug wire. IGNITION SYSTEM The timing is correct if the "F" mark aligns with the index mark on the right crankcase cover at idle for each cylinder. Raise the engine rpm and the "F" mark should begin to rotate counterclockwise for each cylindert It the ignition timing is incorrect, make a system inspection (page 16-3] and replace any faulty parts. (1)"F" MARK (2) INDEX MARK 16-8 MEMO ELECTRIC STARTER (E) CLUTCH SWITCH /‘ I \‘ 2 I I10) SUB-FUSE 10A (7] DIODE (11) IGNITION IeI NEUTRAL I4I SIDE STAND SW'TCH ‘2’ BATTERY I SWITCH SWITCH [12) STARTER RELAv SWITCH I14) SIDE STAND SWITCH (H MAIN FUSE 5'5 30A G: Green R: Red | W: WhiIe I4I SIDE _ STAND (5) Lg: nghl green 99 9 T SW'TCH MODULE % (ZIBATTERY DOWN I2 V SAH I12I STARTER r?” RELAY UP Lg/R G/W SWITCH JG/W (3) To METER *Y/Bl —_L m CLUTCH SWITCH — ¥ (13) STARTER (SI NEUTRAL MOTOR I7I CLUTCH DIODE SWITCH A G”? l} Lg/R o/o—G —R—o\—R/BI—d‘\p—B|—o\o_ T I11) IGNITION (10) SUB-FUSE I9) STARTER SWITCH 10A SWITCH V/R 1 7-0 l7. ELECTRIC STARTER SERVICE INFORMATION 17-1 STARTER RELAY SWITCH 17»6 TROUBLESHOOTING 1 7-1 CLUTCH DIODE 17»7 STARTER MOTOR 1 7-3 SERVICE INFORMATION GENERAL o The starter motor and ignition pulse generator can be removed with the engine in the frame. 0 To inspect the ignition pulse generator, refer to Section 15. 0 Refer to section a for starter clutch removal and installation. SPECIFICATION Unit: mmlinl ITEM STANDARD SERVICE LIMIT Starter motor brush length 12,510.49) 6.5 [0.26) TROUBLESHOOTING NOTE - The starter motor should turn when the transmission 5 in neutral and the clutch disengaged, - Check for the following before troubleshooting the system. — Blown main mom or sub liOAi fuse. — Loose battery and starter motor cables. — Discharged battery. Starter motor does not turn 1-1. Check the starter relay switch for opera- “CLICK” tion. You should hear the relay "CLICK" HEARD 1-2. Apply battery voltage to the starter motor when the starter swuch button is de- directly and check the operation. pressed. lpage 17-6) TURNS DOES NOT TURN t Loose cables - Faulty starter motor "CLICK" NOT HEARD - Faulty starter relay lpage 17-3) switch [page 17-6) ABNORMAL 2 Check the neutral indicator for function. - Faulty neutral switch (page ‘lae‘l H - Loose neutral switch connectors NORMAL - Faulty ignition switch lpage la-ei - ND VOLTAGE 3. ‘Check1tge57tarter relay switch voltage l . Loose clutch diode come]ch page - - Faulty starter relay switch lpage 17-6) BATTERY . Faulty clutch diode lpage 17-7l VoLTAGE COMES t Open or short circuit n Wire harness ' - ABNORMAL 4. Check the starter relay swltch for continuity ' Fau‘w “any relay swim] lpage 17-7) NORMAL Loose starter relay switch connector 17-1 ELECTRIC STARTER The starter motor can turn in the neutral position, but should not turn except with the gear selector in neutral, the side stand up and the cluth lever pulled in BATTERY VOLT- Measure the Voltage between the Green/White AGE MEASURED l+l and Green H terminals or the side stand Che“ "‘9 C'mh Sw'm‘ ‘page 13 H connector (wire harness side]. There should be battery voltage. N0 VOLTAGE (or too little voltage) Check the side stand switch (page 16 5] Starter motor turns engine slowly ‘ Low specific gravity ' Excessive resistance in circuit ' Binding 'n starter motor Starter motor turns. but engine does not turn ' Faulty starter clutch ' Faulty starter motor gears Starter motor and engine turns, but