IMPORTANT SAFETY NOTICE .---- -----. -- Indicates a strong possibility of severe personal injury or death if instructions are not followed. CAUTION: Indicates a possibility of eqiupment damage if instructions are not 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 w ays 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 thoroughly that neither personal safety nor vehicle safety will be jeopardized by the service methods or tools selected. HOW TO USE TH IS MANUAL CONTENTS 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 U.S. 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 1 9 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. GENERAL INFORMATION LUBRICATION MAINTENANCE FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION � w orii CLUTCH/GEARSHIFT LINKAGE ��====== ALTERNATOR/STARTER CLUTCH . CYLINDER HEADIVALVE Most sections start with an assembly or system illustration, service l nform�tion 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. CYLINDER/PISTON CRANKSHAFT/TRANSMISSION � en ALL INFORMATION, ILLUSTRATIONS, DI­ RECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAIL ABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA FRONT WHEEL/SUSPENSION/STEERING 0 �====== (I) 0 REAR WHEEL/BRAKE/SUSPENSION �====== HYDRAULIC DISC BRAKE BATTERY/CHARGING SYSTEM MOTOR CO., L TO. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLI­ GATION WHATEVER. NO PART OF THIS PUBLI­ CATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. HONDA MOTOR CO., LTD. SERVICE PUBLICATIONS OFFICE ELECTRIC STARTER LIGHTS/METER/SWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX Date of Issue: June, 19 9 4 © HONDA MOTOR CO . , LTO. 1 . GEN E RAL INFORMATION G E N ERAL SAFETY 1 -1 TOOLS 1 -8 S ERVI C E R U LES 1 -1 CABLE & HARNESS ROUTING 1-10 M O D E L I D EN T I F I CATI O N 1 -2 EMISSION CONTROL SYSTEMS 1 -21 SPECIFICATI O N S 1 -3 T O RQ U E VAL U ES 1 -5 EMISSION CONTROL I N FORMATION LABELS 1 - 22 GENERAL SAFETY If the engine must be running to do some work, make sure the areals 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. 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. The battery generates hydrogen gas which can be highly explo­ sive. Do not smoke or allow flames or sparks near the battery, especially while charging it. 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 : 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. Used engine oil may cause skin cancer if repeatedly left in con­ tact with the skin for prolonged periods. A lthough this is unlikely unless you handle used oil on a daily basis, it is still adviseable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. SERVICE RULES 1. 2. 3. 4. 5. 6. 7. 8. Use genuine H O N DA or HON DA-recommended parts and lubricants or their equivalents . Parts that don ' t meet H O N DA ' s design specifications may damage to the vehicle . 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 i nterchangeable with English fas­ teners. I nstal l new gaskets, 0-rings, cott e r pins, and lock plates when reassembling . When tightening bolts or nuts, beg i n with the larger-diameter or inner bolts first. Then tighten to the specified torque diagonally in 1-5 steps, u nless a particular sequence is specified . Clean parts in non-flammable or h i gh flash point solvent upon disassembly. Lubricate a ny sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation . 1 -1 GENERAL I N F O RMATION MODEL I DENTI FICATION (1 ) VEHI CLE I DENTIFICATIO N N U M BE R The vehicle identification number (VIN) is attached on the left side of the steering head . The frame serial number i s stamped o n the right side o f the steering head. The engine serial number is stamped on the right crank­ case below the rear cylinder. (5) The carburetor identification numbers are on the carbure­ tor body i ntake side. 1 -2 COLOR LAB E L The color label is attached on the frame under t h e seat. When ordering a color coded part, always specify its desig­ nated color code. G E N ERAL I N FO R MATIO N SPECIFICATIONS ITEM DIME N S I O N S FRAM E ENGINE Overall length Overall width '88 , '89 , ' 9 1 -'94: After' 94 : Overall height Wheelbase Seat height Footpeg height G ro u n d clearance Dry weight '88 , ' 89 , ' 9 1 -93 : '94 : After'94 (Standard type) : After' 94 ( Delux type) : Curb weight ' 8 8 , '89 , ' 9 1 -93 : '94 : After' 94 ( Standard type) : After' 94 ( Deluxe type) : After'94 ( Standard/California type) : After'94 ( Deluxe/California type) : Type Front suspension , travel Rear suspension , travel Front tire size Rear tire size Front Cold tire U p to maximum pressu re vehicle capacity Rear Front U p to 90 kg (200 l bs) load Rear Front b ra ke Swept a rea '88 , '89 , ' 9 1 -'93 : After'93: Rear brake Swept a rea Fuel capacity ' 8 8 , '89 , ' 9 1 -'93 : After' 9 3 : Fuel reserve capacity ' 88 , ' 89 , '9 1 -' 9 3 : After' 93 Caster angle Trail Fork leg o i l capacity '88 , ' 89 : ' 9 1 -'93 : After' 93 : Type Cylinder a rrangement Bore a n d stroke Displacement Compressio n ratio Valve train Oil capacity Lu b ricatio n system Air filtratio n Cylinder compression S PECI F I CATIO N S 2 , 3 1 0m m (90 . 9 in) 7 60mm (29 . 9 in) 890mm ( 3 5.0 i n ) 1 , 1 25 m m (44.3 i n ) 1 , 60 5 m m (63 . 2 i n ) 6 9 0 m m ( 2 7 . 2 in) 28 5 m m ( 1 1 .2 in) 1 40mm ( 5.5 in) 1 9 6 kg (432 1b) 1 99 kg (439 lb) 1 99 kg (43 9 1b) 202kg (445 lb) 207 kg (456 lb) 2 1 3 kg (470 lb) 2 1 3 kg (470 lb) 2 1 6 kg (47 6 lb) 2 1 4kg (472 lb) 2 1 7 kg (478 1b) Double cradle Telescopic fork, 1 46 . 5mm ( 5 . 7 7 in) Swingarm, 90mm (3. 5 in) 1 00/90- 1 9 5 7 S 1 7 0/80- 1 5 M/C 7 7 S 200 kPa (2.00 kg/cm 2 , 29 psi) 250 kPa (2.50 kg/cm2,36 psi) 200 kPa (2 . 00 kg/cm2 , 29 psi) 200 kPa (2.00 kg/cm2,29 psi) Hydraulic single d isc 448cm 2 ( 6 9 . 4 sq in) 482 . 3cm 2 (74 . 8 sq in) M echanical leading & trailing 20 1 cm 2 (3 1 .2 sq in) 9 . 0 liters (2 . 4 US gal , 2.0 Imp gal) 1 1 .0 liters (2.9 U S gal ,2.4 Imp gal) 1 .9 liters (0.5 U S gai, 0.42 Imp gal) 3.4 liters (0.9 U S gai , O. 74 I m p gal) 3 5' 1 64mm ( 6.5 in) 463cc ( 1 5.7 U S oz, 1 3 . 0 Imp oz) 468cc ( 1 5 . 8 US oz, 1 3 . 2 1 m p oz) 449cc ( 1 6 . 9 US oz, 1 5 . 8 Imp oz) Water cooled 4-stroke SO H C 52' V2 cylinders 7 5 . 0x6 6.0mm (2 . 9 5x2.60 in) 583cc ( 3 5 . 5 cu-in) 9 .2: 1 Silent, m u lti-link chain d rive and O H C with rocker arms 2 . 8 lit (2 . 94 U S qt,2.46 I m p qt) after d isassem bly 2 . 1 lit (2.2 1 US qt, 1 .85 Imp qt) after d raining Forced pressu re and wet su m p Paper filter 1 , 324 kPa ( 1 3. 5 kg/cm2 , 1 92 psi) 1 -3 G E N ERAL I N FO RMATIO N ITEM S PECI F I CATI O N S 1 0" ( BTDC) at 1 mm lift I ntake valve O pens Closes 3 0" (AB DC) Exhaust valve O pens 3 0" ( B B DC) ENGINE 1 0· (ATDC) Closes Valve clearance (cold) intake 0. 1 5±0.02m m (0.006±0 . 0008 in) exhaust 0.20±0.02mm (0.008±0 . 0008 in) Engine d ry weight '88 , '89 , ' 9 1 -'93 : 6 1 kg ( 1 34 1b) After'9 3 : 62kg ( 1 3 6 . 7 lb) After' 94 (standard type) : 6 1 kg ( 1 34 1b) After' 94 ( Deluxe type) : 64kg ( 1 4 1 lb) Piston valve,dual carbu retor CAR B U R ETO R Type See page 4- 1 I . D. n u m ber F R O NT:# 1 1 5 R EAR:# 1 1 5 Main jet See page 4- 1 5 Pilot screw opening 7 .0 m m ( 0.28 in) Float level 1 ,200± 1 00 rpm Idle speed Wet,mu lti-plate D R IVE TRAI N Clutch 4-speed constant mesh Transmission 1 .8 8 8 ( 6 8/3 6 ) Primary redu ction 2.7 50 (44/ 1 6 ) Final reductio n 2. 5 7 1 ( 3 6/ 1 4) Gear ratio I 1 . 700(34/20) Gear ratio II 1 .227 (27 /22) Gear ratio Ill 0.9 3 1 (27 /29 ) G ea r ratio IV Left foot o perated return system, 1 -N -2-3-4 Gear shift pattern Ignitio n Battery ignition ( Full transistor) E LECT R I CAL Ignition timing I n itial '88, ' 8 9 , ' 9 1 -' 9 3 : 6.2· BTDC at idle After ' 9 3 : 6 . 5" BTDC at idle Full advance 30" BTDC at 6,000 rpm Alternator 345W/5,000 rpm B attery capacity 1 2V BAH S pa rk plug ��-----------------�--�----------------,-------------------� N I P PO N D ENSO NGK ---- Standard D PR B EA-9 X24 E P R - U 9 For cold climate ( B elow 5" C,4 1 " F) D P R 7 EA-9 X22EPR-U9 For extended high speed riding D P R 9 EA-9 X27 E P R-U 9 Spark plug gap Fuse Starting system H eadlight Turn signal light B ra ke & taillight M eter light Indicator light Licence light Firing o rder 1 -4 Main Sub Front Rear Neutral High beam Tu rn signal 0.8-0.9 m m ( 0.03 1 -0.03 5 i n ) 30 A 1 0 AX3, 1 5 AX 1 Electrical starter 1 2 v 60/ 5 5 w 1 2 V 32/3 C P (23/8 W )X2 S A E No. 1 034 1 2 V 32 C P(23 W)X2 SAE N o. 1 0 7 3 1 2 V 32/3 C P (23/8 W)X2 S A E No. 1 034 1 2 v 3.4 w 1 2 V 1 .7 W 1 2 V 1 .7 W 1 2 V 1 .7 W 1 2 V 4 CP Front(2)- R ear( 1 )308" G E N ERAL I N FO RMAT IO N TORQU E VALU ES ENG I N E ITEM Cylinder head cover bolt Camshaft holder bolt nut bolt Cylinder head n ut bolt nut bolt Camshaft sprocket bolt Primary d rive gear bolt Flywheel bolt Connecting rod bearing cap n ut Clutch lock n ut Oil pressure switch Spark plug Oil d rain bolt Starter clutch torx bolt Oli pump d riven sprocket Oil pass pipe bolt Valve adjustin g screw lock n ut Gearshift retu rn spring pin Starter motor cable nut Clutch lifter plate bolt Cam chain tensioner bolt Oil filter Drive sprocket bolt Timing hole cap Crankshaft h ole cap Cylinder stu d bolt ' 88 , ' 8 9 , ' 9 1 -' 9 5 : Drum stopper plate bolt Stator bolt Stator wire clamp bolt Right cra n kcase cover bolt Left crankcase cover bolt Q'ty Thread dia . (mm) Torque m ( kg-m , ft-lb) 4 6 2 4 8 2 4 2 4 1 1 4 1 1 4 1 6 1 6 8 8 6 10 8 8 6 7 12 12 8 18 12 14 8 6 1 0 ( 1 . 0 , 7 . 2) 23 (2 . 3 , 1 7 ) 23 (2 . 3 , 1 7 ) 1 0 ( 1 . 0 , 7 . 2) 48 (4 . 8 , 3 5 ) 23 (2 . 3 , 1 7 ) 23 (2 . 3 , 1 7 ) 1 0 ( 1 . 0 , 7 . 2) 23 (2 . 3 , 1 7 ) 90 ( 9 . 0 , 6 5 ) 1 30 ( 1 3 . 0 , 94) 34 (3 . 4 , 25 ) 1 30 ( 1 3 . 0 , 94) 1 2 ( 1 . 2 , 9) 1 4 ( 1 . 5 , 1 0) 3 5 (3 . 5 , 25) 30 (3 . 0 , 22) 1 5(1 .5, 1 1 ) 2 1 6 1 1 4 4 1 2 1 1 8 7 8 7 8 6 6 6 20 6 22 30 10 2 8 1 4 2 13 10 6 6 6 6 1 0 ( 1 . 0 , 7 . 2) 23 (2 . 3 , 1 7 ) 23 (2 . 3 , 1 7 ) 26 (2 . 6 , 1 9) 1 0 ( 1 . 0 , 7 . 2) 1 0 ( 1 . 0 , 7 . 2) 1 0 ( 1 . 0 , 7 . 2) 1 0 ( 1 . 0 , 7 . 2) 1 0 ( 1 .0, 7 .2) 3 . 5 (0 . 3 5 , 2 . 5 ) 1 5(1 .5, 1 1 ) 30-50 (3 . 0-5 . 0 . 22-3 6 ) 20-30 (2 . 0-3 . 0 , 1 4-22) 1 2 ( 1 . 2 , 9) 1 2 ( 1 . 2 , 9) 1 2 ( 1 . 2 , 9) 1 2 ( 1 . 2 , 9) 1 2 ( 1 . 2 , 9) Remark Special bolt Apply locking agent U BS bolt U BS bolt left hand threads Apply oil to t h e threads Apply sealant Apply locking agent Flange socket bolt . Apply locking agent . Apply oil Flange bolt Flange bolt Apply g rease t o the threads Apply g rease to the threads Apply locking agent . Apply locking agent . Apply locking agent . 1 -5 G E N E RA L I N FO RMATIO N FRAM E Steering stem nut Steeri ng bearing adjustment n ut Fork top pinch bolt Fork bottom pinch bolt Front axle Front axle pinch bolt Rear axle nut B ra ke torque rod nut '88, ' 8 9, ' 9 1 - ' 93, After '94: '94.: Middle brake a rm M id d le rod joint n ut Caliper mounting bol� B ra ke hose oil bolt After ' 9 4 : '88,'89,' 9 1 -'93: After '93: '88,'89,'9 1 -'93: After '93: B leed valve B ra ke master cylinder holder bolt B ra ke master cylinder cover screw B rake lever pivot bolt nut B ra ke d isc mounting bolt Caliper pin bolt Caliper bracket pin bolt Pad pin Pad pin plug Shock a bsorber u pper mounting bolt Shock a bsorber lower mounting bolt Gearshift arm bolt Foot p e g bracket bolt Swingarm pivot bolt Front u pper engine mounting bolt Front u pper engine bracket bolt Front lower engine mounting bolt Rear u pper engine mounting bolt Rear u pper engine bracket bolt Exhaust pipe joint n ut Fuel tan k mounting bolt Ignition switch mounting bolt Exhaust pipe cover bolt Exhaust m uffler bracket bolt/nut ' 88 , ' 8 9 , ' 9 1 -' 93 : After '93 Helmet holder mounting bolt Side stan d pivot bolt nut Driven sprocket nut Fork tube cap Front socket bolt '88,'89,'9 1 ,'92: Damper rod lock nut Spokes Handlebar mounting nut Ha ndlebar upper holder bolt After ' 9 4 : H a ndlebar lower holder n ut After ' 9 4 : Fuel valve body Throttle l i n k cover stay screw Rear ignitio n coil stay bolt Battery cover mounting bolt F u e l p u m p stay mou nting nut 1 -6 Thread dia. (mm) Torque N · m ( Kg-m,ft-lb) 2 2 1 2 2 2 2 2 1 2 2 1 1 5 1 1 1 1 1 1 1 4 1 1 2 1 1 2 4 1 2 3 24 26 7 10 18 7 16 8 8 8 8 6 8 8 10 10 8 6 4 6 6 8 8 8 10 10 10 10 6 10 14 10 8 10 10 8 8 8 6 6 1 05 ( 1 0.5,7 6 ) 25 (2.5, 1 8 ) 1 1 ( 1 . 1 ,8 ) 5 0 ( 5 .0,3 6 ) 7 5 ( 7 . 5,54) 22(2.2, 1 6) 90(9.0, 6 5 ) 27 (2.7,20) 22(2.2, 1 6) 27 (2.7,20) 27 (2.7,20) 9 (0.9, 6 . 5 ) 27 (2.7,20) 3 1 (3. 1 ,22) 30(3.0,22) 3 5 (3 . 5,25 ) 5 . 5 (0. 5 5,4) 1 2( 1 .2,9) 1 . 5 ( 0. 1 5, 1 . 1 ) 1 (0. 1 ,0. 7 ) 6 ( 0. 6,43 ) 40(4.0,29) 22(2.2, 1 6) 1 2( 1 .2, 9 ) 1 8 ( 1 .8, 1 3 ) 2.5 (0.25, 1 .8 ) 4 5 (4.5,33 ) 45 (4.5,33 ) 1 2( 1 .2, 9 ) 40(4.0,29 ) 90(9.0, 6 5 ) 5 5 ( 5. 5.40) 27 (2.7,20) 5 5 ( 5. 5,40) 5 5 ( 5. 5.40) 27 (2.7,20) 25 (2.5, 1 8 ) 1 9 ( 1 .9, 1 3 . 7 ) 1 1 ( 1 . 1 ,8} 1 2( 1 .2,9) 1/1 1 /4 2 1 1 5 2 2 1 1 08 2 8 8 6 10 10 10 34 10 14 4 8 27 (2.7,20) 20(2.0, 1 4) 1 3 ( 1 .3,9) 1 0( 1 .0,7.2) 30(3.0,22) 6 5 ( 6.5,47 ) 22(2.2, 1 6) 30(3.0,22) 7 0 ( 7 .0,5 1 ) 4(0.4,2.9 ) 25 (2.5, 1 8) 2 8 3 0 ( 3 . 0, 22) 2 1 2 2 2 1 8 22 4 6 6 6 O'ty ITEM 1 1 2 2 1 2 1 23 (2. 3 , 1 6) 23 (2.3, 1 6 ) 2. 1 (0.2 1 ' 1 . 5 ) 9 (0.9,6. 5 ) 9 (0.9, 6 . 5 ) 9 (0.9,6 . 5 ) Remark See page 1 2-23 Apply o i l t o the threads Apply locking agent Apply locking agent Apply locking agent Socket bolt Flange nut Flange bolt Shear bolt Shear bolt Socket bolt Apply locking agent GEN ERAL I N FORMATION 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 5 6 8 10 12 mm mm mm mm mm bolt, bolt, bolt, bolt, bolt, TORQU E N•m ( kg-m, ft-lbl nut nut nut nut nut 5 10 22 35 55 (0.50, 3.6) ( 1 .0, 7 . 2 ) ( 2 . 2 , 1 6) (3.5, 25) (5 .5, 40) TYPE TORQU E N·m (kg-m, ft-lbl 5 mm screw 6 mm screw, 6 mm bolt with 8 mm head 6 mm flange bolt, nut 8 mm flange bolt, nut 1 0 mm flange bolt, nut 4 (0.40, 2 . 9 ) 9 12 27 40 (0.9, ( 1 .2, (2.7, (4.0, 6.5) 9) 20) 29) 1 -7 G E N ERAL I N FO RM ATIO N TOOLS SPECIAL Description Oil pressure gauge Oil pressure gauge attachment Oil filter wrench Vacuum gauge Valve adjusting wrench Vacuum/Pressure pump Snap ring pliers Steering stem socket Clutch center holder Bottom holder pipe - holder attachment - holder handle Bearing remover set - remover handle - bearing remover set - remover weight Valve guide driver attachment (IN) Valve guide driver attachment ( EX) Bearing race remover Steering stem driver D river shaft Fork seal driver , 3 9 m m Ball race remover - driver attachment - driver handle Main bearing d river attachment Valve guide reamer, 5 . 5 1 0 mm (IN) Valve guide reamer, 6 . 6 1 2 mm (EX) Attachment, 28 x 30 mm * Drive chain cutter * Shock absorber compressor attachment * : New for this mode l . 1 -8 Tool number 07 506 - 3000000 07 5 1 0 - 4220 1 00 07HAA - PJ 7 0 1 00 tJ Equ ivalent Alternate tool commercially ' available in U . S.A. 07404 - 0030000 Vacuum gauge N ot availa ble 07908 - KE90000 in U . S . A . Vacuum pump A937X - 04 1 - XXXXX L Pressure pump Equivalent 079 1 4 - 323000 1 commercially available in U.S.A. 07 9 1 6 - 3 7 1 0 1 00 07923 - K E 1 0000 1- N ot available 07930 - KA 50000 I- i n U . S . A . 07930 - KA50 1 00 07930- KA40200 II07936 - 3 7 1 000 1 07936 - 37 1 0 1 00 07936 - 37 1 0600 Remover 0774 1 - 00 1 020 1 weight Tool number Refer to section 2 2 2 07 LMJ -00 1 OOOA 07908 - KE90 1 00 3 ST - AH - 260 - MC 7 ST - AH - 2 55 - MC 7 4 4 2, 1 3, 14 07 H G B -00 1 OOOA 12 7 12 11 07936 - 3 7 1 0200 07943 - M F50 1 00 9 07943 - M F50200 07946 - 3 7 1 0500 07946 - M BOOOOO 07946 - MJ00 1 00 07947 - 4630 1 00 07953 - MJ 1 0000 07953 - MJ 1 0 1 00 07953 - MJ 1 0200 9 12 12 13 12 12 re Attachment D river D river handle Attachment, 32X35mm 07H M F - M M 90400 07984 - 200000 1 07984 -ZE2000 1 07746 - 1 870 1 00 07 H M H - MR 1 01 03 07JM E - M R 1 0 1 00 0 7 9 5 3 - MJ 1 OOOA , 0 7 9 5 3 - MJ 1 OOOB or 07 949- 3 7 1 000 1 and 07746- 00 1 0 1 00 07 9 8 4 0 79 84 N ot available in U . S .A. - 2 00000 D ZE2 000 D 0 7 H M H- M R1010B 11 9 9 13 G E N ERAL I N FO RMATIO N COMMON Description Tool number Float level gauge Lock nut wrench , 1 7 x 2 7 m m Gear holder Flywheel holder Torx bit Rotor puller Valve guide remover, 5 . 5 m m Valve gu ide remover, 6 . 6 m m 0740 1 - 00 1 0000 07 7 1 6 - 0020300 07724 - 00 1 0 1 00 07725 - 0040000 07 703 - 00 1 0 1 00 07733 - 002000 1 07742 - 00 1 0 1 00 07 742 - 00 1 0200 Attachment, 32 x 35 m m Attachment, 42 x 4 7 mm 07 746 - 00 1 0 1 00 07 746 - 00 1 0300 Attachment, 52 x 55 mm Pilot, 1 5 mm Pilot, 1 7 mm Pilot, 20 mm Pilot, 22 mm Pilot, 2 5 mm Bearing remover head, 1 7 m m Bearing remover shaft Bearing remover head, 20 m m 07 746 - 00 1 0400 07 746 - 0040300 077 46 - 0040400 07 746 - 0040 500 07 746 - 004 1 000 07 746 - 0040600 07 746 - 0050 500 07746 - 0050 1 00 07 746 - 0050600 Driver 07 749 - 00 1 0000 Valve spring compressor 07757 - 00 1 0000 Shock absorber compressor - compressor screw Spoke wrench 07G M E - 00 1 0000 07G M E - 00 1 0 1 00 07JMA - M R601 00 Alternate tool Equivalent commercially available in U . S . A . 1-- � N ot available in U . S . A. Tool number 0 7 933-32 9000 1 07942-657 0 1 00 4 7 7 8 8 8 9 9 13 11' 13 11' 13 13 11' 11' 11 13 13 12 :quivalent commercially available in U .S.A. Valve spring compressor Refer to section 07957 - 32 9000 1 1 2, 12 12 13 1 1 ' 1 2, 13 9 13 available in U . S . A . I-- N ot VALVE SEAT CUTTERS (NOT AVAILABLE IN U. S. A. ) Description Valve seat cutter, 2 7 . 5 m m Valve seat cutter, 35 mm Valve seat cutter, 28 mm Valve seat cutter, 35 mm Valve seat cutter, 30 mm Valve seat cutter, 37.5 m m Cutter holder, 5.5 mm Cutter holder, 6 . 6 m m Tool number 07780 - 00 1 0200 07780 - 00 1 0400 07780 - 00 1 2 1 00 07780 - 00 1 2300 07780 - 00 1 4000 07780.,-00 1 4 1 00 0778 1 - 00 1 0 1 0 1 0778 1 - 00 1 020 1 Remarks 45 ° IN 45 ° EX 32 ° I N 32 ° EX 60 ° IN 60 ° EX Valve guide I N Valve guide EX 1 -9 G E N ERAL I N FORMATI O N CABLE & HARN ESS ROUTI N G Note the following when routing cables and wire harnesses: • A loose wire, harness or cable can be a safety hazard . After clamping, check each wire to be sure it is secure . • Do not squeeze wires against welds or clamps. • 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. • Route harnesses so they are neither pulled taut nor have ex­ cessive slack. • 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. • Do not use a wire or harness with broken insulation. Repair by wrapping them with protective tape or replace them. • Route wire harnesses to avoid sharp edges or corners. Also avoid the projected ends of bolts and screws. • Keep wire harnesses away from the exhaust pipes and other hot parts . • Be sure grommets are seated in their grooves properly. • After clamping, check each harness to be certain that it does not interfere with any moving or sliding parts . • After routing, check that the wire harnesses are not twisted or kinked. • 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. • Do not bend or twist the control cables. Damaged control cables will not operate smoothly and may stick or bind . 0 X � X 0: x: 1 -1 0 C O RRECT INCORRECT GENERAL INFORMATION '88- '89 ; '91 : (2) CLUTCH CABLE ( 3) LEFT HANDLEBAR SWITCH W I RE (8) RIGHT HANDLEBAR SWITCH W I RE ( 7 ) HORN W I RE '92-'93 : (2) CL UTCH CABLE (3) LEFT HAN DLEBAR SWITCH WI RE (4) SPEEDOMETE R CABLE (9) F RONT B RAKE HOSE (8) RIGHT HAN DLEBA R SWITCH W I R E 1-11 GENERAL INFORMATION ' 94: (1 ) THROTTLE CABLES (3) LEFT HANDLEBAR SWITCH WIRE (4) SPEEDOMETER CABLE (9) FRONT BRAKE HOSE (5) HEADLIGHT CONNECTOR (8) RIGHT HANDLEBAR SWITCH WIRE After '94: ( 1 ) TH ROTTLE CAB LES (3) LEFT HAN D LE B A R SWITC H WI R E ( 3 ) LEFT HAN D LE B A R SWITC H WI R E , ).::;�1t:::i::::::=-( 1 ) TH ROTTL E CAB LES \-1-'7"'7�7T---t--(4) SPE ED O M ETER CAB LE (9) R I G HT HAN D LE B A R SWITCH WI R E (9) R I G HT HAN D LE B A R SWITC H WI R E ( 8 ) H O R N WI R E 11@f�o ,:....\-mTt-t--+---,_ 1-12 � (2) CLUTCH CAB LE � (6) H EA D Li G HT -(7) H O R N C O N N ECTO R GENERAL INFORMATION '88-'89 '9 1 : ' (2 ) HANDLEBAR SWITCH W I RE BANDS (13) C RANKCASE BREATHER TUBE (12) WATER HOSE (11 ) ENGINE BREATHER T UBE (9) (7) (6) I G N ITI O N P U LS E GENERATOR W I RE CLUTCH CABLE (1 ) HANDLEBA R SWITCH WI RE BANDS '92-'93: (2) C RANKCASE B REATHER SE PA RATO R (11 ) ENGINE B REATHER TUBE (10 ) STARTER M OTO R (8) G RO U ND CABLE (7) CLUTCH CABLE (6) I G N ITI O N P U LS E GENE RATO R W I R E ( 5 ) A I R CLEANE R HOUSING 1 - 13 G E N E R A L I N F O R MAT I O N ' 94 : ( 13) CRANKCASE BREATHER ( 1 ) ·HANDLEBAR SWITCH WIRE BANDS TUBE ( 1 1 ) ENGINE B REATHE R TUBE (2) CRANKCASE BREATHER SEPARATO R �-��--l-1£<:�::.;.(3) .1--l-�#�-;.+--- EVA PORATIVE EM ISSION PURGE CONTROL VALVE (California model only) (9) STARTER M OTOR CABLE (4) SUB-AIR CLEANER (7) CLUTCH CABLE After '94 (1) HANDLE BAR SWITCH WIRE BANDS (2) CRANKCASE BREATHER SE PA R ATO R ( 1) HANDLE BAR SWITCH WIRE BANDS ( 1 0) STA RTE R MOTO R ( 9 ) STA RTE R MOTO R CA BLE ( 8 ) G ROUND CA BLE : � ' ' ' :: (6) IGNIT ION PULSE GENERATOR WIRE 1 -1 4 � r------------------------------------ 0 ] -------� After' 9 5 : G ________ � ( 5 ) A IR CLEANER HOUSING (4) SUB-A I R CLEANE R GENERAL INFORMATION ( 1 ) THROTTLE CABLES (2) FRONT IGNITION COIL (3) FUEL TANK BREATHER TUBE (California model only) (6) NE UTRAL SWITCH W I RE ( 7 ) RIGHT CHOKE CABLE ( 1 0) PEEDOMETER (9) CLEANE R HOUSING ( CABLE HOLDER BREATHE R TUBE THERMOSTATI C SWITCH '88-'89, '91-'93: ( 1 1 ) I G N ITI O N PULSE GENERATOR 4P WHITE CONNECTOR ( 1 2) HORN/FAN MOTOR 2P BLA CK CONNECTOR �:J��ID���� � -(0 .- -----­ (13) T U RN SIGNAL 9P WHITE CONNECTOR ( 1 4) INDICATOR PANEL 6 P GREEN CONNECTOR ( 1 5) SPEEDOMETER 6P BLACK CONNECTOR (16) RIGHT HANDLEBA R SWITCH 9P RED CONNECTOR 1-1 5 GEN ERAL I N F O RMATION '94 : ( 2) FRONT B RA K E H O S E (3) I G N ITI O N P U LS E G E N E RATO R 4 P WH ITE CO N N ECTO R (4) H O R N/FAN M OTO R 2 P B LA C K C O N N ECTO R � TU9 P RWHN SITEI G NACOLN N ECTO R (6) I N D I CATO R PAN EL 6 P G R EE N CO N N ECTO R ( 7 ) S P E E D O M ETER 6 P B LACK C O N N ECTO R (8) R I G HT HAN D LEBAR SWITC H 9 P R E D C O N N ECTO R After '94 : ( 9 ) C RAN K CASE B R EATH E R D RAI N TU B E (10) MAI N WI R E HAR N ESS ( 11 ) 1-16 ( 1 2 ) EVAPO RATIVE EM ISSION P U R G E C O N T R O L VALVE (California model o n ly) FAN MOTO R WI R E GENERAL INFORMATION (1) T U RN SIGNAL RELAY (2) FUEL FILTER (7) (6) BATTERY SUB-FUSE BOX ( 8 ) REAR BRAKE LIGHT SWITCH (1) T U RN SIGNAL RELAY (9) COOLANT RESERVE TANK OVERFLOW TUBE (23) S I DE STAND 2P G REEN CONNECJOR (24) IGNITION SWITCH ""'� 2P BLACK COINNI�Cl"OR -.... '- 1 1 ) FUEL PU M P �-----;��of-41-�_�17) •REGULATOR/ RECTIFIER (21 I ( 1 9 ) IGNITION SWITCH OIL PRESSURE SWITCH S I DE STAND SWITCH 1 -17 GENERAL INFORMATION ( 9 1 GROUND PO INT ( 1 ) STATOR COIL ( 2 ) CLAMPS (3) GROM METS (7) THERMOSTATI C SWITCH W I RE ( 6 1 RIGHT ( 5 ) IGNITION P ULSE CRANKCASE GENERATOR ( 1 1 I BRAKE/TA ILLIGHT CASE ( 1 21 TU RN SIGNAL LIGHT W I RE ( 1 3) LI CENCE LIGHT WIRE 1 -1 8 G E N E RA L I N F O R MATI O N After '93 : ( 1 ) ALTE RNATO R WI RE (4) SIDE STAND SWITCH (3) OIL PRESSU RE SWITCH 1-19 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) NOTE • The hoses shown below are n u mbered as they appear on the Vacu u m Hose Routing Diagram Labe l . ( 1 ) @TUBE ( 7 ) EVAPORAT IVE EMISSION PU RGE CONTROL VALVE ,...::....��r=="1 (5) @T UBE JL\..-bi-\---- ( 7 ) EVAPORATIVE EMISSION PU RGE CONTROL VALVE ( 1 5 ) ENGINE BREATHER TUBE (FROM REAR CYLINDER HEAD ) (3) @T UBE (6) EVA PO RAT IVE EMISS ION CARBURETOR AIR VENT CONTROL VALVE (5) @TUBE ( 1 4) COOLANT RESERVE TANK DRAIN TUBE ( 1 0) TO EVAPORATIVE EM ISS ION CANISTER (9) AIR CHA MBER DU CT ( 1 21 EVAPORATIVE EMISSION CANISTER OPEN AIR TUBE 1 - 20 ( 1 1 l EVAPORAT IVE EM ISS ION CANISTER ( 1 31 REA R SHOCK ABSORBER TUBE G E N ERAL I N FO RMATIO N EMISSION CONTROL SYSTEMS The U . S . Environmental Protection Agency and California Air Resources Board (CARB) requ ire manufacturers to certify that their motorcycles comply with applicable exhaust emissions standards during their useful life, when operated and maintained according to the instructions provided, and that motorcycles built after January 1 , 1 983 comply with applicable noise emis­ sion standards for one year or 6,000 km (3, 7 30 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 i n order to keep the emissions system warranty in effect. SOURCE OF E M I SS I O N S · The combustion process p roduces carbon monoxide and hydrocarbons. Control o f hydrocarbons i s very important because, under certain conditions, they react to form photochemical smog when subjected to sunlight. Carbon monoxide does not react in the same way, but it is toxic. Honda Motor Co . , Ltd . utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide and hydro­ carbons. EXHAUST E M I S S I O N C O N T R O L SYST E M The exhaust emission control system is composed o f a l e a n carburetor setting, and no adjustments should be m a d e except idle speed adjustment with the throttle stop screw. The exhaust emission control-system is separate from the crankcase emission control syste m . CRA N K C A S E E M I S S I O N C O N T R O L S Y S T E M The engine is equipped with a closed crankcase system which routes crankcase emissions through the air cleaner into the combustion chamber. ( 1 l CRAN KCASE BREATHER SEPARATOR c::::> -+ (2) AIR CLEANER HOUSING FRESH A I R BLOW-BY GAS 1 -21 G E N ERA L I N FORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California model only) This model complies with California Air R eso u rces Board evaporative emissio n requirements. Fuel vapor from the fuel tan k and carbureto r is d irected into the evaporative emission canister where it is adsorbed a n d sto red while the engine is stopped.When the engine is running and the evaporative emissio n purge control diaphragm valve is o pen, fuel vapor i n the evaporative emissio n canister is d rawn i nto the engine through the carbu retor. TO OPEN AIR I (3) DRAIN (4) EVAPO RATIVE EMISSIO N CAN I STER ��--( 5 ) EVAPO RATIVE E M I S S I O N CAR B U R ETO R AI R VENT CONTRO L VALVE • IT ' ( 7 ) TO OPEN AIR ( 6 ) EVAPO RATIVE E M I S S I O N CAR B U R ETO R AI R VENT CO NTROL VALVE ( E N G I N E STO P) NOISE EMISSION CONTROL SYSTEM TAM PE R I N G WITH THE NOISE CONTROL SYSTEM IS PRO H I BITED : Federal law prohibits the fol lowing 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 i ncorporated 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 PRESU MED T O CONSTITUTE TAMPERING A R E T H E 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. EM ISSION CONTROL I N FO RMATION LABELS An Emission Control I nformation Label is located on the inside of the left side cover as show n . It contains basic tune-up speci­ fications. 1-22 ( 1 ) VEHICLE EMISSION CONTROL I N FORMATION LABEL G E N ERAL I N F O RMATI O N VACUUM HOSE ROUTING DIAGRAM LABEL (California model only) The Vacuu m Hose Routing Diagram label is on the inside of the left side cover. Route the vacuum hoses as shown on this label. 1-23 L U B R I CATIO N '88, '89: (1) ROCKER A R M ( 2 ) O I L PIPE ( 1 2 ) PISTON l (7) OIL FILTER 2-0 ( 6 ) PRESSU R E R E L I E F VALVE ( 5 ) O I L STRA I N E R MAIN SHAFT 2. LU B R I CATI O N After '89: (1) (12) ROCK E R A R M CAMSH A FT (11) PISTO N (10) O I L JET (9) C R A N KSH A FT ( 2) MA I NSH A FT ( 8) CO U NT E R S H A F T � (7) O I L P R ESSU R E SW ITCH (@n ( 3) O I L PUMP (4) O I L ST R A I N E R ( 5) P R ESSU R E R E L I E F VALVE 2- 1 L U BRICATI O N S ERVIC E I N FO R M ATIO N 2-2 O I L P R ESS U R E C H ECK 2-5 TROUBLESHO OT I N G 2- 3 OIL P U MP 2-6 E N G I N E O I L LEVEL 2-4 CO NTROL CABLE L U BR I CATI O N 2- 1 2 ENGINE O I L C H AN G E 2-4 L U BRIC ATIO N P O I NTS 2- 1 2 O I L FILTER C H A N G E 2-5 SERVICE I N FO RMATION • 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. CAUTION • Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. A lthough 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. G E N ERAL • The o i l p u m p c a n be serviced a f t e r r e m o v i n g the e n g i n e from the fra m e . S P E C I F I CATI O N S Engine oil O i l c a p a city 2 . 8 lit ( 2 . 94 U S qt, 2 . 4 6 I m p qt) after d i sasse m b l y . 2 . 2 5 lit ( 2 . 3 6 U S q t , 1 . 9 8 I m p q t ) at o i l filter a n d o i l c h a n g e . 2 . 1 lit ( 2 . 2 1 U S q t , 1 . 8 5 I m p qt) after d r a i n i n g . Oil recomm e n d a t i o n H O N DA GN4 4-stroke o i l o r eq u ivalent API se rvice class ification: S F o r SG V I SCOS ITY: SAE 1 0W - 40 O I L V I SCO S I T I E S Other viscosities s h o w n i n t h e c h a rt m a y be u s e d w h e n the average tem perature i n your riding area i s w i t h i n the i n d i cated range . 0 -20 Oil 20 -10 60 40 0 10 100 80 20 30 40 °F" •c pump ITEM R o t o r tip c l e a r a n c e STA N DA R D 0 . 1 5 m m ( 0 . 006 i n ) S E R V I C E LI M I T 0 . 20 m m ( 0 . 008 i n ) Pump body clearance 0 . 1 5 - 0 . 2 2 m m ( 0 . 006 - 0 . 009 i n ) 0.35 mm (0.0 1 4 in) P u m p end c l e a r a n c e 0 . 0 2 - 0 . 0 7 m m ( 0 . 00 1 - 0 . 003 i n ) 0 . 1 0 m m ( 0 . 004 i n ) 44 1 kPa ( 4 . 5 kg/cm2, 64 psi) at 6,000 r p m -- O i l pressure T O R Q U E VALU E S O i l pressure s w itch Engine o i l d r a i n bolt Oil filter 2-2 1 2 N•m ( 1 . 2 kg-m, 9 ft-lb) 3 5 N•m ( 3 . 5 kg-m, 25 ft-l b ) 1 0 N · m ( 1 . 0 k g - m , 7 . 2 ft- l b ) L U BRICATIO N T O O LS Special Oil filter wrench Oil pressure gauge Oil pressure gauge attachment Snap ring pliers 07HAA - PJ 70 1 00 07 506 - 3000000 or equivalent commercially available in U . S . A . 0 7 5 1 0- 4220 1 00 J 079 1 4 - 323000 1 - or equivalent commercially available in U . S . A TROUBLESHOOTI NG Oil 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 d riven sprockets Broken oil pump drive chain Faulty oil pump Oil leaks 2-3 LUB R I CATIO N ENGI N E OIL LEVEL Support t h e motorcycle i n a n upright a n d level position using a hoist or a jack under the engine. Start the engine and let it idle for a few minutes. Stop the engine, remove the oil fi ller cap/di pstick and wipe it clean. Check the oil level with the oil filler cap/d ipstick 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 di pstick, fill to the upper level mark with the recommended oil . Check the 0-ring for damage. ENGI N E OIL CHANGE NOTE • Change the engine oil with the engine warm and the motor­ cycle on its side stand to assu re complete and rapid drain­ ing . R emove the o i l f i l ler cap/d ipst ick and d rain bo lt. W ith the engine stop sw itch OFF, push the starter button for a few seconds to drain any o i l which may be left in the eng ine. ( 1 ) DRA IN BOLT ( 1 ) D RA IN BOLT 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 instal l the bolt. TORQUE: 35 N•m (3.5 kg-m, 25 ft-lbl Fill the crankcase with the correct quantity of the recommend­ ed o i l . ( 2 ) SEALING WASHER OIL CAPACITY: 2. 8 lit (2.94 US qt, 2.46 Imp qt) after disassembly 2.25 lit (2.36 US qt, 1 .98 Imp qt) at oil filter and oil change 2.1 lit (2.21 US qt, 1 . 85 Imp qtl after draining RECOMMENDED OIL: Honda GN4 4-stroke oil or equivalent API service classification: SF or SG VISCOSITY: SAE 1 0W - 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 m inutes, then check that the oil level is at the upper level mark with the motorcycle upright. 2-4 \ Check that there are no oil leaks . LUB R I CATION O I L FI LTER CHANGE Drain the engine o i l ( page 2-4) . CAUTION • Do not replace the oil filter when the exhaust system is hot. Remove the oil filter with a filter wrench . TOOL: Oil filter wrench 07HAA - PJ70 1 00 (2) OIL FILTER WRENCH Apply oil to the new oil filter 0-ring and install the new oil filter. Tighten the oil filter with a filter wrench . (1 l OIL F I LTER TORQUE: 1 0 N • m ( 1 .0 kg-m, 7 . 2 ft-lb) Fill the engine with recommended oil (page 2-4) . O I L P RESSU R E CHECK Remove the following: - drive sprocket cover (page 1 3 - 1 4) - drive sprocket cover bracket - switch cover and switch screw (2) 0-RING Disconnect the wire from the oil pressure switch, remove the switch and connect an oil pressure gauge to the switch hole. TOOLS : Oil pressure gauge Attachment 07506 - 0 7 506 - 3000000 07 5 1 0 - 4220 1 00 or equivalent commercially available in U . S . A . Check the oil leve l . Start the engine and allow it to warm-up to operating tempera­ ture . Check the oil pressure at 6,000 rpm. STAN DARD OIL PRESSURE: 44 1 kPa (4. 5 kg/cm2, 64 psi) Stop the engine. Apply sealant to the pressure switch threads and install it. TORQUE : 1 2 N • m ( 1 . 2 kg-m, 8.7 ft-lb) Connect the oil pressure switch wire and pull the dust cover over the switch body securely. Start the engine and check that the oil pressure warning light goes out after one or two- seconds. NOTE • Route the oil pressure switch wire properly ( page 1 - 1 5) 2-5 LU BRICATION O I L PUM P ( 1 ) PRESSURE RELIEF VALVE COVER- PRESS U R E R E L I E F VALVE R E M OV A L � ® Separate the crankcase (Section 1 1 ) . Remove the bolt and pressure relief valve cover. Remove the pressure relief valve from the oil pump. PRES S U R E R E L I E F V A L V E D I SA S S E M B LY Remove the snap ring and disassemble the relief valve . TOOL: Snap ring pliers 079 1 4 - 323000 1 or equivalent commercially available in U . S.A. I N S PECTI O N Check the spring, 0-ring and valve for fatigue, wear or dam­ age. Check the body for clogging or damage . Replace the relief valve as an assembly. � ( 1 ) 0-R I N G Q ( 2 1 BOOY ( 3 ) VALVE Clean all the parts and assemble them i n the reverse order of disassembly. � ( 5 ) SNAP R I N G OIL PU M P R E M OVAL/ D I SA S S E M BLY Remove the oil pump by removing two mounting bolts . Remove the dowel pins and 0-rings. 