engine does not start ' Faulty ignition system ' Engine problems — Low compression — Fouled spark plugs 17-2 ELECTRIC STARTER STARTER MOTOR REMOVAL m— . With the ignition s (eh OFF, remove the negative cable a! the battery before servicing the starter mater. Remove the rubber cap and disconnect the starter motor cable, Remove the motor mounting bolts. Remove the motor from the left side, (2) STARTER MOUNTING “ “sum , A BOLTS _ ' * a DISASSEMBLY m FRONT COVER (4] HEAR COVER Remove the following components: — motor case screwst — front and rear covers, — armaturet NOTE ~ Record the location and number of shims. (a) scnsw/ (2] CASE INSPECTION Measure each brush lengtht SERVICE LIMIT: 6.5 mm (026 in) Check for continuity from the cable terminal to the motor case and from the cable termina to the brush wire (blacklt (1) CONTINUlTV CABLE TERMINAL-MOTOR CASE NO CONTINUITY: NORMAL CABLE TEHMlNAL-BRUSH (BLACK WlRE) CONTINUITY: NORMAL Disassemble the brush holder if necessary, (2) N0 CONTINUITV 1 7-3 ELECTRIC STARTER lnspecr rhe commuramr bars for discolorationi Bars discolored 'n pairs indicate grounded armarure coils‘ Check for cominuiry berween pairs of commurator bars. There should be continuiw. Check for continuity berween individual commutator bars and rhe armature shah. There should be no cominuity. Check rhe from cover oil seal for wear or farigue. (1) OIL SEAL (1) COMMUTATOR (2] FRONT COVER 1 7-4 ELECTRIC STARTER ASSEMBLY (2) CASE (14) LOCK WASHER l3) ARMATURE 15) BRUSH HOLDER (7l O—RING l6) BRUSH SPRINGS 4) SHlMS % M @ (13> SHIMS Wen” mg a a (10)0-R|NG (12) NUTS (8) CASE @e (1 SCREWS 0/ o m FRONT COVER ( V (1110mm: (10) CABLE TERMINAL AND BRUSHES (9) REAR COVER Set the brushes on the brush holder. Align the starter motor case notch with the brush holder tab «1) ALIgN Install the armature in the case. I (1] HOLDER PIN (2) SHIMS Set the brush springs. ' Install the rear shims in the same location and number when disassembled. Install the O-ring on the case. Install the rear cover, aligning its slot with the brush holder pin. (3) SLOT ELECTRIC STARTER Install the front shims in the same location and number when (1) DUST SEAL l2) FRONT " disassembled. '@ COVER . Install the O-ring on the case. Install the lock washer, aligning its tabs with the slots of the front cover. Apply grease to the dust seal and install the front cover. (4) SHIMS I5] LOCK WASHER I3I O-RING Align index marks of the front cover, case and rear cover as (1) ALIGN shown. Install and tighten the starter motor case screws and apply oil to the O-ring and install it on the front cover. I3) REAR COVER SCREWS I2) O-RING INSTALLATION Install the starter motor in the engine. Install and tighten the motor mounting bolts securely. NOTE ' Install the ground cable with one mounting bolt as shown. Connect the motor cable tothe motor terminal and install the rubber cap over the terminal. Connect the battery negative cable. STARTER RELAY SWITCH OPERATION INSPECTION Depress the starte switch button with the ignition switch ON. The coil is normal if the starter relay switch clicks. VOLTAGE INSPECTION If you don't hear the switch "CLICK", disconnect the switch connector. Shift the transmission into neutral and turn the ignition switch 0N. Measure the voltage between the yellow/red H) and green/red H wires of the relay connector as you press the starter. The tester should show battery voltage. If it does not, make the following continuity inspection. 1 7-6 CONTINUITY INSPECTION Remove the starter relay switch. Connect an ohmmeter to the switch large terminals. Connect a fully charged 12 V battery positive wire to the start- er relay switch Yellow/Red wire terminal, and the battery neg- ative wire to the Green/Red wire terminal. There should be continuity while the battery is connected to the terminals, and no continuity when the battery is discon- nected. CLUTCH DIODE REMOVAL Remove the left side cover. Remove the clutch diode from the wire harness. INSPECTION Check for continuity with an ohmmeter. Connect the positive probe to the (+1 terminal and the negative probe to the (a) terminal ol the diode. There should be continuity, then reverse the probes, there should be no continuity. NOTE ' The test results shown above are for a positive ground ohm- meter and the opposite results will be obtained when a neg- ative ground ohmmeter is used. ELECTRIC STARTER (1) CONTINUITY 17-7 MEMO l8. LIGHTS/ METER/ SWITCHES SERVICE INFORMATION 18-1 FUEL PUMP RELAY 18»9 TROUBLESHOOTING 18-2 FUEL PUMP 18- 10 HEADLIGHT 18-3 OIL PRESSURE SWITCH 18-10 BULB REPLACEMENT 18-4 NEUTRAL SWITCH 1 8-11 SPEEDOMETER 184 BRAKE LIGHT SWITCH 18-11 IGNITION SWITCH 18-6 CLUTCH SWITCH 18-11 HANDLEBAR SWITCHES 18-7 TURN SIGNAL RELAY 18-1 2 THERMOSTATIC SWITCH 18-8 HORN 1842 COOLANT TEMPERATURE INDICATOR 18-8 SERVICE INFORMATION - l/ the engine must be running to do 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 o / consciousness and lead to death. ' Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the work area or where gasoline is stored. GENERAL 0 Some wires have different colored bands around them near the connector. These are connected to other wires which cor- respond to the band color. 0 All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned and fully engaged when reconnecting C To isolate an electrical failure, check the continuity of the electrical path through the part. A continuity check can usually be made without removing the part from the motorcycle. Simply disconnect the wires and connect a continuity tester or volt-ohmmeter to the terminals or connections. 0 A continuity tester is useful when checking to find out whether or not there is an electrical connection between the two points. An ohmmeter is needed to measure the resistance of a circuit, such as when there is a specific coil resistance in- volved, or when checking for high resistance caused by corroded connections. SPECIFICATIONS headlight 12 V 60 W/55 W Brake/taillight 12 V 32/3 Cp (27/5 W] x 2 Turn signal lights Front 12 v 32/3 cp (23/8 Wl x 2 Rear 12 V 32 op {23 W] License light 12 V 4 cp Indicator lights turn signal 12 V 1.7 W neutral 12 V 1.7 W high beem 12 V 1.7 W Meter light 12 V 3.4 W Main fuse 30 A Sub-fuse ‘88, ‘39 10Ax6,15A x1 After'89 10Ax3,15Ax1 Fuel pump flow capacity 800 cc [0.76 USqt, 0.70 Impqt) TORQUE VALUES Radiator thermostatic switch 18 Nm (1.8 kg-m, 13 ft-lb) Oil pressure switch 12 N-m (1.2 kg-m, 9 ft-lb) — Apply sealant to the threads Ignition switch mounting bolt 11 N-m (1.1 kg-m, 8 ft-lb) — Shear bolt 18-1 LIGHTS/METER/SWITCHES TROUBLESHOOTING No Lights Come Oh when Ignition Switch Is Turned 0N: - Bulb at fault or burned out - Faulty switch - Wiring to that component has open circuit - Fuse blown ' Wiring loose, broken, or at fault ' Battery dead or disconnected All