2-6 L UB R I CATIO N Remove the oil strainer and oil pipe from the oil pump. Check the 0-rings and oil seal for fatigue or damage. (1 l O I L STRA I N ER ( 1 l O I L SEAL Clean the oil strainer and oil pipe w ith non-flammable or high flash point solvent. (21 OIL STRA I N E R / 0 (31 0-R I N G S Remove the three cover bolts. Disassem bled parts and clean them with non-flammable or high flash point solvent. ( 1 l C O V E R BOLTS O I L PUMP I N S P ECTI O N I nstall t h e outer a n d inner rotors to the pump body. Measure the outer rotor-to-pump body clearance . SERVICE LIMIT: 0.35 mm (0.01 4 in) 2-7 LUBRICATI O N Remove the oil pump shaft from the oil pump and measure the pump end clearance. SERVICE LIMIT: 0.1 0 mm (0.004 in) Temporarily install the shaft i n the pump body. Measure the inner rotor tip clearance. SERVICE LIMIT: 0.20 mm (0.008 in) Replace the oil pump, if necessary as a n assembly. O I L PU M P A S S E M B LY '88 , '89 , '91 -93: (1 I PU M P BODY ( 1 0 1 0-RI N G ( 1 1 I O I L STRA I N E R 2-8 LUB R I CATI O N After '93: (4) P R ESS U R E R ELI EF VALVE B O DY ( 1 ) PU M P B O DY ( 2 ) 0 UT E R R OTO R (3 ) 1 N N E R R OTO R (8)WASHER (9)SPRING I ( 1 4) D R IVE P I N ( 1 3 ) PU M P SHAFT 1 1 ) O I L STRAI N E R I nstal l the outer rotor in the pump body with the punch mark facing the cover, then i nstall the inner rotor. I nstall the drive pin and spacer on the shaft. I nstall the shaft i n the body, aligning the drive pin with the inner rotor groove. (6) I N N E R ROTOR '88 , '89 , '9 1 -'93: ( 1 ) O I L PU M P BODY I nstall the dowel pin and a new gasket on the pump body, then install the cover. (2) OIL PU M P COVER 2-9 LABRICATION After '93: ( 1 ) O I L P U M P B O DY I nstall the dowel pins on the p u m p cover,then i nstall the pump body. ( 3 ) 0 1 L P U M P COVER ( 1 ) COVER BOLTS Tighten the cover bolts securely . Install the 0-rings, oil seal, oil strainer and oil pipe on the oil pump. (2) 0-R I NG (3) 0-R INGS CAUTION • Install the 0-rings on the oil pipe with the tapered side facing out as sho wn, or the engine will be damaged. ( 5) 0-R I NGS After '93: Insta l l the oil seal on the oil pump. Align the edge of oil strainer with the g roove of the pump cover,then i nstall the oil strainer as shown. ( 1 ) 01L S EAL (4) 0 1 L STRAI N E R 2-10 (4) O I L PIPE ( 2 ) E DG E L UB R I CATI O N O I L PU M P I N STALLAT I O N I nstal l the dowel pins a n d n e w 0-rings. I nstall the oil pump as an assembly . ( 2 ) DOWEL PIN I nstall the pressure relief valve in the oil pump. I nstall the pressu re relief valve cover with the bolt. Assemble the crankcase (Section 11 ). (1 l PRESSU R E RELIEF VALVE COVER 2- 1 1 LUBRICATI O N CONTROL CABLE LUBRICATION Periodically disconnect the throttle and choke cable a t their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil . LUBRICATION POI NTS Use gen e ral purpose grease when not otherwise specified here . Apply oil or grease to the other sliding surfaces and cables not shown here . (1 l - , CLUTCH AND BRAKE LEVER ( 2 ) TH ROTTLE GRIP ---- (11 l STE E R I N G HEAD BEAR I N G .. I I I I I - ---- ( 7 ) BRAKE PEDAL PIVOT - (8) 2-12 BRAKE & CHANGE CALI PER PIVOTS (SILICON G R EASE) - � ( 5 ) SWI NGARM PIVOT BALL AND N EEDLE BEARINGS - lijiVft (6) S I D E STAND PIVOT , (4) DRIVE CHAIN ( PR O HO N DA CHA I N LU B E ) 3. MAI NTENANCE S E R V I C E I N FORMAT I O N 3- 1 M A I NTENANC E S C H E D U L E '88; 3-3 MAI NT E NA N C E S C H E D U LE '8 9,'9 1 -'93; 3-4 MAI NT E N A N C E S CH E D U LE After 93; 3-5 < EN G I N E> FUEL LINE 3-6 T H ROTTLE OP E RATIO N 3-6 CA R B U R ETO R C HO K E 3- 7 A I R C LEAN E R 3- 7 C RA N KCAS E B R EAT H E R 3-8 S PA R K PLUGS 3-8 VALV E CLEARANC E 3-8 CAR B U R ETO R S Y N C H RO N IZATIO N 3- 1 0 CA R B U R ETO R I D L E SP E E D 3- 1 1 RADIATO R COO LA N T 3- 1 1 C OO LI N G SYSTEM 3- 1 2 C Y LI N D E R CO MP RESS IO N 3- 1 2 EVA PO RATIVE E M IS S IO N CONTROL S YSTEM 3-1 3 < C HASSIS> D R I V E CHAIN 3-1 3 BRAKE F L U I D 3-1 5 BRAKE S H O E/PAD WEAR 3-1 6 BRAKE SYSTEM 3- 1 6 BRAKE L I G HT SWITCH 3-1 7 H EADLIGHT AIM 3- 1 8 CLUTCH SYSTEM 3-1 8 S I D E S TAND 3-1 9 S US PE N S IO N 3-1 9 N UTS, BO LTS, FASTENERS 3 -20 W H E E LS/TIRES 3 - 20 S T E E R I N G H EAD BEA R I N G S 3-21 SERVICE I N FORMATION • • 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. 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. G E N ERAL • • Engine oil Engine oil filter change See page 2-4 See page 2-5 S P E C I F I CATI O N S �E N G I N E� Ignition timing Spark plug Initial '88 . ' 8 9 ,'9 1 - ' 9 3; 6 . 2 ° BTDC at idle After ' 93; 6 . 5 ° BTDC at idle 30° BTDC at 6 , 000 rpm Full advance Spark plug gap IN Valve clearance (COLD) EX Idle speed Cylinder compression Throttle grip free play Standard For cold climate ( below 5 ° C/4 1 ° F) For extended high speed driving 0 . 8 - 0 . 9 mm (0.03 1 - 0.035 in) 0 . 1 5 ± 0.02 mm (0.006 ± 0 . 0008 in) 0 . 20 ± 0.02 mm (0.008 ± 0 . 0008 in) 1 , 200 ± 1 00 rpm 1 , 324 ± 98 kPa ( 1 3 . 5 ± 1 .0 kg/cm2, 1 92 2 - 6 mm ( 1 / 1 6 - 1 /4 in) ± NGK N I PPON DENSO DPR8EA-9 DPR7 EA-9 DPR9EA-9 X24EPR-U9 X22EPR-U9 X27 EPR-U9 1 4 psi) 3- 1 Ill MAINTENAN CE �C H A S S I S� 20 - 30 mm 43 mm ( 1 . 7 1 0 - 20 mm 20 - 30 mm Rear brake free play Brake pedal height C l utch lever free play D rive chain slack (3/4 - 1 -3/1 6 in) in) ( 3/8 - 3/4 in) ( 3/4 - 1 -3/ 1 6 in) Tires Tire size Cold tire pressures kPa (kg/cm2, psi) U p to vehicle capacity load Up to 90 kg ( 200 lbs) load M aximum weight capacity Tire brand Bridgestone Dunlop Front Rear 1 00/90- 1 9 57S 200 ( 2 . 00, 29) 1 70/80- 1 5 7 7 S 2 50 ( 2 . 50, 3 6 ) 2 0 0 ( 2 . 00, 2 9 ) 200 ( 2 . 00, 29) 1 6 1 kg ( 3 5 5 lbs) G 546 L309 F24 K555 TO R Q U E VALU E S Rear axle nut Valve adjusting screw lock nut S pokes (front/rear) Timing hole cap Crankshasft hole cap 90 N· m ( 9 . 0 kg-m, 65 ft-lb) 23 N•m ( 2 . 3 kg-m, 1 7 ft-lb) 4 N•m (0.4 kg-m, 2.9 ft-lb) 3 . 5 N•m (0. 3 5 kg-m, 2 . 5 ft-lb) 1 5 N ·m ( 1 . 5 kg-m, 1 1 ft-lb) T O O LS Special Valve adjusting wrench Vacuum gauge Drive chain cutter Spoke wrench 3-2 07 908 - KE90000 07908 - KE90 1 00 07404-0030000 or 07 LMJ - 00 1 000A 07HMH- M R 1 0 1 00 or 07HMH- M R 1 0 1 0 B 07J MA- M R 6 0 1 00 N ot available in U . S . A . U . S . A . Only N ot available in U . S . A . U . S . A . Only U . S . A . Only N ot available in U . S . A . MAINTENANCE MAI NTENANCE SCHEDULE '88; Perform the PRE-RI D E I N SPECTI O N in the Owner ' s Manual at each scheduled maintenance period . 1: I N SPECT AND C LEAN , ADJUST, LUBRICATE OR REPLAC E I F N ECESSARY . C : CLEAN R : REPLAC E L : L U B R I CATE FREQU E N CY ITEM * * * en � w !:::: * 0 w I<{ ...J w a: z 0 U5 en * * � w * * FUEL L I N E THROTTLE OPERATI O N CARBU RETOR CHO K E A I R CLEANER CRANKCASE BREATHER WHICHEVER COMES FI RST • EVERY .. ODOMETER READI N G ( N OTE 1 ) x 1 ,000 mi 0.6 4 8 x 1 00 km 64 1 28 10 R R R R R R I I I I 3- 1 0 I *R I 3- 1 1 3- 1 1 3- 1 2 I 3-1 3 I 2 YEARS * R EVAPO RATIVE E M I S S I O N CONTROL SYSTEM (NOTE 4) BRAKE FLU I D � w !:::: 0 w * ...J w * I<{ a: z 0 U5 � w en z 0 z * * BRAKE SHOE/PAD WEAR BRAKE SYSTEM BRAKE LIGHT SWITCH HEADLIGHT A I M CLUTCH SYSTEM S I D E STAND I I ** WHEELS/TIRES ** STE E R I N G HEAD BEA R I N G S I I I R c I I I c R I c R I R I I I c R I I c R I EVERY 600 mi ( 1 ,000 km) I. L *R *R I I I I 2 YEARS * R I I I I I I I I I I I I SUSPE N S I O N NUTS, BOLTS, FASTEN ERS REFER TO PAG E R I R c R CARBURETOR-IDLE SPEED RADIATOR COOLANT COOLING SYSTEM 24 I I I R (NOTE 3) E N G I N E O I L F I LTER CARBU RETORSYNCHRO N IZAT I O N 20 3-6 3-6 3-7 3-7 3-8 3-8 3-8 2 -4 2-5 (NOTE 2 ) SPARK PLUG VALVE C LEARA N C E ENGINE OIL 16 1 92 256 320 384 I I I DRIVE CHAIN en 12 I I I I I I I I I I I I I I I I I I I I I I I I I I I I 3- 1 3 3-1 5 3- 1 6 3- 1 6 3-1 7 3- 1 8 3-1 8 3-1 9 3-1 9 3-20 3-2 0 3-2 1 I I I I * Should be serviced by a n authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified . ** I n 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. 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 MAI NTENANCE SCHEDULE '89 , ' 9 1-' 9 3; Perform the PRE-RIDE I N SPECTION in the Owner ' s Manual at each scheduled maintenance period . 1: I N SPECT AND C LEAN , ADJ U ST, LUBRICATE OR REPLACE I F NECESSARY . C : CLEAN R : REPLACE L: LU BRICATE The following items require some mechanical knowledge . Certain items ( particularly those m arked * and * * ) may requ i re more tec h nical i nformation and tools . Consult their authorized Honda deale r . � M * FUEL LINE * THROTTLE OPERATION * CARBU RETOR CHOKE (/) :2 w !::: A I R CLEANER C RA N KCASE BREATHER O D O METER READ I N G ( N OTE 1 ) NOTE x 1 ,000 mi 0.6 4 x 1 ,000 km 1 6.4 8 16 20 R R c 24 1 2 . 8 1 9 . 2 2 5 . 6 32.0 38.4 I I I I I I I I I ( NOTE 2 ) ( N OTE 3 ) 12 c c c c c REFER TO PAG E 3-6 3-6 3-7 3-7 3-8 R R R R R R SPARK PLUG 3-8 * VALVE CLEARANCE I I I 3-8 I ....J R R R R 2-4 ENG I N E O I L w a: R 2-5 R R R ENG I N E O I L FILTER z Q * CARBURETOR SYNCHRON IZATION I I I I 3- 1 0 (/) (/) - * CARBURETOR IDLE SPEED I I I I I I I 311 :2 w * ( N OTE 5 ) I R RAD IATOR COOLANT I 3- 1 1 * COOLING SYSTEM 3- 1 2 I I I * EVAPORATIVE EMISSION CON( NOTE 4) I I 3- 1 3 TROL SYSTEM DRIVE CHA I N I , L EVERY 600 mi ( 1 ,000 km) 3- 1 3 * * R I (/) I ( N OTE 5) B R A K E FLU I D I 3- 1 5 I R :2 w BRAKE SHOES/PADS WEAR I I I I I I 3- 1 6 !::: I I BRAKE SYSTEM I I 316 c w 1- * BRAKE LIGHT SWITCH I I I 3- 1 7 <( ....J w * HEADLIGHT AIM I I I 3- 1 8 a: z I CLUTCH SYSTEM I I I 3-1 8 I I I 0 U5 I S I DE STAND I I 3- 1 9 (/) * I 3- 1 9 SUSPENSION I I � w * N UTS, BOLTS, FASTENERS I I I I 3-20 z 0 z ** WHEELS/TI RES I 3-20 I I I I I I ** STEERING HEAD BEARI N G 3-2 1 I I I I * SHOU L D BE SERVICED BY AN AUTHORIZED HONDA DEALER, U N LESS THE OWN ER HAS PROPER TOOLS A N D SER­ VICE DATA AND IS M ECHANICALLY QUALI FIED. ** I N THE I NTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED O N LY BY AN AUTHORIZED HONDA DEALE R . NOTES : 1 . A t higher odometer readings, repeat a t 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 ful l throttle. 4 . California type only. 5 . Replace every 2 years, or at indicated odometer interval , whichever comes first . Replacement requires me­ chanical skill. c w 1<( 3-4 MAI NTE N A N C E MAI NTE NANCE SCHEDULE After '9 3; Perfo rm t h e P R E - R I D E I N SPECTI O N i n the Ownera n u a l at each sched u led mai ntenance period . ! : I N S P E CT A N D C L E N A , ADJ U ST , LU B R I CATE O R R E PLACE I F N E C ESSARY . C : C LEAN R : R E P LAC E L : LU B R I CAT E The following items req u i re mech a n ical kn owle dge . Certa i n items (parti c u l a rly th o se ma rked i nformatio n and tools, Consu lt their a uth orized Honda dealer. F R EQU E N CY ITEM * F U EL LI N E * TH R OTTLE O PE RATI O N * CAR B U R ETO R C H O K E AI R C LEAN E R (/) :2: w C RAN KCAS E B R EATH E R !::: S PA R K PLU G c w * VALVE C LEARAN CE ENGINE OIL w a: E N G I N E O I L F I LTER z 0 * CAR B U R ETO R SYN C H R O N IZATIO N en (/) * CAR B U R ETO R I D LE S P E E D :2: w R A D I ATO R COOLANT ( N OTE5) * C O O LI N G SYSTEM � * (/) :2: w !::: � c w w a: z 0 en � :2: w I z 0 z * * * * ** ** EVAPO RATIVE E M I SS I O N C O N T R O L SYSTEM D R IVE CHAI N B RA K E F LU I D B RA K E S H O ES/ PADS WEAR B RA K E SYSTEM B RA K E LI G HT SWITC H H EA D L I G HT A I M C LUTCH SYSTEM S I D E STA N D SUSPENSION N UTS , B O LTS , FASTEN E R S W H E E LS/TI R ES STE E R I N G H EAD B EAR I N G N OTE ( N OTE2) ( N OTE3) x 1 , 000mi 1 00km x • and • • ) may req u i re more tec h n ical O D O M ET E R R EAD I N G ( N OTE 1 ) 0.6 1 6 20 24 12 4 8 1 0 64 1 2 8 1 92 2 5 6 3 2 0 384 I I I I I I I I I R R c R I R R I I ( N OTE4) I c R I R R I I I I c R I c R I R R I I I I c R I I ( N OTE5) I I I I I I , L EVERY 500mi (80 0 km ) I I I I R I I I I I I I I I I I I I I I I I I I I I I I I I I I I I R E F E R TO R I R R I I R I PAG E 3-6 3-6 3-7 3-7 3-8 3-8 3-8 2 -4 2-5 3- 1 0 3- 1 1 3- 1 1 3- 1 2 I 3- 1 3 R I I I I I I I I I I 3-1 3 3- 1 5 3- 1 6 3- 1 6 3- 1 7 3- 1 8 3- 1 8 3- 1 9 3- 1 9 3-20 3-20 3-2 1 c * S H O U LD B E S E RVICED BY YO U R AUTH O R IZ E D H O N DA D EALE R , U N LESS TH E OWN E R HAS P R O P E R TOO LS AN D S E RV I C E DATA AN D IS M EC H AN I CALLY QUALI F I E D . * * I N TH E I NT E R EST O F SAF ETY , W E R E CO M M E N D THESE ITEM S B E S E RVI C E D O N LY BY YO U R AUTH O R IZ E D H O N DA D EALE R . N OTES : 1 . At higher odometer readings, rep eat a t the frequency interval established here . 2 . Service more frequently when riding in u nusually wet or d u sty a reas . 3 . Service more frequently when rid i n g in rain or at fu ll throttle . 4 . California type only . 5 . Replace every 2 years , or at indicated odometer interva l , whichever comes first . Replacement requ i res me­ chanical skill . 3-5 MAI NTENAN C E FUEL LI N E Remove the seat . Check the fuel li nes for deterioration, damage or leakage . Replace the fuel l ines if necessary . F U E L F I LTER Pul l the fuel filter out, clip the inlet line closed and remove the filter. Replace the fuel filter with new one, if necessary (page 4-3 ) . TH ROTTLE O P E RATION Check for smooth throttle grip full opening and automatic full closing in all steering positions. C heck the throttle cables and replace them if they are deterio­ rated , kinked or damaged . Lubricate the throttle cables, if throttle operation is not smooth . M easure the free play at the throttle grip flange . FREE PLA Y : 2 - 6 mm ( 1 / 1 6 - 1 /4 in) 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 operatio n . Replace any damaged parts, if necessary. 3-6 t M A I NTENANC E CARBU RETOR CHOKE NOTE • C hoke knob operating friction can be adjusted by turning the adjuster. Check for smooth operation of the choke knob. Lubricate the choke cable and/or adjust the choke knob operat­ ing friction if operation is not smooth. To adjust the friction, pull the rubber cover away and turn the adjuster. Direction Friction A B Increase 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 for smooth operation of the choke knob. There should be no free play. Check the valve seat on the choke valve for damage. Reinstall the choke valve in the reverse order of removal . AI R CLEANER Remove the a i r cleaner housing cover bolt and cover. Remove the holder bolts and the air cleaner element. Replace the element i n accordance with the maintenance schedule. Also, replace the element any time it is excessively dirty or damaged . 3- 7 MAINTENANCE CRAN KCASE BREATHE R The crankcase breather drain tube i s behind the left frame pipe and front cylinder head . Pull the drain tube out of the frame clamp. Remove the drain plug from the tube to empty any deposits . Reinstal l the drain plug. NOTE • Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned . Service if the deposit level can be seen i n the transparent section of the drain tube. (1 ) SPARK PLUGS PLUG GAP 0 . 8 - 0 . 9 mm (0.03 1 - 0.035 in) Disconnect the spark plug cap and remove the spark plugs. ( 3 ) CENTER ELECTRODE RECOMMENDED SPARK PLUG : Standard For cold climate ( below 5 ° C/4 1 ° F) For extended high speed driving NGK NIPPON DENSO DPR8EA-9 X24EPR-U9 DPR7 EA-9 X22EPR-U 9 DPR9EA-9 X27EPR-U 9 Measure the spark plug gap with a wire-type feeler gauge . S PARK PLUG GAP: 0 . 8 - 0 . 9 mm (0.03 1 - 0 . 035 in) Adjust by bending the side electrode carefully. With the plug washer attached, thread each spark plug i n by hand to prevent c rossthreading . Continue tightening by hand until the spark plug bottoms. Then, tighten the spark plugs a nother 1 /2 turn with a spark plug wrench to compress the plug washer. Connect the spark plug caps. VALVE CLEARANCE NOTE • I nspect and adjust valve clearance while the engine is cold ( below 3 5 ° C/9 5 ° F) . Remove the following parts : - fuel tank ( page 4-3) - air cleaner housing (page 4-4) - air cleaner chamber and intake duct. 3 -8 • (2) SIDE ELECTRODE MAINTENAN CE 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. F R O N T C Y L I N D E R H EA D 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. I nspect the clearance of all three valves by inserting a feeler gauge between the adjusting screw and the valve . VALVE CLEARANCES : Intake : 0 . 1 5 ± 0 . 02 mm (0.006 Exhaust : 0 . 20 ± 0 . 02 mm (0.008 ± ± 0 . 0008 in) 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 0790 8 - K E90000 N ot ava i lable i n U . S . A . 07908- K E 9 0 1 00 TORQUE : 23 N · m ( 2 . 3 kg-m, 1 7 ft-lbl Apply oil to the nut and bolt threads. 3- 9 MAINTENANCE R E A R C Y L I N D E R H EA D Rotate 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 0-rings of the valve adjusting covers ( I N/EX) for damage and replace if necessary . I nsta l l the front and rear valve adjusting covers. Apply g rease 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 ft-lbl Crankshaft hole cap: 1 5 N•m ( 1 . 5 kg-m, 1 1 ft-lb) CARBU RETOR SYNCH RON IZATION N OTE • Perform this maintenance with the engine at normal operat­ ing temperature . Remove the fuel tank mounting bolt. Carefully raise the tank and support it in the frame using a suitable base (see page 39) . . Remove the air cleaner case ( page 4-4) . Remove the plugs from the cylinder intake ports and install the vacuum gauge adaptors as shown . 1l Connect the vacuum gauge. TOOL: Vacuum gauge 07404 - 0030000 N ot ava i lable in U . S . A . 07 LMJ - 0 0 1 OOOA Warm up the engine and adjust the idle speed with the throttle stop screw. I DLE SPEED: 1 , 200 3- 1 0 ± 1 0 0 rpm VAC U U M GAUGE M A I NTENANC E Check that the difference in vacuum readings is 40 mm ( 1 . 6 i n ) Hg or less. NOTE • The rea r cylinder carburetor is the base carburetor . If necessary, synchronize t o t h e specification b y turning the synchronization adjusting screw. Recheck the idle speed and synchronization. Disconnect the gauge and adaptors and install the removed parts . CARBU RETOR I DLE SPEED NOTE • • Inspect and adjust idle speed after all other engine adjust­ ments are within specifications . The engine must be warm for accurate adjustment . Ten m inutes of stop-and-go riding is sufficient. Warm up the engine, shift to N EUTRAL, 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 ± 1 00 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 " U P" 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 . 3- 1 1 MAI NTENAN C E COOLI NG 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. .. llllf ·-- --- --· -- . - Make sure the hoses are in good condition . Replace any hose that shows any sign of deterioration. Check that all hose clamps are tight. (1 l CYLI N DER COM P R ESSION Warm up the engine. Stop the engine and remove the spark plug. Connect a compression gauge. Turn the engine stop switch OFF. O pen 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 ± 98 kPa ( 1 3 . 5 ± 1 . 0 kg/cm2, 1 92 ± 1 4 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- 1 2 RESERVE TAN K ( 2 ) RADIATOR MAINTENAN CE EVAPORATIVE EM ISSION CONTROL SYSTEM (California model only) Check the hoses between the fuel tan k,evaporative emission canister,evaporative emissio n purge control valve(EVAP PU R G E CONTRO L VALVE),evaporative emission carburetor air vent control valve(EVAP CAV C O NTRO L VALVE),and carbu retor for deterioration,damage o r loose connections. ( 1 )EVAP CAN I STER Also check the tubes for clogging due to bending or twisting. Check the evaporative emissio n canister for cracks deterio­ ration,or other damage. Refer to the vacuu m h ose routing diagram label for hose connections. VACUIII HOSE ROUTI NG DIAGRAM ENGINE FAMILY-c=� EYAI'tiiAT IVE FAMILY-c=:_._ . .=::J CALl FDRIIIA VEHICLE DRIVE CHAIN CHAIN SLACK INSPECTION • Never inspect or adjust the drive chain while the engine is run­ ning. Turn the ignition switch off, su pport the motorcycle on its stand, and shift the transmission into n e utr a l . side Check slack in the d rive chain lower run midway between the sprockets . SLACK: 20 - 30 mm (3/4- 1 -3/ 1 6 in) "' CHAIN ADJ USTMENT Loosen the axle nut . Loosen both lock nuts and turn both adjusting bolts as neces­ sary. Make sure the index m arks on both the adjuster collars are aligned with the corresponding scale grad uations on both sides of the swingarm . Tighten both lock nuts, then tighten the rear axle nut. TORQUE: 90 N•m (9.0 kg-m, 65 ft-lb) 3- 1 3 MAINTENANCE Recheck chain slack and free wheel rotation . Lubricate the d rive chain with Pro Honda Chain Lube o r equiv­ alent chain l ubrica nt designed specifically for use on 0-ring chains . Check the chain wear label. If the red zone on the label aligns with the arrow mark of the chain adjuster after the chain has been adjusted , the chain must be replaced . REPLACEMENT CHAI N : R K525 S M 5 0 1 0525 VB L U B R I CATI O N A N D C LE A N I N G When the drive chain becomes extremely dirty, i t should be cleaned prior to lubrication. Clean the drive chain with a non-flammable or high flash point and wipe dry. (1) W I PE D RY The d rive chain on this motorcycle is equipped with small 0rings between the link plates . The 0-rings can be damaged by stea m cleaners, high pressure washers and certain solvents . Lubricate the d rive chain with Pro Honda Chain Lube or equiv­ alent chain l ubricant desig ned specifically for use on 0-ring chains . C H A I N R E PLAC E M E N T The VT600C uses a drive chain ( 1 20 pins) with a staked master link. Loosen the drive chain (page 3- 1 3 ) . 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 M R 1 0 1 03 N ot ava i l a b l e i n U . S . A . 07 H M H - M R 1 0 1 0B - NOTE • When using the special tool, follow the manufacturer ' s op­ erating instructions. (1) SWINGARM CAUTION • Never reuse the old drive chain, master link, master link plate and 0-rings. REPLACEMENT CHAI N : RK525 SM 5 0 1 0 52 5 VB I nstal l the new drive chain through the swingarm as shown. 3- 1 4 (2) D RIVE CHA IN MAINTENANCE Assemble the new master link, 0-rings and plate . (2) 0-RINGS CAUTION • Insert the master link from the inside of the drive chain and in­ stall the plate with the identification mark facing the outside. Make sure that the master link pins are installed properly. Measuring the master link pin length projected from the plate. Standard length: R K: 1 .2-1 .4 m m (0.05 -0.06 i n ) MASTER LI N K D I D : 1 . 1 5-1 . 5 5 mm (0.05 -0.06 i n ) Stake the master link pins using the special tool. Make sure that the pins a re staked properly by measuring the diameter of the staked a rea using a slide calipers. D I A M ET E R OF (4) D R IVE CHAI N CUTIER ( 1 ) SLI DE CALI PER 1m (5) STAN DAR D LEN GTH L (2) GOOD TH E STA K E D A R EA: 5.50-5.80 m m (0.2 1 7-0.228 i n ) After staking, check the staked area of the master link for cracks. If there is any cracking , replace the master link, 0-rings and plate . (3) N O G O O D ( 4 ) CRACKED CAUTION • Drive chain with clip-type master link must not be used. D R I V E A N D D R I V E N SPRO C K ET Inspect the sprocket teeth for excessive wear or damage . Re­ place if necessary . NOTE • Never install a new d rive 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. (2) NORMAL I BRAKE FLU I D Check the front brake fluid through the sight glass; if the level is visible, remove the cover, set plate and diaphrag m . Fill the reservoir to the upper level with DOT 4 fluid from a sealed con­ tainer. Check the system for leaks. CAUTION • • • • Do not remo ve 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 allo w foreign material to enter the system when filling the reservoir. A void spilling the fluid on painted, plastic or rubber parts. Place a rag o ver these parts whenever the system is serviced. Refer to section 14 for brake bleeding procedures . 3- 1 5 MAINTENAN C E BRAKE SHOE/ PAD WEAR BRAKE PAD W E A R '88 , '89 , '9 1 -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 1 4-5) . CAUTION A lways replace the brake pads as a set to assure even disc pres­ sure. • After '93 : I nspect 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 (page 1 4-5 ) . CAUTION • A lways replace the brake pads as a set to assure even disc pres­ sure. B R A K E S H O E I N S P E CT I O N Replace t h e brake shoes i f the arrow on t h e brake a r m aligns with the reference mark " !::." on full application of the rear brake pedal. BRAKE SYSTEM I nspect the brake hoses and fittings for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required . BRAKE P E D A L H E I G H T Adjust the brake pedal so that the pedal height is 43 mm ( 1 . 7 in) above the top of the footpeg . 3- 1 6 MAINTENANCE To Adjust : Loosen the stopper bolt lock nut and turn the stopper bolt . Retighten the lock nut . NOTE • After a djusting the brake pedal height, check the rear brake light switch and brake pedal free play and adjust if neces­ sary. B R A K E P E D A L F R E E P LAY NOTE • Perform brake pedal free play adjustment after adjusting brake pedal height. Check the brake pedal free play. t 20 - 30 mm ( 3/4 - 1 - 1 /4 in) FR EE PLAY : 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 l ight switch operation and adjust if necessary. B RAKE LIGHT SWITCH N OTE • • 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 . 3- 1 7 MAINTENANCE HEADLIGHT AI M ( 1 ) HORIZONTAL ADJUSTING SCREW Adjust vertically by turning the vertical adjustment screw . Adjust horizontally by turning the horizontal adjusting screw . NOTE • • Adjust the headlight beam as specified by local laws and regulations. A n improperly adjusted headlight may blind oncoming drivers, or it may fail to light the road for a safe distance. (2) VERTICAL ADJUSTING SCREW ---- CLUTCH SYSTEM Measure the clutch lever free play at the lever end. FREE PLAY : 1 0 - 20 mm (3/8 - 3/4 in) i ( 1 ) 1 0 - 20 mm ( 3/8 - 3/4 in) Minor adjustments are made with the upper adjuster. Pul l 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 . \ ( 1 ) U PPER ADJ U STER I "" L . After'9 5 : M ajor 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 . ( 1 ) LOWE R ADJ U ST E R 3- 1 8 MAI NTENANCE SI DE STAND Check the spring for damage o r 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 1 . 0 kg-m, 7.2 ft-lbl NUT: 30 N•m (3.0 kg-m, 22 ft-lbl Check the side stand ignition cut-off system : - Sit astride t h e motorcycle and raise t h e side stan d . - Start t h e engine with t h e transmission in neutral , t h e n shift the transmission into gear, with the clutch lever squeezed . - Move the side stand full dow n . - The engine should stop as t h e side stand is lowered . If there is a problem with the system , check the side stand switch (section 1 6 1 . 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 a l l nuts and bolts to the specified torque value. • D o n o t ride a vehicle with faulty suspension. Loose, worn, or damaged suspension parts may affect stability and rider con­ trol. 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 a l l nuts and bolts to the specified torque value. 3- 1 9 MAI NTENAN C E N UTS, BOLTS, FASTEN ERS Tighten the bolts, nuts and fasteners at the i ntervals shown in the Maintenance Schedule (page 3-3 ) . Check that a l l chassis nuts and bolts are tightened t o their cor­ rect torque values ( page 1 -5 , 6 and 7 ) . Check a l l cotter pins and safety clips. WHEELS/TI RES TI R E P R E S S U R E NOTE • Tire pressure should be checked when the tires are COLD . Front Rear 1 00/90- 1 9 5 7 S 1 70/80- 1 5 7 7 S Tire size C o l d tire pressures kPa ( kg/cm2, psi) Up to vehicle 200 ( 2 . 00, 29) 2 50 ( 2 . 50, 36) capacity load U p to 90 kg 200 ( 2 .00, 29) 200 ( 2 .00, 29) (200 lbs) load Maximum weight capacity 1 61 kg ( 3 5 5 lbs) Tire brand Bridgestone Dunlop L 3 09 F24 G 546 K555 Check t h e tires for cuts, imbedded nails, or other sharp ob­ jects . Check the front and rear wheels for trueness ( Section 1 2 and 13). 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: 1 . 5 mm (0.06 in) Rear: 2.0 mm (0.08 in) Tighten the wheel spokes periodically. TORQUE (front/rear) : 4 N•m ( 0 . 4 kg-m , 2 . 9 ft-lb) TOOL: Spoke wrench 3 -20 07JMA - MR601 00 N ot ava i l a b l e in U . S . A . ( 1 ) SPO K E M AI N T E N A N C E STE ER I N G H EAD BEAR I NGS NOTE • Check that the control cables do not interfere with handle­ bar rotatio n . Raise t h e front w heel 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 1 2 ) . 3-2 1 FUEL SYSTEM 1 9 N ·m ( 1 . 9 kg-m, 1 3 . 7 ft-lbl 4-0 4. FU EL SYSTEM S ERV I C E I N FO RMATIO N 4- 1 CARBU R ETO R I NS TALLATIO N 4- 1 5 T RO U BLESHOO T I N G 4-2 PILO T S C R EW ADJ USTMENT 4- 1 5 F U EL TAN K 4-3 A I R CLEAN ER H O U S I N G 4-4 H I G H ALTIT U D E ADJ USTMENT ( U . S . A . ONL V) 4- 1 6 CARB U R ETO R REM OVAL 4-6 CAR B U R ETO R D I SASS E M BL V 4-6 CA R B U R ETO R ASS E M B L V 4- 1 0 CARB U R ETO R S E PA RATIO N / ASS E M B L V 4- 1 3 EVA P O R AT I V E E MI S S I O N PU R G E CO NT RO L VALVE I N S PECTIO N ( California model only) 4- 1 6 EVA P O R ATIVE E M I S S IO N C A R B U R ETO R A I R VENT CO NTRO L VALVE 4- 1 7 I NS PECTIO N ( Californ ia model only) SERVICE I N FORMATIO N • • 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. G E N ERAL • • • • • Refer to Section 3 for carburetor synchronization, throttle cable and choke cable adjustments . When d isassembling fuel system parts, note the locations of the 0-rings; replace them with new ones on reassembly . The carburetor float chambers have d rain screws that can be loosened to drain residual gasol ine . For fuel pump refer to section 1 8 . All hoses used in the evaporative emission control system are numbered for identification . When connecti ng one of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label on page 4- 1 6 (California model only) . for its routing. CAUTION • Do not bend or twist control cables. Damaged control cables will not operate smoothly and may stick or bind. N OTE • If vehicle is to be stored for more that one month , drain the float bowls. Fuel left in the float blowls will cause clogged jets resulting in starting and drivability complaints . S P E C I F I CATI O N S Item 49 Type Throttle bore Identification No. Float level Main jet Slow jet Idle speed Throttle grip free play Pilot screw initial opening 34 7.0 Front : California model St. model mm Constant Vacuum dual carburetor 34 mm in) ( 1 .4 VDFDA mm ( 0 . 2 8 i n ) # 1 1 5, Rear: 2-6 mm ± 1 00 in) VD FEA 7 . 0 mm ( 0 . 2 8 i n ) Front : # 1 1 5, Rear: # 1 #1 1 5 15 #40 #40 1 , 200 ( 1 .4 rpm ( 1 / 8 - 1 /4 1 , 200 in) 2-6 mm ± 1 00 rpm ( 1 /8 - 1 /4 in) See page 4-15. 4- 1 Ill F U E L SYSTEM TO R Q U E VA LU E Fuel tank mounting bolt 1 9 N•m ( 1 . 9 kg-m , 1 3 . 7 ft-lb) TOOLS Special Vacuum/Pressure pump Pressure pump Vacuum pump Valve guide driver, 7 mm A937X - 04 1 - XXXXX or ST - AH- 2 5 5 - M C 7 ( U S A . only) ST - AH - 260 - M C 7 ( U . S A . only) 07942 - 8230000 ( U . S A. only) . . . . Common Float level gauge 0740 1 - 00 1 0000 TROU BLESHOOTI NG 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 Misfiring during acceleration • Backfiring • • • • • • • • • • • 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 operatio n . • • • • • • • • Faulty ignition system Incorrect idle speed Incorrect valve clearance (Section 3 1 Incorrect carburetor synchronization Faulty carburetor Fuel contaminated Faulty air cut off valve (California model only : ) : Fau lty evaporative em ission purge control valve : Fau lty evaporative em issio n carbu retor air vent control valve : Worn/damaged emission system hoses Afterburning during deceleration • • • Faulty ignition system Faulty air cut off valve Lean mixture (California model only : ) : Worn/damaged emission system hoses 4- 2 Clogged fuel system Faulty ignition system Dirty air cleaner (California model only : ) : Faulty evaporative emissio n carbu retor a i r vent control valve : Warn/damaged emission system hoses Lean mixture Rough idle • Faulty ignition system faulty carburetor Poor performance (driveability) and poor fuel economy • Hard starting or stalling after starting Faulty ignition system • • Clogged fuel jets Stuck vacuum piston Faulty float valve Low float level Clogged fuel tank breather Clogged fuel strainer Restricted fuel line I ntake air leak Restricted or faulty fuel pump Rich mixture • • • • Clogged air jets Faulty float valve Float level too high Dirty air cleaner F U EL SYSTEM FUEL TAN K ( 2 ) FUEL TAN K MOUNTING BOLT REMOVAL • 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. 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 (t o canister: California model only) . Check that fuel flows out of the fuel valve freely. If flow is restricted , clean the fuel strainer. Remove the fuel tank from the frame. I N STALLAT I O N Install the fuel tank in the reverse order o f remova l . Install t h e f u e l valve knob onto t h e fuel valve as shown a n d tighten t h e bolt . . Tighten the fuel tan k mounting bolt securely. ( 1 ) FUEL TAN K (3) F U E L STRAINER SCREEN (5) FUEL FILTER N OTE � The fuel filter with its narrow pointing toward the outside . • l1i< � �($., ' � t. (8) TO FUEL PU MP � � rt. ( 9 ) TO CARBU R ETOR � The fuel pipe joint with its nar­ 171 FUEL VALVE K N O B NOTE . ( 2 ) FUEL PIPE JOINT i . _ • row end toward outside . 4-3 FUEL S YSTEM AI R C LEA N ER HOUSING REM OVAL Remove the fuel tank mounting, and lift the tank and remove the air cleaner housing mounting bolts . Loosen the air cleaner housing -to-air cleaner chamber band . Disconnect the crankcase breather tube from the air cleaner housi ng. I N STALLATI O N Wipe clean the mating surfaces shown and apply a cemment (or equivalent) . I nstall the removed parts i n the reverse order of removal . S U B-A I R C L E A N E R E L E M E N T Remove t h e fol lowing : - seat (page 1 3- 1 8) and fuel tank (page 4-3) - air cleaner housing Disconnect the air hoses (carburetors-to-sub-air cleaner cov­ er) . Remove the sub-air cleaner mounting bolt and cover and remove the element. 4-4 � ( 1 ) A I R CLEAN ER H O U S I N G� " MOUNTING BOLTS 1""'"' ' F U E L SYSTEM Wash the element in non-flammable or high flash point sol­ vent, squeeze out the solvent thoroughly, and allow the ele­ ment to dry. Soak the element in gear oil (SAE #80 - 90) and squeeze out the excess . Reinstal l the element and cover, and tighten the bolt. Reconnect the air tubes from the carburetors . ¢�¢ ! (1 ) WASH I N SOLVENT (2) (3) DRY ¢ �¢� � ! J t (4) (5) S Q U E EZ E O U T GEAR O I L S Q U E EZ E OUT SOLVENT (SAE #80 - 90 1 EXCESS O I L T H O R O U G H LY A I R C L EA N E R C H A M B E R R E M OV A L/ I N STA LLAT I O N Remove t h e air cleaner housing and sub-air cleaner element ( page 4-4 ) . Loosen t h e intake duct hose b a n d s a t t h e carburetors and unhook the air cleaner chamber drain tube from the frame . Remove the air cleaner chamber from the frame . To reinstal l the chamber: position it i n the frame, and connect the i ntake ducts to the carburetors and tighten the band screws . I nstall the sub-element and cover ( page 4-4) . I nstall the air cleaner housing (page 4-4) . -----( 8 ) PLUG (3) (6) A I R CLEA N E R H O U S I N G HOLDER 4- 5 FUEL SYSTEM CARBURETOR REMOVAL • 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. Loosen the drain screws and drain the fuel into a container. 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. Disco n nect the evaporative emission p u rge control valve No.5 tubes and evaporative emission carburetor air vent control valve No.6 and 1 0 tubes from the carburetor (California model only) . Pull the carbu retors the u pward and out of the engine. CARBURETOR DISASSEM BLY NOTE • The carburetors can be disassembled without being sepa­ rated . Remove the air tubes (carburetors-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. VAC U U M C H A M B E R Remove the four screws a n d vacuum chamber cover. 