Lights Come On, but Dimly, when Ignition Switch ls Turned 0N: ' Battery voltage low . Faulty bulb Headlight Beam Does Not Shift When Hl—LO Switch Is Up- erated: - Beam filament burned out ' Faulty dimmer switch - Wiring loose, broken, or at fault 1 8-2 HEADLIGHT REMOVAL/INSTALLATION Remove the two screws and headlight. Disconnect the headlight connector and remove the rubber protector. Remove the headlight retainer clip and replace the headlight bulb. CAUTION ' This motorcycle is equipped with a halogen headlight bulb. - Do not put finger prints on the headlight bulb, they may create hot spal: on the hulb. - If you touch the bulb with your bare hands, Elean it with a cloth moistened with alcahnl to prevent its early failure. ' Do not try in replace the bulb or clean the headlight with the light 0N. - After replacing the bulb, install the rubber boot tightly against the unit. NOTE ' Install the rubber protector with the top mark facing up. Install the headlight in the reverse order of removal. LlGHTS/METER/SWITCH ES 3» \ ‘~ (2)RUB_BE ffiol’ECTOR l1) RETAINER CLIP (2) HALOGEN BULB LlGHTS/METER/SWITCHES BULB REPLACEMENT . m TURN SIGNAL LIGHT NOTE - See page 18-5 for speedometer bulb replacement. TURN SIGNAL LIGHT Remove the turn signal lens attaching screws. While pushing in, turn the bulb counterclockwise to remove. Replace the bulb, if desired. Install in the reverse order of removal. NOTE ' Seat the rubber packing properly. BRAKE/TAILLIGHT Remove the taillight lens attaching screws. While pushing in, turn the bulb counterclockwise to remove. Replace the bulb, if desired. Install in the reverse order of removal. NOTE ~ Seat the rubber packing properly. LICENSE LIGHT Remove the bolts and license light case mounting nuts. Replace the bulb with a new one. [1] SPEEDOMETER CABLE REMOVAL Disconnect the speedometer cable from the meter. Remove the steering covers and disconnect the speedometer connector [GP Black). Remove the speedometer stay mounting bolts and meter irom the fork bridge. 18-4 BULB REPLACEMENT Remove the trip-meter knob by removing the attaching screwt Romove the speedomater cover mounting screws and cover. Replace the meter bulb with new one (4) METER BULB l3] STAY (2) MOUNTING SCREWS (1) O-RING [10) SPEEDOMETEH CABLE (9) SPEEDOMETER COVER Assemble the removed parts in the reverse order of disassem- bly Route the speedometer wire as shown and install and tighten the mounting screws. INSTALLATION Install the speedometer in the reverse order ol removalt (3] GP BLACK LIGHTS/METERISWITCHES (5] SPEEDOMETEH Km) TRIP-METER KNOB (7) ATTACHING SCREW CONNECTOR (1 ) SPEEDO- METER 18-5 LIGHTS/METER/SWITCHES INDICATOR PANEL BULB REPLACEMENT Remove the indicator bulbs from the indicator panel, by first pulling out each bulb and socket together. Replace the bulb, if desired. IGNITION SWITCH INSPECTION Remove the seat and right side cover. Disconnect the ignition switch 4P White and 2P Black connec- tor. Check for continuity between the ignition sw1tch connector terminals In each switch position. Continuity should exsist between the color coded wires in each chart below. '88, '89: EAT IG FAN TLI TL2 P 0N O—r~O——O o——o OFF P o; —o COLOR R FI/Bl Bu/O Br/W Br V/Bl Alter '89: BAT lG ON REPLACEMENT Remove the Ignition switch cover by removing the bolt. Remove the shear bolt heads using a dnll then remove the switch (cylinder). Install the new switch and new shear bolts. Tighten the shear bolts until the head tw1st off. Ill HOLDER (4) SHEAR BOLT 18-6 LlGHTS/METER/SWITCHES l1) LEFT HANDLEBAR \ SWITCH HANDLEBAR SWITCHES The handlebar switches (dimmer. turn signals, horn, starter, engine stop, etc.) must be replaced as assemblies. Remove the steering covers. LEFT HANDLEBAR SWITCH Disconnect the left handlebar switch connector (9P White). And check for continuity between the terminals. Continuity should exsit between the color coded wires in each chart. Dimmer Switch HL2 Hi Lo Lo 0* #0 l1) RIGHT HANDLEBAR W) O O SWITCH Hi O——O Color code Bu/W Bu W Turn Signal Switch '88.'89,'91: W R L TLl PR PL HIGHT o—~o Of *0 N O**O--—O LEFT 0 O o—~o Colorcode Gr Lb O Br/BI OIW Lb/W Horn Button Turn Signal Switch '831‘39/91: After ‘91: Alter ‘91: Hol Ho2 Ho. H02 W R L TL. PR PL Released Released RIGHT o——o (F _O Depressed oifio Depressed o—‘o N O—+—o Color code W/G Lg “Color code Bl/Br Lg LEFT I-~=n== 00 a: E. E .3 .5 i. 010 s. O O: 2: .3 a, a E .. :. ,5 a i. . as! 52:... 5.3... .95.; : E: a 5;. .. 2. a was a 53. . is. a i. . 3,313.23! .. .T u ._ £2.35. :3... EEEQW :5: :15. 2:: a ES... 19-2 WIRING DIAGRAM '52/93‘, 3:. => i .32.: .5 a a: . E I. n i . s .535 z E: . : .2: . . . s. g E 5...! = 3. ‘ a «ii... 5.3:: a!!! sill Ii .. sa, . .I. . a: . u i isiiééiiiségiax .l. i. 3.35:... . ~ . . ass. .5... 5.52. .55 _. i. 3. O 525;: Z 193 WIRING DIAGRAM After '93: ago-aNE nuance an m 0 sun .“ u 00 :2 . lfl/s a 225/ E: 53...? :5; S. E :5 $55.5. A :3 S 3. :2 55 a 5:3. 4|mMH ES... 34.. 2. :1. i 5 a. .5. 51/ 1 9-4 20. TROUBLESHOOTING HARD TO START ENGINE LACKS POWER IDLE SPEEDS ENGINE DOES NOT START OR IS POOR PERFORMANCE AT LOW AND 20-1 SPEED 20»2 POOR HANDLING 20»3 POOR PERFORMANCE AT HIGH 204 204 ENGINE DOES NOT START OR IS HARD TO START 1. Check fuel flow to carburetor REACHING CARBURETOR 2. Perform spark test SPARK 3. Test cylinder compression COMPRESSION NORMAL 4. Start by following normal procedure ENGINE DOES NOT FIRE 5. Start with choke applied NOT REACHING CARBURETOR —>' WEAK OR NO SPARK .' WET PLUG —‘>c LOW COMPRESSION —- ENGINE STARTS BUT STOPS—#- POSSIBLE CAUSE Fuel tank empty Clogged fuel line or fuel filter Sticking float valve Faulty fuel pump Faulty fuel pump relay Clogged fuel tank vent hole Loose or disconnected fuel pump relay wire 00 TO PAGE 16-2 Mixture too rich Carburetor flooded Carburetor choke on, or partially closed Cylinder flooded Air cleaner dirty Improper valve clearance (too small) Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper valve timing Improper valve and seat contact Improper choke operation Carburetor incorrectly adjusted Intake pipe leaking Improper ignition timing (Faulty spark unit or pulse gener- ator) Fuel contaminated 20-1 TROUBLESHOOTING ENGINE LACKS POWER Raise wheels off ground and spin by hand WHEELS SPIN FREELY Check tire pressure PRESSURE NORMAL Check for clutch slippage CLUTCH ENGAGED PROPERLY Accelerate lightly ENGINE SPEED INCREASES Check ignition timing CORRECT Check valve clearance CORRECT Test cylinder compression NORMAL Check carburetor for clogging NOT CLOGGED Check spark plug condition NOT FOULED OR DISCOLORED t Check oil level and condition CORRECT WHEELS DO NOT SPIN FREELY —>' PRESSURE LOW—_' CLUTCH SLIPS —_- ENGINE SPEED DOES NOT INCREASE—>' INCORRECT ————-——-—>~ INCORRECT—>‘ T00 LOW—>r CLOGGED—p. FOULED OR DISCOLORED—p- INCORRECT—.' POSSIBLE CAUSE Brake