4-6 . (2) C H O K E CABLE LOCK ' FUEL SYSTEM Remove the spring, and diaphragm/vacumm piston. Inspect the vacuum piston for wear, nicks, scratches or other damage. ( 1 I D IAPHRAG M/PISTON (2) SPRING Make sure the piston moves up and down freely in the cham­ ber. Push the needle jet holder in and turn it in 90 degrees counter­ clockwise. (1 I Then remove the needle holder, spring, jet needle and washer from the piston . Inspect the needle for excessive wear a t the tip, bending or other damge . Inspect the diaphragm for damage, fatigue or pin holes. Inspect the vacuum piston for wear or damage. (1 N EEDLE J ET HOLDER ( 2 ) J ET (3) HOLDER N EEDLE I (4) SPRING FLOAT CHAMBER, FLOAT AND JETS Remove the four screws and float chamber. 4- 7 F U E L 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. (2) Check each part for wear or damage . Blow open all jets with compressed air. Clean each jet 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 u nless the carburetors are overhauled . The pilot screw plugs are factory i nstalled to prevent pilot screw misadjustment. Do not remove the plugs unless the pilot screws are being removed. Cover all openings with tape to keep metal particles out when the plugs are drilled . 4-8 / lt. � ow • ( 5 ) F I LTER (4) VALVE SEAT �' · /'' ' ,.., SLOW J ET (3) MAIN J ET FUEL SYSTEM Center punch the pilot screw plug to center the drill point. Drill throug h the plug with a 4 mm ( 5/32 in) drill bit. Attach a drill stop to the bit 3 m m (1/8 i n ) from the end to prevent drilling into the pilot screw . CAUTION • • Be careful not to drill into the pilot screw. Both pilot screws must be replaced even if only one requires it, for proper pilot screw adjustment (page 4-15). Force a self-tapping 4 mm screw, P/N 93903 - 3 5410) i nto 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 p ilot screw area and remove metal shavings. Turn each pilot screw in and carefully count the n umber of turns until it seats lightly. Make a note of this to use as a refer­ ence when reinstalling the pilot screws . CAUTION • Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. Remove the pilot screws and inspect them. Replace them if they are worn or damaged . 0 (4) / WASHER (3) PILOT SCREW / � A I R C U T O F F V A LV E Remove t h e two screws, t h e set plate and t h e air cut off valve cover. NOTE • The air cut off valve cover is under spring pressure. Do not loose the spring and screws. 4-9 FUEL SYSTEM 0-RING Visually check the following : - 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. - 0-ring for damage. (3) DIAPHRAG M Replace the air cut off valve as an assembly, if necessary. (4) cl / S PR I N G Separate the carburetors ( page 4- 1 3 ) . Blow open all passages with compressed air before i nstalling jets and valves . CARBU R ETOR ASSEMBLY ( 5 ) HOLDER ( 1 4) PISTON ( 1 5) FLOAT ( 1 3) FLOAT CHAMBER --:-i�� ( 1 2) VALVE ( 1 0) SLOW JET SEAT 4- 1 0 (9) A I R-CUT VALVE COVER F U E L SYSTEM ER P I LOT S C R EW · I nstall the pilot screws and return them to their original posi­ tion as noted during remova l . Perform pilot screw adjustment if n e w 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 i n one carburetor, you must replace the pilot screw in the other carburetor for proper pilot screw adjustment. (3) PILO T SCREW 1 / (4) SPRING FLOAT C H A M B E R , F LOAT A N D J ETS I nstall the pilot screw and turn it i n until it seats lightly. Turn the pilot screw out the number of turns recorded during remova l . CAUTION • Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. I nstall the valve seat, slow jet, needle jet holder and main jet. Install the float with float valve i n the carburetor body, then in­ stall the float arm pin through the body and the float. GAUGE FLOAT L E V E L Measure the float level with the float tang just contacting the float valve. TOOL: Float level gauge 0740 1 - 00 1 0000 FLOAT LEVEL: 7 mm (0.28 in) Adjust the float level by carefully bending the float tang . 4- 1 1 FUEL SYSTEM I nstall the 0-ring on the float chamber groove. I nstall the float chamber and tighten the screws securely . NOTE • I nstall the fuel tube clamp. VAC U U M CHAM B E R I nstall t h e washer, jet needle, spring and needle holder t o the vacuum piston. Push the jet needle holder i n and turn it in 9 0 degrees cloc­ kwise . Hold vacuum piston u p to almost full open to avoid pinching the diaphragm with the chamber cover. (1 l The vacuum piston with the tab of the diaphragm aligned with the groove of the carburetor. I nstall the chamber cover with the spring, aligning the cover cavity with the hole i n the carburetor, and secure with at least two screws before releasing the vacuum piston. 4- 1 2 J ET NEEDLE HOLDER ( 2 ) CAVITY (4) F I N G E R FUEL SYSTEM Install the right choke valve and choke knob. · ·� · (21 Install the fuel and air tubes as shown. CHOKE KNOB ( 1I . ....-....... FUEL TUBE;:,p:s .lib CARBU RETOR SEPARATIO N / ASSEM BLY SEPARATION Loosen the synchronization adjusting 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. (2) SYNCHRON IZATION SPRING . .. 4- 1 3 FUEL SYSTEM ASSEMBLY 111 THRUST SPRING loosen the synchronization adjusting screw until there is no spring tension. Install the thrust spring between the throttle links. Secure the carburetors together with the two screws. - Install the synchronization spring and synchronization adjust­ ing screw. 121 SYN C H RON IZATION ADJUSTING SCREW Inspect throttle operation a s described below : • Open the throttle slightly by rotating the throttle valve, then release the throttle. M ake sure that there is no drag when opening and closing the throttle. Turn the throttle stop screw to align the rear cyli nder carbure­ tor throttle valve with the edge of the by-pass hole. (2) Align the front cylinder carburetor throttle valve with the by­ pass hole edge by turning the synchronization adjusting screw. Make sure the throttle returns smoothly. 4- 1 4 (1 ) THROTTLE STOP SCREW SYN C H RO N IZATION ADJUSTIN G REW FUEL SYSTEM CARB U RETOR I NSTALLATION I nstall t h e carburetors onto the cylinder heads a n d tighten the insulator bands securely. I nstal l the following parts - air cleaner chamber - air cleaner housing - fuel tank - throttle cables Adjust as follows: - pilot screw ( page 4- 1 51 - carburetor synchronization ( page 3- 1 0 ) . - throttle grip free play ( page 3-6 ) - carburetor idle speed ( page 3- 1 1 ) - carburetor choke ( page 3-7 ) 0 0 0 P I LOT SCR EW ADJ USTM ENT I D L E D R O P P R O C E D U R E ( U . S . A . O N LY l NOTE The pilot screws are factory p re-set and no adjustment is necessary u nless the pilot screws are replaced . Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate a 50 rpm change . • • Remove the pilot screw plugs ( page 4-8) Turn each pilot screw clockwise until it seats lightly and back it out to the specification give n . 1. 2 0 o CAUTION Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. • This is an initial setting prior to the final pilot screw adjust­ ment. I NITIAL OPENI N G : 1 - 1 /4 turns out 3 . Warm u p the engine to operating temperature . Stop and go driving for 1 0 minutes is sufficient. 4 . Attach a tachometer according to the manufacturer ' s in­ structions . 5 0 Adjust the idle speed to the specified rpm with the throttle sto p screw . I D LE S P E E D : 1 , 200 ± 1 00rpm 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 u ntil engine speed does not increase 0 8 Adjust the idle speed with the throttle stop screw . 9 . Turn the rear cylinder carburetor pilot screw i n until the engine speed drops 50 rpm . 1 0 . Turn the rear cylinder carburetor pilot screw 1 turn out from the position obtained in step 9 1 1 Adjust the idle speed with the throttle stop screw. 1 2 Perform steps 9, 1 0 and 1 1 for the front cylinder carbu­ retor pilot screw 1 3 0 Drive new pilot screw plugs i nto the pilot screw bores with a 7 mm valve guide driver (P/N 07 942 - 8230000 ) . W h e n fully seated the plug surfaces w i l l b e recessed 1 mm. 0 0 0 0 o 0 ( 1 I PLUG 4- 1 5 F U E L SYSTEM H IGH ALTITUDE ADJ USTM ENT (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 d riving for 1 0 minutes is sufficient. Turn each pilot screw to the specification below . H I G H ALTITU D E S ETTI N G : 1/2 Turns in Adjust the idle speed to 1 , 2 00 ± 1 00 rpm , with the th rottle stop screw . Drive new pilot screw plugs i nto the pilot screw bores ( page 41 5) . NOTE This adjustment must be made at high altitude to ensure proper high altitude operation . � LE E M ISSION CONTROL I N FOR MATI O N UP DATE LAB E L • Attach a Vehicle Emission Control I nformation u p date label o nto the inside of the left side cover as shown.See S L# 1 3 2 for information on o btaining the label. NOTE Do not attach the label to any part that can be easily re­ moved from the vehicle. • VEHICLE EMISSION CONTROL INFORMATION UPDATE • HONDA MOTOR CO., LTD THIS VEHICLE HAS BEEN ADJUSTED TO IMPROVE EMISSION CONTROL PERFORMANCE WHEN OPERATED AT HIGH ALmUDE. � � �. ALmuDE PERFORMANCE ADJUSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER. •·'·'5111¥1d Sustained operation at an altitude lower than 1, 500 m (5, 000feet) with the carburetors adjusted for high alti­ tude may cause the engine to idle roughly and engine may stall in traffic and may cause engine damage due to overheating. • When the vehicle is to be operated continuously below 1 , 500m (5 , 000 feet), turn each pilot screw to the specificatio n below, its o riginal position . LOW A LTITU D E S ETTI N G : 1/2 turn out Adjust the idle speed to 1 , 2 00 ± 1 00 rpm with the th rottle stop screw . D rive 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 U pdate Label that attached to the inside of the left side cover after adjusti ng for the low altitude . EVAPORATIVE E M ISSION P U RG E CONTROL VALVE INSPECTION (Ca l iforn ia mod e l o n l y) NOTE The evaporative em1ss1o n p u rge control valve should be inspected if hot restart is d ifficult. • Check all fuel tan k, Evaporative Emission Purge Control Valve ( EVAP P U R G E CONTROL VALVE),and evaporative emission canister hoses to be su re they a re not kin ked and a re secu rely connected. Replace any hose that shows signs of damage or d eterioration. NOTE · The EVAP PU R G E CONTROL VALVE is located u nder the fuel tan k. 4- 1 6 VACUUM HOSE ROUTI NG DIAGRAM ENGI NE FAMI LY- ';:;-;-;-; ==---:: ------,:J EVAPORAT I VE FAMILY;r::: L =::: CAL l FORNIA VEHI C L E ____ "' ..: z w "0 EVAP CAN I ST E R MZS -930 F U E L SYSTEM Disconnect the EVAP P U R G E CONTROL VALVE hoses from their connections and rem ove the EVAP P U R G E CONTRO L VALVE from its mou nt. R efer t o the routin g label on the i nside of the left side cover for hose connections. Connect a vacuum p u m p to the 8 m m (0.3 1 in.) I . D.hose No.5 that goes to the 3-way joint.Apply the specified vacu u m to the EVAP PU R G E CONTR O L VALVE. ( 1 ) EVAPO RATIVE E M I S S I O N P U R G E CONT R O L VALVE SPECIFIED VACUUM: 250 mm (9.8 in) Hg The specified vacuu m should be m aintained. Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not maintained. TOOL: Vacuum/Pressure pump Vacuum pump A937X - 041 - XXXXX or ST - AH - 260- MC7 ( U .S.A. only) Remove the vacu um p u m p a n d con n ect it to the vacuum hose N o . 1 1 that goes to the left carbu retor body. Apply the specified vac u u m to the EVAP P U R G E CONTRO L VALVE. SPECIFIED VACUU M : 250 mm (9.8 in) Hg I I ( 1 ) VAC U U M PUMP The specified vacu u m should be maintained. Replace the EVAP PU R G E CO NTRO L VALVE if vacuu m is not maintained. TOOL: Vacuum/Pressure pump Vacuum pump \' \ � ( 5 ) T VAPO RATIVE E M I S S I O N CAN I STER ( 2 ) VACUUM PUMP (4) TO CARBU RETOR BODY A937X - 041 - XXXXX or ST - AH - 260- MC7 ( U . S.A. only) Con nect a p ressu re p u m p to the 8 m m (0.3 1 in. ) I . D .hose N o.4 that goes to the evaporative emission canister.While a pplying the specified vacu u m to the EVAP PU R G E CONTROL VALVE hose that goes to the 3-way joint p u m p air through the evaporative emission canister hose.Air shoud flow through the EVAP PU R G E CONTR O L VALVE and out the hose that goes to the 3-way joint. R eplace the EVAP P U R G E CONTROL VALVE if air does not flow out. CAUTION • To preven t damage to the evaporative emission purge con trol valve, do not use high air pressure sources. Use a hand operated air pump only. TOOL: Vacuum/Pressure pump Vacuum pump Pressure pump A937X - 041 - XXXXX or ST -AH - 260- MC7 ST -AH - 255 - MC7 ( U . S.A. only) ( 2 ) VACUUM PU MP R emove the p u m ps, i n stal l the EVAP P U R G E CONTR O L VALVE on its mount, route and reconnect the house accord­ ing to the routing label. EVAPORATIVE EM ISSION CARBU R ETOR AIR VENT CONTROL VALVE INSPECTION (Ca l iforn i a mod e l o n l y) D isconnect the Evaporative Emission Carburetor Air Vent Control Valve( EVAP CAV CONTR O L VALVE)hoses from their connections and remove the EVAP CAV CO NTRO L VALVE from its mou nt. R efer to the routing label on left side cover for hose connections. 4- 1 7 F U EL SYSTEM Connect a vac u u m pump to the No. 1 0 hose that goes to the rig ht carbu retor body. Apply t h e specified vacuum t o t h e EVAP CAV CONTR O L VALVE. SPECIFIED VACU U M : 250 mm (9.8 in) Hg TOOL: Vacuum/Pressure pump Vacuum pump A937X - 04 1 - XXXXX or ST - AH - 260 - MC7 ( U .S.A. only) The specified vacuu m should be maintained. Replace the EVAP CAV CONTRO L VALVE if vacuum is not maintained. (21 TO OPEN A I R ( 1 1 TO A I R J O I NT PIPE ( 3 ) EVAPO RATIVE E M I SS I O N N o . 6 HOSE CAR B U R ETO R AI R V E NT CONTROL VALVE (4) TO EVAPO RATIVE EM ISSION CAN I STER N o . 4 HOSE / ( 5 ) TO R I G HT CARBU RETOR BODY No. 1 0 HOSE CAUTION • To prevent damage to the evaporative emission carburetor air vent con trol valve, do not use high air pressure sources. Use 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. R eplace the EVAP CAV CONTRO L VALVE if vacuum leaks. TOOL: Vacuum/Pressure pump Vacuum pump A937X - 04 1 - XXXXX or ST - AH - 260 - MC7 ( U .S.A. only) Connect the vacuum pump to the No. 1 0 hose that goes to the right carb u retor body. Connect the pressu re pump to the air vent port of the EVAP CAV CONTROL VALVE. While a pplying the vacuu m to the EVAP CAV CONTR O L VALVE N o . 1 0 hose that goes t o t h e rig ht carburetor body, pump air through the air vent port. Air should flow through the EVAP CAV CONTROL VALVE and out the hose that goes to the carb u retor air joint pipe. TOOL: Vacuum/Pressure pump Vacuum pump Pressure pump A937X - 04 1 - XXXXX or ST - AH - 260 - MC7 ST - AH - 25 5 - MC7 ( U .S.A. only) Plug the hose that goes to the carburetor air joint pipe. While applying vacuu m to the EVAP CAV CONTROL VALVE No. 1 0 hose that goes to the rig ht carburetor body,apply air pressure. It should hold steady. R eplace the EVAP CAV CONTR O L VALVE if pressure is not retained. Remove the p u m ps,install the EVAP CAV CONTROL VALVE o n its mou nt,route and reconnect the hoses according to the routing label. TOOL: Vacuum/Pressure pump Vacuum pump Pressure pump 4- 1 8 A937 X - 04 1 - XXXXX or ST - AH - 260- MC7 ST - AH - 25 5 - MC7 ( U .S.A. only) c..,_,��' ( 6 1 VAC U U M PU M P M EMO COO L I N G SYSTEM 5-0 5. COOLI NG SYSTEM S ER VIC E I N FO RMAT I O N 5- 1 THERMOSTAT 5-3 T R O U BL ES HOO T I N G 5- 1 RADIATOR/CO O LING FAN 5-5 S Y S T E M TESTING 5-2 WATER P U M P 5-7 C O O LA N T REPLAC E M E N T 5-3 COO LANT/RESERVE TAN K 5-9 SERVICE I N FORMATION G E N ERAL • • • • • • • • Do not remove the radiator cap when the engine is hot. The coolant is under pressure and severe scalding could result. The engine m ust be cool before servicing the cooling system. 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. Use only distil led water and ethylene glycol in the cooling system. A 50 - 50 mixture is recommended for maximum corro­ sion protection. Do not use alcohol-based antifreeze . Add coolant at the reserve tank. Do not remove the radiator cap except to refi l l , coolant mixture testing or drain the system, or to test the coolant mixture. Avoid spilling coolant on painted surfaces . After servicing the system , check for leaks with a cooling system tester. For thermosensor and thermostatic switch removal and inspection, refer to section 1 8 . To service the water pump, the engine must be removed from the frame. S P E C I F I CAT I O N S ITEM SPEC I F I CATIONS Radiator cap relief pressu re Freezing point (Hydrometer test ) : Coolant capacity: Coolant change : Total system: 88 - 1 27 kPa (0. 9 - 1 . 3 kg/cm2, 1 3 - 1 8 psi) 55 % Distilled water + 45 % ethylene glycol: -32 ° C (-2 5 ° F) 50 % Distilled water + 50 % ethylene glycol: -37 ° C (-34 ° F) 45% Distilled water + 5 5 % ethylene glycol : -44. 5 ° C (-48 ° F) 1 .45 lit ( 1 . 3 7 U S qt, 1 . 28 Imp qt) 1 . 6 lit ( 1 . 5 1 US qt, 1 .4 1 Imp qt) Thermostat Begins to open: 80 ° to 84 ° C ( 1 7 6 ° to 1 83 ° F) Valve lift: Minimum of 8 m m at 9 5 ° C (0.3 in at 203 ° F) Boiling point (with 50 - 50 mixture ) : Unpressurized : 1 07 . 7 ° C (226 ° F) Cap on, pressurized : 1 2 5 . 6 ° C ( 2 58 ° F) TROUBLESHOOTI NG Engine temperature too high Faulty thermosensor bulb or sensor Thermostat stuck closed Faulty radiator cap I nsufficient coolant or coolant l evel too low Passages blocked in radiator, h oses or water jacket Cooling fan motor does not turn - Burned or loose sub fuse - Faulty fan motor - Faulty thermostatic switch - Poor connector contact or open circuit in harness Faulty water pump Engine temperature too low • • Faulty thermosensor bulb or sensor Thermostat stuck open Coolant leaks • • Faulty pump mechanical seal Deteriorated 0-rings 5- 1 COO LING SYSTEM SYSTEM TESTI NG C O O LANT M I XT U R E Remove the fuel tank (page 4-3) . Remove the steering covers by removing the bolt. Remove the radiator cap. • Be sure the engine is cool before removing the cap or you may be severely scalded. Test the coolant mixture with an antifreeze tester. For maximum corrosion protection, a 50- 50% solution of ethylene glycol and distilled water is recommended. RAD I ATOR 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 - 1 27 kPa (0. 9 - 1 . 3 kg/cm2, 1 3 - 1 8 psi) i � · - t . I ( 1 I RAD IATO R CAP SYSTEM PRES S U R E 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 125 kPa (1 . 25 kg!cm2, 18 psi) Repair or replace components if the system will not hold speci­ fied pressure for at least six seconds . 5-2 COOLING SYSTEM COOLANT R E P LACE M ENT • (2) REAR CYLINDER DRAIN BOLT The engine must be cool before replacing the coolant or severe scalding may 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 rea r cylinder coolant drain bolt and drain the collant using a vinyl as shown . Reinstal l the drain bolt. ( 1 ) DRAIN BOLT (3) VINYL Fill the system with 50 - 50 mixture of distilled water and eth­ ylene glyco l . Bleed a i r from t h e cooling system . Lower the side stand and shift the transmission into neutra l . Start 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 R E M O VAL 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 u pper radiator hose at the radiator and remove filler and the radiator hose from the frame. Remove the thermostat housing cover. 5-3 COOLI N G SYSTEM Remove the thermostat from the housing . I N S P E CT I O N ( 1 ) THERMOSTAT I nspect t h e thermostat visually for damage . Suspend the thermostat in heated water to check its opera­ tion. NOTE • If the thermostat or thermometer touches the pan, you ' l l 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 Valve lift 80° to 84 ° C ( 1 7 6 - 1 8 3 ° F) 8 mm (0.3 in) minimum when heated to 9 5 ° C (203 ° F) for five minutes . I N STALLAT I O N I nstall t h e thermostat into the housing . I nstall a new 0-ring on the housing cover and i nstall the hous­ ing cover onto the housing. 5-4 COOLING SYSTEM Tighten the thermostat housing cover mounting bolts . NOTE Be sure to secure the thermostat ground wire with the cover mounting bolt shown. I nstall a new 0-ring on the radiator filler, and connect the u pper radiator hose to the radiator. I nstall the radiator filler onto the thermostat housing. Tighten the filler and thermostat housing mounting bolts . Install the remaining removed parts in the reverse order of re­ mova l . F i l l t h e system with coolant. RADIATOR/COOLI NG FAN REM OVAL NOTE • For fan motor i nspection, refer to section 1 8 . Remove the steering cover and disconnect the fan motor con­ nector ( 2 P 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. 5- 5 COOLI N G SYSTE M U nhock the radiator mounts from the grommets from in frame. Unclamp the upper radiator hose and disconnect the hose from the radiator. D I SAS S E M B LY Disconnect the thermostatic switch wire connector from the switch and remove the wire from the clamp. Remove the ground wire terminal bolt. ( 1 ) G R O U N D "-.. TERM INAL /""' Remove the fan motor shroud mounting bolts, and remove the fan motor shroud and fan motor as an assembly. ( 2 ) WIRE CONN ECTO R ( 1 ) NUT Remove the nut to separate the fan from the shroud . ( 2 ) FAN Remove the fan motor mounting nuts and fan motor from the shroud. 5-6 COOLING SYSTEM A S S EM B LY Inspect the radiator soldered joints and seams for leaks. Blow dirt out from between core fins with compressed air. If insects, etc . , are clogging the radiator, wash them off with low pressure water. Carefully straighten any bent fins. I nstal l 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 in the reverse order of the disassembly. If removed the thermostatic switch from the radiator, refer to page 1 8-8. NOTE • Do not overtighten the thermostatic switch, when reinstall it. TORQU E : 1 8 N • m ( 1 . 8 kg-m , 1 3 ft-lb) . WATE R P U M P ME C H A N I CA L S E A L I N S P E C T I O N NOTE • The w ater pump cover and 0-ring can be removed with engine i n 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 0-ring and dowel pins from the water pump as­ sembly and disconnect the water hose . Remove the water pump from the crankcase. ( 3 ) WATER HOSE 5- 7 COOLING SYSTEM I N S P E CTI O N ( 1 ) 0-RING Check t h e water pump f o r mechanical seal leakage a n d bear­ ing deterioration. Replace the water pump as an assembly if necessary . (4) 0-RING I N STA L LAT I O N Apply a coat of clean engine oil to a new 0-ring and install it i n t h e water p u m p shaft housing groove . Align the water pump shaft g roove with the oil pump shaft and insert the water pump into the crankcase. Apply a coat of engine oil to a new 0-ring and install it around the impeller housing . I nstal l the two dowel pins. Connect the water hose with the clamp. I nstall the water pump cover and tighten the cover mounting bolts . Connect the water hose with the clamp. I nstall the engine in the frame (section 6 ) . Fill the system with coolant ( page 5-3 ) . Fill the engine with the recommended engine o i l (page 2-4) . Check the cooling system for leakage. 5-8 ( 2 ) WATER P U M P ASSEM BLY COOLI N G SYSTEM COOLANT / R ESERVE TANK (1 I G R O M M ET (21 TAB REMOVAL/INSTALLATION Raise and support the motorcycle rear frame using a hoist or jack u nder the engine. Remove the evaporative emission canister(California model only) . Place a clean container u nder the reserve tank. 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 u pright and remove the reserve tank from the frame. Empty the tank, if necessary. I nstall the reserve tank i n the reverse order of removal . Fill the tank with coolant, i f necessary. CAUTION • The tab of the reserve tank should be aligned with the grommet in the frame. 5-9 EN G I N E REM OVAL/INSTALLAT I O N � 2 5 N•m, ( 2 . 5 kg-m, 1 8 ft-lb) 2 7 N•m, ( 2 . 7 kg-m, 20 ft-lb) 6-0 6. ENG INE REMOVAL/ I NSTALLATION S ERVI C E I N F O RMAT I O N 6-2 E N G I N E R E M OVAL 6-3 6- 5 EN G I N E I N STALLATION Ill 5 5 N • m ( 5 . 5 kg-m, 40 ft-lb) 27 N·m (2. 7 kg-m, 20ft-lb) 6- 1 E N G I N E REM OVAL/ I N STALLATION SERVICE I N FO RMATION G E N E RAL • • • Support the motorcycle using a hoist, a floor jack or other adjustable support. The following parts can be serviced with the engine i nstalled in the frame: • • Alternator Clutch • • Starter motor Gearshift linkage • • Carburetors Camshafts • Front cylinder head/cylinder To service the water pump body, oil pump, and rear cylinder head/cylinder the engine m ust be removed from the frame. S P E C I F I CATI O N S Engine dry weight Oil capacity Coolant capacity 6 1 kg ( 1 34 lb) 2 . 8 l it ( 2 . 94 U S qt, 2.46 Imp qt) at disassembly 1 . 6 1it ( 1 . 5 1 U S qt, 1 .4 1 Imp qt) total TO R Q U E VALU E S Rear axle Shock 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 Rear upper engine mounting bolt Rear upper engine bracket bolt Exhaust pipe joint nut Fuel tank mounting bolt Exhaust muffler bracket bolt 6-2 90 45 12 40 90 55 27 55 55 27 25 19 27 N•m N•m N·m N•m N·m N·m N•m N·m N•m N•m N·m N•m N·m (9.0 (4. 5 ( 1 .2 (4.0 (9.0 (5.5 (2. 7 (5.5 (5.5 (2. 7 (2.5 ( 1 .9 (2. 7 kg-m , 65 ft-lb) kg-m , 33 ft-lb) kg-m , 9 ft-lb) kg-m , 29 ft-lb) kg-m , 65 ft-lb) kg-m , 40 ft-lb) kg-m, 20 ft-lb) kg-m, 40 ft-lb) kg-m, 40 ft-lb) kg-m , 20 ft-lb) kg-m, 1 8 ft-lb) kg-m , 1 3 . 7 ft-lb) kg-m , 20 ft-lb) E N G I N E REM OVAL/ I N STALLATION ENG I N E REMOVAL Support the motorcycle using a hoist or a jack. CAUTION • Do not jack up the engine at the oil filter. Drain the engine oil (page 2-4) and the radiator coolant (page 5-3 ) . Disconnect the battery negative cable from the battery termi­ nal . Remove the following: - fuel tank (page 4-3) - air cleaner housing (page 4-4) - air cleaner chamber ( page 4-4) - carburetor (page 4-6) - exhaust pipe protectors - exhaust pipe and muffle rs Loosen the drive chain ( page 3 - 1 3 ) . Remove the drive sprocket cover ( page 1 3- 1 4 ) . then remove the sprocket from the drive chain by removing the two sprock­ et bolts. Disconnect the oil pressu re and neutral switch wires from the switch terminals and free 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 moving the holder bolt. Remove the right foot peg and rear brake pedal by removing the two bracket mounting bolts. 6-3 EN G I N E REMOVAL/ I N STALLATIO N Disco n ncet the ignition pulse generator wire connector(4P WH ITE) . Remove t h e lower radiator hose ( radiator-to-water pump) . Disconnect the water hoses (thermostat housing-to-cylinder heads) from the cylinder heads ( page 9-3 ) . Place a floor jack o r other adjustable support under the engi ne. NOTE • The jack height must be continually adjusted to relieve stress for ease of bolt removal . Remove the following : - rear wheel (page 1 3-3) - swingarm (page 1 3- 1 4) - front upper engine bracket (two 8 mm bolts, 1 0 mm bolt and collar) - front lower engine bracket ( 8 mm bolts and 1 0 mm bolt) - rear engine bracket (two 8 mm bolts and 1 0 mm bolt) N OTE • Do not damage the radiator fin . 6-4 � �41 SWI N ARM PIVOT ., , ( 3 ) FRONT LOWER BOLT BOLT E N G I N E R E MO VAL/IN STALLATIO N ENG I N E I N STALLATION Engine insta l l ation is essentially the reverse order o f removal . Use a floor jack or other adjustable support t o carefu lly manuever the engine into place. CAUTION • Carefully align mounting points with the jack to prevent damage to m ounting bolt threads and wire harness and cables. NOTE • Be sure to i nstall the mounting collars and swingarm dust seals i n their correct positions. Tighten all the fasteners to the specified torque given on page 5-0, 1 and 2. ( 1 ) SWI NGARM LEFT S I D E COLLAR I -- NOTE • • • • Route the w i res and cables properly (section 1 ) . Fill the cran kcase to the proper level with the recommended oil (page 2 - 4 ) . Fill the cooling system (page 5-3) . Perform the following inspection and adjustments : Throttle operation ( page 3-6) . Clutch ( page 3- 1 8 ) . / ( 2 ) SWI NGARM RIGHT SIDE CO LLARS 6-5 CLUTCH/GEARS H I FT L I N KAGE 1 2 N · m ( 1 . 2 kg-m , 9ft-lb) - - - - - - - - - - - - - - - - - - - - - , After' 8 9 : 7 -0 ' , , ' ' ' ' ' ' ' 2 3 N · m (2 . 3 kg-m , 1 7ft-lb) ' ' ' ' ' ' ' ' ' ' After' 9 5 : ' ' 'I 7. CLUTCH/G EARSH I FT LI N KAG E S ER V I C E I N FO RMAT I O N 7-1 P RI MARY DRIVE G EAR 7- 1 1 T R O U B L ESHOOTI N G 7-2 CLUTCH I N STALLATION 7- 1 2 R I G H T C RANKCASE C O V ER R E MOVAL 7-3 C L U T C H REMOVAL 7-4 RIGHT CRANKCASE COVER I N STALLATION 7- 1 4 G EA RS H I FT L I N KA G E 7-8 S E RV I CE I N FORMATION G E N ERAL • 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. • If the shift fork, drum and transmission require servicing, remove the engine and separate the crankcase (section 1 1 ). • C oat the new clutch discs w ith clean engine oil before reassembly. S P E C I F I CAT I O N S U nit: mm (in) ITEM C l utch STANDARD Spring free length 39.0 ( 1 . 54) 3 7 . 4 ( 1 .47) 43 . 2 ( 1 . 70) 25. 2 5 - 27 . 2 5/2 6 . 2 kg/mm 2 . 62 - 2 . 7 8 (0. 1 03 - 0 . 1 07 ) 4 1 . 6 ( 1 . 64) 2 . 30 (0. 090) 2 . 92 - 3 .08 (0. 1 1 5 - 0. 1 2 1 ) 2 . 60 (0. 1 02) -- 0.30 ( 0 . 0 1 2 ) I. D. 2 1 . 9 9 1 - 22 . 0 1 6 (0.8658 - 0 . 8668) 2 2 . 09 (0. 870) O.D. 3 1 . 9 59 - 3 1 .025 32.000 - 32.025 32.000 - 32.025 2 1 . 967 - 2 1 . 980 3 1 . 98 ( 1 . 2 59) 3 2 . 1 0 ( 1 . 264) 3 2 . 1 0 ( 1 . 2 64) 88; After 88; Spring preload/length Disc thickness A 8 Plate warpage Outer guide Outer I . D . O i l pump d rive sprocket I . D . M ainshaft O . D . at clutch outer guide SERVICE LIMIT ( 1 . 2 582 - 1 . 2 589) ( 1 . 2 598 - 1 . 2608) ( 1 . 2 598 - 1 . 2608) (0. 8648 - 0 . 8654) -- 2 1 . 9 2 ( 0 . 863) T O R Q U E VALU ES Drum stopper plate bolt Primary d rive gear bolt Oil pump d riven sprocket bolt C lutch lock nut Oil pass pipe bolt (8 mm) ( 7 mm) 1 2 N·m ( 1 . 2 kg-m, 9 ft-lb) Apply locking agent 90 N•m (9.0 kg-m, 65 ft-lb) 1 5 N•m ( 1 . 5 kg-m, 1 1 ft-lb) Apply locking agent 1 30 N ·m ( 1 3.0 kg-m, 94 ft-lb) 23 N•m ( 2 . 3 kg-m, 1 7 ft-lb) 1 0 N•m ( 1 .0 kg-m, 7.2 ft-lb) T O O LS Special 07923 - KE 1 0000 o r 07 H G B -00 1 000A( U . S . A . only) 07724 - 00 1 0 1 00 Clutch center holder Gear holder Common Luck nut wrench, 1 7 x 27 mm 077 1 6 - 0020300 Equ ivalent com mercially available i n U . S . A . 7- 1 • CLUTCH/GEARS H I FT LI N KAGE TROU BLESHOOTI NG Faulty clutch operation can usually b e corrected b y 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 feels rough • • Clutch outer slots rough Dirty clutch cable 7-2 CLUTCH/GEARS H I FT L I N KAGE R IGHT CRAN KCASE COVER REMOVAL '88, '89: Drain the engine oil ( page 2 - 4 ) . Remove the clutch cable holder and disconnect the clutch cable from the clutch lifter 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 2 - 4 ) . Remove the clutch cable holder and disconnect the clutch cable from the clutch l ifter arm . Remove the right crankcase cover bolts and cover. Remove the dowel pins and gasket. '88, '89 : Remove the oil orifice. C L U T C H L I FT E R S H A FT 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 scratching . Check the return spring for fatigue or damage. 7 -3 CLUTCH/GEARS H I FT L I N KAGE 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 . (1 l I nstall the clutch lifter shaft, snap ring and return spring. Hook the spring end in the cover tab securely, and turn the shaft. Install the clutch lifter piece, aligning the piece end with the groove i n the clutch lifter shaft. CLUTCH REMOVAL Remove the following: - clutch bolts - clutch lifter plate - springs Unstake the clutch lock nut with a drill or grinder. NOTE • Be careful not to damage the shaft threads . 7 -4 D U ST SEAL CLUTCH/G EARS H I FT L I N KAGE 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 Lock nut wrench, 1 7 x 27 mm 07923- K E 1 0 0 00 or 07 H G B-00 1 000A ( U . S.A. only) 077 1 6-0020300 Equivalent com mercially avai lable in U . S .A. Remove the following : - spring washer (After' 9 5 o nly) - washer - clutch center. judder spring and sprin g seat - discs a n d plates - pressu re plate Remove the thrust washer and clutch outer. Remove the oil pump d riven sprocket mounting ·bolt, driven sprocket and oil pump drive cha i n . (1 l - - O I L PU MP DRIVEN SPROCKET 7-5 CLUTCH/GEA R S H I FT L I N KAGE Remove the drive sprocket and clutch outer guide from the mainshaft. I N SPECT I O N (1 1 BEARI N G 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 t h e bearing outer race fits tightly in t h e clutch lifter plate . Replace the bearing if necessary . ."-- -� .. · ·� / ..._ ___ ( 2 ) CLUTCH L I FTER PLATE Measure the spring free length . SERVICE LIMIT: 88; 88; 37.4 mm ( 1 .47 in) After 89; 4 1 , 6 mm ( 1 . 6 5 in) Replace the � lutch discs if they show signs of s coring or dis­ coloration. -� - Measure the thickness of discs A and B. SERVICE LIMIT: ( A I 2 . 30 m m (0.090 in) (8) 2 . 60 mm (0. 1 02 in) N OTE • Replace the discs and plates as a set if any one is beyond the service limit. 7 -6 CLUTCH/GEARS H I FT L I N KAGE Check the plate warpage on a su rface plate using a thickness gauge. SERVICE LIMIT: 0 . 30 mm (0.0 1 2 in) 111 Check the cl utch center for nicks or indentations made by the clutch plates. Check the spring seat and judder spring for distortion, wear or damage. Replace them it necessary . CLUTCH C ENTER �,! (1 I . _......... .. J U DDER SPRING Check the slots in the clutch outer for nicks or indentations made by the clutch discs. Measure the outer guide. I. D. of the clutch outer and the O . D . of the clutch SERVICE LIMITS: Clutch outer I . D. Clutch outer guide O.D. 32. 1 0 mm ( 1 . 264 3 1 .98 mm ( 1 . 259 in) in) 7- 7 CLUTCH/GEARS H I FT LI N KAGE Check the oil pump drive sprocket for damage. Measure I . D of the d rive sprocket and the O . D . of the outer guide. SERVICE LIMITS: Oil pump drive sprocket Clutch outer guide 0 . 0 . 1.0. 32. 1 0 mm ( 1 .264 in) 3 1 .98 mm ( 1 .259 in) Measure the mainshaft O . D . at the clutch outer guide. SERVICE LIMIT: 2 1 .92 mm (0.863 in) GEARSH I FT LI N KAGE R E M OVAL Remove the following : - drive sprocket cover ( page 1 3- 1 4) - gearshift pedal arm from the gearshift spindle - right crankcase cover ( page 7-3) - clutch assembly ( page 7-4) - oil pump drive chain ( page 7-5) Loosen the two oil pipe stay mounting bolts and remove the oil pipe mounting bolt. Pull the oil pipe out of the stay and oil pump. 7 -8 CLUTCH/GEARS H I FT L I N KAGE Remove the following : - gearshift spindle - drum stopper arm bolt, stopper arm, collar and spring - drum stopper plate bolt and stopper plate/drum I N S PECTI O N Check the gearshift spindle for bending o r damage. Check the return spring for fatigue or damage. ( 1 ) GEARSH I nspect the gearshift pedal shaft for damage or loose lock nuts. Replace the shaft if necessary. l ,_ r (2) RETU RN SPRING PEDAL SHAFT _ ,_ I nspect 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. 7-9 CLUTCH/GEARS H I FT L I N KA G E I N STA L LATI O N I nstall the collar, spring, stopper arm, washer a n d stopper arm bolt and tighten the bolt. I nstall the dowel pins into the holes of the gearshift dru m . Lift up t h e d r u m stopper a r m and install t h e d r u m stopper plate. Apply locking agent to the threads of the stopper plate bolt and tighten the bolt. TORQUE : 1 2 N·m ( 1 . 2 kg-m, 9 ft-lbl I nstall the gearshift spindle, aligning the return spring ends with the pin in the case. Install the oil pipe with a new 0-ring onto the oil pipe stay and oil pump. Tighten the bolts securely. I nstall the removed parts in the reverse order of removal. I nstall the gearshift arm to the gearshift spindle. Align the punch mark on the arm with the punch mark on the spindle . Tighten the gearshift arm mounting bolt. 7- 1 0 ., (1 l G EARSH I FT SPI N O ! " � C LUTCH/G EARS H I FT L I N KA G E I nstal l the gearshift pedal mounting bolt and tighten the bolt securely. I nstal l the d rive sprocket cover (page 1 3- 1 7 ) . (1 ) 1 FT PEDAL MOUNTING BOLT P R I MARY DRIVE GEAR REMOVAL Remove the followin g : - right crankcase cover (page 7-3) - clutch assembly ( page 7-4) Remove the ignition pulse generator mounting bolts and ig nition pu lse generators. Temporarily install the clutch outer, (page 7- 1 3 ) then install the gear holder as shown. TOOL: Gear holder 07724 - 00 1 0 1 00 Remove the fol lowing: - ignition p ulse generator rotor bolt and rotor - clutch outer and gear holder - primary d rive gear I N STALLAT I O N Instal l the primary drive gear with the " O UT" mark facing out. _, ( 1 ) PRIMARY DRIVE ,_, GEAR NOTE • The p ri m a ry d rive gear and ignition p u lse generator rotor will only g o on i n one position becau se of the extra wide aligning spline. Instal l the ignition pulse generator rotor . (4) I G N ITI O N P U LS � G E N E RATO R R OTO R 7- 1 1 CLUTCH/GEARS H I FT LI N KAGE Temporarily install the clutch outer and install the gear holder as shown . TOOL: Gear holder 07724 - 00 1 0 1 00 Install the washer and bolt and tighten the bolt. TORQUE: 90 N • m (9.0 kg-m, 65 ft-lbl Remove the gear holder and clutch outer. Install the following: - ignition pulse generators - clutch ( page 7 - 1 2 ) NOTE • If removed the ignition pulse generator wire grommets were removed from the case g roove,reinstall them securely. CLUTCH I NSTALLATION Apply MoS2 paste grease t o t h e outside o f the clutch outer guide and install the oil pump d rive sprocket over the outer guide. I nstall the oil pump d rive chain on the drive sprocket. I nstall the oil pump driven sprocket with the " I N " 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: 1 5 N·m ( 1 . 5 kg-m, 1 1 ft-lbl 7- 1 2 'iiToiL PU MP D R I VEN SPROCKET CLUTCH/G EARS H I FT L I N KAGE Align the grooves in 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 m a i nshaft. I nstall the spring seat, judder sprin g and clutch disc 8 on the c l utch center. N OTE • N ote the positions of the seat, spring and disc B. I nstal l clutch discs, clutch plates, clutch disc A, the plates, d i scs, and pressure plate on the clutch center and install them in the clutch outer as an assembly. Align the tabs in the disc 8 w ith the slots on the clutch outer. N OTE • • (3) DISC B J U DDER SPRING ( 1 ) SPR I N G SEAT (2) Stack the discs and plates alternately as shown. Coat the new clutch discs with clean engine oil. I n stall the washer on the mainshaft . After' 9 5 : I n stall the spring washer o n the mainshaft with the " O U T S I D E" mark facing o utside . 7- 1 3 CLUTCH/G EARS H I FT LI N KA G E Hold the clutch center with the clutch center holder, and tight­ en the lock nut to the specified torque . TO RQU E : 1 30 N·m ( 1 3.0 kg-m , 94 ft-l b) TOOLS : Clutch center holder Lock nut wrench, 1 7 x 27 mm 07923 - K E 1 0000 or 07 H G B-001 000A ( U . S .A. only) 077 1 6-0020300 Equivalent com mercially available in U .S .A. Stake the lock nut with the center punch . Install the clutch springs, lifter plate and bolts . Tighten the bolts in a crisscross pattern in 2 or 3 steps. NOTE • Make sure the pressure plate firmly pushes the discs and plates. I nstall the bearing into the l ifter plate . R IGHT CRAN KCASE COVE R I NSTALLATION '88, '89 : I nstall a new 0-ring on the oil orifice . I nstall the oil orifice with its smaller hole facing in. 7- 1 4 CLUTCH/G EARS H I FT LI N KA G E Install the dowel pins and new gasket. '88, '89 : Tighten t h e right c r a n kcase cover mounting bolts in a crisscross pattern in 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 . TORQU E : 23 N · m ( 2 . 3 kg-m, 1 7 ft-lbl Fill the crankcase with engine oil (page 2 -4 ) Adjust the clutch lever free play (page 3- 1 8 ) After '89: Tighten t h e right c r a n kcase cover m o u nti n g bolts i n a crisscross pattern in 2 or 3 steps and i nstall 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 2 - 4 ) Adjust the c l utch lever free play (page 3- 1 8 ) 7- 1 5 ALTERNATO R/STARTER CLUTCH 8-0 8. ALTERNATOR/STARTE R CLUTCH S E R V I C E I N FORMATI O N 8- 1 F LYW H E E L I N STALLATION 8- 5 L E F T C R A N KCASE C O V E R R E M OVAL 8-2 F LYW H E E L REMOVAL 8-3 LEFT CRANKCASE COVER I N STALLAT I O N 8-6 S TA R T E R CLUTCH 8-4 SERV I CE I N FORMATION GENERAL • • This section covers the removal and i nstallation of the alternator, starter clutch and starter gears. These o pe ration can be done with the engine installed in the frame. Refer to section 1 5 for troubleshooti ng and inspection of the alternator. S P EC I F I CATI O N S mm (in) ITEM Starter d riven gear O . D . STANDARD SERVICE L I M IT 5 7 . 749 - 5 7 . 768 ( 2 . 2 7 36 - 2 . 2743) 5 7 . 60 ( 2 . 268) TORQU E VALUES Flywheel bolt Starter clutch torx bolts 1 30 N·m ( 1 3 . 0 kg-m, 94 ft-lb) Left-hand thread 30 N·m ( 3 . 0 kg-m , 22 ft-lb) Apply locking agent TOOLS Common Rotor puller Flywheel holder Torx bit 07733- 002000 1 or 0 7 9 3 3 - 3 2 9000 1 ( U . S . A . only) 0 7 7 2 5 - 0040000 Equivalent commercially available in U . S . A . 07 703 - 00 1 0 1 00 Equivalent commercially available in U . S . A . 8- 1 . ALTE RNATO R/S TARTER CLUTCH LEFT CRAN KCASE COVE R REMOVAL Remove the left side cover and disconnect the alternator wire 3P connector (WHITE ) . Remove the drive sprocket cover (page 1 3- 1 4) . 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. STATOR R E P LAC E M E N T Remove the wire clamp bolts and the clamps. Remove the stator mounting bolts and stator. Position the new stator and the grommets in the cover. Apply a locking agent to the th reads of the stator mou nting bolts and wire cla m p bolts . Tighten the stato r mounting bolts and the clamp bolts . ( 1 ) BOLTS 8-2 ALTERNATO R/STARTER CLUTCH FLYWH EEL REMOVAL Remove the starter d rive and i d l e/reduction gears by removing the s h afts . H o l d the flywheel with the f l y w h e e l h o l d e r and remove the fly­ wheel bolt a n d w a s h e r . TOOL: Flyw heel holder 0 7 7 2 5 - 0040000 Equivalent commerc i a l l y ava i lable i n U . S . A . NOTE • The flywheel bolt h a s l eft- h a n d thre a d s . Remove t h e flywheel w ith the rot o r p u l l e r . TOO L : Rotor puller 07733 - 002000 1 or 07933-329000 1 ( U . S . A . only) Remove the starter d r i v e n gear, washer and needle bearing from the c r a n kshaft . Remove t h e wood ruff key . 8-3 ALTERNATOR/STARTER CLUTCH STARTER CLUTCH ( 1 l STARTER DRIVEN GEAR D I SA S S E M B LY Reinstall the starter driven gear i nto the flywheel . I nspect the starter clutch by turning the starter driven gear. The gear should turn counterclockwise freely and should not turn clockwise: if it turns i ncorrectly, replace the starter clutch. Hold the flywheel with the flywheel holder and remove the torx bolts using a torx bit. Remove the starter clutch outer and oneway clutch. TOOLS : Flywheel holder 07725-0040000 Equivalent commercia l ly ava i l a ble in U .S.A. Torx bit 07703-001 0 1 00 Equivalent commercially available in U .S.A. I N S PECTI O N ( 1 l STARTER DRIVEN GEAR Measure the O . D . of the starter driven gear. SERVICE LIMIT: 57.6 0 mm (2.268 in) I nspect the oneway clutch for wear or damage and replace if necessary . 8-4 ( 1 l ON EWAY CLUTCH ALTERNATOR/STARTER CLUTCH ASS E M B LY Install the oneway clutch i nto the clutch outer with the flange side facing inside. (3) ON EWA Y CLUTCH 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 Torx bit 07725-0040000 Equivalent commercially available i n U . S.A. 07703-00 1 0 1 0 0 Equivalent commercially avai lable i n U . S.A. FLYWHEEL I NSTALLATION Clean the crankshaft and install the woodruff key. Install the needle bearing onto the crankshaft. Instal l the starter d riven gear and washer onto the crankshaft . 8- 5 ALTERNATO R/STARTER CLUTCH Instal l the flywheel, aligning the woodruff key on the crank­ shaft with the flywheel keyway. Hold the flywheel with the flywheel holder, install the washer and flywheel bolt and tighten the bolt. TORQUE: 1 30 N·m ( 1 3 . 0 kg-m, 94 ft-lbl TOOL: Flywheel holder NOTE • 07725-0040000 Equivalent comm ercially available i n U . S.A. The flywheel bolt has left hand threads. Install the starter idle/reduction gear with the longer shaft . Install the starter d rive gear with the " O UT" mark facing out and the shorter shaft . Install t h e dowel p i n s a n d n e w gasket . LEFT CRAN KCASE COVER I NSTALLATION Install the left crankcase cover a n d tighten t h e cover bolts with the neutral and oil pressure switch wire harness clamps as shown. Route the alternator wire and connect the alternator 3P con­ nector. Install the drive sprocket cover and the left side cover. Check the oil level and add oil if necessary . 8-6 M E MO CYLI NDER H EAD/VALV E 10 N·m ( 1 .0 kg-m, 7.2 ft- l b l 23 N·m After ' I �I �' � - "0 " '89 : � 2 3 N•m ( 2 . 3 k g - m, 1 0 N•m ( 1 7 . 2 ft- l b ) .0 () 23 N·m ( 2 . 3 kg-m ' 1 7 ft- l b ) kg-m, /� @ '88, '89 : 1 0 N·m ( 1 7 . 2 ft- l b ) 9-0 ft- l b) e 2 3 N • m ( 2 . 3 kg-m 1 7 ft- l b ) 48 N · m ( 4 . 8 k g - m, 35 ft- l b ) �� kg-m, 1 7 : � '�� ' (2.3 .0 kg-m, 2 3 N•m ( 2 . 3 k g - m , 1 7 ft- l b ) � 10 N·m ( 1 ft-l b ) .0 kg-m ' 9. CYLI N DE R H EAD/VALVE SERVICE I N FORMATI O N 9-1 VALVE SEAT I N S PECT I O N / REFAC I N G 9- 1 2 TROUBLES H OOTI N G 9-2 CYLIN DER H EAD ASSEM BLY 9- 1 5 CYL I N D E R H EAD COVER REMOVAL 9-3 CYL I N DER H EAD I N STALLATION 9- 1 6 CAM S HAFT R E M OVAL 9-4 CAMS HAFT I N STALLATION 9- 1 8 CYL I N D E R H EAD 9-8 VALVE G U I D E REPLAC E M ENT 9-1 1 CYL I N DER H EAD COVER I N STALLATION 9-21 SERVICE I N FORMATION G E N ERAL • • • • The front cylinder head can be removed without removing the engine. To service the rear cylinder head, the engine must be removed from the frame. (See section 6 for engine removal and in­ stal lation . ) However, the rear cylinder head cover can be removed to service the camshaft, rocker arms, cam chain and cam chain tensioner. Camshaft l ubricating oil is fed through an oil pass pipe. Be sure the holes in the oil pass bolts are not clogged . D u ring assembly a p ply molybd e n u m disu lfide oil (a 50/50 m ixtu re of engine oil a nd molybde n u m disulfide g rease) to the camshaft h olders , camshaft journals of the cylinder head , rocker a rm shafts, rocker a rm slipper faces and valve stems to p rovide initial l u b rication . S P E C I F I CATI O N S Unit: mm (in) ITEM STANDARD Compression pressure Camshaft Cam lobe height EX Journaf O . D . Runout Oil clearance Rocker arm Valves and valve guides 3 7 . 730 ( 1 .48 54) 3 7 . 9 50 ( 1 .494 1 ) 37 . 7 50 ( 1 .4862) 2 1 . 9 59 - 2 1 . 980 (0. 8645 - 0 . 8 6 54) 0. 030 (0.00 1 2) 0.050 - 0. 1 1 1 (0.0020 - 0 . 0044) 2 1 . 90 (0.862) 0.05 (0.002) 0. 1 30 (0.005 1 ) ± -- Rocker arm I. D . IN/EX 1 2 . 000 - 1 2 . 0 1 8 (0.4724 - 0 . 47 3 1 ) 1 2 .05 (0.474) Rocker arm shaft O.D. Valve stem O . D . IN/EX 1 1 . 966 - 1 1 . 984 (0.47 1 1 - 0 . 47 1 8) 1 1 . 83 (0.466) IN 5 . 47 5 - 5. 490 (0. 2 1 56 - 0 . 2 1 6 1 ) 5.45 (0.2 1 5) EX 6 . 5 5 5 - 6 . 570 (0.2580 - 0 . 2 5 8 7 ) 6 . 5 5 (0.258) Valve guide I . D . IN EX 5 . 500 - 5 . 5 1 2 (0.2 1 6 5 - 0 . 2 1 70) 6 . 600- 6 . 6 1 5 (0.2598 - 0 . 2604) 5 . 56 (0.2 1 9) 6 . 6 5 (0.262) Stem-to-guide clearance IN 0 . 0 1 0 - 0.037 (0.0004 - 0 . 00 1 5) 0. 1 0 (0.004) EX 0 . 030 - 0 .060 (0.00 1 4 - 0 . 0024) 0. 1 1 (0.004) 1 . 5 (0.06) Valve seat width Valve guide projection height Valve springs 1 , 324 kPa 1 .0 kg/cm2, 1 92 ± 1 4 psi) 3 7 . 930 ( 1 .4933) (1 3.5 IN SERVICE LIMIT Free length IN EX OUTER INNER Cylinder head warpage IN EX IN EX 0.9- 1 . 1 1 9.4- 1 9.6 1 7.9- 1 8. 1 42. 1 4 (0.03 5 - 0.043) (0.76 - 0 . 7 7 ) (0. 7 0 - 0. 7 1 ) ( 1 .659) 42.83 ( 1 . 686) 38 . 1 1 ( 1 . 500) 38. 8 1 ( 1 . 765) -- -- -- 40 . 58 ( 1 . 598) 41 .25 36.47 37. 5 1 0. 1 0 ( 1 . 624) ( 1 .436) ( 1 .47 7 ) (0.004) 9- 1 g CYL I N D E R H EAD/VALVE TORQU E VALU E S Cylinder head cover bolt Camshaft holder 8 mm 8 mm 6 mm 1 0 mm Cylinder head 8 mm 8 mm 6 mm Camshaft sprocket bolt Cam chain tensioner bolt Oil pass pipe 7 mm 8 mm bolt nut bolt nut bolt nut bolt bolt bolt 1 0 N·m 23 N · m 23 N · m 1 0 N·m 48 N · m 23 N • m 23 N · m 1 0 N·m 23 N · m 1 0 N·m 1 0 N•m 23 N · m ( 1 .0 kg-m, (2.3 kg-m, ( 2 . 3 kg-m, ( 1 .0 kg-m , (4.8 kg-m , (2.3 kg-m, ( 2 . 3 kg-m, ( 1 .0 kg-m , ( 2 . 3 kg-m, ( 1 .0 kg-m, ( 1 .0 kg-m, (2.3 kg-m, 7 . 2 ft-lb) 1 7 ft-lb) 1 7 ft-lb) 7 . 2 ft-lb) 3 5 ft-lb) 1 7 ft-lb) 1 7 ft-lb) 7 . 2 ft-lb) 1 7 ft-lb) 7.2 ft-lb) 7 . 2 ft-lb) 1 7 ft-lb) TO O L S Special Valve Valve Valve Valve guide guide guide guide reamer ( I N ) reamer ( E X ) driver attachment ( I N ) driver attachment (EX) 07984 - 200000 1 o r 0 7 9 8 4 - 2 00000D 07984 -ZE2000 1 o r 0 7 9 8 4-ZE2000D 07943 - M F50 1 00 07943 - MF50200 Common Valve guide driver, 5 . 5 mm ( I N ) Valve guide driver, 6 . 6 mm (EX) Valve spring compressor 07742 - 00 1 0 1 00 07742 - 00 1 0200 N ot available i n U . S . A . 07942 - 6 5 7 0 1 00 0 7 7 5 7 - 00 1 0000 or 07957 - 329000 1 Valve seat cutter (Not available in U . S . A . ) Cutter holder I N 5 . 5 mm EX 6 . 6 mm I N 28 mm (32 ° ) Flat cutter E X 3 5 m m ( 32 ° ) Interior cutter I N 3 0 m m (60 ° ) E X 3 7 . 5 m m (60 ° ) Seat cutter I N 2 7 . 5 mm (45 ° ) E X 3 5 m m (45 ° ) 0778 1 - 00 1 0 1 0 1 0778 1 - 00 1 020 1 07780 - 00 1 2 1 00 07780 - 00 1 2300 07780 - 00 1 4000 07780 - 00 1 4 1 00 07780 - 00 1 0200 07780 - 00 1 0400 TROUBLESHOOTI NG Engine top-end problems are usually performance-related and can usually be diagonosed by a compressio n 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 - I ncorrect valve timing - Broken valve spring Cylinder head - Leaking or damaged head gasket - Warped or cracked cylinder head Cylinder and piston ( Refer to Section 1 0) High compression • Excessive carbon build-up on piston crown or combus­ tion chamber 9-2 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 CYL I N D E R H EAD/VALVE CYLI N DE R H EAD COVE R REMOVAL Remove the following parts: - steering covers - fuel tank ( page 4-3 ) - air cleaner housing (page 4-4) - carburetors (page 4-6 ) Drain t h e coolant (page 5-3 ) . Front: Disconnect the spark plug caps and the water hose. Remove the water pipe mounting bolt, front water pipe and 0ring. NOTE • If coolant drips on the engine, wipe it off immediately . Remove the cylinder head cover bolts and cover. Rear: '88-'89 , ' 9 1 -'94 : Disconnect the spark plug caps, crankcase breather tube and water hose . Remove the water pipe mounting bolt, rear water pipe and 0ring . Remove the cylinder head cover bolts and cover. Unclamp the wire harness from the frame. After '94 : D iscon nect the spark plug caps, c ra nkcase b reather tube and water hose . Remove the water p i pe mounting bolt, rea r water pipe and 0-ri n g . Remove the socket bolt and valve adjusti ng cover. ( 2 ) VALVE ADJ U STI N G COV E R 9-3 C Y L I N D E R H EA D IV ALVE Remove the cylinder head cover bolts, washers and rubber. (3) Alig n the wire harness with the valve adjusting hole, then re­ move the rear cylinder head cover forward . RUBBER ( 1 ) R EA R CYLI N D E R H EA D COVER CAUTI O N • B e careful not t o damage the the wire harness . CAMSHAFT R EMOVAL 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 i n ) . T o replace the c a m chain, drain the o i l from t h e engine and remove the following parts : FRONT CYLI NDER HEAD Left crankcase cover Front camshaft Flywheel ( 1 ) WEDGE B 6.0 mm (0.24 in) REAR CYLINDER H EA D Right crankcase cover Rear camshaft Primary drive gear ( 2 ) CAM C H A I N TEN SIONER 9-4 CYLI N D E R H EAD IVALVE Pull wedge A straight up while holding wedge 8 down. Secure wedge A with a 2 m m 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 . '88, '89: Remove the three camshaft holder mounting bolts and the nut, the oil plate and the holder. After '89: Remove the three camshaft ho ld er mou nting bo lts, nuts, o i l p late and the ho lder. 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 d ropped into the crankcase. 9-5 CYLI N D E R H EAD IVALVE I N S PE CT I O N Cylinder head Inspect the camshaft holder and cylinder head journal surfaces for scoring or evidence of i nsufficient 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. SERVICE LIMIT: IN: 37. 730 mm ( 1 .4854 in) EX: 3 7 . 7 50 mm ( 1 .4862 in) Check the camshaft journals for wear or damage . Measure the O . D . of each journ a l . SERVICE LIMIT: 2 1 .90 mm (0.862 in) Camshaft bearing oil clearance Wipe any oil from the journals. Lay a strip of plastigauge lengthwise on top of each camshaft journa l . NOTE • Avoid placing plastigauge over the oil hole . 9-6 2 I nstall the camshaft holders and tighten the mounting bolts in a crisscross pattern i n or 3 steps . NOTE • CYLI N D E R H EAD/VALVE ' 88 '89 : , Do not rotate the camshaft when using plastigauge. TORQUE: 6 mm flange bolt: 1 2 N·m ( 1 . 2 kg-m, 9 ft-lb) 8 mm flange bolt: 23 N•m ( 2 . 3 kg-m, 1 7 ft-lb) 8 mm flange nut: 23 N•m (2.3 kg-m, 1 7 ft-lb) /(2) 6 mm FLANGE i BOLTS After '89 : Remove the camshaft holder and measure the width of each plastigauge. The widest thickness determines the oil clear­ ance. SERVICE LIMIT: 0.23 mm (0.009 in) When the service limit exceeded, replace the camshaft and re­ check the oil clearance . 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. ( 1 ) ROCKER ARM SHAFTS 9- 7 CYLI N D E R H EAD/VALVE Remove the rocker arms and wave washers from the shafts . (2) Inspect the rocker arm shafts and rocker arms for wear or damage. Check the rocker arms for clogged oil holes. Measure the O . D . of each rocker arm shaft. SERVICE LIMIT: IN/EX : 1 1 .83 mm (0.466 in) Measure the I . D . of each rocker arm. SERVICE LIMIT: 1 2 .05 mm (0.474 in) CYLI N DE R H EAD 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 5-31 and remove the following: - front camshaft (page 9-31 - the cam chain tensioner mounting bolts and washers from the cylinder head and cylinder - cam chain tensioner 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 a n d 1 0 mm nuts/ washers in a criss-cross pattern in 2 or 3 steps. Remove the bolts and nuts. 9-8 � WAVE WASHERS CYLI N D ER H EAD/VALVE Remove the upper radiator hose and the radiator mounting bolts (page 5-5 ) . Release the radiator from t h e frame grommets a n d 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 . - o i l pass pipe ( '88, ' 89) , cy linder head cover, and cam chain tensio ner - head bolts and nuts, as described for front cylinder head re­ moval - cylinder head , head gasket, dowel pins, and cam chain guide D I SAS S E M BLY/ I N S P E CT I O N Cylinder head Clean the cylinder head surfaces of any gasket materia l . CAUTION • • A void 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 LIMIT: 0 . 1 0 mm (0.004 in) Remove the valve spring cotters, retainers, springs, and valves using a Valve Spring Compressor. TOOL: Valve spring compressor 07757 -001 0000 or 07957 - 329000 1 CAUTION • To prevent loss of tension, do not compress the valve springs more than necessary to remove the cotters. NOTE • Mark all parts during disassembly so they can be placed back in their original locations. 9-9 CYLI N D ER H EAD/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 (EX) : 37 . 5 1 OUTER (IN ) : 40 . 58 (EX) : 41 . 2 5 mm mm mm mm ( 1 .436 ( 1 .477 ( 1 . 598 ( 1 .624 in) in) in) in) Replace the springs as a set if they a re shorter than the service limit. Valve stem-to-guide clearance Inspect each valve for bending, burning, scratches or abn o rmal stem wear. Check valve movement i n the guide and measure and record each valve stem O . D . SERVICE LIMITS: I N : 5.45 m m (0. 2 1 5 in) EX: 6.55 mm (0.258 in) Measure and record each valve guide I . D . NOTE • Ream the guides to remove any carbon deposits before checking clearances. SERVICE LIMIT: IN: 5 . 56 mm (0.2 1 9 in) EX: 6.65 mm (0. 262 in) Subtract each valve stem O . D . from the corresponding guide I . D . to obtai n the stem to guide clearance. SERVICE LIMIT: IN: 0. 1 0 mm (0.004 in) EX: 0. 1 1 mm (0.004 in) 9- 1 0 (1 ) V VE STEM CYLI N D ER H EAD/VALVE If the stem-to-guide clearance exceeds the service limits, de­ 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 : Valve guide reamer IN: EX: 07984-2000001 or 07984-2000000 07984-Z E2000 1 or 07984-Z E2000D NOTE • It is important that the reamer always be rotated in 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 • Reface the valve seats whenever the valve guides are re­ placed . VALVE G U I DE REPLACEM ENT Chill the valve guides in the freezer section of a refrigerator for about an hour. Heat the cylinder head to 2 1 2 ° F ( 1 00 ° C ) with a hot plate or ove n . Maximum allowable temperature is 300 ° F ( 1 50 ° C ) . • To avoid burns, wear heavy gloves when handling he heated cylinder head. CAUTION • Do not use a torch to heat 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: Valve guide driver ( I N ) : (EX) : 07742-00 1 0 1 00 07742-00 1 0200 N ot ava i l a ble i n U .S.A. 07942-65701 00 NOTE • Avoid damaging the cylinder head . ( 1 ) VALVE G U I D E DRIVER MENT Make note of the valve guide projection specifications (follow­ ing ) , then drive i n new guides from camshaft side of the cylin­ der head . TOOLS: Valve guide driver 5 . 5 mm (IN) : 07742 - 00 1 0 1 00 6 . 6 mm (EX) : 07742 - 00 1 0200 Attachment 5 . 5 mm (IN): 07943 - MF50 1 00 6 . 6 mm (EX) : 07943 - MF50200 9- 1 1 CYLI NDER H EAD/VALVE VALVE GUIDE PROJECTION HEIGHT: IN: 1 9.4- 1 9 .6 mm (0.76 - 0 . 77 in) EX: 1 7 . 9 - 1 8 . 1 mm (0.70 - 0 . 7 1 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 i n the same directio n when it is inserted or removed. • • Clean the head thoroughly after reaming the valve guides. TOOLS : Valve guide reamer I N : EX: 07984-2000001 o r 07984-200000 D 07984-Z E200 0 1 or 07984-Z E2000D VALVE SEAT I NSPECTION/ REFACI NG Clean a l l intake a n d exhaust valves thoroughly t o remove carbon deposits . Apply a light coating of Prussian Blue to each valve seat. Lap each valve and seat using a rubber hose or other hand-lapping tool . Remove and inspect each valve . CAUTION • The valve cannot be ground. I/ the valve face is burned or badly worn or if it contacts the seat unevenly, replace the valve. Inspect the width of each valve seat. STANDARD: 0 . 9 - 1 . 1 mm (0.035 - 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 . 9- 1 2 VALV E S EAT C U TT E R S Honda Valve Seat Cutters, grinder or equivalent valve seat refacing equipment are reco m m ended to correct a worn valve seat. NOTE • Follow the refacer manufacturer's operating instructions. \--- 16 l'--- 60 ° ------� ___._� _ I N : 07780 - 00 1 4000 (30 c/>) EX: 07780 - 00 1 4 1 00 (37 . 5 c/>) CYLI N D E R H EAD/VALVE l }\ I N : 07780 - 00 1 2 1 00 (28 c/>) EX: 07780 - 00 1 2300 (35 c/>) I N : 07780 - 00 1 0200 (27 .5 EX: 07780 - 00 1 0400 ( 3 5 VALV E S EAT R E FAC I N G 32 ' ) ) ( 1 ) R O U G H N ESS/I RREGULARITI ES Use a 4 5 degree cutter t o remove any roughness o r 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 material . Use a 60 degree cutter to remove the bottom 1 /4 of the old seat. Remove the cutter and i nspect the area you have ref aced . 9- 1 3 CYLI N DER H EAD IVALVE 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 Prussia n Blue to the valve seat. Press the valve through the valve guide and onto the seat to make a clear pattern. ( 1 ) CONTACT TOO H I G H NOTE • The location of the valve seat i n relation to the valve face is very important for good sealing . If the contact area is too high on the valve, the seat must be lowered using a 32 degree flat cutter. If the contact area is too low on the valve, the seat must be raised using a 60 degree inner cutter. Refinish the seat to specifications, using a 45 degree finish cutter. 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 a llow lapping compound to enter the guides. 9- 1 4 ( 1 ) CONTACT T O O LOW CYLINDER H EAD/VALVE CYLI N DE R H EAD ASSEM BLY ( 1 ) VALVE (4) RETAINER I nstall the valve spring seats and new stem seals. Lubricate each valve stem with m olybdenum disulfide oil and i nsert the valve i nto the valve guide. Turn the valve slowly while i nserting to avoid damaging the seals . � 171 SPRING j·/_· 11(. SPR I N G ( 6 ) I N N E R S EAT SPR I N G 1" · ( 5 ) COTTERS ? Move the valves u p and down to check for smooth operation. Install the valve springs with the tightly wound coils facing the combustion chamber. I nstall the spring retainers. Compress the springs and i nstall the valve cotters. CAUTION • To prevent loss of tension, do not compress the valve springs more than necessary to install the valve cotters. TOOL: Valve spring compressor 07757 - 00 1 0000 or 07957 - 329000 1 9- 1 5 CYLI N D E R H EAD/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. CYLI N DER HEAD I NSTALLATION I nstall the cam c h a i n g u i d e into the cylinder. Make sure that the cam chain guide bosses are i n the grooves of cylinder. Clean the cylinder head surface of any gasket material . I nstall the dowel pins and a new head gasket. 9- 1 6 CYLI N D E R H EA D IV ALVE I nstall the carburetor insulator o n the cylinder head, aligning the boss on the cylinder head with the slot in the insulator. ( 1 ) BOSS (2) SLOT After '9 1 (Cal ifornia model only) : I nstall the insulator bands align i n g the pins o n the insulator bands with the slots o n the insulato rs as shown . Tighten the band screws secu rely . I nstall the cylinder head . I nstall the 1 0 m m nut/washer, 8 m m nut/washer, 8 mm bolt/ washer and 6 mm bolt and tighten them in a crisscross pattern i n 2 or 3 steps. TORQUE : 1 0 mm 8 mm 8 mm 6 mm nut: bolt: nut: bolt: 48 23 23 10 N•m N•m N·m N•m (4.8 (2.3 (2.3 ( 1 .0 kg-m, kg·-m, kg-m, kg-m, 35 ft-lb) 1 7 ft-lbl 1 7 ft-lbl 7.2 ft-lbl . ( 3 ) 8 m m BOLTS/WASHE '88, '89: Check the oil pass pipe bolts and oil pass pipe for clogging or bending. I nstall the oil pass pipe, new sealing washers, oil pass pipe bolts and the pipe holder bolt. Tighten the bolts . RS! 41 .. ( 1 ) SEALING WASH ERS .-- TORQU E : O i l pass pipe bolt: 7 mm: 1 0 N•m ( 1 .0 kg-m, 7 . 2 ft-lb) 8 mm: 23 N • m (2.3 kg-m, 1 7 ft-lb) ( 3 ) O I L PIPE (2) r HOLDER 9- 1 7 CYLI N D ER H EAD/VALVE I nstal l the following : - cam chain tensioner with washers and bolts . TORQUE: 1 0 N·m ( 1 . 0 kg-m , 7 . 2 ft-lbl - camshaft ( page 9- 1 8 ) - camshaft holders ( page 9 - 1 9 ) - cylinder head cover (page 9-2 1 ) ( 1 l CHAIN TEN SIONER WASH ERS/SOLTS -------� .,_,� 'il!lltW' CAMSHAFT I NSTALLATION """"' ( 1 ) WAVE WASHERS Apply m ol ybdenum disulfide oil to t h e rocker arm shafts . I nstal l the ·ocker arms, rocker arm shafts and wave washers i n t h e camshaft holders . NOTE • I nstal l the wave washers in the proper position as show n . Position the grooves in the rocker a r m shafts vertically, align­ ing the bolt holes of the holder with the holes of the shafts . Apply molybdenum disulfid e oil to the rocker a rm slipper faces . F R O N T CYLI N D E R 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 " RT" 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 counter­ clockwise approximately 1 - 1 /8 turn (41 2° ) and begi n instal l ation of t h e front camshaft. If the notch mark faces down ( cannot be seen) , turn the cra nkshaft cou nterclockwise approxi matel y 1 /8 turn ° ( 52 ) and beg i n insta l lation. 9- 1 8 , MoS2 ( 1 ) G ROOVES CYLI N D ER H EAD IV ALVE Align the " FT" mark on the flywheel with the index mark on the timing hol e . N OTE • If the front and rear cylinder c a mshafts were removed, do not confuse the m . Check the i dentification mark on the neck of the camshaft flange. I nstall the camshaft i n the cylinder h ead through the cam chain and install the cam sprocket on the camshaft with the I N mark facing inside . With the notch mark on the camshaft flange facing up, align the timing marks ( i ndex lines) on the cam sprocket with the top of the cylinder head. ( 1 ) N OTCH Place the cam chain on the sprocket. Install the cam sprocket on the camshaft flange and recheck that the timing marks (index lines) a l ign with the top of the cyl­ inder head . Align the cam sprocket bolt holes in the cam sprocket and camshaft, install and tighten the cam sprocket bolt. ( 1 ) CAM SPROCKET BOLT (2) HOLDER TORQUE: 23 N · m (2.3 kg-m, 1 7 ft-lbl T u rn the crankshaft cou nterclockwise one fu l l t u rn (360° ) . and insta l l the other sprocket b o lt . ° T u rn the crankshaft counterclockwise one fu l l t u rn (360 ) . a l i gning the "FT" mark with the i ndex mark, then check that the tim ing marks on the cam sprocket a l ign with the to p of the cy l ind er head . 9-19 CYLI NDER H EAD/VALVE '88, '89: I nstal l the dowel pins into the cylinder head . I nstal l the holders, oil plate, 8 mm bolts, 8 m m nut and 6 mm bolts . After '89: I nsta l l the dowel p ins into the cy linder head . 1 11sta l l the ho lders, o i l pipe 8 m m bo lts, 8 m m nuts and 6 mm bo lts. TORQU E : '8 mm bolt: 23 N • m (2.3 kg-m, 1 7 ft-lb) 8 mm nut: 23 N•m (2.3 kg-m, 1 7 ft-lbl 6 mm bolt: 10 N • m ( 1 .0 kg-m, 7.2 ft-lb) CAUTION • Note the direction of the camshaft end holder, install the flat surface on the holder facing in. After insta l l ing the front cy l inder camshaft, t u rn the crank­ ° shaft counterclockw ise approximate ly 7 /8 t u rn ( 308 ) and a l i gn the RT mark with the index on the t i m ing ho le, then insta l l the rear cylinder camshaft. Lubricate the cam lobes with fresh engine o i l . If the cylinder head w a s removed from t h e engine in t h e frame, instal l the following : - radiator with upper radiator hose - exhaust pipe R E A R CYLI N D E R NOTE • 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 countercl ockwise approx i mate l y 7/8 tu rn (308° ) a n d begin insta l lat ion of the rear camshaft. I f the camshaff notch mark faces down (cannot be seen) , t u rn the crankshaft co unterclockw i se appro x i mately 1 -7 /8 t u rn (668° ) and begin insta l lation. 9-20 After '89 : C Y L I N D E R H EADNA L V E Make sure that the " RT" ma�k 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 procedu re as for the front cylinder. Remove the 2 m m pin holding cam chain tensioner wedge A. NOTE • • Be careful not to let the 2 mm pin fal l i nto the crankcase . Do not forget to remove the 2 m m pin before installing the cylinder head cover. CYLI N DE R H EAD COVE R I NSTALLATION ( 1 ) APPLY C ONTACT CEMENT Clean the gasket and apply contact cement to the gasket groove . Apply sealant around the gasket. Install the cylinder head cover, rubber washer, washer cover and cylinder head cover bolts . Tighten the cover bolts. TORQUE: 1 0 N • m ( 1 .0 kg-m, 7 . 2 ft-lb) � '\\ ( 1 ) R U BB ER WASH E R ( 2 ) WASH E R COVER "\ (3) BOLT CYLI NDER H EAD IV ALVE I nstall the 0-ring on the water pipe with the tapered side facing out and install the water pipe i nto the cylinder head . Connect the water hose to the water pipe and i nstall the spark plug caps. I nstall the following parts : - carburetors (page 4- 1 5) - air cleaner housing (page 4-4) - fuel tank ( page 4-3) - steering covers Fill the cooling system (page 5-3) ' 2 9- 2 MEMO CYLI N D ER/P IS TO N 1 0-0 10. CYLI N DE R/ P I STO N S E RVIC E I N FO R M ATIO N 1 0- 1 P IS TO N R I N G I NS TALLATIO N 1 0- 5 TRO U BLES HOO T I N G 1 0- 1 PISTO N I NS TALLATIO N 1 0- 5 C Y LI N D E R 1 0- 2 C Y L I N D E R I NS TALLATIO N 1 0- 6 PIS TO N 1 0- 3 SERVICE I N FORMATION GEN ERAL • • • • This section covers service of the cylinder and pisto n . The front cyl inder/piston c a n b e serviced with t h e engine installed in the frame. The engine must be removed to service to rear cylinder/piston. To service the crankcase stud bolts, refer to page 1 1 - 1 5 . Unit: mm ( i n ) S P E C I F I CATI O N S STANDARD SERVICE LIMIT 7 5 . 000 - 7 5 . 0 1 5 ( 2 . 9 5 2 8 - 2 . 9 5 3 3 ) 75. 1 0 (2.957) ITEM Cylinder I. D . Warpage across top Taper Piston, piston rings and piston pin O ut-of-round Piston ring-to-ring g roove clearance Ring end gap TOP SECO N D TOP SECOND OIL -- 0 . 1 0 ( 0 . 004) -- 0 . 06 ( 0 . 00 2 ) -- 0 . 0 6 ( 0 . 00 2 ) 0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 ) 0 . 1 0 ( 0 . 004) 0 . 0 1 5 - 0 . 0 4 5 ( 0 . 0006 - 0 . 00 1 8 ) 0 . 1 0 ( 0 . 004) 0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 ) 0 . 50 ( 0 . 020) 0 . 1 0 - 0 . 30 ( 0 . 004 - 0 . 0 1 2 ) 0 . 50 ( 0 . 020) 0 . 20 - 0 . 7 0 ( 0 . 00 8 - 0 . 0 2 8 ) 0 . 90 ( 0 . 0 3 5 ) Piston O . D . 7 4 . 9 6 5 - 7 4 . 9 90 ( 2 . 9 5 1 4 - 2 . 9 5 2 4 ) 7 4 . 90 ( 2 . 94 9 ) Piston pin bore Connecting rod smal l end I . D . 1 8 . 0 0 2 - 1 8 . 008 ( 0 . 7 08 7 - 0 . 7 0 9 0 ) 1 8 .05 (0. 7 1 1 ) 1 8 . 0 1 6 - 1 8 . 034 ( 0 . 7 0 9 3 - 0 . 7 1 0 0 ) 1 8.07 (0. 7 1 1 ) 1 7 . 9 94 - 1 8 . 000 ( 0 . 7084 - 0 . 70 8 7 ) 1 7 . 98 (0.708) Piston pin O . D . Piston-to-piston pin clearance Cylinder-to-piston clearance Piston pin-to-connecting rod small end clearance 0 . 00 2 - 0 . 0 1 4 ( 0 . 000 1 - 0 . 00 0 6 ) 0 . 040 ( 0 . 00 1 6 ) 0 . 0 1 0 - 0 . 0 5 0 ( 0 . 0004 - 0 . 00 2 0 ) 0 . 1 0 ( 0 . 004) 0 . 0 1 6 - 0 . 040 ( 0 . 0006 - 0 . 00 1 6 ) 0 . 060 ( 0 . 00 2 4 ) TROUBLESHOOTI NG Low o r uneven compression • • • Worn cylinder or piston rings. Leaking head gasket . Incorrect valve timing. Piston noise • • Worn cylinder and piston. Excessive carbon deposits . Excessive smoke • • • Worn cylinder and piston rings. Improperly insta lled piston rings. Damaged piston or cylinder. Overheating • Excessive carbon deposits on piston or combustion chamber. Faulty water p u m p . 1 0- 1 CYLI N D E R/PI STO N CYLI N DER R E M OVAL 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 . I N S PE CT I O N Clean the top o f each cylinder thoroughly. I nspect the cylinder walls for scratches and wear . Measure and record t h e cylinder I . D . a t three levels in both an X and Y axis . Take the maximum reading to determine the cyl­ inder wear. SERVICE LIMIT: 7 5 . 1 0 mm ( 2 . 9 5 7 in) Calculate the piston-to-cylinder clearance . Take the maximum reading to determine the clearance. SERVICE LIMIT: 0. 1 0 mm (0.004 in) Calculate the cylinder for taper at three levels i n an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.06 mm (0.002 in) Calculate the cylinder for out-of-round at three levels in an X and Y axis . Take the maximum reading to determine the out­ of-roun d . SERVICE LIMIT: 0.06 mm (0.002 in) The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded. The following oversize piston are available: 0.25 mm (0.01 0 in) and 0 . 