dragging Worn or damaged wheel bearings Wheel bearing needs lubrication Drive chain too tight Axle nut excessively tight Punctured tire 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 Clogged fuel cap vent hole Faulty fuel pump Faulty fuel pump relay Loose, broken or shorted, wire or connection of pump relay Faulty lgnltlon Control module Faulty lgnmon 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 contact Carburetor not serviced frequently enough Plugs not serviced frequently enough Wrong heat range Oil level too high Oil level too low Contaminated oil 20-2 11. Remove cylinder head cover and inspect lubrication VALVE TRAIN LUBRICATED PROPERLY 12. Check for engine overheating NOT OVERHEATING i 13. Accelerate or run at high speed ENGINE DOES NOT KNOCK VALVE TRAIN NOT LUBRICATED—>- PROPERLY ~ OVERHEAT|N6__. ENGINE KNOCKS —>' POOR PERFORMANCE AT LOW AND IDLE SPEEDS 1. Check ignition timing and valve clearance CORRECT 2. Check carburetor pilot screw adjustment CORRECT 3‘ Check for leaking intake pipe NO LEAKAGE 4. Perform the spark test GOOD SPARK INCORRECT INCORRECT —_- LEAKING ———>' WEAK OR INTERMITTENT SPARK—h. TROUBLESHOOTING POSSIBLE CAUSE Clogged oil passage Clogged oil control orifice Contaminated oil Faulty oil pump Coolant level low Fan motor not working (thermostatic switch) Thermostat stuck closed Excessive carbon build-up it com- bustion chamber Use of poor quality fuel Clutch slipping Lean Iuel mixture Worn piston and cylinder Wrong type of fuel Excessive carbon build-up '71 com- bustion chamber Ignition timing too advanced [Faulty lgrlltlon Control module) Lean fuel mixture POSSIBLE CAUSE Improper valve clearance Improper ignition timing — Faulty ignition control module — Faulty ignition pulse generator See Fuel System, Section 4 Loose carburetor Damaged insulator Faulty, carbon or wet fouled spark plug GO TO PAGE 16-2 20-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED POSSIBLE CAUSE 1. Check ignitlon timing and valve INCORRECT ._- Improper valve clearance clearance - lmproper ignition timing 7 Faulty ignition control module CORRECT a Faulty IgnlIlOn pulse generator 2. Dlsconnect fuel line at carburetor FUEL FLOW RESTRICTED—>v Clogged fuel line - Clogged fuel cap vent hole FUEL FLOWS FREELV - Clogged fuel valve - Faulty fuel pump or relay ~ Clogged fuel filter 3. Remove carburetors and Check for CLOGGED —»~ Clogged jets clogged jets NO CLDGGED JETS 4_ Check valve ‘iming lNCORRECT-~ Camshaft not lhstalled properly CORRECT 5. Check valve Sprlng tension WEAK—>- Faulty valve spring POOR HANDLING—Check tire POSSIBLE CAUSE 1. If steering is heavy - Bearlhg adjustment nut too tight - Damaged steering head bearings - Bent steering stem 2. If either wheel is wobbling—hps Excesslve wheel bearing play - Bent rimlsl - Improperly installed wheel huplsl - Swingarm pivot bearlngs excessively worn - Bent frame or Swlngarm - Loose swingarm pivot bolt 3. If the motorcycle pulls to one side ——.. lnporreot drive chain adjustment - Front and rear wheels not aligned - Bent fork legs - Bent swingarm - Bent frame 20-4 Air Cleaner .. 3-7 Housing 4.4 Alternator/Starter Clutch 3.1 Alternator a. 15.9 Battery/Charging System Battery Brake Caliper Brake Fluid . 3-15 Replacement/Air Bleeding . 14-4 Brake Light Switch Switch Brake Pad/Disc Pedal . Shoe/Fad Wear . System Bulb Replacement Cable 54 Harness Routing Camshaft Installation Removal .... a. Carburetor Assembly Choke Disassembly . Idle Speed Installation Removal Separation/Assembly . 