50 mm (0. 020 in) The cylinder must be rebored so that the clearance to a n over­ size piston is 0. 0 1 0 - 0.050 mm (0. 0004 - 0 . 0020 in) . 1 0- 2 (1) IN (3) o� � TOP F""-....,.;;1;;;;�� X ( 2 ) EX CYLI N D E R/PISTON Inspect the cylinders for transverse warpage across the top. NOTE • Measure warpage using a straight edge and feeler gauge as shown . SERVICE LIMIT: 0 . 1 0 mm (0.004 in) P I STON R E M OVAL Place a shop towel i nto 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 . I N SPECTI O N Clean the piston domes, ring lands and skirts . Measure the piston ring-to-groove clearance . SERVICE LIMIT: Top : 0 . 1 0 mm (0.004 in) Second : 0 . 1 0 mm (0.004 in) If 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. 1 0-3 CYLI N D ER/PISTON I nsert the old piston ring into the proper ring groove and clean the groove by rol l i n g the ring around the pistons circumference . Inspect the piston for cracks or other damage. Measure the piston O . D . NOTE • Take measurements 1 0 mm 9 0 ° to the piston pin hole. (0.4 in) from the bottom , and SERVICE LIMIT: 74.90 mm ( 2 . 949 in) Calculate the piston-to-cylinder clearance by subtracting the piston O . D . from the cylinder I . D . (page 1 0- 2 ) . SERVICE LIMIT: 0.32 mm (0.0 1 3 in) Measure the top and second piston ring end gaps : using a pis­ ton , push the ring into the cyl inder squarely 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: 1 8 .05 mm (0. 7 1 1 in) Measure each piston pin O . D . SERVICE LIMIT: 1 7 . 98 mm (0. 708 in) Calculate the piston pin-to-piston clearance . SERVICE LIMIT: 0.40 mm (0.00 1 6 in) 1 0-4 CYLI N D E R/P ISTON Measure the I . D . of the connectin g rod small end . SERVICE LIMIT: 1 8 .07 mm (0. 7 1 1 in) Calculate the piston pin-to-con n e cting rod clearance . SERVICE LIMIT: 0.060 mm ( 0 . 0024 in) Refer to section 1 1 for connecting rod replacement. P I STON R I N G I NSTALLATION NOTE • Insert the outside surface of the ring into the proper ring groove and rol l around in the g roove to make sure that the ring has a free fit around the p i ston ' s circumference. Carefully install the piston rings o nto the piston with the mark­ ings facing u p . NOTE • Be careful not to damage the p i ston and piston rings during assembly. Stagger the ring end gaps show n . 1 20 ° apart from each other as NOTE • (7) (7) mm OR 20 mm OR MORE MORE 20 To install the oil ring, instal l t h e spacer first, then instal l the side rails. After installing the rings, check that they rotate freely without sticking. P I STON I N STALLATION Place a shop towel into the cra n k case . 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 • • • I nstall the pistons with the m a rk " I N " facing towards the intake side . After installing the piston pin c l ips, 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 . 1 0- 5 CYLI N D E R/PISTON CYLI N DER I NSTALLATION Clean the cylinder gasket surface being careful not t o drop any gasket material into the crankcase . I nstall the dowel pins and new gasket. 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 remova l . N OTE 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. • • I nstal l a new 0-ring onto the cylinder joint and install the cylin­ der joint collar by sliding the collar toward eigther cylinder. I nstal l the clip securely. Clean the cylinder gasket surface being careful not to drop any gasket material . NOTE • Avoid damaging the gasket surface . Install the cam chain guide. NOTE • • Align the guide boss with the groove in the cylinder. Make sure that the end of the guide is inserted into place in the crankcase . 1 0- 6 CYLI N D ER/PISTON I nstal l a new 0-ring into the connecting pipe and install and tighten the connecting pipe mounting bolts, if the connecting pipe was removed . If only the water hose was removed , connect the hose with clamp. I nstal l the dowel pins and a new gasket . I nstal l the cylinder heads and covers (Section 9 ) . , (1) DOWEL PINS \ 1 0- 7 CRAN KSHAFT/TRANSM ISSION '88 -'89 , ' 9 1 -' 9 5 : 20 - 30 N • m ( 2 . 0 - 3 . 0 kg-m, 1 4 - 22 ft-lb) 34 N·m (3.4 kg- m 2 5 ft-lb) ' '88 -' 8 9 . ' 9 1 -' 9 5 : 30-50N · m (3 . 0-5 . Okg - m , 2 2 - 3 6ft- lb) 1 1 . CRAN KSHAFT/TRANSM I SSION S E RVIC E I N FO R MATIO N 1 1 -1 C RA N KC A S E 1 1 -1 3 T RO U BLESHOOT I N G 1 1 -3 C RA N KCASE SEPARAT I O N 1 1 -4 TRAN S M I S S IO N ASS EMBLY I I N STALLATIO N 1 1 -1 7 C RA N KS H AFT/CO N N EC T I N G RO D 1 1 -5 T RA N S M I SSIO N 1 1 -1 1 C RA N KC A S E ASSEM BLY 1 1 -1 9 SERVICE I N FORMATION G E N ERAL • • • • To service the connecting rods, crankshaft, transmission and oil pump, the engine must be removed from the frame ( Sec­ tion 6 ) . A l l bearing i nserts are select fitted a n d are identified b y color code. Select replacement bearings from the code tables. After instal l ing new bearings, recheck them with plastigauge to verify clearance. Apply molybdenum disulfide g rease to the main journals and crankpins during assembly. Before separating the crankcase, the following parts must be removed . Section 9 Cylinder head cover Water pipe Camshaft holder Cam chain and drive sproket Section 1 0 O i l pass pipe Cylinder joint collar Water hose connecting pipe Cam chain tensioner Section C a m chain guide Crankshaft Connecting rod Transmission O i l pump 9, Section 9 NOTE . - Camshaft l Section - The front cylinder camshaft and cylinder head service c an be performed without removing the engin e from the frame. 9 Cylinder head Section 1 0 10 ------ - C R A N KCASE _ SEPA RATIO N Cylinder Piston + Starter motor ( Section 1 7 ) R ight crankcase cover ( Section 7 ) - Clutch - Gearshift linkage - Primary drive gear - Oil pipe Left crankcase cover ( Section 8 ) - Flywheel - Starter gears 1 1 -1 Ill C RA N KS HAFT/TRAN S M I S S I O N S P E C I F I CATI O N S mm (in) ITEM Con nectin g rod big end side clearance Cra n kshaft/ connecting rod Crankpin o i l clearance Main journal oil clearance Crankshaft ru nout C1 Gear I . D . Transmission M 4 , M 2 , C3 Gear bushing O . D . C 1 M 4 , M 2 , C3 C1 Gear bushing I . D . M2 C1 B ushing-toshaft clearance M2 S hift fork/ fork-shaft Gear-tobushing clearance M4, M2 C 1 , C3 Cou ntershaft 0 . D . Mainshaft 0 . D . Backlash C 1 bushing M 2 bushing 1 st, 2 n d , 3rd 4th Claw thickness '88 , ' 89 , ' 9 1 -' 9 5 : After'9 5 : ' 88 , ' 89 , ' 9 1 -' 9 5 : Shaft O . D . After'9 5 : Shift drum 0 . D . (at the left side journal) Right and left shift fork I . D . 2 4 . 000-24 . 02 1 ( 0 . 9449-0 . 94 5 7 ) 2 8 . 000-2 8 . 02 1 ( 1 . 1 02 4- 1 . 1 03 2 ) 2 3 . 9 59-23 . 980 ( 0 . 9433-0 . 944 1 ) 2 7 . 9 59-2 7 . 980( 1 . 1 007- 1 . 1 0 1 6) 2 0 . 0 1 6-2 0 . 03 7 ( 0 . 7 880-0 ._7889) 2 5 . 000-2 5 . 02 1 ( 0 . 9843-0 . 9 8 5 1 ) 0 . 02 3 -0 . 05 7 (0 . 0009-0 . 02 2 ) 0 . 020-0 . 062 ( 0 . 0008-0 . 0024) S E RV I C E LI M IT 0 . 30(0 . 00 1 ) 0 . 07 ( 0 . 003) 0 . 06 (0 . 002) 0 . 05 ( 0 . 002) 2 3 . 94 (0 . 943) 2 8 . 04 (0 . 1 04) 2 4 . 94 (0 . 982) 2 7 . 94 ( 1 . 1 00) 2 0 . 06 ( 0 . 790) 2 5 . 04 (0 . 986) 0. 1 0 (0 . 004) 0. 1 0 (0 . 004) 0 . 002-0 . 062 ( 0 . 0008-0 . 0024) 0. 1 0 (0 . 004) 1 9 . 980- 1 9 . 99 3 ( 0 . 7 8 6 6-0 . 7 8 7 1 ) 2 4 . 9 59-24 . 980(0 . 98 3 5 -0 . 9 8 2 6 ) 1 . 02 1 -0 . 1 1 0 ( 0 . 0008-0 . 0043) 1 . 02 3 -0 . 1 1 7 ( 0 . 0009-0 . 0046) 5 . 93-6 . 00(0 . 2 3 3 -0 . 2 3 6 ) 1 3 . 000- 1 3 . 0 1 8 ( 0 . 5 1 1 8-0 . 5 1 2 5 ) 1 3 . 000- 1 3 . 02 1 ( 0 . 5 1 1 8-0 . 5 1 2 6 ) 1 2 . 9 6 6 - 1 2 . 984(0 . 5 1 05-0 . 5 1 1 2 ) 1 2 . 9 6 6- 1 2 . 984(0 , 5 1 05-0 . 5 1 1 2 ) 1 1 . 9 6 6 - 1 1 . 984 ( 0 . 47 1 1 -0 . 47 1 8) 1 9 . 9 6 (0 . 786) 2 4 . 94 (0 . 982) STAN DAR D 0 . 05-0 . 2 0 (0 . 002-0 . 008) 0 . 02 8 -0 . 05 2 (0 . 00 1 1 -0 . 0020) 0 . 02 5-0 . 04 1 (0 . 00 1 0-0 . 00 1 6 ) - T O R Q U E VALU ES Connecting rod bearing cap nut Crankcase 8 mm stud bolt 1 0 mm stud bolt 34 N ·m ( 3 . 4 kg- m , 2 5 ft-lb) 20 - 30 N · m ( 2 . 0 - 3 . 0 kg-m, 1 4 - 2 2 ft-lb) 30 - 50 N ·m ( 3 . 0 - 5 . 0 kg-m, 2 2 - 36 ft-lb) TOOLS Special Main bearing driver attachment Bearing remover set - remover handle - bearing remover set - remover weight 0 7 H M F - M M 90400 07936 - 3 7 1 000 1 07936 - 3 7 1 0 1 00 07936 - 3 7 1 0600 07741 - 00 1 020 1 or 07936 - 3 7 1 0200 Common Driver Attachment, 42 Pilot, 20 mm Attachment, 52 Pilot, 22 mm Pilot, 2 5 mm 1 1 -2 x 4 7 mm x 55 mm 07749 - 00 1 0000 07 746 - 00 1 0300 077 46 - 0040 500 07746 - 00 1 0400 07 746 - 004 1 000 07746 - 0040600 N ot available in U . S . A . U . S . A . Only 5 . 63 ( 0 . 2 2 2 ) 1 3 . 04 (0 . 5 1 3) 1 3 . 04 (0 . 5 1 3) 1 2 . 9 0 (0 . 508) 1 2 . 9 5 (0 . 509) 1 1 . 94 (0 . 47 0) CRA N K S HA FT/TRANSMISS I O N TROU BLESHOOTI N G Excessive noise Crankshaft - Worn main bearing - Worn crankpin bearing • connecting rod - Worn rod small end - Worn crankpin bearing • Hard to shift • • • • • Shift Shift Shift Shift Shift forks bent fork shaft bent spindle claw bent drum cam grooves damaged fork guide pin damaged Transmission jumps out of gear • • • Gear dogs worn Shift shaft bent Shift forks bent 1 1 -3 CRANKS HAFT/TRANSMISSION CRAN KCASE SEPARATION Remove the engine from the frame ( Sectio n 6). Refer to the service i nformation ( page 1 1 - 1 ) for the 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 sprocket. Remove the bolt and cam chain tensioner set plate . Remove the front cam chain from the crankshaft. Remove the 8 mm bolts and 6 mm bolts from the left crank­ case . NOTE • • 2 Remove the bolts in a crisscross pattern in or 3 steps. Loosen the 6 mm bolts first, then loosen the 8 mm bolts . Remove the 8 m m bolts and 6 mm bolts from the right crank­ case . NOTE • • 2 Remove the bolts in a crisscross pattern in or 3 steps. Loosen the 6 mm bolts first, then loosen the 8 mm bolts . 1 1 -4 •• • CRANKS HAFT/TRA N S M I S S I O N 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 w ith a soft hammer. Remove the dowel pins and clean the cran kcase halves of any sealant materia l . (1) DOWEL PINS .__ CRAN KSHAFT/CON N ECTI NG ROD C RA N K S H A FT R E M OVAL Remove the crankshaft from the left crankcase . C RA N K S H A FT S I D E C L EARA N C E I N S PECTI O N (1 l FEELER GAUGE Check t h e 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 crankshaft. I nspect the crankshaft for rough spots or damage. 1 1 -5 CRANKSHAFT/TRA N S M I S S I O N C O N N ECTI N G R O D D I SA S S E M B LY ( 1 ) BEA R I N G CAPS 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 crankpin bearings. They must be in­ stalled in their original positions or the correct bearing oil clear­ ance may not be obtained resulting in engine damage. • C RA N K S H A FT R U N O U T I N S P ECTI O N 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 tota l indicator read ing . SERVICE LIMIT: 0.05 mm (0.002 in) NOTE • The crankshaft cannot be repaired . Replace it if the journals or crankpins are burnt, cracked, or if the runout is beyond limits . C O N N E CTI N G R O D B E A R I N G I N S P E CT I O N Inspect the bearing insert� for damage or separation . Clean all oil from the bearing inserts and crankpins. ( 2 1 SEPARATION O I L C LEARA N C E I N S P ECTI O N Put a piece o f plastigauge o n each crankpin avoiding the oil hole . I nstal l the bearing caps and rods on the correct crankpins, and tighten them evenly. TORQUE: 34 N • m (3.4 kg-m, 25 ft-lbl NOTE • Do not rotate the crankshaft during inspectio n . 1 1 -6 ( 1 ) PLASTI GAU G E ( 1 1 DAMA G E CRAN KS HAFT/TRA N S M ISSION 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 i n ) I f the rod bearing clearance is beyond tolerance, select re­ placement bearings. C O N N E C T I N G ROD B EA R I N G S E LECT I O N ( 1 ) I . D . CODE N U M BER Determine t h e connecting rod I . D . code number. The code will be either a number 1 or 2 located on the rod in the area shown. Determine the corresponding crankpin O.D. code (or measure the crankpin O . D . ) . The code will be either a letter A or B on the crank weight. C ross reference the crankpin and connecting rod codes to de­ termine the replacement bearing color. 1\ C RANKPIN O . D . CODE C O N N ECTI NG R O D I.D. CODE 1 2 \ 43.000 - 43 . 007 mm ( 1 . 6 9 29 - 1 . 6932 i n ) 43.008 - 43 .0 1 6 m m ( 1 . 6932 - 1 .6935 i n ) A 3 9 . 982 3 9 . 990 mm ( 1 . 5 741 1 . 5 744 in) c ( BROWN ) B ( B LACK) B 39.97439.98 1 mm ( 1 . 57381 . 5741 in) B (BLACK) A ( BLUE) ( 1 l O . D . CODE LETTERS ( 1 ) CRANKPIN BEAR I N G S / BEARING I NSERT THICKN ESS A ( B L U E ) : 1 . 49 5 - 1 .499 mm (0.0589 - 0 .0590 i n ) B ( B LACK) : 1 .49 1 - 1 .495 mm (0.0587 - 0 . 0589 i n ) C ( BROWN ) : 1 .487 - 1 .49 1 mm (0.058 5 - 0. 0587 in) 1 1 -7 CRANKS HAFT/TRA N S M ISSION M A I N BEAR I N G I N S PECTI O N Measure the main journal O . D . and record it. Measure the main journal bearing I . D . and record it. Calculate the clearance between the main journal and the main bearing . SERVICE LIMIT: 0.06 mm (0.002 in) If the oil clearance is beyond the service limit, select a replace­ ment bearings as follows: M A I N BEAR I N G S E LECTI O N 2 Determine the crankshaft main journal O . D . code. The code will be either a number 1 or on the crank weight. Determine the replacement main bearing. Determine the corresponding main bearing I . D . code . The code will be either a letter A or 8 on the crankcase . 1 1 -8 C RAN KSHAFT/TRAN S M ISSION Choss replacement main bearings i n accordance with the table below . � M A I N J O U RNAL O . D . CODE CASE I . D . C O D E A B \ 1 44. 9924 5 . 000 mm ( 1 . 7 7 1 31 . 77 1 7 i n ) 48 . 9 90 - 49 . 000 mm ( 1 . 9 2 8 7 - 1 . 9 2 9 1 in) 49.000 - 49 .0 1 0 mm ( 1 . 9 2 9 1 - 1 . 92 9 5 i n ) c ( B ROWN ) B ( B LACK) 2 44. 984 44 . 9 9 1 mm ( 1 . 77 1 01 . 7 7 1 3 in) B ( BLACK) A ( BLU E) BEARING I NSERT THICKNESS A (BLU E ) : 2 . 003 - 2 . 0 1 3 mm ( 0 . 0789 - 0.0793 in) B (BLACK) : 1 . 998 - 2 . 008 mm ( 0 . 0787 - 0 . 0 7 9 1 in) C ( BROWN ) : 1 . 9 93 - 2 . 003 mm ( 0 . 0785 - 0.0789 in) MAI N B EA R I N G R E P LA C E M E N T Press the main bearing out of the crankcase using a hydraulic press and special tools. NOTE • Always use a press to remove the main bearing. TOOLS : Driver 07749 - 0 0 1 0000 Main bearing remover attachment 07HM F - MM90400 Mark a vertical line below each side of the bearing tab. Apply molybdenum disulfide grease to the outer surface of the main bearing. (2) MARKS (3) G ROOVE Align the marks on the bearing w ith the groove in the bearing hole, and press the main bearing i nto the crankcase . CAUTION • Be careful not to damage the bearings. TOOLS : Driver Main bearing driver attachment 07749 - 00 1 0000 07HMF - MM90400 (3) MAIN BEARING 1 1 -9 CRAN KS HAFT/TRANSMISSION C O N N ECTI N G R O D/ C RA N K S H A FT S E L E CT I O N If a connecting rod requires replacement, y o u 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 chart. NOTE The " 0 " mark in the table indicates that the matching is possible in the crossed codes. • SELECTIO N TABLE Front rod code Rear rod code A B c A B c * 0 0 0 0 0 0 0 * * CAUTION For selecting crankshaft weight: Select "L " crankshaft weight, if the front rod and rear road have code A ( •) . Select "H" crankshaft weight, if the front rod and rear rod have code C ( * *) . Select crankshaft weight with no code, other than the above two cases. • • • C O N N ECTI N G R O D A S S E M B LY Install the bearing inserts on the rods and caps . NOTE • • Align the boss on the bearing with the groove in 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 i nstalled i n its original position, as noted during re­ mova l . Tighten t h e bearing c a p nuts. NOTE • • Align the I . D . code on the cap and rod . Tighten the nuts in two or more steps. After tightening, check that the rods move freely without binding. TORQUE : 34 N · m (3.4 kg-m, 25 ft-lbl CRA N K S H A FT I N STALLAT I O N Install t h e crankshaft in the left crankcase . Install the dowel pins and assemble the crankcase . 1 1-10 ( 2 ) CRANKSHAFT WEIGHT CODE ( " L" or "H" or no mark) ( 1 ) Apply molybdenum disulfide g rease C RAN KSHAFT/TRAN S M ISSION TRANSM ISSION ( 1 ) MAI N­ SHAFT R EMO V A L ' 8 8 . '89 . ' 9 1 -'9 5 : Remove the mainshaft, cou ntershaft, shift fork shaft and shift drum as a n assembly. After'9 5 : Remove the shift fork shaft then remove the shift drum and shift forks . Remove the mainshaft and countershaft as a n assembly. ' 8 8 , '89 , ' 9 1 -' 9 5 : Separate the shift fork/shaft, mainshaft a n d cou ntershaft assemblies from each other: ( 2 .) S H I FT FORK/ AFT After'9 5 : Separate the mainshaft and countershaft assemblies from each other. (3) COUNTERSHAFT ASSEM BLY D I SASS EMBLY/ I N SPECT I O N Temporarily i nstall t h e mainshaft and countershaft t o the left crankcase . Measure the backlash of each gear. STANDARD : 1 st, 2nd, 3rd 1 .02 1 - 0. 1 1 0 mm (0.0008 - 0.0043 in) 4th 1 .023 - 0. 1 1 7 mm (0.0009 - 0 . 0046 in) ' 8 8 , '89 , ' 9 1 -'9 5 : Bend down the lock washer tabs and remove the bolt and lock washer from the left shift fork. Remove the shift fork shaft. ( 1 ) LOCK WASHER ( 2 ) BOLT Disassemble the mainshaft and countershaft. Remove the C4 gear by removing the stop rin g . 1 1 -1 1 C RAN KSHAFT/TRA N S M I S S I O N I nspect the shift drum end for scoring, scratches, or evidence of insufficient l ubrication . Check the shift drum grooves for damage. Measure the shift drum shaft O . D . at the left side journal. SERVICE LIMIT: 1 1 . 94 m m (0.470 in) Check the bearing inner and outer races for damage . The bearing should turn smoothly and quietly. I 1 2 1 S H I FT DRUM Check the shift fork shaft for scratches, scoring or evidence of insufficient lubrication . Measure the shift fork shaft O . D . S E RV I C E LI M I T : '88 , '89 , '91 -'95 : 1 2 . 90mm (0 . 508 in) After'95 : 1 2 . 95mm (0 . 509 in) M easure the shift fork I. D. ( right and left) and the shift fork claw thickness . SERVICE LIMIT: 1 3 .04 m m (0 . 5 1 3 in) I.D.: CLAW THICKNESS: 5.63 mm (0. 222 in) I nspect 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 l ubrication . Measure the I . D . of the following mainshaft countershaft at C3, C 1 gears. 24.04 mm (0. 947 in) SERVICE LIMITS : C 1 gear: M2, M4, C3 gear: 28.04 mm ( 1 . 1 04 in) 1 1 -1 2 CRANKSHAFT/TRANSMISSION Measure the O . D . of the mainshaft following bushings: SERVICE LIMITS : M4 gear bushing : C3 gear bushing : M 2 gear bushing : C1 gear bushing : 27 . 94 2 7 . 94 2 7 . 94 24. 94 mm mm mm mm ( 1 . 1 00 ( 1 . 1 00 ( 1 . 1 00 ( 0 .982 in) in) in) in) Calculate the clearance between each bushing and gear. SERVICE LIMIT: 0. 1 0 mm (0.004 in) Measure the I . D . of the M2 and C 1 bushings: ( 2 ) M 2 or C 1 BUSHING or C3 BUSH I N G SERVICE LIMITS : M2 gear bushing : I . D . 2 5 . 04 mm (0.986 in) C1 gear bushing : I . D . 24.06 mm (0. 790 in) Measure the O . D . of the mainshaft and countershaft at the M 2 a n d C 1 bushings. SERVICE LIMITS : Mainshaft (at M2 gear bushing) 24. 90 mm (0.980 in) Countershaft (at C 1 gear bushing) 1 9 .92 mm (0. 784 in) (1) 2 Calculate the clearance between each bushing and shaft. (2) C 1 SERVICE LIMIT: 0.06 mm (0.0024 in) Check the each shaft grooves for damage. ( 1 ) SNAP R I N G GROOVES I Replace if necessary . ( 2 ) LOCK A N D STOP WASHER G ROOVES + + t ( 3 ) SNAP RING G ROOVE t (4) STOP R I N G GROOVE CRAN KCASE BEA R I N G R E P LA C E M E N T Turn the inner race of each bearin g with your finger. The bear­ ings should turn smoothly and q uietly . Also check that the bearing outer race fits tightly i n the crankcase. Remove and discard the bearin g s if the races do not turn smoothly, quietly, or if they fit l oosely i n the crankcase. 1 1 -1 3 CRAN KSHAFT/TRAN S M I S S I O N Left crankcase Remove the left mainshaft bearing using the special tools. TOOLS: Bearing remover set - remover handle - bearing remover set - remover weight 07936 - 37 1 000 1 N ot ava i lable i n U . S . A . 07936 - 37 1 0 1 00 07936 - 37 1 0600 0774 1 - 00 1 020 1 or 07936-37 1 0200 Drive the countershaft bearing and oil seal out of the crank­ case . I nstal l the new mainshaft bearing set plate on the left crank­ case. NOTE • Apply fresh engine oil to the new crankcase bearings before installation . I nstall t h e n e w bearings with t h e following tools. TOOLS : Left mainshaft bearing Driver Attachment, 42 x 47 mm Left countershaft bearing Driver Attachment, 52 x 55 mm Pilot, 25 mm 07749 - 00 1 0000 07746 - 00 1 0300 07749 - 00 1 0000 07746 - 00 1 0400 07746 - 0040600 I nstall a new countershaft oil sea l . Check the gearshift spindle oil seal for wear or damage, re­ place if necessary. 1 1-14 (1 ) BEARING S ET PLATE CRANKSHAFT/TRANSMISSION Right crankcase Remove the mainshaft bearing set plate and drive the counter­ shaft bearing, mainshaft bearing and shift drum bearing out of the crankcase . TOOLS : Right mainshaft bearing Driver Attachment, 52 x 55 mm Pilot, 22 mm Right countershaft bearing Driver Attachment, 42 x 47 mm Pilot, 20 mm 07749 - 00 1 0000 07746 - 00 1 0400 07746 - 0041 000 07749 - 00 1 0000 07746 - 00 1 0300 07746 - 0040500 Apply a locking agent to the threads of the mainshaft bearing set plate attaching bolt. I nstall the set plate and tighten the bolt securely. ( 1 ) 1 0 mm STU D BOLT HOLES I N SPECTI O N Crankcase studs '88 ' ' 8 9 ' ' 9 1 -'9 5 : Check that the studs a re tight. I f any are loose, remove them , clean their threads with c ontact cleaner, then reinstall them using Honda Anaerobic Thread Lock , o r equivalent. (2) 8 mm STU D BOLT HOLE After i nstalling, be sure to measure the distance from the top of each stud to the crankcase surface . ( 1 ) 8 mm STU D BOLT ( 2 ) 1 0 mm STUD BOLT Tighten the stud bolts to the specified torque. TORQUE: 8 mm stud bolt: 20 - 30 N · m ( 2 . 0 - 3.0 kg-m, 1 4 - 22 ft-lb) 1 0 mm stud bolt: 3 0 - 50 N•m (3.0 - 5 .0 kg-m, 22- 36 ft-lb) 1 78 - 1 80 mm ( 7 .008 - 7 .087 in) 1 68 - 1 70 mm ( 6 . 6 1 4 - 6 . 693 i n ) 1 1 -1 5 C RAN KS H A FT /TRAN S M ISSI O N After'9 5 : Check that the studs a re tight, I f any a re loose, remove them , clean their threads with contact cleaner, then reinstall them apply engine oil to the threads . NOTE • Install the studs with the flat side into the crankcase . (1 ) \�I=-=;1..1 �%,... .--� .. 1 1�1, FLAT SI DE (2 ) B OSS S I DE After installing , be sure to measure the distance from the top of each stud to the crankcase surface as shown . (1) 8 mm STU D BOLT 1 8 5- 1 8 7 mm ( 7 . 2 83-7 . 3 62 O I L J ET Remove the oil jets from the front cylinder bore of the right and left crankcase . Check the 0-ring for fatique and damage . 1 1 -1 6 in) (2) 1 0 mm STU D BOLT 1 68 - 1 70 mm (6.6 1 4 - 6.693 in) CRAN KSHAFT/TRA N S M ISSION TRANSM I SSION ASSEM BLY I I NSTALLATION Apply molybdenum disulfide grease to the fol lowing. - shift fork grooves - inside and outside of the bushings - outside of the spline bushings ( 51 C1 ( 36TI (4) C2 (34T) ( 3 ) C3 ( 2 7TI (6) MAINSHAFT ( 1 I COUNTERSHAFT M4 ( 1 0) M4 (29TI (2) C4 C O U NTERSHAFT C3 C 2 C1 I nstal l the stopper ring and C4 gear onto the countershasft. 1 1 -1 7 C RAN KSHAFT/TRANSMISSION I nstall 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. I nstall the stop washer first, and then the lock washer for the C3 gear. Align and lock the washers using the procedure above. I Assemble the countershaft and mainshaft. Check the gears for freedom of movement or rotation on the shaft . Check that the snap rings are seated in the grooves and align their end gaps with the lands of the splines. ( 1 ) STOP WASHER I ( 2 ) LOCK WASHER ' 8 8 , ' 89 , ' 9 1 -' 9 5 : I nstall the left shift fork on t h e shaft with M R 1 mark facing the groove on the shaft end and the bolt hole aligned with the shaft hole. ( 1 ) MR1 MARK ( 2 ) G ROOVE ' 8 8 , ' 89 , ' 9 1 -' 9 5 : Tighten the bolt with the lock washer a n d bend up the tabs of the lock washer. ( 1 ) BOLT ( 2 ) TABS 1 1 -1 8 CRANKSHAFT/TRANSMISSION '88 . '89 . ' 9 1 -' 9 5 : I nstall the right shift fork with the " R " mark o n the fork facing up. Assemble the mainshaft, countershaft, shift fork shaft and shift drum. I nstall them into the l eft crankcase as an assembly. After'9 5 : Assemble the mainshaft a n d countershaft . I nstall them into the left cankcase as an assembly . I nstall the shift forks into the shifter gear g rooves with the markings facing up ( right crankcase side) . I nstall the shift drum by aligning the shift fork guide pins wiht the shift drum guide g rooves . I nsert the shift fork shaft throug h the shift forks into the left crankcase with the stepped end facing u p . STE P P E D EN D CRAN KCASE ASSE M BLY Apply sealant to the crankcase mating surfaces. I nstall the dowel pins. ( 1 I DOW EL PINS , 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 case and check for misaligned parts. 1 1 -1 9 C RAN KSHAFT/TRANSMISSION 2 Apply oil to all crankcase bolts . Instal l and tighten the right crankcase bolts i n a crisscross pat­ tern in or 3 steps. NOTE • Tighten the 8 mm bolts first, then tighten the 6 mm bolts. 2 I nstall and tighten the left crankcase bolts in a crisscross pat­ tern in or 3 steps. NOTE • Tighten the 8 mm bolts first, then tighten the 6 mm bolts . I nstall the rear cam chain drive sprocket over the crankshaft, aligning the extra-wide splines i n the sprocket and crankshaft. Instal l the rear cam chain over the drive sprocket. Install the oil pipe stay and cam chain tensioner set plate . Tighten the bolt sercurely. 1 1 - 20 C RAN KS HAFT/TRA N S M ISSION I nstal l the front cam chain over the front cam chain d rive sprocket. I nstall the cam chain tensioner set p l ate and tighten the bolt securely. I nstal l the rema1mng parts in the reverse order of removal (page 1 1 - 1 ) . 1 1 -2 1 F R O NT W H E E L/ S U S P E N S I O N / STE E R I N G After •g4 . 3 0 N · m (3 . 0 K g-m , 2 2 ft-lb ) 1 05 N · m ( 1 0 . 5 Kg -m, 76 ft-lb) 2 3 N · m (2 . 3 K g-m , 1 7 ft-lb) � 2 2 N · m (2 . 2 K g-m , 1 6 ft-lb) '88 , ' 8 9 ' ' 9 1 - . 93 • 2 7 N · m (2 . 7 K g-m , 2 0 ft-lb) After ' 9 3 :. 3 1 N · m (3 . 1 K g-m , 22 ft-lb) 12-0 1 2. FRONT WH EEL/SUSP ENSION/STEER I NG SERVICE I N F O RMATION 1 2- 1 FRONT W H EEL 1 2-6 TROU BLES H O O T I N G 1 2-2 FORK 1 2- 1 2 HAN D LEBAR 1 2-3 STEERING STEM 1 2- 1 9 SERV I CE I N FORMATION • • • • • 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 OSHA -approved vacuum cleaner or alternate method approved by OSHA, designed to minimize the hazard caused by air borne asbestos fibers. This section covers maintenance of the front wheel, fork and steering ste m . Refer to section 1 4 for front (hydraulic) brake service . Support the motorcycle using a hoist or a jack under the engine. The VT600C uses leaf valve to the left . S P E C I F I CATI O N S STAN DAR D ITE M Axle ru nout Front wheel rim runout Fork spring free length - Radial Axial ' 8 8 , ' 8 9 ' ' 9 1 -' 9 3 : After' 93: Fork tu be runout '88.' 8 9 : Fork flu id capacity ' 9 1 -' 9 3 : After'93 : R ight '88.'89 Left Fork fluid level R ight ' 9 1 -'93 Left After'9 3 : - - 3 0 5 m m ( 1 2 . 0 in) 333.9 m m ( 1 3. 1 in) - 463 cc( 1 5.7 U S oz, 1 3.0 Imp oz) 468 cc( 1 5.8 US oz, 1 3.2 Imp oz) 449 cc( 1 6. 9 US oz, 1 5.8 Imp oz) 9 5.0 m m ( 3 .74 in) 93.0 mm(3.66 i n ) 89.0 m m ( 3 . 5 0 in) 87.0 m m ( 3 .43 i n ) 1 1 1 m m (4.4 in) S E RVICE LI M IT 0.2 m m (0.008 in) 2 . 0 m m ( 0.08 in) 2 . 0 mm (0.08 in) 299 mm ( 1 1 .8 in) 3 2 7 . 2 m m ( 1 2.9 i n ) 0.2 m m ( 0.008 in) - - - - - - - - T O R Q U E VALU E S H andlebar mounting bolt H andlebar upper holder bolt After ' 94 : Clutch lever holder bolt Brake m astercylinder holder bolt Spokes Brake disc mounting bolt Front axle Fork axle pinch bolt Fork socket bolt Fork top pinch bolt Fork bottom pinch bolt ' 8 8 , ' 8 9 , ' 9 1 -' 9 3 : B ra ke caliper mounting bolt After ' 9 3 : Steering bearing adjustment nut Steering stem nut 23 N·m (2.3 kg·m, 17 ft-lb) 3 0 N · m ( 3 . 0 kg-m, 2 2 ft-lb) 1 2 N·m ( 1 . 2 kg-m, 9 ft-lb) 1 2 N·m ( 1 .2 kg-m, 9 ft-lb) 4 N·m (0.4 kg-m, 2.9 ft-lb) 40 N·m (4.0 kg-m, 29 ft-lb) 75 N·m ( 7 . 5 kg-m, 54 ft-lb) 22 N•m ( 2 . 2 kg-m, 1 6 ft-lb) 30 N•m ( 3 . 0 kg-m, 22 ft-lb) 1 1 N • m ( 1 . 1 kg-m, 8 ft-lb) 50 N • m ( 5 . 0 kg-m, 36 ft-lb) 2 7 N•m ( 2 . 7 kg-m, 20 ft-lb) 3 1 N· m ( 3 . 1 kg-m,2 2 ft-lb) 2 5 N • m ( 2 . 5 kg-m, 1 8 ft-lb) 1 05 N·m ( 1 0. 5 kg-m, 76 ft-lb) 1 2- 1 FRONT WHEEL/S U S P E N S I O N/STE E R I N G T O O LS Special j Spoke wrench Bottom holder pipe - holder attachment - holder handle 07JMA - M R60 1 00 o r equivalent commercially available in U . S . A . 07930- KA50000 N ot available i n U . S . A . 07930- KA50 1 00 07930 - KA40200 Ball race remover - driver attachment - driver handle 07953 - MJ 1 0000 07953 - MJ 1 0 1 00 T 07953 - MJ 1 0200 J Fork seal driver , 39mm Steering stem socket Steering stem driver Bearing race remover 07 947 - 4630 1 00 079 1 6 - 37 1 0 1 00 07 946 - M BOOOOO 07946 - 37 1 0500 N ot available in U . S . A . 0 7 9 5 3- MJ 1 000A . 0 7 9 5 3- M J 1 000B o r 0 7 949 -37 1 000 1 a n d 0 7 7 4 6-00 1 0 1 00 Common Driver Attachment, 42 x 47 mm Pilot, 20 mm Bearing remover shaft Bearing remover head , 20 m m Attachment, 52 x 55 m m 07 749 - 00 1 0000 07 746 - 00 1 0300 07 746 - 0040500 07 746 - 0050 1 00 -r--Equivalent commercially available i n U . S . A . 07 746 - 0050600 _j 07 746 - 00 1 0400 TROUBLESHOOTI N G Hard Steering • • • Steering bearing adjustment nut too tight Faulty steering stem bearings Insufficient air in front tire Soft Suspension • • Weak fork springs I nsufficient fluid in fork legs Hard Suspension Steers to One Side or Does Not Track Straight • • • Bent fork legs Bent front axle, wheel installed incorrectly Unequal oil quantity i n each fork tube Front Wheel Wobbling • • • • • Distorted rim Worn front wheel bearings Loose or broken spokes Faulty tire Axle or axle holder not tightened properly 1 2- 2 • • Fork oil level too high Fork tube(s) bent or fork slider(s) damaged Front Suspension Noise • • • Slider binding Insufficient fluid in fork legs Loose fork leg fasteners FRONT WH EEL/SUSPENSION/STEERING HAN DLEBAR G R I P R E PLAC E M E N T Remove t h e right handlebar switch screws a n d disconnect the throttle cables from the throttle pipe. Remove the grip end cap and right handlebar grip. Remove the grip from the throttle pipe. ( 1 ) CEMMENT 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 i nstall the right handlebar switch. I nstall the grip end cap. (3) Remove the grip end cap and pull the grip off of the left handle­ bar. "() � ROTTLE PIPE ( 2 ) G R I P END CAP ( 1 ) C E M M ENT Apply Honda Bond A or Honda Grip Cemment ( U . S . A . only) to inside surface of the left grip to the clean surface of the handlebar. Wait 3 - 5 minutes and install the grip. Rotate 1:he grip for even application of the adhesive. NOTE • Allow the adhesive to d ry for a n hour before using . Check for smooth throttle operation after the right grip is installed . I nstall 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 1 2-3 FRONT W H EEL/S USPENSION/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 ( 1 l BARKE LIGHT SWITCH WIRE Loosen the throttle cable lower adjusting nuts at the carbure­ tors and disconnect the throttle cables from the throttle pipe. Remove the handlebar mounting nuts, handlebar and rubber seat from the fork bridge . After '94 : Remove the ha ndlebar upper holder bolts caps . Remove the socket bolts , upper holders and handleba r . Remove t h e n uts and handlebar lower holders . R>/"1�------, 1 2-4 ( 2 ) LOW E R H O LD E R S F R O N T WHEEL/SUSPENSIO N/STEERING I N STA LLAT I O N '88 , '89 , '9 1 -'94 : I n stall the rubber seat into the fork bridge . I n stall the washers and handlebar mounting n uts. Tighten the nuts . TO RQU E : 23 N · m ( 2.3 kg-m, 1 7 ft-lb ) After '94 : I nstall the handlebar lower holders a n d tem porarily tighten the n uts . I nstal l the handlebar and upper holders with their pu nch marks facing forward . Tem porarily tighten the socket bolts . Tig hten the lower holder nuts to the specified torque . TO RQU E : 23 N • m ( 2 . 3 kg-m, 1 6 ft-lb) ( 1 ) LOWER H O L D E R N UTS Loosen the u pper holder socket bolts a nd align the punch m arks o n the handlebar with the splits of the handlebar holders . Tighten the forward bolts first, then tig hten the rear bolts . T O R QU E : 3 0 N · m ( 3 . 0 kg-m , 22 ft-lb) I nstal l the u pper holder bolt caps . Install the left handlebar switch set collar on the upper switch housing . Align the locating pin in the lower switch housing w ith the hole in the handlebar. Install the left handlebar switch attaching screws, and tighten the forward screw first, then tighten the rear screw. 1 2- 5 FRONT WH EEL/S U S PE N S I O N/STE E R I N G Install the clutch holder/lever and with the " U P" 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-lbl Connect the clutch switch wires. I nstall the right rea r 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. I nstal l the right handlebar switch onto the handlebar, aligning the locating pin with the hole in the handlebar. I nstall the right handlebar switch screws and tighten the for­ ward screw first, then tighten the rear screw. I nstall the front brake master cylinder/holder with the " U P" 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. TORQU E : 12 N · m ( 1 . 2 kg-m, 9 ft-lbl Connect the front brake light switch wires. I nstal l the right rear-view mirror into the master cylinder/ holder. Secure the wire with wire bands. Adjust the following: - throttle operation and free play (page 3 - 6 ) . - clutch lever free play (page 3 - 1 8 ) . 1 2-6 FRONT WHEEL/S U S PE N S I O N /STEERING FRONT WHEEL R E M OVA L Raise and support the motorcycle using a hoist or a jack u nder the engine . Remove the set screw and pull the speedometer cable out of the speedometer gearbox . t- ( .. ( 2 ) SET SCREW Remove the axle pinch bolt caps, a n d bolts from the right front fork leg . 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 2- 7 FRONT W H E E L/SUSPEN S I O N/STEE R I N G I N S P E CT I O N e (1 ) FRONT AXLE AXLE Set the axle in V blocks and measure the runout . Actual ru nout is 1 /2 the tota l i n dicator reading . - SERVICE LIMIT: 0 . 2 mm (0 . 0 1 in) � e WHEEL Check the spokes and tighten any that are loose . TORQU E : 4 N • m (0.4 kg-m, 2 . 9 ft-lbl Check the rim runout 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) (1) CAUTION • Wheel balance directly affects the stability, handling and over­ all safety of the motorcycle. A lways check balance when the tire has been removed from the rim . NOTE • • For optimum balance, the tire balance mark (a paint dot on the sidewall) must be located next to the valve stem. Remount the tire if necessary . \ \�a (2) Mount the front wheel in a inspection stand . Spin the wheel, allow it to stop, and mark the lowest (heaviest) part of 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 i n the same position. 1 2- 8 VALVE BALANCE MARK I F R O N T W H EEL/S USPENSION/STEERING To balance the wheel, i nstall 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 i n the same po­ sition when it is spun . D o not a d d more than 70 grams. "'( 1 ) WHEEL WEIGHT e WHEEL BEARING Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly i n the hub. Remove and discard the bearings if the races do not turn smoothly, quietly, o r if they loosely in the hub. ( 1 ) WHEEL BEARING B EA R I N G R E P LA C E M E N T - ( 1 ) DUST SEALS Remove the front wheel ( page 1 2-7) . 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. 1 2-9 FRONT WH E E L/S USPENSION/STE E R I N G Drive out the wheel bearings and distance collar. CAUTION Never reuse old bearings. • TOOLS : Bearing remover shaft Bearing remover head, 20 mm 07746-005 0 1 0 0 Equivalent commercially available in U .S.A. 07746-0050600 Equivalent commercially available i n U .S.A. ( 1 ) DRIVER Drive in the new left bearing first until it seats. I nstall the distance collar and drive in the right bearing. N OTE • • Install the bearings with the vendor markings facing the outside. Be sure to drive the bearings i n squarely. Always replace wheel bearings in pairs . TOOLS : Driver Attachment, 42 Pilot, 20 mm x 07749 - 00 1 0000 47 mm 07746 - 00 1 0300 07746 - 0040500 A S S E M B LY • Do not get get grease on the brake disc or stopping power will be reduced. (1 1 l ' -� SIDE CO LLAR (1 l DISTAN C E COLLAR __:::..c:o . . (9) BEARI NG (4) (6) 1 2- 1 0 SPEEDOMETER GEARBOX f?� SPEEDO­ M ETER (5) WASHERS G EAR FRONT WH EEL/S U S PEN S I O N /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 d istance ( B ) , and make a calculatio n . (A) 7 0 . 8 mm ( 2 . 787 in) ( 8 ) + 2 Adjust the hub position so that the d ista n ce from the hub sur­ face where the brake disc mounts to the side of rim is (A) . Tighten the spokes in 2 or 3 progreassive steps. = TOOLS : Spoke wrench : - 07JMA - MR60 1 00 or equivalent commercially available in U . S .A. TORQU E : 4 N•m (0.4 kg-m, 2 . 9 ft-lb) Check the wheel runout (page 1 2-8) . I nstall the tube and tire . Coat the speedometer gear retainer with grease and install the retainer i nto the wheel hub, aligning the tangs with the slots in the hub. Apply grease to the oil seal lip and instal l 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 . N OTE • Tighten the bolts in a crisscross pattern in 2 or 3 steps . TORQUE : 40 N · m 14.0 kg-m, 29 ft-lb) • Do not get grease on the brake disc or stopping power will be reduced. Apply grease to the dust seal lips and install the seal on the right side of the hub. ( 1 ) DUST SEAL 1 2- 1 1 FRONT WHEEL/SUSPENSIO N/STEERING Apply grease to the speedometer gearbox and gear. I nstall the speedometer gear and washers into the gearbox. (1 I G EAR BOX I nstall the speedometer gearbox into the wheel hub, aligning the tangs with the slots . Clean the brake discs with a high quality degreasing agent. I nstall the right side collar. INSTALLATION Place the front wheel between the front fork legs. Fit the caliper over the brake disc, taking care not to damage the brake pads. Clean the axle and holder. I nstall 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. t2 1 S�T SCREW Tighten the front axle. TORQUE: 75 N•m (7 . 5 kg-m, 54 ft-lbl Tighten the fork pinch bolts . TORQUE: 22 N·m (2.2 kg-m, 1 6 ft-lb) I nstall the speedometer cable and set screw securely. 1 2- 1 2 FRONT W H EEL/S U S PENSION/STEERING FORK R E MOVAL Remove the front wheel ( page 1 2 - 7 ) . Remove the brake caliper mounting bolts and brake caliper. Unhook the brake hose from the hook on the fender. 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. Q l il Loosen the following bolts : - turn signal mounting bolt - fork top pinch bolt - fork bottom pinch bolt . FO R KT O P P IN C H BOLT Pull the fork tubes out of the top bridge and steering stem. (3) ( 2 ) TURN SIGNAL LIGHT / FORK BOTTO M PINCH BOLT . MOUNTING BOLT 1 2- 1 3 FRONT W H E E L/S U SPENSION/STE E R I N G ( 1 ) FORK CAP D I SA S S E M BLY Remove the fork cap bolt . The cap bolts are under spring pressure. Take care when re­ moving, and wear eye and face protection. • Remove the fork spring, seat washer and spacer. Pour out the fork fluid by pumping the fork up and down sever­ al times . '\ \ Hold the fork slider in a vise with soft jaws or a shop towe l . ( 1 ) HOLDER HANDLE CAUTION Do not distort the fork slider in the vise. • I nstall the special tool i nto the fork tube and hold the piston, then remove the socket bolt. TOOLS : Bottom holder pipe - holder attachment - bottom holder handle 07930-KA50000 N ot available i n U . S .A. 07930- KA5 0 1 00 N ot available i n U . S .A. 07930- KA40200 N ot available i n U . S .A. Remove the dust seal and stop ring . CAUTION • Be careful not to damage the fork tube. 1 2- 1 4 ( 1 ) D U ST SEAL FRONT W H E EL/S USPENS I O N/ST E E R I N G I n quick successive motions, pull the fork tube out of the slid­ er. NOTE • The slider bushing that is pressed into the slider, and the fork tube bushing on the end of the fork tube, must be forced out. Remove -th e 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 tube. Do not remove the fork tube bushing until inspection determines it is necessary ( page 1 2- 1 5 ) . \ (4) BACK-U P RING (3) TUBE BUS H I NG I N S PE CT I O N ( 1 ) FO Fork spring Measure the fork spring free lengt h . S E RV I C E L I M IT: '88,'89 .' 9 1 -'93: 2 9 9 mm ( 1 1 .8 i n ) After'93: 333 . 9 mm ( 1 3 . 1 i n ) SPRI NG •J\/"""fJ\J 'v'\I/lJJIIIIIIlf/1 Replace the spring if it is shorter than the service limit. . ( 1 I FORK S L I D E R Fork tube/slider/piston ( 2 ) FORK TUBE � 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. (5) �� . , ! REBO U N D SPRING (4) PISTON \ • '\(3) OIL LOCK PIECE 1 2- 1 5 FRONT W H E E L/SUSPEN S I O N/STEERING Set the fork tube i n V blocks and read the ru nout. Actual runout is 1 /2 the total indicator reading. SERVICE LIMIT: 0 . 20 mm (0. 008 in) Bushings Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratch­ ing, or if the teflon is worn so that the copper surface a ppears on more than 3/4 of the entire surface. (11 BUSH I N G (21 BACK-UP RING .. ...... ~ Check the back-up ring; replace it if there is any distortion at the points shown. (31 CHECK PO INTS (41 COPPER SU RFACES A S S E M BLY (1 I ( 1 91 ( 1 81 ( 1 71 ( 1 61 ( 1 51 � --_JJ FORK TUBE CAP '88 . '89 . ' 9 1 -'93 O N LY 0-RING SPAC ER SPR I N G SEAT FORK SPRING -----1/ ;:! (1 I ( 1 31 REBOU N D SPRING 1 2- 1 6 � .� RIGHT FO RK TUBE (61 (71 SLIDER BUSHING FORK SLIDER ( 3) LEAF VALVE � ""'== - �� ( 9 1 DRAIN BOLT ��� PISTO N (21 �>+--�-rl 5 1 BACK-UP RING PISTON RING ( 1 41 LEFT FORK TUBE ( Except after'9 5) @> J.--( 1 01 SOCKET BOLT FORK TUBE BUSH I N G O I L LOCK PIECE (1 1 I ( 1 21 CAUTION • • The fork tube cannot be disassembled. Do not interchange the right and left fork tube when in­ stalling the fork tu be in th e fork slider. FRONT WHEEL/S U S P E N S I O N /STEERING I nstall the rebound spring i nto the fork tube. I nstall a new postion ring i nto the piston groove . Place the oil lock piece on the end of the piston and insert the fork tube i nto the slider. ( 1 I OIL SEAL (21 BACK-U P R I N G / PISTON (61 SLIDER BUSH I N G ( 5 ) TUBE BUSH I N G I nstal l the special tools i nto the fork tube to hold the pis­ ton,and i nstall and tighten the socket bolt. TOOLS : Bottom holder pipe - holder attachment - bottom holder handle ( 2 1 BOTTO M HOLDER HANDLE (1 I HOLDER ATTACH MENT � 07930- KA50000 N ot ava i l a ble i n U . S.A. 07930- KA50 1 00 N ot ava i lable i n U . S.A. 07930- KA40200 N ot ava i l able i n U . S.A. Place the fork slider i n a vise with soft jaws or use a shop towel. Apply a locking agent to the socket bolt and thread it i nto the piston . Tighten w ith a 6 mm hex wrench . NOTE • I ( 4 ) LOCK PIECE ( 1 l SOCKET BOLT , ..... ' ..... ' ' Temporarily install the fork sprin g and fork cap bolt to tight­ en the socket bolt. TORQU E : 30 N·m (3.0 kg-m, 22 ft-lbl Place the sl ider bushing over the fork tube until it rests on the slider. N OTE • Tape the upper edge of the fork tube to avoid damaging the oil seal lip, while i nstalling the o i l sea l . U s i n g a fork seal driver , drive t h e bushing into place . I nstal l the back-up ring with the c hamfered side facing the slider bushing. Coat the oil seal lip with the recom mended fork oil. D rive the oil seal i nto place using a fork seal driver. I nstall the oil seal stop ring and the dust sea l . TOOL: Fork seal driver, 39mm d� Iv ( 3 ) STOP RING �� (4) O I L SEAL V l �- ( 2 ) D U ST SEAL ( 5 ) BACK-U P RING 07947 - 4630 1 00 1 2- 1 7 FRONT WHEEL/S U S P E N S I O N/STEERING Com press the fork leg and pour Honda Su spensio n F luid SS-8 o r equ iva lent i nto the fork tube. SPECI F I E D L E V E L : '88, 89: Right fork : 95.0 mm Left for k : 93.0 mm '91 -'93 : . R ight fork : 89.0 m m Left fork: 87.0 mm After '93: R i g ht and l eft forks : ' r� U (1 ) O I L LEVEL (3.74 in ) (3.36 i n ) LR (3.50 in) (3.43 i n) 1 1 1 m m (4 . 4 i n ) CAPAC I TY : '88, '89: 463 cc ( 1 5.7 US oz , 1 3.0 I mp oz) ' 9 1 -'93 : 468 cc ( 1 5.8 U S oz, 1 3. 2 Imp oz ) After '93: 449 cc( 1 6 . 9 U S oz , 1 5.8 1 m p oz) I nstal l the fork spring, washer and spacer into the fork tube. '88 . '89 . ' 9 1 - '93 : NOTE • l\Jt . · Note the direction: the tightly wound coils should be at bot­ tom . � ( 1 )TI G HTLY WO U N D C O I LS t r t' �J r · r , t r . ' ' '' \I v 11 V 'iJ 'v J J111/(({(r � : . . · A Fter '93 : N OT E • N ote the directio n :the tightly wound coils should be at top. Loosely install the fork tube cap with a new 0-ring. I N STA LLAT I O N I nstall t h e fork tube, aligining its top e n d with the upper sur­ face of the top bridge as show n . Temporarily install a n d tighten the fork top pinch bolts and turn signal mounting bolts . : ; .: 1 2- 1 8 ( 1 l 0-RING (2) FORK TUBE CAP . . , � , FRONT WHEE L/S U S P E N S I O N/STEERING I nstall and tighten the bottom pinch bolt. TORQU E : 50 N · m (5.0 kg-m, 36 ft-lbl Tighten the top pinch bolt. TORQU E : 1 1 N·m ( 1 . 1 kg-m, 8 ft-lb) I nstall the front fender and tighten the mounting bolts secure­ ly. ,1 �" (2) � M O U N T I N G BOLTS Hook the brake hose onto the hose clip. I nstal l the brake caliper with the mounting bolts . Tighten the bolts to the Specified torque. TORQU E : '88 . '89 . ' 9 1 - ' 9 3 ; 27 N•m ( 2 . 7 kg-m, 20 ft-lb) After '93 : 3 1 N · m ( 3 . 1 kg-m , 22 ft-l b ) I nsert the speedometer cable through the fender holder. 1 2- 1 9 FRONT W H EEL/S U S P E N S I O N /STEER I N G STEER I NG STEM (2) SPEEDO­ M ETER R E M OVAL Remove the fork legs and handlebar. Disconnect the speedometer cable from the speedometer, and the 6P black connector (see page 1 - 1 3 ) . Remove the following : - speedometer from the fork bridge - headlight from the headlight case - headlight stay and mounting nuts, headlight stay and case (4) Remove the steering stem nut and washer. STAY (1 l STE E R I N G STEM NUT (1 ) LOCK NUT 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 2-20 (2) LOCK WAS H E R TABS FRONT WHEEL/S U S P E N S I O N/STEERING Loosen the steering head bearing adjustment nut. TOOL: Steering stem socket 079 1 6 - 37 1 0 1 00 ( 1 ) STEE R I N G STEM S O C K ET Hold the steering stem by hand and remove the adjustment nut, dust sea l , 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. B EA R I N G R E PLAC E M E N T ( 9 ) LOWER B E A R I N G � ( 1 0 ) L O W E R B EA R I N G I N N E R RACE ( 1 1 ) D U ST S E A L 1 2- 2 1 FRONT WH EEL/S U S P E N S I O N /STEERING ( 2 ) STEM NUT NOTE • Always replace the bearing and race as a set. I nstal l the steering stem nut o n the top end of the steering stem to protect the threads from damage. Remove the lower i n ner race and dust seal using a punch or d river. Replace the dust seal with a new one whenever it is removed . (3) Remove the lower outer race using the special tools and a suit­ able shaft. TOOLS : Bearing race remover: 07946 - 37 1 0500 Remove the upper bearing outer race using the special tools. TOOLS : Ball race remover - attachment - driver handle or Attachment 07953 - MJ 1 0000 07953 - MJ 1 0 1 00 07953 - MJ 1 0200 J N ot ava i l a b l e in U . S . A . 0 7 9 5 3 - MJ 1 OOOA , 07953 - MJ 1 0008 or 0 7 949-3 7 1 000 1 and D river Attachment, 32 X 35 m m 0 7746-00 1 0 1 00 Install a new dust seal over the steering stem. Press a new lower bearing inner race onto the stem. TOOL: Steering stem driver 07946 - MBOOOOO Drive new upper and lower bearing outer races into the steer­ ing head pipe . TOOLS : U pper bearing outer race : Drive Attachment, 42 x 47 mm Lower bearing outer race : Driver Attachment, 52 x 55 mm 1 2-22 07749 - 00 1 0000 07746 - 00 1 0300 07749 - 00 1 0000 07746 - 00 1 0400 LOWER I N N E R R A C E I FRONT WH EEL/S USPEN S I O N /STE E R I N G ,, I N STALLAT I O N Pack t h e bearing cavities w i t h grease. I nstall the lower bearing onto the stem. Insert the stem i nto the steering head pipe and i nstall the upper bearing, inner race, dust seal and steering bearing adjustment n ut. E R I N G B EA R I N G A DJ U ST M E N T NUT ( 1 ) 1NNER RACE .... Apply e n g i n e o i l to the a d j u st m e n t n ut t h reads . Tighten the steering bearing adjustment nut to the specified torque. TOOL: Steering stem socket (1 I t STE E R I N G STEM SOCKET 0 79 1 6 - 37 1 0 1 00 TORQUE: 2 5 N·m ( 2 . 5 kg-m, 1 8 ft-lbl Turn the steering stem back and forth five times to seat the bearings. Retighten the adjustment nut to the same torque. Turn the steering stem to seat the bearings. I nstall a new lock washer and bend the two opposite tabs down into the grooves i n the adjustment nut. ( 1 I LOCK WA S H E R (2) LOCK NUT Install and finger tighten the lock n ut all the way. Hold the bearing adjustment nut and further tighten the lock nut, within 90 degrees, to align its g rooves with the tabs of the lock washer. Bend up the lock washer tabs i nto the grooves of the lock nut. 1 2-23 FRONT WH EEL/S U S PENS I O N /ST E E R I N G I nstall the indicator panel with two screws. I nstall the fork bridge then temporarily i nstal l the fork legs. Tighten the steering stem nut. TORQUE : 1 05 N • m ( 1 0 . 5 kg-m, 76 ft-lb) Instal l the following parts: - fork legs (page 1 2 - 1 8 ) . - front wheel (page 1 2 - 1 2 ) . Check the steering head bearing preload . ST E E R I N G H EA D B EA R I N G P R E L O A D Place a stand under the engine and raise the front wheel off the groun d . Position t h e steering stem t o 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 . 3 1 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 , instal l the removed parts in the reverse order of removal . 1 2 - 24 MEMO REAR WHEEL/BRAKE/S U S PENSION 1 3-0 1 3. REAR WH EEL/ B RAK E/SUSP E NSION SERVICE I N FO R M AT I O N 1 3- 1 BRAKE PEDAL 1 3- 1 0 T R O U BLESHOOTI N G 1 3-2 S H O C K ABSORBER 1 3- 1 1 REAR WH EEL 1 3- 3 SWINGARM 1 3- 1 4 R EAR BRAKE 1 3- 7 S EAT /REAR FENDER/S U B-FRA M E 1 3- 1 8 SERVICE I N FORMATION G E N ERAL Support the motorcycle using a hoist or a jack under the engine. • CAUTION Do not jack up the motorcycle using the oil filter. • • • • • • Use only genuine Honda replacement fasteners for the rear suspension. Note the i nstallation direction of the bolts. A ny attempt to mount automobile tires on a motorcycle rim may cause the tire bead to separate from the rim with enough explosive force 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 nitro­ 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 mothod approved by OSHA, designed to minimize the hazard coused by airborne asbestos fibers. S P E C I F I C AT I O N Unit: mm (in) ITEM Rear wheel runout STANDARD SERVICE LIMIT Radial -- 2 . 0 mm (0.08 in) Axial -- Rear axle runout Rear brake drum I . D . Rear brake lining thickness Shock absorber spring free length Rear suspension damper compression -- 2 . 0 mm (0.08 in) 0 . 2 mm (0.01 in) 1 6 1 mm ( 6 . 3 in) 1 60 mm ( 6 . 3 in) 5 mm (0. 2 in) 1 37 . 5 m m ( 5 . 4 1 in) 2 mm (0.08 in) 1 3 5 . 0 mm ( 5 . 3 1 in) 1 3 . 4 - 1 7 . 4 kg ( 2 9 . 5 4 - 3 8 . 36 lb) 1 3 . 3 kg ( 2 9 . 3 2 lb) T O R Q U E VALU E S Spokes Sprocket nut Shock absorber mounting bolt Swingarm pivot bolt Rear axle Damper rod lock nut Brake torque rod nut 4 N•m (0.4 kg-m, 2.9 ft-lb) 65 N·m ( 6 . 5 kg-m, 4 7 ft-lb) 45 N•m (4. 5 kg-m, 33 ft-lb) 90 N•m ( 9 . 0 kg-m , 6 5 ft-lb) 90 N•m ( 9 . 0 kg-m, 6 5 ft-lb) 70 N·m (7.0 kg-m , 51 ft-lb) 27 N•m (2. 7 kg-m , 20 ft-lb) 1 3- 1 IIEI:f:l ..:I REAR WHEEL/BRAKE/S USPEN S I O N T O O LS Special Driver shaft Attachment, 28 x 30 mm Spoke wrench Shock absorber compressor Attachment Compressor screw Snap ring pliers 07 946 - MJ00 1 00 07746 - 1 870 1 00 07JMA - M R60 1 00 or equivalent commercially available i n U . S .A. 07G M E - 00 1 0000 07 J ME - M R 1 0 1 00 07G M E - 00 1 0 1 00 079 1 4 - 323000 1 Common Bearing remover shaft Bearing remover head , 1 7 mm D river Attachment, 42 x 47 mm Pilot, 1 7 mm Attachment, 32 x 35 mm Pilot, 1 5 mm Pilot, 22 mm TROUBLESHOOTI NG Wobble o r vibration i n motorcycle Bent rim Loose wheel bearing(s) Loose or bent spokes Damaged tire Axle not tightened properly Swingarm pivot bearing worn Chain adjusters not adjusted equally Bent frame or swingarm Soft suspension • • Weak spring I mproper shock absorber spring preload Hard suspension • • • • I mproper 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 :,,1 3-2 07 746 - 0050 1 OO or equivalent commercially available in U . S . A . 07 746 - 0050500 07749 - 00 1 0000 07 746 - 00 1 0300 077 46 - 0040400 07 746 - 00 1 0 1 00 07 746 - 0040300 07 746 - 004 1 000 J R E A R W H EEL/BRAKE/S U S P E N S I O N REAR WHEEL REM OVAL · Support the motorcycle using a hoist or a jack under the en­ gine. CAUTION • Do not jack up the oil filter. 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 I N S PE CT I O N e AXLE Set the axle on V blocks and measure the runout. SERVICE LIMIT: 0.2 mm (0.01 in) e WHEEL Check the spokes and tighten any that are loose . TORQUE : 4 N • m (0.4 kg-m, 2.9 ft-lbl TOOL: Spoke wrench 07JMA - MR60 1 00 or equivalent commercially available in U .S.A. Check the rim runout by placing the wheel on a truing stan d . S p i n t h e w h e e l h a n d and read t h e runout using a d i a l indicator. SERVICE LIMITS: RADIAL: 2.0 m m (0.08 in) AXIAL: 2.0 mm (0.08 in) e WHEEL BEARING Turn the i n ner race of each bearing with your finger. The bearings should turn smoothly and quietly . Also c h e c k that t h e bearing outer race fits tightly in t h e hub. Remove a n d discard the bearings if the races do not turn smoothly, q uietly, or if they fit loosely i n the hub. NOTE • Replace wheel bearings i n pairs . For bearin g replacement, see page 1 3-4. e WHEEL BALANCING Refer to page 1 2- 7 . NOTE • Do not add more than 70 grams of balancing weight to the rear wheel 11 l WHEEL BEA RING 1 3- 3 REAR W H EEL/BRAKE/S USPENSION S P R O C K ET/D R I V E N FLAN G E D I SA S S E M B LY / I N S PECTI O N Remove the wheel ( page 1 3-31 . 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 d rive chain and d rive sprocket must also be inspected if the driven sprocket is worn or damaged . Never instal l a new drive chain on worn sprockets or a worn chain on new sprockets . Both chain and sprocket must be i n 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 . D rive out the driven flange bearing, if necessary . I nspect 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 . BEA R I N G R E PLAC E M E N T Wheel bearing Drive out the wheel bearings and the distance collar. NOTE • If the bearings are removed , they must replaced . TOOLS : Bearing remover shaft Bearing remover head, 1 7 mm 1 3-4 07746 - 0050 1 00 07746 - 0050500 or equivalent commercially available in U . S . A . ( 1 1 GOOD ( 2 1 REPLACE REAR WH EEL/BRAK E/S U S PENSION First, drive in a new left wheel bearing until it is fully seated, in­ stall the distance collar, then drive in a new right bearing. TOOLS : Driver Attachment, 42 Pilot, 1 7 mm x 47 mm 07749 - 00 1 0000 07746 - 00 1 0300 07746 - 0040400 NOTE • Drive the wheel bearings i n w ith the vendor mark facing out. Flange bearing Drive out the bearing using a suitable tool. Drive the new bearing in with its vendor mark facing out. TOOLS : Driver Attachment, 42 Pilot, 1 7 mm x 47 mm 07749 - 00 1 0000 07746 - 00 1 0300 07746 - 0040400 ( 3 ) ATTACHM ENT A S S E M B LY - - �j A (3) 0-RING ( 1 1 1 BEARING 1 1 01 DAMPER RUBBER /1 (4) DRIVEN SPROCKET ( 9 ) COLLAR (8) FLANGE ( 7 ) NOISE ARRESTER 1 3- 5 REAR WH EEL/BRAKE/S U S P E N S I O N Place the rim and hub on the work bench and begin lacing with a new spoke from the hole of inside i n the hub. Install the spoke with a space of two holes in between . Measure the distance ( B ) , a n d make a calculation. (A) 79 mm ( 3 . 1 1 0 in) ( B ) + 2 Adjust the hub position so that the distance from the hub right end surface to the side of rim is (A) . Tighten the spokes i n 2 or 3 progressive steps. = TOOL: Spoke wrench - 07JMA - MR60 1 00 or equivalent commercially available in U . S .A. TORQUE : 4 N•m (0.4 kg-m, 2 . 9 ft-lb) Check the wheel runout ( page 1 3-3) . Install the tube and tire. I nstall the collar in the driven flange bearing. I nstall the damper rubbers on the flange and place flange i n the hub. Apply grease to a new 0-ring and i nstall it onto the flange groove . (2) Apply grease to the dust seal lip and install it. I nstall the driven sprocket, if removed, and a new seal . Tighten t h e driven sprocket mounting nuts. TORQU E : 65 N•m ( 6 . 5 kg-m, 47 ft-lb) 1 3-6 0-RING REAR WH EEL/BRAKE/S USPENSION I nstal l the axle collar. · --= I N STALLAT I O N I nstall the brake panel on the wheel hub. Position the rear wheel between i n 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. I nstall the adjuster collar and axle nut. Tighten the axle nut lightly. Adjust the drive chain ( page 3 - 1 3 ) . Tighten the axle nut. TORQUE: 90 N · m (9.0 kg-m, 65 ft-lbl Connect the brake torque rod to the brake panel with bolt, seat washer, washer and nut. (page 1 3-8 ) . Tighten the nut. TORQUE: 27 N • m (2. 7 kg-m, 20 ft-lbl I nstall 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 3 - 1 6 ) . R EAR BRAK E I N S PECT I O N Remove t h e rear w heel (page 1 3-3) Remove the brake panel and measure the rear brake drum I . D. SERVICE LIMIT: 1 6 1 mm ( 6 . 3 in) Measure the rear brake lining thickness. SERVICE LIMIT: 2 m m (0.08 in) Replace the brake shoes if either one is thinner than the service limit. 1 3- 7 REAR WHEEL/BRAKE/S USPENSION D I SASS E M B LY Remove the cotter pins and set plate . (2) COTTER PINS 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 - felt seal A S S E M BLY ( 1 ) BOLT (2) I N D I CATOR PLATE (3) FELT SEAL ( 1 0) BRAKE ARM (9) BRAKE PANEL 1 3-8 (8) SPRINGS (4) BRAKE SHOES �7(6) (7) SET PLATE COTTER PINS REAR W H E E L/BRAKE/S USPENSION ( 1 ) BRAKE CAM Apply grease to the brake anchor pins and brake cam. I nstall the brake cam into the brake panel . - I nstall the felt seal. Install the indicator plate on the brake cam aligning its tab with cut-out on the brake cam . Install the brake arm by aligning the punch marks on the arm and cam. I nstall and tighten the bolt. (3) Position the brake shoes in their original locations and install the springs . • Grease on the brake linings will reduce stopping power. Keep grease off of the brake linings. Wipe excess grease off the cam and anchor pin. I nstall the set plate and cotter pins, then bend back the pins. I nstall the brake panel onto the wheel hub and install the rear wheel (page 1 3-7 ) . (4) SET PLATE .... ( 3 ) COTTER PI N� ( 2 ) SPRINGS 1 3-9 REAR WHE EL/BRAKE/S U S PE N S I O N BRAKE PEDAL R E M OVAL Remove the foot peg bracket mounting bolts and washers . Remove t h e brake pedal b y removing t h e cotter p i n , washer and bolt. I N STA LLAT I O N Install the brake pedal in the reverse order o f removal . NOTE Note the locations of the washers . (4) BRAKE SHAFT ARM ( 1 ) BRAKE PEDAL ADJ U STER BOLT -� ( 2 ) DUST SEALS (5) PUNCH M A R K - ljiii@ (8) PIVOT CO LLAR 1 3- 1 0 M I DDLE BRAKE ARM NOTE Align the punch mark on the brake shaft arm end with the punch mark on the middle brake arm. (7) • R EAR W H EEL/BRAK E/S USPEN S I O N REAR SHOCK ABSORBER REM OVAL • The rear shock absorber contains nitrogen under high pressure. Do not allow fire or heat near the shock absorber. Support the motorcycle using a hoist, or a jack under the en­ gine. Remove the follow i n g : - seat, right and left s i d e cover - rear ignition coil mounting bolts (page - rear ignition coil stay mounting bolt 1 6- 5 ) 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 t h e upper and lower shock absorber mounting bolts and nuts then remove the shock absorber. ( 2 ) ATTACH M ENT D I SA S S E M BLY Set the spring preload adjuster to No. 1 position . Compress the shock absorber with the compressor a n d attach­ ment. .;:f;:.'�:·� 'I CAUTION • ·, Be sure the base is adjusted correctly for the shock spring seat and the clevis pin is all the way in. TOOLS : Shock absorber compressor Attachment Compressor screw 07GME - 00 1 0000 07J ME - MR 1 0 1 00 07GME - 00 1 0 1 00 (1 ) No. 1 POSITION 11 1 Loosen the lock nut and remove the lower joint and nut. Remove the com pressor and disassemble the shock absorber. ::: J INT . �- LOCK NUT 1 3- 1 1 REAR WHEEL/BRA K E/S U S PENSION SPRING FREE LEN GTH Measure the shock absorber spring free length . SERVICE LIMIT: 1 35 . 0 mm ( 5 . 3 1 in) Mark the damper rod at 1 0 mm below the case as show n . Place the damper rod on a scale a n d measure t h e force re­ quired to compress the damper to the 1 0 mm (0.4 i n ) mark. COMPRESSION FORCE: 1 3 . 4 - 1 7 . 4 kg (29 . 54 - 38 . 36 1bl If the force required is less than 1 3 . 3 kg ( 2 9 . 3 2 l b ) , gas is leak­ ing. Examine the damper rod and replace the damper unit if it is bent or scored . 1 0 mm (0.4 i n ) 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 . S H O C K A B S O R B E R D I S POSAL PR O C E D U R E Center punch the damper case t o mark a drilling point, a pproxi­ mately 45 mm ( 1 . 8 in) from the mount top surface . Wrap the damper unit inside a plastic bag and support the damper unit upright i n 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. • • • Do not use a dull drill bit which could cause a build-up of exces­ sive heat and pressure inside the damper, leading to explosion and severe personal injury. The shock absorber contains nitrogen gas and oil under high pressure. Do not drill any farther down the damper case than the measurement given above, or you may drill into the oil chamber; oil escaping under high pressure may cause serious personal injury. Always wear eye protection to avoid getting metal shavings in your eyes when the gas pressure is released. The plastic bag is only intended to shield you from the escaping gas. Hold the bag around the drill motor and briefly run the drill motor inside the bag; this will inflate the bag with air from the motor and help keep the bag from getting caught in the bit when you start. 1 3- 1 2 (3) D A M P E R U N I T R EAR W H EEL/BRAKE/S U S PENSION A S S E M B LY ( 1 ) DAMPER � ( 2 ) SPRING • ( 1 2 ) ADJU STER ADJUSTER SEAT (4) SPRING ( 5 1 LOWER SPRING SEAT p (3) U PPER SPRING SEAT a l�Q :\' (B) PLUG (7) LOWER JO I NT ( S) DRAI TU BE ( 1 01 STOPPER RUBBER N ( 9 ) LOCK N UT Install the following: - stop rubber onto the damper rod - spring a djuster seat and spring a djuster 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 LOCK NUT Compress the spring with the compressor (07GME 00 1 0000) and attachment (07 J M E - M R 1 0 1 00) . Screw the lower joint onto the d a m per rod fully, hold it, and tighten the lock nut. TORQUE : 70 N·m (7 .0 kg-m, 51 ft-lb) I N STA L LAT I O N Install the rear shock absorber w ith the drain tube pointing dow n . Install a n d tighten the upper and lower mounting bolts and nuts. ( 1 ) UPPER MOUNTING BOLT TORQUE : 45 N·m (4. 5 kg-m, 33 ft-lb) Route the drain tube into the tube guide in the swingarm . Install the removed parts in the reverse order of removal . Adjust t h e shock absorber spring preload b y turning the spring adjuster, if necessary . 1 3- 1 3 REAR WH EEL/BRAKE/S U S P E N S I O N SWI NGARM R E M OVAL Remove the rear wheel (page 1 3-3) Remove the gearshift pedal mounting bolt from the foot peg . ( 1 I PEDAL BOLT Remove the drive sprocket cover. Remove the drive sprocket bolts, set plate and drive sprocket. Disconnect the gearshift arm from the gearshift spindle. (i') DRIVE S � 2 ) � !?W�, . COVER BO LTS Remove the reserve tank from the frame ( page 5-9) Remove the shock absorber lower mounting bolt and nut. Remove the swingarm pivot bolt caps, pivot bolt and nut then remove the swingarm from the frame . D I SA S S E M B LY 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 3 - 1 4 ) Remove the following : - drive chain slider and chain cover - dust seals and pivot collars 1 3- 1 4 ( 1 I CHAIN COVER REAR W H E E L/BRAKE/S U S PE N S I O N I N S PECT I O N I nspect the swingarm f o r deformation o r cracks. Check the pivot bearings, collars and dust seals for wear or damage. \ (3) DUST SEALS Disassemble the drive chain cover and inspect the chain pro­ tector for wear or damage, Replace if necessary . ' ' \ ' (4) BEARINGS ( 1 ) CHAIN COVER (2) PROTECTOR P I VOT B E A R I N G R E PLAC E M E N T Remove the dust seals from t h e right a n d left swingarm pivots . Remove the snap ring from the right pivot. TOOL: Snap ring pliers 079 1 4 - 323000 1 Drive the right pivot ball bearing out of the swingarm using a hydraulic press and driver shaft. TOOL: Driver shaft: 07946 - MJ00 1 00 1 3- 1 5 REAR WHEEL/ BRAKE/SUSPENSION Drive the left needle bearing out of the swingarm . TOOL: Driver shaft 07946 - MJ00 1 00 Carefully press new bearings into the swingarm pivots . NOTE • I nstall the bearings with the marks facing out. Right side ball bearing: TOOLS : Driver Attachment, 32 Pilot, 1 5 mm x 35 mm 07749 - 00 1 0000 07746 - 00 1 0 1 00 07746 - 0040300 Left side needle bearing: TOOLS : Driver Attachment, 28 Pilot, 22 mm Snap ring pliers x 30 mm 07749 - 00 1 0000 07746 - 1 870 1 00 07746 - 0041 000 079 1 4 - 323000 1 I nstall the snap ring into the right pivot. Apply grease to the new dust seal lips and install them , and the collars i n the correct positions . ( 2 ) PIVOT COLLARS 1 3- 1 6 REAR WH EEL/BRAKE/S USPENSION ( 1 ) CHAIN COVER A S S E M B LY / I N STA L LAT I O N I nstall the chain slider a n d chain cover with protector . (2) CHAIN SLIDER I nstall t h e swingarm in t h e frame. I nstall the swingarm pivot bolt and nut, and tighten the nut to the specified torque. TORQU E : 90 N · m ( 9 . 0 kg-m, 6 5 ft-lb) I nstall the li·h ock absorber lower mounting bolt and nut. TUr1\:..� E : 45 N•m (4. 5 kg-m , 33 ft-lb) I I I I ( 1 ) PIVOT NUT I nstall the following : - swingarm pivot caps - reserve tank (page 5-9) - evapo rative e m iss i o n canister (California model only) - drive sprocket with the drive chain - gearshift arm I nstall the drive sprocket cover and tighten the mounting bolt. I nstall the gearshift pedal mounting bolt. Apply grease to the gearshift pedal pivot collar refer to page 7-9. Adjust the drive chain (page 3 - 1 3 ) and rear brake pedal free play ( page 3 - 1 6 ) - rear wheel (page 1 3-7) 1 3- 1 7 REAR W H E E L/BRAKE/S U S P E N S I O N SEAT/ R EAR FEN DER/SUB-FRAM E R E M OVAL/ I N STA L LAT I O N Remove the seat mounting socket bolts a n d unhook the seat hooks from 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 fuel tank (page 4-3) and the rear fender 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 from the main frame and sub-frame. Remove the two sub-frame mounting bolts and two nuts, then remove the sub-frame. I nstall the removed parts i n the reverse order of remova l . · ·- - - . . ( 2 ) SEAT (3) RIGHT SIDE COVER ( 9 ) REAR FENDER -----�· (6) TAILLIGHT CASE MOUNTING N UTS ( 7 ) SUB-FRA M E MOUNTING N UTS 1 3- 1 8 M E MO HYDRA U LI C D I S C BRAKE '88 , '89 , '9 1 -'93 : 1 . 5 N • m (0 . 1 5 kg-m , 1 . 1 ft-lb) 12 2 7 N · m ( 2 . 7 kg-m, 20 ft-lb) 1 4-0 N·m ( 1 .2 kg-m , 9 ft- l b ) 14. HYDRAU LIC DISC BRAK E After '93 : 1 2 N · m ( 1 .2 Kg-m,9 ft-lb ) 7 � 3 5 N · m ( 3 . 5 Kg-m,2 5 ft-l b ) 0 /:0 � 2 2 N · m (2 . 2 Kg-m, 1 6 ft-lb) co go () � 5 . 5 N · m(0.5 0 � 4 ft-lb ) � 1 2 N · m ( 1 .2 Kg-m,9 ft-lb) 3 1 N · m ( 3 . 1 Kg-m,22 ft-lb) 2.5 N · m (0.2 5 Kg-m, 1 .8 ft-lb) 1 4- 1 H Y D RA U LI C D I S K B R A K E S ERVICE I N FORMATION 1 4- 2 BRAKE PAD/DISC 1 4- 5 TROU BLES H O OTI N G 1 4- 3 MASTER CYL I N D E R 1 4- 8 BRAKE F L U I D R EPLACEM ENT/ AIR BLEED I N G BRAKE CALIPER 1 4-1 1 1 4- 4 SERVICE I N FORMATION G E N E RAL • • • • • • • • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality 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 if the 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 off immediately with a clean cloth. A lways 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. S P E C I F I CAT I O N S U n it: m m ( i n ) ITEM Disc thickness Disc runout Master cylinder B rake caliper ' 8 8,'89, '9 1 -'93: After ' 9 3: ' 88,'89, ' 9 1 -'93 : After ' 9 3: STAN DA R D E R V I C E LI M IT 5.0(0.2 ) 4.0(0. 1 6) 0.30(0.0 1 2 ) 1 2 . 7 6 (0.502 ) 1 2 . 6 5 (0.498 ) 1 1 .05(0.43 5 ) 1 0.94 5 ( 0.4309) 30.2 9 ( 1 . 1 93 ) 3 0. 1 6 ( 1 . 1 87 ) 2 7 .06 ( 1 .065 ) 2 6.93 ( 1 .060) - I. D. piston O.D. I . D. piston O.D. cylinder I . D . piston O.D. cylinder I . D. piston O.D. 1 2. 7 00- 1 2 .743 (0.5000-0. 50 1 7 ) 1 2 . 6 5 7 - 1 2 .684(0.4983-0.4994) 1 1 .0- 1 1 .043 (0.433 1 -0.4348) 1 0.9 5 7-1 0.984(0.43 1 4-0.4324) 30.2 3 0-30.280( 1 . 1 902 - 1 . 1 92 1 ) 30. 1 6 5-30. 1 9 8 ( 1 . 1 8 7 6- 1 . 1 8 8 9 ) 2 7 .000-2 7 .050( 1 .0630- 1 .06 50) 2 6.93 5-2 6 . 9 6 8 ( 1 .604- 1 .06 1 7 ) T O R Q U E VA L U E S Caliper mounting bolt Brake hose oil bolt Bleed valve M aster cylinder holder bolt Master cylinder cover screw 27 N • m ( 2 . 7 kg-m , 20 ft-lb) 30 N·m (3.0 kg-m, 22 ft-lb) 5 . 5 N · m (0. 5 5 kg-m, 4 ft-lb) 1 2 N·m ( 1 . 2 kg-m, 9 ft-lb) 1 . 5 N·m (0 . 1 5 kg-m, 1 . 1 ft-lb) TOOL Special Snap ring pliers 1 4- 2 07 9 1 4 - 32 3000 1 or equivalent commercia lly available in U . S . A . H Y D RA U L I C D I S C BRAKE TROUBLESHOOTI N G Brake lever soft o r spongy • • • • A i r bubbles in hydra u l i c syste m . Low f l u i d leve l . H y d r a u l i c system l e a k i n g . F a u lty dust s e a l or piston s e a l . Brake lever too hard • • • Sticking pisto n ( s ) . C logged hyd ra u l i c syste m . Pads g l a zed or w o r n e x c e s s i ve l y . Brake drag • • H y d r a u l i c system stic k i n g . Sti c k i n g piston ( s ) . Brake grab o r pull t o one side • • Pads conta m i n ated . D i s c or wheel m i sa l ig n e d . Brake chatter or squeal • • • • Pad conta m i n ated . Excessive d i s c r u n o u t . C a l i p e r insta l l e d i n correct l y . D i s c or w h e e l m i s a l i g n e d . 