4-13 Synchronization . 3-10 Charging System 15-7 Clutch/Gearshift Linkage . 7-1 Diode 17-7 Installation 7-12 Removal Switch System . Control Cable Lubrication Coolant Replacement .. Temperature Indicator Coolant/Reserve Tank . Cooling System Crankcase Assembly . Breather Separation 11-4 Crankshaft/Transmission 11-1 Crankshaft/Connecting Rod 11-5 Cylinder Head/Valve . 9—1 Cylinder/Piston Cylinder ..... .. Compression Cylinder Head . Assembly a Cylinder Head Cover Installation Removal Cylinder Head Installation . Installation Drive Chain .. Electric Starter Emission Control Information Labels . 1—22 Systems 1-21 Engine Removal/Installation 6-1 Engine Installation 6-5 Engine Oil Change . 2-4 21. INDEX Engine Oil Level . Engine Removal EVAF Carburetor Air Vent Control Valve Inspection (California model only) Evaporative Emission Control System . Evmorative Emission Purge Control Valve Inspection (California model onyl a. Flywheel Installation Removal Fork 12-13 Front Wheel/Suspension/Steering 12—1 Wheel 12—7 Fuel System . 4-1 Line Fuel Pump Relay a Fuel Tank . Gearshift Linkage .. 7-8 General Information . 1-1 Safety 1-1 Handlebar Switches . Headlight Aim .. High Altitude Adjustment (USA. Only) t Horn u Hydraulic Disc Brake Ignition Control Module Inspection Ignition Pulse Generator Ignition System . Coil Switch a Timing a Left Crankcase Cover Installation . Removal Lights/Meter/Swltches Lubrication Points Maintenance Schedule ’88 Schedule '89,'91-'9 ' Schedule After '93 Master Cylinder Model Identifiction Neutral Switch .. Nuts, Bolts, Fasteners Oil Filter Change Oil Pressure Check Switch . Oil Pump .. Pilot Screw Adjustment . Piston Installation Ring Installation Primary Drive Gear Radiator Coolant Radiator/Cooling Fan Rear Wheel/Erake/Suspension Brake Wheel Regulator/Rectifier INDEX Right Crankcase Cover Installation ‘‘‘‘ t. Removal Seat/Rear Fender/Sub-frame . Service Information Alternator/Starter Clutch Battery/Charging System Clutch/Gearshift Linkage Cooling System Crankshaft/Transmission Cylinder Head/Valve Cylinder/Piston Electric Starter Engine Removal/lnstalla on Front Wheel/Suspension/Steering . Fuel System ............ .. . Hydraulic Disc Brake Ignition System Lights/Meter/Switches Lubrication a Maintenance Rear Wheel/Brake/Suspension Service Rules .. Shock Absorber Side Stand Switch Spark Plugs . Specifications t Speedometer Starter Clutch t Motor Relay Swutch Steering Head Bearings t Stem Suspension Swingarm . System Testing t Thermostat .. Thermostatic Switch Throttle Operation Tools Torque Values . Transmission Assembly/Installation . Troubleshooting Battery/Charging System . Clutch/Gearshift Linkage t. Cooling System Crankshaft/Transmission t Cylinder Head/Valve Cylinder/Piston . Electric Starter r Front Wheel/Suspension/Steering t Fuel System Hydraulic Disc Brake Ignition System Lights/Meter/Switches Lubrication ttttttttttt .. Rear Wheel/Brake/Suspension Turn Signal Relay 11-11 11-17 15—3 7-2 5—1 11-3 9—2 10-1 17-1 12-3 4-3 14-2 16-2 18-2 2-2 13-2 18-12 Valve Clearance Guide Replacement Seat inspection/Refacing . Water Pump Wheels/Tires .. Wiring Diagram . 3—8 9-1 1 9-12 5—7 3—20 1 9-1 21-2 ‘ (278) ® MADE FROM ea-/. RECYCLED PAPE HONDA MOTOR CO., LTD TOKYO. JAPAN MINIMUM 10% POST-CONSUMER CONTRENT 61MR107 ‘A20009506J~T PRINTED IN USA.