1 4-3 HYDRAULIC DISC BRAKE BRAKE FLU I D REPLACE M ENT/ AI R BLEEDI NG CAUTION Be careful not to allo w dust or water to enter the brake system when filling the reservoir. USE ONL Y D O T 4 BRAKE FL UID Do not mix different types of fluid since they are not compatible. A void spilling fluid on painted surfaces. Place a rag 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 F LU I D D RA I N I N G 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 FLU I D F I L L I N G /A I R B L E E D I N G 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. Add fluid when the fluid level in the reservoir is low. Repeat above procedures until no air bubbles appear in the plastic hose . NOTE • If 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 reservoi r hole a n d lever or pedal resistance is felt. 1 4-4 H Y D RAU LIC D I SC 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 (or pedal) u ntil 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 i n the fluid at the end of the hose. Tighten the bleed valve . TORQUE : 5 . 5 N • m ( 0 . 5 5 kg-m, 4 ft-lbl Close the bleed valve, fill the reservoir with the specified brake fluid to the casting ledge leve l . Reinstal l t h e diaphragm, set plate and cover. • A contaminated brake disc or pad reduces stopping po wer. Dis­ card contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. .. BRAKE PAD/DISC F R O N T B RA K E PAD R E PLAC E M E N T • A contaminated brake disc or pad reduces stopping po wer. Dis­ card contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. NOTE • Always replace the brake pads i n pairs to assure even disc pressure . '88 , '89 , '9 1 -'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 agai nst the caliper with a screwdriver to push the pistons i nto the caliper. 1 4- 5 HYDRA U L I C D IS C BRAKE Pull the pad pins out of the caliper and remove the brake pads. Position the pad spring in the caliper as show n . I nstall new pads in the caliper. NOTE • Always replace the brake pads in pairs to assure even disc pressure . I nstall 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 i n the bracket . Apply silicone grease to the caliper and bracket pin bolts . I nstall the bracket . 1 4- 6 I nstal l the brake caliper over the disc, being careful not to damage the pads, then tighten the caliper mounting bolt. - � H Y D R A U LI C D I S C B RA K E ' ( 1 ) CALIPER MOUTING BOLTS TORQUE : 27 N·m (2. 7 kg-m, 20 ft-lbl 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. �( . . " -l · f . f /, ( 1 ) PAD PI N Pull the pad pin out of the caliper. Remove the bra ke pads. I nsert new outsid e pad and push the caliper piston in allow clearance for installation of the new inside pad . Instal l 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. TO R Q U E : 1 8 N · m ( 1 . 8 Kg-m, 1 3 ft-lb) I nstall a n d tig hten the pad pin plug to the specified torque. TO R Q U E : 2 . 5 N · m(0.25 Kg-m, 1 .8 ft-l b) 1 4- 7 HYDRAULIC DISC BRAKE D I S C TH I C K N E S S Measure the thickness of the d isc . SERVICE LIMIT: 4.0 mm (0. 1 6 in) BRA K E D I S C WA R PA G E Measure the brake disc for warpage with a dial indicator as shown. SERVICE LIMIT: 0.30 m m (0.0 1 2 in) MASTER CYLI N DER R E M OVAL Drain brake fluid from the hydraulic system . Remove the rear view mirror from the master cylinder a n d dis­ connect the brake light switch wires. Disconnect the brake hose by removing the oil bolt and sealing washers . CAUTION • A void-spilling brake fluid on painted surfaces. Place a rag over the fuel tank whenever the brake system is serviced. N OTE • When removing the oil hose bolt, cover the end of the hose to prevent contamination . Secure the hose to prevent fluid from leaking out. Remove the master cylinder holder bolts and holder, then remove the master cylinder from the handlebar. D I SA S S E M B LY Remove the brake lever and brake light switch. (1 ' ) BRAKE LEVER ( 2 ) BRAKE LIGHT SWITCH 1 4-8 H Y D RA U LIC DISC BRAKE ( 1 ) SNAP R I N G Remove the boot . Remove the piston and spring by removing the snap ring . TOOL: Snap ring pliers 079 1 4 - 323000 1 or equivalent commercially available in U . S . A. Clean the inside of the master cylinder, reservoir, spring and piston with clean brake fluid . ( 2 ) BOOT • ( 1 )SPRING , .,.._ ( 2 ) PISTON I N SPECT I O N Measure the master cylinder I . D . S E RV I C E L I M IT: '88,'89,'9 1 -' 9 3 : 1 2. 7 6 m m (0. 502 in) After'93: 1 1 .05 m m (0.435 i n ) Check the master cylinder for scores, scratches or nicks. Measure the master piston O . D . at the shown position. S E RV I C E L I M IT: '88,'89,'9 1 -'93: 1 2.65 m m (0.498 i n ) 1 0. 945 m m (0.4309 in) After'93: Check the primary and secondary cups for damage before as­ sembly. AS S E M B LY CAUTION • Handle the master cylinder piston, cylinder and spring as a set. Coat all parts with clean brake fluid before assembly. If the spring and seat were disassembled, assemble the wide end of the spring on the seat . Install the spring in the master cylinder with its seat facing in­ side. Instal l the piston. CAUTION • When installing the piston, do not allo w the cup lips to turn iside out. 1 4-9 HYDRA U L I C DISC BRAKE I nstal l the snap ring using a snap ring pliers. Install the boot . (1 ) SNAP RING CAUTION • Be certain that the snap ring is seated firmly in the groove. TOOL: Snap ring pliers � 079 1 4 - 323000 1 or equivalent commercially available in U . S A . . ( 2 ) BOOT Install t h e brake lever a n d brake light switch. I N STALLAT I O N Set the master cylinder onto the handlebar with the holder " U P" mark facing up. Temporarily install the holder bolts. Align the slit of the master cylinder with the punch mark on the handlebar. Tighten the upper bolt first, then the lower bolt. Connect the brake light switch wires to the switch terminals. I nstall the rear view mirror. Connect the brake hose with the oil bolt and two sealing wash­ ers and tighten the oil bolt. TORQU E : 30 N·m (3.0 kg � m. 22 ft-lb) Fill the reservoir with DOT 4 brake fluid to the casting ledge and bleed the brake system (page 1 4- 4) . 1 4- 1 0 I1 ) BRAKE LEVER / HYDRAULIC DISC BRAKE BRAKE CALl P E R R E M OVAL Place a clean container under the caliper and disconnect the brake hose from the caliper by removing the oil bolt and sealing washers. CAUTION • A void spilling brake fluid on painted surfaces. Remove the brake pads ( page 1 4- 5 ) . D I SA S S E M BLY Remove the following: - pad spring and pin bolt boot from the caliper - retainer spring and pin bolt boot 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 i n short spurts. CAUTION • Do not bring the nozzle too close to th inlet. Push the dust seals and piston seals in, lift them out and dis­ card the m . ( 1 ) PISTON SEAL NOTE • The seals must be replaced whenever they are removed. Clean the seal grooves with clean brake fluid . CAUTION • Be careful not to damage the piston sliding surfaces. (2) DUST SEAL I N S P ECTI O N Check the pistons for scoring, scratches o r other faults. Measure the piston O . D . S E RV I C E LI M IT: '88,'89.'9 1 -'93: 30. 1 6 m m ( 1 . 1 87 i n ) 26.93 m m ( 1 .060 in) After'93: Check the caliper cylinder for scoring, scratches or other faults . Measure the caliper cylinder I . D . S E RV I C E L I M IT: '88.'89.'9 1 -'93: 30.29 m m ( 1 . 1 93 in) 27.06 m m ( 1 .065 in) After'93: 1 4- 1 1 HYDRAULIC D I S C BRAKE A S S E M BLY Coat new piston seals and dust seals with clean brake fluid and install them in the caliper. I nstall the pistons anrJ i nstall them with the open ends toward the pads. ( 2 ) D U ST SEALS Instal l the pad spring on the caliper as show n . Apply silicone grease t o t h e inside o f t h e boot, and instal l it. -� (3) SILICONE ( 1 ) RETAINE R SPRING I nstall the retainer spring as shown. Apply silicone grease to the inside of the boot and install it. I nstall the following: - pads and pad pins to the caliper - bracket to the caliper I nstall the caliper assembly over the brake disc so that the disc is positioned between the pads. CAUTION • ( 2 ) BOOT I nstall and tighten the caliper mounting bolts . TO R Q U E : '88,'89,'9 1 -'93: 27 N · m (2.7 Kg- m,20 ft-lb) After'93: 3 1 N · m (3. 1 Kg- m,22 ft-lb) Tighten the pad pins and i nstall and tighten the pad pin plugs. Connect the brake hose to the caliper with the hose bolt and two new sealing washers. TORQU E: 30 N·m (3.0 kg-m, 22 ft-lb) Bleed the air from the brake system (page 1 4-4) . 1 4- 1 2 -� (2) SILICONE Be careful not to damage the pads. MEMO BATTERY CHARG I N G SYSTEM ( 3 ) ST SWITCH MAIN FUSE 30A 1 5-0 1 5. BATTERY /CHARG I NG SYSTEM ' 8 8- ' 8 9 , ' 9 1 : y y ( 3 ) MAIN F U S E 30A y R/W G 8 1 /G (4) ALTER NATO R 81 81 81 ( 1 ) R E G U LATO R/R E CTI F I E R Y : Yellow 8 1 : Black G : G reen R : Red W : White After '9 1 : y y G (4) ALTER NATO R y ( 3 ) M A I N F U S E 3 0A ( 1 ) R E G U LATO R/R ECTI F I E R R/W Y : Yellow G : G reen R : Red W : white 1 5- 1 B ATTERY/ C H A R GING SYSTEM S E RVI C E I N F O R M ATION 1 5-2 CHARG I N G SYSTEM 1 5- 7 TROUBLESHOOTING 1 5-3 REGU LATO R/RECT I F I E R 1 5- 8 BATTERY 1 5-4 ALTERNATOR 1 5-·9 SERVICE I N FORMATION G E N E RA L • • The battery generates hydorogen gas which can be highly explosive. Do not smoke or allow flames or sparks near the battery, expecially while charging it. If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in an enclosed. The ex­ haust contains posisonous carbon monoxide gas that may cause loss of consciousness and, lead to death. • The following color codes are used throughout the electrical sections . Bu = Blue G = Green Lg = Light Green Bl Black Gr = Gray 0 = Orange Br = Brown Lb = Light Blue P = Pink • Slow charge the battery whenever possible, quick charging should be an emergency procedure only. Remove the battery from the motorcycle for charging. 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. All charging system components can be checked on the motorcycle. When i nspecting the charging system , check the system components and circuits step-by-step according to the trouble­ shooting chart on the next page. Alternator removal is described in Section 8. • • • • • R = Red W = White Y = Yellow S P E C I F I CATI O N S STANDARD ITEM Battery Capacity Voltage at 20 ° C ( 68 ° F) Fully cahrged Needs charging Charging current Charging time 1 2 V - 8 AH 1 3.0- 1 3.2 v 1 2.3 v 0.8 amperes 1 0 Hr Regulator/rectifier Type Three-phase/ful l-wave Alternator Regulated voltage Charging coil resistance at 20 ° C (68 ° F) 1 4 - 1 5 V/4, 000 rpm 0. 1 - 1 . 0 0 0 . 345 kw/5,000 rpm Output Charging start rpm 1 ,000 TO O LS Digital multitester ( KOWAl or Circuit tester ( SANWA) or Circuit tester ( K OWAl 1 5-2 0 7 4 1 1 - 0020000 or KS-AHM-32-003 ( U . S . A . only) 07 308 - 002000 1 TH-5H ± 1 00 rpm BATTERYI CHARG I N G SYSTEM TROU BLESHOOTI NG I ABNORMAL Measure the battery leakage (page 1 5- 7 ) . Check the regulator/rectifier resistances between each regulator/rectifier terminals (page 1 5- 8 ) NORMAL . Short circuit in wire harness ABNORMAL ----+• Faulty ignition switch NORMAL I Check for an overcharged battery (page 1 5-8 ) . J NOT OVE CHARG E D I ABNORMAL I REG U LATED . L. Faulty regulator/ rectifier Fault y battery Measure the voltage between the R/W (+) and G NO VOLTAGE with terminals (-) of the regu lator/rectifier 4P t-------_.• Open or short circuit in wire harness • Loose connecotor Black connector. (wire harness side) (page 1 5-8 ) + BATTERY VOLT AGE C O M ES Disconnect the 3P connector of the regulator/ rectifier, check the alternator stator coil resitances ( page 1 5-8) 1..._ STA N DARD Loose 3P connector _. . _______ ABNORMAL Faulty stator coil ...___________.,. Check the regulator/recrifier resistan ces be­ tween each regulator/rectifier terminal ( page 1 5- 8 ) . ABNORMAL t-------....• Faulty regulator/ rectifier NORMAL · Faulty battery '"----• -- 1 5-3 BATTE RY/CHARG I N G SYSTEM BATTERY R E M OVAL CAUTIO N • D o not remove the battery while exhaust pipe is hot. Remove the right side cove r . U n hook t h e fuse box from t h e battery case cove r . Remove t h e battery case cover by removi ng t h e bolts . ( 1 ) BATTE RY CASE COVER · �-......:..)�.:t:::;;;.::::...u-121 s o LT s - Remove the left side cove r . ( 1 ) N EGATIVE TERMINAL Disconnect t h e battery negative terminal lead from t h e battery fi rst , then disconnect the positive terminal lead . Pull the battery out of the battery case . --\ ', 2:,L.)� - - " _..__ � v v< r\\ -\ \\ (2) POSITIVE "'TER M I NAL \ I N STALLATION P l a c e the battery i nto the case and connect the battery posi­ tive cable to the battery fi rst from the rig ht side, then connect the negative cable from the left side . Coat the battery term i n a l with clean g rease . I nsta ll the battery case cover by hooking the tab on the cover to the hook on the case . I nsta ll and tighten the cover m o u nting bolts . I nstall the fuse box onto the battery case cover . I nstall the ru bber covers in the seq uence as shown . I nstal l the right and left side covers . R oute the battery cables as shown on the battery caution la bel . CAUTI O N WIRING 1 5-4 AS SHOWN BELOW BAlTERY/CHARG I N G SYSTEM I VO LTAGE I N S PECTI O N R emove the right a n d left side covers . Remove the battery case cove r . M easu re the battery voltage using a digital multimete r . VO LTAG E : Fully charged : 1 3 . 0- 1 3 . 2V U nder charged : Below 1 2 . 3V TOO L : Digital multimeter 0741 1 -0020000 ( KOWA) KS-A H M -32-003 ( U . S. A. only) (1\ BATTERY BATTERY TESTI N G N OTE Always clear the work a rea of flammable materials such as gasoline, brake flu i d , electrolyte , or cloth towels when operating the tester , the heat generated by the tester may cause a fire . • R emove the battery (page 15-4) . Secu rely con nect the tester's p ositive ( + ) cable first, then connect the negative ( - ) cable . N OTE For accu rate test result, be s u re the tester's cables and clamps a re in good working condition and that a secu re connection can be made at the battery . • Set the tem pe ratu re switch to " H I G H" o r " LOW" depending o n the ambient tem pe ratu re . ~ � ©©©00@ @ 0 LJ M- LIM HIGH: 6 0 ° F ( 1 5 ° C ) o r higher LOW: 6 0 ° F ( 1 5.° C ) or lower LJ Push in the appropriate test b utton for th ree secon d and read the condition of the battery on the mete r . N OTE Be sure you 've selected the test butto n of 5 . 5 Ah-9Ah . For the first check, DO N OT charge the battery before testing-test it is an "as is" condition . � lQoOOOO@ @ O Test B utton s 1 5- 5 BATTERY/CHARG I N G SYSTEM CAUTIO N 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. YELLOW (- 1 ) RED (-3, -2) G RE E N (+ 1 ' +2, +3) - The tester is used without being allowed to cool 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-down period. N OTE The result of a test on the meter scale is relative to the amp . hour rating of the battery . Any BATTERY R EA D I N G I N T H E G R EE N ZO N E I S O K . B atteries should only b e char­ ged if they register in the YELLOW o r R E D zone . • BATTERY C H AR G I N G N OTE B e sure the a rea a round 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 . D o not place batteries below the charger-gases from the battery may corrode and damage the charger. D o not place batteries on top of the charger. B e sure the air vents a re not blocked . • • • • 1 . Tu rn the Power Switch to the O F F position . 2 . Set the battery Amp . H r . Selector Switch for the size of the battery being charged . 3 . Set the Timer to theposition indicated by the Honda Battery Tester ; R E D-3 , R E D-2 or YELLOW- 1 . If you a re charging a new battery , set the switch to the N EW BATT position . 4 . Attach the clam ps to the battery terminals-R E D to Posi­ tive, B LACK to N egative . Connect the battery cables only when the Power Switch is OFF. Connect the battery cables only when the Power Switch is O F F . Connecting the cables with the Power Switch can pro­ duce a spark which could ignite or explode the battery. 1 5- 6 BATTERY A M P H R . SELECTOR SWITCH � . ... . 5.5 10 1.0 3 . • •• ··� \11) .. . . Set the a ppropriate a m p . hour ratin g . BATTE RY/CHARG I N G SYSTEM Turn the Power Switch to the O N position . 6 . When the timer reaches the "Trickle" position , the charg­ ing cycle is complete . Turn the Power Switch OFF a n d disc o n n ect t h e cla m ps . 5. N OTE The c h a rger will automatically switch to the Trickle mode after the set charging time has elapsed . • 7. Retest the battery using the Honda Battery Tester a n d rech a rg e i f necessary using t h e above steps . N OTE For accurate test results, let the battery cool for at least ten m i nutes o r u ntil gassing subsid es after charging . • CHARG I NG SYSTEM N OTE When i nspectin g the charging system , check the system components and lines step-by-step according to the tro ubleshootin g o n page 1 5-2 . Measurin g circuits with a large capacity that exceeds the capacity of the tester may cause damage to the tester . Before starting each test, set t h e tester a t the high capacity range first, then g radually down to low capacity ranges i n order that y o u have t h e correct range a n d d o not damage the tester . When measuri n g small capacity circuits, keep the ignition switch off . If the switch is suddenly turned on d u ring a test, the tester fuse ·may blow . • • • (1 ) BATTERY NEGATIVE TERM INAL LEAKAG E I N S PECTIO N Check the battery a mpere leakage before making the regulat­ ed ampere inspection . Turn the ignition switch off and d i sco n n ect the battery nega­ tive cable from the battery . Connect the tester between the negative cable and the nega­ tive battery terminal . The voltag e should i n dicate less than 0 . 1 rnA with the ignition switch off. ( 2 1 BATTERY N EGATIVE CABLE LEAKAG E AM P E R ES : 0 . 1 mA max. 1 5- 7 BATTERY/ C HA R GING SYSTEM R E G U LATED V O LTAG E I N S P E CT I O N N OTE • Be sure the battery is i n good condition before performing this test . Warm up the engine to normal operating temperature . Stop the engine, a n d connect the voltmeter a s shown . Start the engine a n d allow i t to idle, then increase the engine speed gradually. The voltage should be controlled to 1 4. 3 - 1 5 . 1 V at 5,000 rpm . CAUTION • Be careful not to let the battery positive cable contact the frame while testing. REGULATOR/ RECTI Fl ER I N S PECT I O N Remove the left side cover. Disconnect the 3P (WHITE) and 4P ( 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 . TER M I NALS STANDARDS Red/White (+) and Green (-) Yellow and Yellow Battery voltage should come 0 . 1 - 1 . 0 0 (20° C/68 ° F) ITEM Battery charging line Alternator coil line Check the resistances between the leads with an ohmmeter. If the resistance is out of the specifications, replace the regulator rectifier. � e NOTE • • • • Red/White Use a SANWA [SP- 1 0Dl or [TH-5Hl tester or KOWA D I G I ­ TAL VOLTO M ETER (074 1 1 - 0020000 ) . The reg ulator/rectifier has a semi-co nducto r . If a d ifferent tester is used , the results will be out of specification . You ' ll get a false reading if your finger touches the tester probe . If the pointer of the tester fails to swing to zero when the adjusting knob is turned fully clockwise or counter­ clockwise, replace the battery in the tester. Range Tester SP- 1 0D TH-5H 15- 8 KO RX 1 00 U n it : KO '88-'89 , '9 1 G reen Yellow Yellow Yellow Red/White � 5 "' 30 4.2 4.2 4.2 Yellow G reen Yellow ------ 00 00 1 "' 20 1 "' 20 00 00 � 00 00 00 00 -----00 00 e Red/White Yellow Yellow Yellow G reen 00 1 "' 20 00 -----00 U n it: KO After '9 1 : � Yellow Red/White -----0.5- 1 0 0.5- 1 0 0.5- 1 0 0. 7 - 1 5 Yellow � 00 00 Yellow 00 -----00 00 00 0.5- 1 0 0.5- 1 0 Yellow G reen 00 00 00 00 � 00 00 0.5- 1 0 ---- 00 B ATT E R Y/ C HA R GIN G SYST E M ALTERNATOR I N S P ECTI O N NOTE • It is not necessary to remove the stator coil to make this test. Remove the left side cover. Disconnect the alternator 3P (WHITE) connector. M easure the resistance between the yellow wire terminals and check for no continuity between each terminal and ground. STANDARD: 0 . 1 - 1 . 0 0 Replace the stator if the resistance is out of specification or if there is continuity between each yellow wire terminal and ground ( page 1 5 - 8 ) . 1 5- 9 I G N I T I O N SYST E M ENGINE STOP SWITCH (4) MAIN FUSE ( 5 ) IGN ITION SWITCH ( 1 1 ) NEUTRAL SWITCH A FTE R '93 ; ( 1 4) S I D E STAN D SWITCH 1 6-0 (6) REAR I G N ITION ( 1 2 ) I G N ITI O N COIL CONTR O L M O D U LE 1 6 . I G N I T I O N SYST EM '88 , '89 r----B I/W ---�B I R/BI -o ( 1 ) ENGINE STOP SWITCH (5) I G N I T I O N ( 4 ) M A I N (2) SUB FUSE 10 A SWITCH FUSE 30 A e ( 1 3 ) S I D E STA N D SWITCH ( 3 ) BATT E RY 1 2 V BAH G/W B l : Black Y : Yellow B u : Blue G : G reen R : Red W : White Lg : Light G re e n ( 1 2 ) TO FUEL CUT R E LAY � � ( 9 ) FRONT � >- ( 1 2 ) I G N ITION CONTRO L M O D U LE ( 1 0) REAR 11 - y - 11 - ( 7 ) I G N IT I O N C O I L ( 9 ) FRONT ( 1 0) REAR ( 1 4 ) I G N ITION P U L S E G E N E R A T O R - AFTER '89 : .----BI/W ---�BI ( 1 ) ENGINE STOP SWITCH R/BI-o (2) SUB FUSE 10 A ( 5 ) I G N I T I O N (4) M A I N SWITCH ( 1 3 ) S I D E STA N D SWITCH B l : Black Y : Yellow Bu : B l u e G : G reen R : Red W : White Lg : Light G reen -::­ ( 1 2 ) TO FUEL C U T R E LAY � � ( 9 ) FRONT 11 - - ( 7 ) I G N ITION COIL e ( 3 ) BATT E R Y 1 2 V BAH G /W G FUSE 30 A ::J > aJ - >: � � Bl a: G/W G Y :J aJ � Bu � >- ( 1 2 ) I G N ITI ON CONTROL M O D U LE ( 1 0) REAR 11 - - 1 6- 1 I G N I TIO N S Y ST E M S E RVIC E I N FO R MATIO N 1 6- 2 I G N I T IO N P U LS E G E N E R ATO R 1 6- 6 TRO U BLES HOO T I N G 1 6- 3 S I D E STAND SWITCH 1 6- 7 I G N I T IO N CO N T RO L MO D U LE I N S P E CT IO N 1 6_ 4 I G N ITIO N T I M I N G 1 6- 8 I G N ITIO N CO I L 1 6- 5 SERVICE I N FORMATION • If the engine must be running to do some work, make sure the area is well-ventilated. Never run the engine in on enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and lead to death. G E N ERAL • Ignition timing cannot be adjusted since the ignition control module is non-adjustable.lf ignition timing is incorrect.check the system inspectio n and replace any faulty parts. • For spark plug gap inspectio n and adjustment procedu re,see page 3-8. • For alternator removal and i nstallation,see sectio n 8. • For ignition pulse generator removal and installation,see page 7 - 1 1 . • When i nspecti n g the i g n ition system,check the system components a n d li nes step-by-step according to the tro u ble­ shooting on next page. • Each pair of the spark plugs( Front and Rear) has its own ignition circu it. • To test the neutral switch,refer to section 1 8. S P E C I F I CAT I O N S ITEM STAN DARDS (20° C/68 ° F) NGK S p a r k plug N I PP O N D E N SO X24EPR-U9 DPR8EA-9 0.8-0.9 S p a r k plug I g nition t i m i n g I n it i a l ( F m a r k ) I g n ition c o i l resistance Pri m a ry Secondary 6.2 g e n e rator With p l u g w i re BTDC/i d l e 1 9 . 8 - 24 . 2 4 50 - 550 C o i l resistance TOOLS Tester 1 6-2 kO n F ( 2 ) - R ( 1 ) 308 ° Firing order D i g it a l m u ltitester ( KOWAl or C i rc u i t tester (SANWA) or C i rc u it tester (KOWAl (0.03 - 0.04 1 .89- 2.32 n 2 3 . 5 5 - 30 . 4 5 kO Without p l u g w i re Ignition pulse mm 074 1 1 - 0020000 07 308 - 0020000 TH-5H or J KS-AH M-32-003 ( U . S . A . N ot available in U .S.A. only) in) I G N ITI O N SYSTEM TROU BLESHOOTI N G When performing a spark test, keep open flames or sparks away from the work area. • No spark at one spark plug • • Faulty spark plug Faulty spark plug wire No spark at all plugs 1 . Check the i g n ition contro l m od u le connectors for loose contact. ABNORMAL • Faulty Fuel cut relay (page 1 8-9) • Fuel pump (page 1 8- 1 0) Open circuit in wire harness NORMAL 2 . Measure voltage betWeen the B l ( + )and G (-)/ between the B u/Y( + )a n d G (-)/between Y ( + )and G (-)of the ignition control module 6 P connector. B attery voltag e should appear with the ignition switch ON and engine stop switch at R U N . • ,.- • ABNORMAL NORMAL • (page 20- 1 ) Faulty • Side stand switch ( page 1 6-6) • Neutral switch ( page 1 8- 1 1 ) • Short circuit in wire harness � NORMAL 3- 1 . C h e c k the i g n it i o n p u lse g e n e rato r resistances at the ignition control module 4P connector( page 1 6-4). loose connectors . 3-2. Check the ignition pulse generator( page 1 6- 6 ) . ABNORMAL NORMAL • • l Open or short circuit in wire harness loose connectors • � ABNORMAL � ABNORMAL Faulty pulse gener­ ator No spark at either spark group ( Front or Rear) - (CHECK WRONG SPARK GROUP) A_L_--1� · Faulty ignition coil B_N_O_R_M 1 . Check the ignition secondary coil resistance 1--- A _ _ • Faulty spark plug wire ( page 1 6-4) . - � NORMAL O_R_M_A_L 2- 1 . Check the ignition primary coil resistance at 1---A_B_N_ the ignition control module 6 P connector ( page 1 6-4) . 1 �r __ NORMAL • NORMAL • } l 2-2. Check the ignition coil (page 1 6-4) . loose connectors Open or short circuit in wire harness • • \ Faulty ignition coil Open circuit in wire harness I 3-2. Check the ignition pu lse generator( page 3- 1 . C h e c k the i g n it i o n p u lse g e n erator resist- I -ABNORMAL -.! 6 -_6) 1_ ances at the ignition control module 4P con - - --- -- L____ ,.:-. ________....-________� nector(page 1 6- 4). ABNORMAL NORMAL • NORMAL • 4. Exchange the ignition coil and try the spark test. GOOD JUMP r------t�'· l Open or short circuit in wire harness loose connectors. • � Faulty ignition pulse generator Faulty ignition coil 1 6-3 I G N ITION SYSTEM I G N ITION CONTROL MODULE I N S P ECTION Remove the left side cover and connector plate . N OTE • Check the system components and lines step-by-step ac­ cording to the troubleshooting chart on page 1 6-3. Disconnect the ignition control module connectors and check them for loose o r corroded termi nals. Measure the resistance between connector terminals using the following chart. <6P CONN ECTOR> ITEM TERMI NALS Ignition primary coil Y and D C power supply circuit line 81 81 ( Rear) Bu!Y and 81 ( Front) (+) and G (- ) , Bu/Y (+) and G ( - ) , Y (+) and G (-) with the ignition switch " O N " and engine stop switch " R U N " STANDARD ( 2 0 ° C/68 ° F) 1 . 89 - 2 . 3 2 (} Battery voltage should come. < 4 P C O N N ECTOR> ITEM TERMINALS I g n ition pulse generator coil W/Y and Y ( Front) W/Bu and Bu ( Rear) Each terminal and body ground I G N ITION COI L I N S PECTI O N Remove the fuel tank ( page 4-3) a n d 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 terminals. STANDARD : 1 .89 - 2 .32 0 (20 ° C/68 ° F) Disconnect the spark plug caps from the plugs and measure the secondary coil resistance with the spark plug caps in place. STANDARD : 23 . 5 5 - 30.45 1 6 -4 kO (20° C/68 ° F) STANDARD ( 2 0 ° C/68 ° F) 450 - 550 (} NO CONTI N U ITY I G N ITION SYSTEM If the resistance is out of range, remove the spark plug wires and measure the resistance between the secondary coil termi­ nals. STAN DARD : 1 9 . 8 - 24 . 2 kO (20° C/68 ° F) R E PLAC E M E N T Rear ignition coil Remove the right side cover. Disconnect the fuse connectors and starter relay switch from the case . Front ignition coil Remove the fuel tank ( page 4-3 ) . Remove the crankcase breather tank from the frame. 1) CRAN KCASE BR EATH E R TA N K • Remove the ignition coil mounting bolts and disconnect the primary terminals from the coils. 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 coi l : black terminal - black/white wire green terminal - yellow/blue wire Rear coi l : black terminal - black/white wire green termina l - blue/yellow wire 1 6- 5 r(i') IGN ITIO N S YSTEM I G N ITION P U LS E G E N ERATOR I N S PECT I O N " NOTE • I G N ITI O N P U LS E G E N E RATO R C O N It is not necessary to remove the ignition pu lse generator to make this i nspection. Remove the left steering cover. Disconnect the ignition pulse generator 4P connector (WH ITE) . M easure the resistan ces between the white/yellow a n d yellow wires(front ignition pulse generator) and white/blue and blue wires( rear ignition pulse generator) STAN DAR D : 450 - 550 0 (20° C/68 ° F) For ignition pulse generator replacement, refer to section 8 . SIDE STA N D SWITCH I N SPECT I O N '88 , '89 , '9 1 -'93 : Re move the seat a n d left side cove r . D i s c o n n ect the 2 P ( G reen) c o n n e ctor a n d t h e G reen/White w i r e . C h e c k the conti n u ity between e a c h term i n a l of t h e s i d e sta n d switch . SIDE STAND DOWN (RELEASED) Side sta n d position Term i n a l s Tester Reading S i d e stand up (pushed ) -ignition circuit open G ree n/White to Green Y e l l o w / B l a c k to G reen N o conti n u ity C o nti n u ity Side sta nd down ( released) -ig nition circuit closed G re e n/White to G reen Y e l l o w / B l a c k to G re e n Conti n u ity N o conti n u ity rO 0 <,.) � ( 1 1 TO WA R N I N G LIGHT -. Y/BI (21 TO SPARK U N I T --GIW I II ,..() ( 1 ) TO WA R N I N G LIGHT .,. G 1 6- 6 S I D E STA N D U P ( PU S H E D ) ( 2 ) TO -- Y/BI SPARK U N I T ---G/W ()- ·� 9- I G I G N IT I O N S Y ST E M After '93 : Remove the left side cover. Disconnect the side stand 3 P g reen connector and check for conti n u ity between each terminals as shown below. There should be continuity between the 0-0 positions on the conti n u ity chart. G reen/White Yellow/ B lack Side sta n d down Side stan d up () 0 G reen -o ( 1 ) D OWN 0 ( 1 ) B O LT R E M OVAL/ I N STA L LATI O N Remove t h e left side cover. Discon nect the side stand 3 P g reen connector. Remove the side stand switch mounting bolt,setting plate, washer a n d side stand switch. I nstall the switch in the reverse order of removal. N OTE • Align the switch pin with the side stan d h ole.Aiign the switch g ro ove with the setting plate tang and align the setting plate solt with the side stand return spring holding pin. TO R Q U E : Side stand switch mounting bolt : 9 N · m (0 . 9 kg-m , 7 ft-lb) R oute the side stand switch wire properly. I G N ITION TI M I NG NOTE The ignition control module system is factory pre-set and can not be adjusted.lgnition tim i n g inspectio n procedures a re g iven to inspect the fu nction of the ignition control module com ponents. Con nect the timing light to the other spark plug wire if you see that the ignition timing is i ncorrect,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. r Connect the timing light to the front spark plug wire. 1 6-7 I G N ITION 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 cylinder. If the ignition timing is incorrect, make a system inspection ( page 1 6-3) and replace any faulty parts . (1 l "F" MARK (2) I NDEX MARK 1 6-8 MEMO ELECTRIC S TARTER ( 8 ) CLUTCH SWITCH I I I I I I I I I (7) D I O D E A FT E R '93 ; ( 1 2) ( 1 4) S I D E STAN D SWITCH ·- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ( 1 l M A I N FUSE 30A (4) ( 2 l BATT E R Y ( 1 2) STARTER RELAY SWITCH 1 2 V 8AH STARTER RELAY SWITCH SIDE STAND SWITC H ( 5 ) I G N ITI O N C O NT R O L M O D U LE I DOWN (8) CLUTCH SWITCH Lg/R -=- B l : Black Y : Yellow G: G reen R: Red W: White Lg : Light green I G/W G ( 6 ) N EUTRAL (7) CLUTCH D I O D E SWITCH G/R--+------+-t-+-1L g/R_...�-a-R--o'--o--R t BI-----BI ----o I G N ITION ( 1 0 } S U B- F U S E ( 9 ) STARTER SWITCH 1 OA SWITCH '------Y t R·--------' (1 1 ) 1 7 -0 1 7. ELECTR IC STARTER S ERV I C E I N FO RMATIO N 1 7- 1 STARTER RELAY SWITCH 1 7-6 T RO U B L E S HOOTING 1 7- 1 C L UTC H D IO D E 1 7-7 STARTER MOTO R 1 7-3 SERVICE I N FORMATION G E N E RA L • T h e starter motor a n d i g mt1 o n p u l s e g e n e rator c a n be removed with the e n g i n e i n t h e f r a m e . • To i ns p e ct t h e i g n it i o n p u l s e ge nerator, r e f e r to Secti o n 1 6 . • Refer to secti o n 8 for starter c l utch removal a n d i n sta l l at i o n . SPEC I F I CATI O N Unit: m m (in) ITEM S t a rter m o t o r b r u s h le ngth STA N DA R D SERVICE LIMIT 1 2 . 5 (0.49) 6.5 (0.26) TRO U BLESHOOTI NG N OT E • • T h e starter motor s h o u l d turn w hen t h e tra n s m i s s i o n is i n neutral a n d the c l u t c h d i seng aged . C h e c k f o r t h e f o l l o w i n g before t r o u b l e s hooting the syste m . - B l o w n m a i n ( 3 0 A ) or s u b ( 1 O A ) f u s e . - Loose battery a n d starter motor c a b l e s . - D i s c h a rg e d batte ry . Starter motor does not turn 1 -1 . "CLICK" H EA R D C h e c k the starter relay s w it c h for operati o n . Y o u s h o u l d h e a r the r e l a y " C LI C K " w h e n t h e starte r switch button is depr e s s e d . ( pa g e 1 7 - 6 ) _I I 1 - 2 . A p p l y battery voltage t o t h e starter motor d i rectly a n d check the operati o n . TURNS • " C L I C K " NOT H E A R D . A B N O R M AL 2. Check t h e n e u t r a l i n d icator for f u n cti o n . . . N O R MAL 3. . N O V O LTAGE C h e c k t h e starter r e l a y s w i t c h v o l t a g e ( page 1 7-6) 4 . C h e c k t h e starter r e l a y switch f o r c o n t i n u ity ( p age 1 7 - 7 ) N ORMAL I J DOES NOT TURN Fau lty sta rter motor ( page 1 7 - 3 ) F a u lty neutral s w itch ( p age 1 8 - 1 1 ) Loose neutral s w itch connectors Fau lty i g n it i o n s w itch ( p age 1 8 - 6 ) . . . F a u lty st a rter relay switch . Loose starter rela y switch c o n n e ctor . ABN ORMAL Loose c a b l e s Fau lty sta rter relay switch ( page 1 7 - 6 ) . Loose c l u t c h d i o d e con nector F a u lty starter relay sw itch ( page 1 7 - 6 ) Fau lty cl utch d i o d e ( page 1 7 - 7 ) Open or s h o rt c i rcuit in w i re harness . . BATTERY V O LTA G E C O M E S J I 1 7- 1 ELECTRIC S TARTER The starter motor can turn i n the neutral position, but should not turn except with the gear selector i n neutral , the side stand up and the cluth lever pulled in. BATTERY VOLT­ AGE M EASURED Measure the Voltage between the Green/White t-------+!J Check the clutch switch ( page (+) and Green (-) terminals of the side stand connector (wire harness side ) . There should b e battery voltage . N O VOLTAG E (or too l ittle voltage) Check the side stand switch ( page 1 6- 5 ) Starter motor turns engine slowly • • • Low specific gravity Excessive resistance i n circuit Binding in 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 1 7-2 1 8-1 1 ) . I ELECTRIC STARTER STARTER MOTOR R E M OVAL • With the ignition switch OFF, remove the negative cable at the battery before servicing the starter motor. Remove the rubber cap and disconnect the starter motor cable. Remove the motor mounting bolts . Remove the motor from the left side. D I S A S S E M B LY Remove the following components : - motor case screws. - front and rear covers. - armature . (1 l (4) REAR COVER FRONT COVER � NOTE • Record the location and number of shims. ( 2 ) CASE I N S P ECT I O N Measure each brush length . SERVICE LIMIT: 6 . 5 mm (0.26 in) Check for continuity from the cable terminal to the motor case and from the cable termina to the brush wire ( black) . (1 CONTINU ITY CABLE TERMINAL-MOTOR CASE N O CONTI N U ITY : NORMAL CABLE TERMI NAL-BRUSH ( B LACK WIRE) C O N T I N U ITY: NORMAL Disassemble the brush holder if necessary . 1 7-3 ELECTRIC STARTER I nspect the commutator bars for discoloration . Bars discolored in pairs indicate grounded armature coils. (1 l C O M M UTATOR Check for continuity between pairs of commutator bars . There should be continuity . Check for continuity between individual commutator bars and the armature shaft. There should be no continuity . Check the front cover oil seal for wear or fatigue. (1 ) O I L SEAL (2) FRONT COVER 1 7 -4 ELECTRIC STARTER A S S E M B LY ( 2 ) CASE (5) BRUSH HOLDER (7) (4) ( 1 0) 0-RI N G ( 1 3) S H I M S ( 1 ) FRONT COVER 0-RING SHIMS �,� ( 1 2 ) N UTS ( 1 0) CABLE TERM I NAL AND BRUSHES ( 9 ) REAR COVER Set the brushes on the brush holder. Align the starter motor case notch with the brush holder tab . I nstall the a rmature i n t h e case. Set the brush springs. Install the rear shims in the same location and number when disassembled . Install the 0-ring on the case. Install the rear cover, aligning its slot with the brush holder pin. (3) SLOT 1 7-5 ELECTRIC STARTER (2) I nstall the front shims in the same location and number when disassembled . FRONT COVER Instal l the 0-ring on the case . I nstall the lock washer, aligning its tabs with the slots of the front cover. Apply grease to the dust seal and instal l the front cover. (5) LOCK WASHER (3) 0-RING Align i ndex marks of the front cover, case and rear cover as shown. Instal l and tighten the starter motor case screws and apply oil to the 0-ring and install it on the front cover. (3) REAR COVER (2) 0-RING I N STALLATI O N I nstall the starter motor in the engine. I nstall and tighten the motor mounting bolts securely. NOTE • Install the ground cable with one mounting bolt as show n . Connect t h e motor cable t o t h e motor terminal a n d install the rubber cap over the terminal. Connect the battery negative cable . STARTER RELAY SWITCH O P E RATI O N I N S PECT I O N Depress t h e starte switch button with the ignition switch O N . The c o i l is normal if the starter relay switch clicks. V O LTA G E I N S PE CT I O N If you don ' t hear t h e switch "CLI C K " , disconnect t h e switch connector. Shift the transmission into neutral and turn the ignition switch ON. Measure t h e voltage between the yellow/red (+) a n d green/red (-) 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 �T t OR ELECTRIC STARTER C O N T I N U I TY I N S P E C T I O N Remove the starter relay switc h . Connect an ohmmeter t o t h e switch large terminals. Connect a fully charged 1 2 V battery positive wire to the start­ er relay switch Yellow/Red wire terminal, and the battery neg­ ative wire to the G reen/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 R E M OVAL Remove the left side cover. Remove the clutch diode from the wire harness. I N S P ECTI O N Check for continuity with a n ohmmeter. Connect the positive probe to the (+) terminal and the negative probe to the (-) terminal of the diode. There should be continuity, then reverse the probes, there should be no continuity . N OTE • 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 . ( 1 ) CONTI N U ITY 1 7- 7 MEMO 1 8. LI GHTS/ M ETER/SWITCH ES S E RVI C E I N FO R MATIO N 1 8- 1 F U E L P U MP RELAY 1 8-9 T RO U BL ES HOO T I N G 1 8-2 F U E L P U MP 1 8- 1 0 H EA D L I G H T 1 8-3 O I L P R ESS U R E SWITCH 1 8- 1 0 B U L B R EP LA C E M ENT 1 8-4 N E UTRAL SWITCH 1 8- 1 1 SP E E DO M ET E R 1 8-4 BRAKE L I G H T SWITCH 1 8- 1 1 I G N ITIO N SWITCH 1 8-6 CLUTCH SWITCH 1 8- 1 1 H A N D L EBAR S WITCH ES 1 8- 7 TURN S I G NAL R E LAY 1 8- 1 2 T H E R MO STAT I C SWITCH 1 8-8 HO RN 1 8- 1 2 COO LA N T T E MP ERATURE I N D I CATO R 1 8-8 SERVICE I N FORMATION • • 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. Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area with the engine stopped. Do not smoke or allo w flames or sparks in the work area or where gasoline is stored. G E N E RA L • • • • Some wires have different colored bands around them near the connector. These are connected to other wires which cor­ respond to the band color. A l l p last i c co nnecto rs have lock ing tabs that must be released befo re d isco nnect i ng, and must be a l igned and fu l ly engaged when reco nnect i ng. 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 o r connections. A contin u ity 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 , o r when checking for high resistance caused by corroded connections. S P E C I F I C ATI O N S headlight Brake/ta i l l ight Turn signal lights 12 V 60 W/55 1 2 V 32/3 cp W ( 2 7/8 W) 1 2 V 32/3 cp ( 2 3/8 W) 1 2 V 32 cp ( 2 3 W) Front Rear License light Indicator lights 12 V 4 2 2 cp turn signal 1 2 V 1 .7 W neutral 1 2 V 1 .7 W high beem 1 2 V 1 .7 W M eter light Main fuse x x 1 2 v 3.4 w 30 A Sub-fuse '88, '89 After '89 F uel pu m p f low capacity 1 0 A x 6, 1 5A x 1 1 0 A x 3, 1 5A x 1 800 cc ( 0.76 USqt, 0.70 l mpqt) TO R Q U E V A L U E S Radiator thermostatic switch Oil pressure switch Ignition switch mounting bolt 1 8 N•m N·m N·m 12 1 1 (1 .8 (1 .2 (1 .1 kg-m, 1 3 ft-lb) kg-m, 9 ft-lb) - Apply sealant to the threads kg-m , 8 ft-lb) - Shear bolt 1 8- 1 LIG HTS/METER/S W I TC H ES TROUBLESHOOTI NG N o Lights Come O n When Ignition Switch I s Turned O N : • • • • • • 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 O n , but Dimly, when Ignition Switch I s Turned ON: • • Headlight Beam Does Not Shift When HI-LO Switch Is Op­ erated: • • • 1 8-2 Battery voltage low Faulty bulb Beam filament burned out Faulty dimmer switch Wiring loose, broken, or at fault L I G HTS/M ETER/SWITC H ES H EADLIGHT I I I I R E M OVAL/ I N STALLAT I O N • Remove the two screws a n d headlight. Disconnect the headlight connector and remove the rubber protector. Remove the headlight retainer clip and replace the headlight bulb. (1 ) RETAINER CLIP (2) HALOGEN BULB CAUTION • • • • • This motorcycle is equipped with a halogen headlight bulb. Do not put finger prints on the headlight bulb, they may create hot spots on the hulb. If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. Do not try to replace the bulb or clean the headlight with the light ON. After replacing the bulb, install the rubber boot tightly against the unit. NOTE • Instal l the rubber protector with the top mark facing u p . I nstall t h e headlight in t h e reverse order of removal . 1 8-3 LIG HTS/M ETER/SWITC H ES BULB REPLACE M E NT NOTE • See page 1 8- 5 for speedometer bulb replacement. T U R N S I G NAL LIGHT Remove the turn signal lens attaching screws. While pushing i n , turn the bulb counterclockwise to remove . Replace the bulb, if desired . I nstall i n the reverse order of removal . NOTE • Seat the rubber packing properly. B R A K E/TA I L L I G H T Remove the taillight lens attaching screws . While pushing i n , turn the bulb cou nterclockwise to remove . Replace the bulb, if desired . I nstall i n the reverse order of removal . N OTE • Seat the rubber packing properly. LICENSE LIGHT Remove the bolts and license light case mounting nuts . Replace the bulb with a new one. SPEEDOM ETER R E M OVAL Disconnect the speedometer cable from the meter. Remove the steering covers and disconnect the speedometer connector (6P Black) . Remove the speedometer stay mounting bolts and meter from the fork bridge . 1 8-4 (1 l S P E E D O M ET E R CABLE LIG HTS/M ETER/SWITC H ES B U L B R E PLAC E M E N T Remove t h e trip-meter knob b y removing the attaching screw . Romove the speedomater cover mounting screws and cover. Replace the meter bulb with new one. ( 5 ) SPEEDOMETER (3) STAY ( 2 ) MOUNTI NG SCREWS (8) 6P BLACK CON NECTOR ( 1 ) 0-RI N G ( 1 0) SPEEDOMETER CABLE ( 9 ) SPEEDOM ETER COVER Assemble the removed parts in the reverse order of disassem­ bly ( 1 ) SPEEDO­ M ETER WIRE Route the speedometer wire as shown and instal l and tighten the mounting screws. I N STA L LAT I O N I nstall the speedometer i n the reverse order o f remova l . 1 8- 5 LIG HTS/M ETER/SWITC H ES I N D I CATO R PAN E L B U L B R E PLAC E M E N T Remove the indicator bulbs from the indicator panel, b y first pulling out each bulb and socket together. Replace the bulb, if desired . I G N ITION SWITCH I N S PECTI O N Remove the seat and right side cover. Disconnect the ignition switch 4P White and 2P Black connec­ tor. Check for continuity between the ignition switch connector terminals in each switch position . Continuity should exsist between the color coded wires in each chart below. '88, '89: ON OFF p COLOR BAT IG 0 � 0 R R/BI FAN TL1 TL2 -o 0 -o Bu/0 Br/W Br p -o Y/BI After '89: R E PLAC E M E N T ( 2 ) MOUNTING RUBBER Remove t h e ignition switch cover b y removing t h e bolt. Remove the shear bolt heads using a drill then remove the switch (cylinder) . Install the new switch and new shear bolts . Tighten the shear bolts u ntil the head twist off. (1 ) 1 8- 6 HOLDER LIGHTS / M ETER/S WITC H ES HAN DLEBAR SWITCHES (1 ) LEFT HANDLEBAR SWITCH The handlebar switches (dimmer, turn signals, horn, starter, engine stop, etc . ) must be replaced as assemblies. Remove the steering covers. L E FT H A N D L E B A R SWITCH Disconnect the left handlebar switch connector (9P White) . And check for continuity between the terminals. Contin uity should exsit between the color coded wires in each chart. Dimmer Switch ------Lo (N) Hi Color code H L2 Hi -o 0 � � 0 -o Bu/W Lo � Bu w R L Turn Signal Switch ' 8 8 . ' 89 . '9 1 : ------RIGHT N LEFT Color code w 0--- --o 0 Gr Lb Released D epressed Color code PR 0 � Horn Button '88 . '89 . '9 1 : ------ TL1 -o 0 0 B r/BI PL -o � -o 0/W � Lb/W Turn Signal Switch After '91 : After '9 1 : Ho1 0 W/G Ho2 -o Lg ------ Released Depressed Color code Ho1 0 BI/Br Ho2 -o Lg R I G H T H A N D L E B A R SWITC H ------ R I G HT N LEFT Coler code w R L TL (). Gr .() 0 0 0 PL PR Lb {) 0 0 B r/ B I -o � -o Lb/W 0/W Disconnect the right handlebar switch connector (9P Red) and check for continuity between the terminals . Continuity should exist between the color coded wires as indi­ cated in each chart. After '93 : '88 . '89 . '9 1 -'93 : ------ IG1 ST Pushed � � Color code Bl Y/R Released Engine Stop Switch '88 , '89 , ' 9 1 -'93 : HL HL1 0 --o BI/R Bu/W � R � leased Pushed Color code IG2 ST 0 {) HL H L1 0 81/W Y/ R IG, I G2 BI/G B I /W BI/R B u /W After '93: ------ IG1 RUN OFF 0 -o Color code Bl BI/W IG2 ------RUN OFF Color code 1 8-7 LIG HTS/ M ET ER/SWITC H ES THERMOSTATIC SWITCH I N S P E CT I O N T h e the rmostati c switch senses t h e temperature o f t h e r a d i a ­ tor coolant a n d s i g n a l s t h e f a n moto r . The motor c o m e s i nto action at 9 8 ° - 1 0 2 ° C ( 2 08 ° - 2 1 6 ° F ) a n d stops at b e l o w 9 3 ° - 9 7 ° C ( 1 9 9 ° - 2Q1 ° F ) . Before testing c h e c k the c o o l a n t level at warm-up the e n g i n e to operating temperature . If the fan does not t u r n , d i s c o n n ect the connectors from t h e thermostatic s w itch a n d j u m p the term i n a l s using a j u m p e r w i r e . T u r n t h e i g n it i o n s w itch O N . I f the fan turns, replace t h e thermostatic switc h . If t h e f a n does n o t start test t h e f a n moto r : D i sconn ect t h e f a n motor connecto r . ( 2 P B l a c k ) at t h e l eft steering h e a d c o n n e c ­ tor h o l d e r . Check for battery b o l t a g e b e t w e e n the b l ue/black w i re a n d g r o u n d with the i g n it i o n s w itch O N . I f there i s n o voltage, c h e c k the su b-fuse ( 1 0 A ) . o r loose ter­ m i n a l s or connector, o r an o p e n c i r c u it Suspend the therm ostati c switch i n a p a n of coolant ( 50 - 50 m i xture) a n d c h e c k the tempe ratures at w h i c h the s w itch opens a n d closes . M a ke s u re that there is no conti n u ity at room temperat u re a n d t h e n g r a d u a l l y r a i s e the c o o l a nt temperature . The switch s h o u l d show c o n t i n u ity ( c l o s e ) at 9 3 ° - 9 7 ° C ( 1 9 9 ° 207 ° F ) . N OTE o o o Keep the temperature for 3 m i n utes to confirm cont i n u it y . A s u d d e n c h a n g e of t e m p e rature w i l l c a u se error tempera­ ture reading between the thermometer a n d switc h . Do not let the s w itch or thermo meter touch the pan as it w i l l g i ve a false read i n g . I m merse the s w itch i n c o o l a n t u p to its thread s . I nsta l l a n e w 0 - r i n g on t h e switc h . A p p l y sea l a nt t o t h e switch thread a n d i n sta l l i t . T i g hten the s w i t c h to the s p e c i f i e d torq u e . TORQUE: 1 8 N • m ( 1 .8 kg-m, 1 3 ft-l b ) NOTE o Do not over tig hten t h e sw itch . COOLANT TEM P E RATU RE I N DICATOR SYSTEM I N S P E C T I O N R e m ove the horn . Disconnect the sensor w i re from the thermosensor a n d s h o rt it to ground using a j u m pe r w i r e . T u r n t h e ignition s w i t c h O N . T h e temperature i n d icator l i g h t s h o u l d come o n . I f the i n d i c a ­ tor l i ght d o e s n o t c o m e o n , c h e c k the su b-fuse ( 1 0 A ) a n d w i res f o r a loose c o n n ection o r a n o p e n c i rcuit; if n o rm a l , re­ p l a c e the meter with a new one . 1 8-8 ( 1 ) T H E R M O M ET E R []] 0 ( 2 ) T H E R M OSTAT I C SWITCH L I G HTS/ M ETER/SWITC H ES (1) TH ERMOS E N S O R I N S PECTI O N D r a i n the coo l a nt from t h e t h e r m ostat housing by removing the d r a i n bolt i n t h e h o u s i n g . D i sconn ect the w i re from t h e t h e rmosensor a n d remove the thermosenso r . Suspend t h e thermosensor i n o i l o v e r a he ater a n d measure the resistance thro u g h t h e sensor as the o i l heats u p . Temperatur ( ° C/ ° F ) 50/ 1 2 2 Resista nce ({}) 1 53 . 9 80/ 1 7 6 51 .9 1 20/248 T H E R M O M ET E R m Q 1 6. 1 Wear gloves and eye protection. NOTE • • O i l must be u s e d as the h e ated l i q u i d to check the f u n ction a bove 1 00 ° C ( 2 1 2 ° F ) . You w i l l get f a l s e rea d i n g s if either the sensor or thermometer touches t h e p a n . R e p l a ce t h e sensor if i t is o u t o f s pecifications by more t h a n 1 0 % a t a n y temperature l i sted . A p p l y sea l a n t to t h e threads of t h e thermosensor a n d tig hten it i n the thermostat h o u s i n g . NOTE • Keep the c l e a r n a c e of 3 - 4 mm ( 0 . 1 - 0 . 2 i n ) betw een the case and the t h e rmosensor threads e n d s . C o n nect the w i r e to t h e thermose nsor. FU EL PUM P R E LAY • Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Do not smoke or allow flames or sparks in the your work area or where gasoline is stored. Remove the seat a n d right s i d e cover. Check the sub-fuse ( 1 0 A ) . Re move the r e l a y from t h e rubber b racket a n d check the re l a y c o n n e ctor term i n a l s for l o o s e n e s s and co rrosi o n . Inspect as follows : D i s con nect t h e c o n n e ctor a n d test the w i res on the m a i n har­ ness side . ITEM STA N DA R D Between Bl ( + ) a n d b o d y g r o u n d ( - ) w ith the i g n it i o n s w itch " O N " Battery voltage s h o u l d come . Y /Bu wire bet w e e n the p u m p relay a n d s p a r k u n it C O N T I N U I TY BI/Bu wire betwe e n the p u m p re l a y and fuel p u m p C O N T I N U ITY 1 8-9 L I G H TS / M ETER/SWITC H ES FU EL PUM P S Y S T E M I N S P ECTI O N Turn the ignition switch O F F a n d remove the seat and discon­ nect the fuel pump wire connectors and temporarily connect the balck and black/blue wire teminals at the main harness connector with a jumper wire. Disconnect the fuel outlet tube at the fuel pump and connect a fuel tabe or equivalent to the pump outlet line. Hold a graduated beaker under the pump outlet line. • Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Do not smoke or allow flammes or sparks in your work area or where gasoline is stored. Turn the ignition switch on and let fuel flow into the beaker for 5 seconds, then turn the ignition switch off . M u ltiply the amount in the beaker by 1 2 to determine the fuel pump flow capacity per minute . FUEL PUMP FLOW CAPACITY : 800 cc (0. 76 US qt 0. 70 Imp qt) min . /minute O I L P R ESSU RE SWITCH Make sure that the oil pressure warning light comes on with the ignition switch " O N " . I f the light does not come on, inspect a s follows: Remove the drive sprocket cover ( Page 1 3- 1 4) . Disconnect the oil pressure switch wire from the switch by re­ moving the terminal screw. Short it to ground using a jumper wire . Turn the ignition switch "ON". The oil pressure warning l ight should come on. If the light does not come on, check the bulb, sub-fuse a n d wires f o r a loose connection or an open circuit. ( 1 0 AI Start the engine and make sure that the light goes out. If the light does not go out, check the oil pressure (page 2 -5) . If the oil pressure is normal, replace the oil pressure switch ( page 2 -5) . 1 8- 1 0 !I� ( 1 ) O I L PRESS � R E SWITC � - LIGHTS/METER/SWITC H ES N EUTRAL SWITCH I N S P E CT I O N Remove t h e left side cover a n d disconnect the 2P ( Black) con­ nector. Check the neutral switch for continuity between the light green/red connector and body gro u n d . There s h o u l d b e contin uity between t h e l ight green/red con­ nector and body ground . There should be continuity with the transmission i n neutral and no continuity with the transmission in any gear. If there is no continuity i n neutral , remove the drive sprocket cover (page 1 3- 1 4) and check the wire connection for an open circuit. BRAK E LI GHT SWITCH F R O N T I N S P E CT I O N Disconnect the front brake light switch connectors and check for contin u ity between the switch terminals. There should be continuity with the front brake applied, and no continu ity with the brake release d . Replace t h e switch i f necessary . R E A R I N S P ECTI O N Disconnect the rear brake light switch connector and check for contin u ity between the terminals. There should be continuity with the rear brake applied and no continuity with the rear brake released . Replace the rea r brake light switch , if necessary . CLUTCH SWITCH I N SPECTI O N Disconnect the clutch switch wire connectors. Check for continuity between the switch terminals. There should be continuity with the clutch applied and no con­ tinuity with the clutch released . \ Replace the clutch switch if necessary. 1 8- 1 1 LIG HTS/ M ET E R/SWITC H ES TU RN SIG NAL RELAY Remove the seat, then remove the turn signal relay from the rubber bracket . Check the turn signal circuit for proper connections before making this test. Connect each terminal as indicated below : D . C . 1 2 V Positive ( + ) White/G ree n : G reen : D . C . 1 2 V Negatvie (-) Turn signal wire of one side; connect the G ray: other side to ground (frame ) . Check for correct lighting ON a n d OFF. If the turn signal relay fails this test, replace it. HORN Disconnect the wire connectors from the horn a n d connect a 1 2 V battery to the horn wire terminals. The horn is normal if it sounds. 1 8- 1 2 1 9. WI R I N G DIAG RAM ·as. ·as: 0 0 ...... �i CD HHn · . ·� ��,:� l!:d:: u 9·· ;• :;: w.: F:,� � 1!:.�� � ·�� � r-�· '··�·· . · ·· l 0 ··· ..,., � C., e l!:.j ! r---•r•.. '',: < :� � . i '--t--"'' r- .c. �9 Ul r----A I t-- ,!.I! 9 r .... --:- · ·��· LS_ � I•A z� � �• '" C>t-• � lM 0 IIIII ... fi!�= ; - I � J!r- ! ... . .. . .. J ..., -, a � II I � � �� . . .. . . -ill�� .�� � i g � I I � ; � � I ; � !I � t K� 0 a • � � ·I·!) "' �h\ ... "� . -g 6 ��= �� � · - ��� � � .,. -� g � - '-ii ·· ...... � � r::� ���r-· �+ �g�:: I il ! - : � .... 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I I 3 t)§ :. � � I � i � �� L � � !:2 ; iii � � � � 1 9- 3 W I R IN G DIAGRAM After '93 : 1 9-4 20. TROUBLESHOOTI NG E N G I N E DO ES NOT START O R I S H A R D TO START 20- 1 POO R PERFO R MANCE AT H I G H SPEED 20-4 E N G I N E LACKS PO W E R 20-2 POO R H A N D L I N G 20-4 PO O R PERFO RM A N C E AT LOW A N D IDLE SPEEDS 20-3 E N G I N E DOES NOT START OR IS HARD TO START POSSIBLE CAUSE 1 . Check fuel flow to carburetor REAC H I N G CARBURETOR 2. Perform spark test SPARK 1 3 . Test cylinder compression l l C O M PRESSION NORMAL 4. Sta by fol lowing no,mal pmcedu" E N G I N E DOES NOT FIRE 5 . Sta N OT REAC H I N G CARBU RETO R ---·• • • • • • • 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 WEAK OR NO SPARK ------•·• GO TO PAG E 1 6-2 WET PLUG ------·• Mixture too rich • Carburetor flooded • Carburetor choke on, or partially closed • Cylinder flooded • Air cleaner dirty LOW COMPRESSION ------+• • • • • • • Improper valve clearance (too small ) Valve stuck open Worn cylinder and piston rings Damaged cylinder head gasket Seized valve Improper valve timing I mproper valve and seat contact Improper choke operation Carburetor incorrectly adjusted I ntake pipe leaking Improper ignition timing ( Faulty spark u nit or pulse gener­ ator) • Fuel contaminated E N G I N E STARTS BUT STOPS ---•• • • • with choke applied 20- 1 TROUBLESHOOTING E N G I N E LACKS POWER POSSIBLE CAUSE 1. Raise wheels off ground and spin by hand WHEELS SPIN FREELY 2. � Check tire pressure PRESS U R E NORMAL 3. + Check for clutch slippage C LUTCH ENGAGED PROPERLY 4. � Accelerate lightly E N G I N E SPEED I N C REASES 5. Check ignition timing CORRECT 6. t Check valve clearance CORRECT 7. + Test cylinder compression NORMAL 8. j Check carburetor for clogging N OT CLOGGED 9. t Check spark plug condition t NOT FOULED OR DISCOLORED 1 0 . Check oil level and condition 1 CORRECT 20-2 WHEELS DO NOT SPIN FREE LY ---· • • • • Brake dragging Worn or damaged wheel bearings Wheel bearing needs lubrication Drive chain too tight Axle nut excessively tight PRESSURE LOW--------1�· Punctured tire • Faulty tire valve CLUTCH SLIPS --------.• • • • Faulty clutch l ifter system Worn clutch disc/plate Warped clutch disc/plate Weak clutch spring E N G I N E SPEED DOES NOT I N C REASE -· • • • • • • • 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 INCORRECT ----------.....• • F a u lty i g n it i o n c o ntrol m o d u l e F a u lty i g n it i o n p u lse g e n e rator INCORRECT ----------.....• I mproper valve adjustment • Worn valve seat TOO LOW ------·• • • • • • Valve stuck open Worn cylinder and piston rings Leaking head gasket I mproper valve timing Seized valve I mproper valve and seat contact CLOGGED ------· Carburetor not serviced frequently enough FOU LED OR D I SCOLORED----___,�·· Plugs not serviced frequently enough • Wrong heat range I N C O RRECT--------•• Oil level too high • Oil level too low Contaminated oil TROUBLESH OOTI N G POSSIBLE CAUSE 1 1 . Remove cylinder head cover and inspect lubrication VALVE TRAI N LUBRICATED PROPERLY • 1 2 . Check for engine overheating NOT OVERH EATI N G 1 3 . Accelerate o r r u n a t h i g h speed VALVE TRAIN NOT LUBRICATED --•• • PROPERLY • • Clogged oil passage Clogged oil control orifice Contaminated oil Faulty oil pump OVERHEATING --------___,�. Coolant level low • Fan motor not working (thermostatic switch) • Thermostat stuck closed • Excessive carbon build-up in combustion chamber • Use of poor quality fuel • Clutch slipping • Lean fuel mixture ENGINE KNOCKS Worn piston and cylinder • Wrong type of fuel • Excessive carbon build-up in com­ bustion chamber • Ignition timing too advanced _..,. ___ _____ E N G I N E DOES NOT KNOCK ( Fa u lty i g n ition control m o d u l e ) • Lean f u e l mixture POOR P ERFORMANCE AT LOW AND I DLE SPEEDS . POSSIBLE CAUSE 1 Check ignition timing and valve clearance + CORRECT 2. Check carburetor pilot screw adjustment I NCORRECT I mproper valve clearance • Improper ignition timing - Faulty i g n it i o n control m o d u l e ___,�. _________ - F a u lty i g n it i o n p u lse g e n e rator I N CO RRECT -------___,�. See Fuel System, Section 4 CORRECT • 3 . Check for leaking intake pipe NO LEAKAG E 4. + Perform the spark test GOOD SPARK LEAKING ------· Loose carburetor • Damaged insulator WEAK OR I NTERM ITTENT SPARK-· Faulty, carbon or wet fouled spark plug • GO TO PAG E 1 6-2 20-3 TRO U BLESH OOTI N G POOR PE RFORMANCE AT H IGH SPEED POSSIBLE CAUSE 1. Check i g n ition t i m i n g a n d v a l v e clearance I N C O R R E C T -------__,�. • C O R R ECT • 2 . D i s c o n n ect fuel l i n e at c a r b u retor 1 F U E L FLOW R E ST R I CT E D __,�. ____ • F U E L F LOWS F R E E LY • • • 3 . Remove carbu retors a n d c h e c k for clogged jets I m p roper I m p roper - F a u lty - F a u lty valve clearance i g n it i o n t i m i n g i g n it i o n c o ntrol m o d u l e i g n it i o n p u lse g e n e rator Clogged fuel l i n e Clogged fuel c a p vent h o l e Clogged f u e l v a l v e Fau lty fuel p u m p o r relay Clogged fuel filter C L O G G E D -------· Clogged jets I N C O R R E C T --------�· C a m s h aft not i n s t a l l e d properly W E A K -----·-- Fau lty v a l v e s p r i n g NO C L O G G E D J ETS 4 . Check t alve t i m i n g C O R RECT • 5 . Check valve spring tension POOR HA N DL I N G ----C h e c k t i r e pressure POSSIBLE CAUSE 1 . I f steering is heavy ---· Bea r i n g adjustment nut too tight D a m a g e d ste e r i n g h e a d bearings Bent stee r i n g stem • • 2. If either wheel i s w o b b l i n g ----· • • • • • 3. If the motorcycle pulls to o n e side -------· • • • • 20-4 Excessive w h e e l b e a r i n g p l a y Bent rim(s) I m p roperly i n st a l l e d w h e e l h u b ( s ) S w i n g a r m p ivot b e a r i n g s excessively w o r n Bent frame or s w i n g a rm Loose s w i n g a r m p i vot bolt I n co rrect d rive c h a i n adjustment Front a n d r e a r w h e e l s not a l i g n e d Bent fork legs Bent swingarm B e n t fra m e Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-9 Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-4 Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 1 1 Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 5 Replacement/Air Bleeding . 1 4-4 Brake Light Switch . . . . . 1 8- 1 1 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 7 Brake Pad/Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-5 Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 - 1 0 Shoe/Pad Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 6 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 6 Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4 Cable & Harness Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1 0 Camshaft Installation . . . . . . . . s- ·1 8 Removal . . . . . . . .. 9- 4 Carburetor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 0 3-7 Choke . . . . 4-6 D isassembly . . . .. . Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 1 I n stallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 5 Removal . .. . . . 4-6 Separation/ Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1 3 Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 0 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5-7 Clutch/Gearshift Linkage . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 1 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-7 I nstallation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1 2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 1 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 8 Control Cable Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1 2 Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Temperatu re Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8 Coolant/Reserve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Cooling System . . . .. . . . . . 3- 1 2 , 5 - 1 Crankcase . ... . . . 1 1 -1 3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 9 Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -4 Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 Crankshaft/Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -5 Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-2 Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 2 Cylinder Head . ... . 9-8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 5 Cylinder Head Cover Installation . . . . . . . . . . . . . . . . . . . . . . . 9-2 1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1 6 I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0-6 D rive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3 Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 - 1 Emission Control I nformation Labels . . . . . . . . . . . . . . . . . . . 1 -22 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2 1 Engine Removal/Installation . . . . 6 1 6-5 Engine I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 2 1 . I N DEX Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Carburetor Air Vent Control Valve I nspectio n (California m o d e l o n ly) . . . . . . . . . .. Evaporative Emission Control System . . . . . . . . . . . . . . . . . Evaporative Emission Purge Control Valve Inspection (California model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flywheel I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork . . . . . . . . . . : . .. ... Front Wheel/Suspension/Steering . . . . . . . . . . . . . . . . . . . . . . Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line . . . ..... Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay . . ... . . .; . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . .. . . . . . . . . . . . Gearshift Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General I nformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety . . .. H andlebar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Aim . . . . High Altitude Adjustment ( U . S . A . Only) . . . . . . . . . Horn Hydraulic Disc Brake . . ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Control Module Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Pulse Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left Crankcase Cover I nstallation . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sched u le ' 8 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schedule ' 8 9 , ' 9 1 -'93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sched ule After '93 : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model ldentifiction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Switch . . . . N uts, Bolts, Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O i l Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Check . . . . . . Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pilot Screw Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ring I nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary Drive Gear . . ... Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator/Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . Brake . . . . Wheel . . . . . . . Regulator/Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -· . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 6-3 4- 1 7 3- 1 3 4- 1 6 8-5 8-3 1 2- 1 3 1 2- 1 1 2-7 4- 1 3-6 1 8- 1 0 1 8-9 4-3 7-8 1 -1 1 -1 1 2-4 1 8-7 1 8-3 3-1 8 4- 1 6 1 8- 1 2 1 4- 1 1 6-4 1 6-6 1 6-2 1 6-4 1 8-6 1 6-6 8-6 8-2 1 8- 1 2- 1 2- 1 2 3- 1 3-3 3-4 3-5 1 4-8 1 -2 1 8- 1 1 3-20 2- 5 2- 5 1 8- 1 0 2-6 4- 1 5 1 0-3 1 0-5 1 0-5 7-1 1 3-1 1 5-5 1 3- 1 1 3-7 1 3-3 1 5- 8 21 -1 I N D EX Right Crankcase Cover Installation . 7-1 4 7-3 Removal . .. . . . .. . . . . Seat/Rear Fender/Sub-frame 1 3- 1 8 Service I nformation Alternator/Starter Clutch . . . . . . . . . . . . . . . . . . . . . . . . 8- 1 Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-2 Clutch/Gearshift Linkage . .. .. .. .. .. .. .. .. .. .. .. . . 7- 1 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1 Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . 1 1 - 1 Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1 Electric Starter . . . . . .. . . 1 7- 1 Engine Removal/Installation . . . . . . . . . . . . . . . . . . . . 6-2 Front Wheel/Suspension/Steering . . . . . 1 2- 2 Fuel System . .. . . . . . . .. 4- 1 Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4- 2 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6- 2 Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8- 1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 Rear Wheel/Brake/Suspension . . . . . . . . . . . . . . . . . 1 3- 1 Service Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 1 3- 1 1 Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6-6 Spark Plugs .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . 3- 8 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -3 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-4 Starter Clutch . . ... .... .. .. .. . . 8-4 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7-3 Relay Switch . .. . .. . 1 7-6 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 2 1 Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2- 20 Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1 9 Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3- 1 4 System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Thermostatic Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-8 Throttle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Tools 1 -8 Torque Values ........................................... 1 -5 Transmission . . . ......... .. . ........... 1 1 -1 1 Assembly/Installation . . . . .... . ..... 1 1 -1 7 Troubleshooting Battery/Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1 5-3 Clutch/Gearshift Linkage . . . . . . . . . . . 7-2 Cooling System . . .. .. .. .. .. .. .. . . .. . . .. .. .. .. .. . . . . 5- 1 Crankshaft/Transmission . . . . . . . . . . . . . . . . . . . . . . . . 1 1 -3 Cylinder Head/Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Cylinder/Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0- 1 Electric Starter . . .. .. . . . 1 7- 1 Front Wheel/Suspension/Steering . . . . . . . . . . . . 1 2- 3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 3 Hydraulic Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4-2 Ignition System .. .. . . . . . . .. . . . . . . . . .. . . . . . . . . . . .. . . 1 6-2 Lights/Meter/Switches . . . . . . . . . . . . . . . . . . . . . . . . .. . 1 8-2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Rear Wheel/Brake/Suspension . . . . .. . . . . . . . . .. 1 3-2 Turn Signal Relay . . . . . . . . . 1 8- 1 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guide Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat l nspection/Refacing . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels/Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 9- 1 1 9- 1 2 5-7 3- 20 1 9- 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. .. .. . . 2 1 -2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (278)