‘ HOW TO use THIS MANUAL is service manual describes the service procedures Jr the VTGDOC/CD. Follow the Maintenance Schedule (Section Bl recomr mendations to ensure that the vehicle is in peak operating condition and the emission levels are within the standards set by the Us Environmental Protection Agency and California Air Resources Board. Performing the first scheduled maintenance is very important. it compensates for the initial wear that occurs duringthe breakrin period. Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates procedures for removal/ installation of components that may be required to perform service described in the following sections. Sections 4 through 19 describe parts of the motorcycle, grouped according to location. Find the section you want on this page, then turn to the table of contents on the first page of the section. Most sections start with an assembly or system illustration, service information and troubleshooting for the section. The subsequent pages give detailed procedures. .. vou don't know the source of the trouble, go to section 21, Troubleshooting. ALL INFORMATION, ILLUSTRATIONS, DIREC- ‘ TIONS AND SPECIFICATIONS INCLUDED IN l THIS PUBLICATION ARE BASED ON THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF APPROVAL FOR PRINTING. HONDA MOTOR CO., LTD. RESERVES THE RIGHT TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE AND WITHOUT INCURRING ANY OBLIGATION WHATEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT WRITTEN PERMISSION. THIS MANUAL IS WRITTEN FOR PERSONS WHO HAVE ACOUIRED BASIC KNOWLEDGE OF MAINTENANCE ON HONDA MOTORCYCLES, MOTOR SCOOTERS 0R ATVS. HONDA MOTOR CO., LTD. SERVICE PUBLICATION OFFICE CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM MAINTENANCE ENGINE AND DRIVE TRAIN LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM ENGINE REMOVAL/INSTALLATION CLUTCH/GEARSHIFI' LINKAGE ALTERNATOR/STARTER CLUTCH CYLINDER HEAD/VALVES CYLINDER/PISTON CRANKSHAFT/TRANSMISSION CHASSIS FRONT WHEEL/SUSPENSION/ STEERING REAR WHEEL/BRAKE/SUSPENSION HYDRAULIC BRAKE ELECTRICAL BATTERY/CHARGING SYSTEM IGNITION SYSTEM ELECTRIC STARTER LIGHTS/METERSISWITCHES WIRING DIAGRAM TROUBLESHOOTING INDEX afiahaaaalalaaaalaunnaa Date of Issue: June, 1998 © HONDA MOTOR co, LTD. SYMBOLS The symbols used thruughout this manual show specific service praceduresi If supplementary infurmation is required pertaining to these symbols, it would be explained specifically in the text without the use ofthe symbols. . Replace the pants) With new onels) before assembly. Use recommended englne oil, Unless otherwise specified. Use multipurpose grease (Lithium based mum-purpose grease NLGI t: 2 or equivalentl. Use molybdenum disulltde grease lcontaining more than a % molybdenum disulfide, NLGI #2 or equivalent). Example: Mdlylrote0 5sz plus manufactured by Dow Corning, U. s. A. Multipurpose M72 manufactured by Mitsubishi Oil, Japan was :3 Use molybdenum oil solution lmixture oitne engine oil and molybdenum grease In a ratio of 1 : ll. Use molybdenum disulfide paste (containing more than 40 % molybdenum disultide, NLGl #2 or equivalent]. ,efim Example: Molykotem Ann paste, manufactured by Dow Corning, U, s, A. Honda Moly so (U. s. A. only) Rocol ASP manutactured by Rocol Limited, U. K. Roeol Paste manufactured by Sumieo Lubricant, Japan (El Use silicone grease. QM Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Jam; Apply sealant. a Use DOT 4 brake fluld Use the recommended brake fluid unless otherwise specified. fl Use Park or Suspension Fluid. Rewssd Ocluber 1999. 1997 -2000 VTGDOC/CD ©1399 American Honda Motor Co . ind ~All Rights Reserved MsV 8617 (9910) 1. GENERAL INFORMATION 1 GENERAL SAFETY 1-1 SERVICE RULES 1-2 MODEL IDENTIFICATION 1—3 SPECIFICATIONS 1—5 TOROUE VALUES 1-14 TOOLS 1-17 LUBRICATION 8: SEAL POINTS 1-19 CABLE 8i HARNESS ROUTING EMISSION CONTROL SYSTEMS 1-33 EMISSION CONTROL INFORMATION LABELS 1-36 GENERAL SAFETY CARBON MONOXIDE 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. M;— The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to USED ENGINE OIL Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible altar handling used oil. KEEP death. OUT OF REACH OF CHILDREN. Run the engine in an open area or with an exhaust BRAKE FLUID evacuation svstem in an enclosed area. CAUTION: GASOLINE Work in a well ventilated area. Keep cigarettes, flames or sparks away from the work area or where gasoline is stored. M Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. HOT COMPONENTS Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. Spilling fluid on painted, plastic or rubber parts will damage them Place a clean shop towel over these parts whenever the system is serviced. KEEP OUT OF REACH OF CHILDREN, 1-1 ll GENERAL INFORMATION COOLANT Under some conditions, the ethylene glycol in engine coolant is combustible and its flame is not visible. If the ethylene glycol does ignite, you will not see any flame, but you can be burned. ma 0 Avoid spilling engine coolant on the exhaust system or engine parts. They may be hot enough to cause the coolant to ignite and burn without a visible flame. 0 Coolant (ethylene glycol) can cause some skin irritation and is poisonous if swallowed. KEEP OUT OF REACH OF CHILDREN. I Keep out of reach of pets and some pets are attracted to the smell and taste of coolant and can die if they drink it. . Do not remove the radiator cap when the engine is hot. The coolant is under pressure and could scald you. lf coolant contacts your skin, wash the affected areas immediately with soap and water. if coolant contacts your eyes, flush them thoroughly with fresh water and get immediate medical attention. If swallowed, the victim must be forced to vomit then rinse mouth and throat with fresh water before obtaining medical attention. Because of these dangers, keep out of the reach of children. Recycle used coolant in an ecologically correct manner. SERVICE RULES BATTERV HYDROGEN GAS & ELECTROLVTE ma U The battery gives off explosive gases; keep sparks, flames and cigarettes away, Provide adequate ventilation when charging. 0 The battery contains sulfuric acid felectrofytel. Contact with skin or eyes may cause severe burns. Wear protective clothing and a lace shield. — If electrolyte gets on your skin, flush with water. 7 If electrolyte gets in your eyes, flush with water for at least 15 minutes and calla physician immediately. I Electrolyte is poisonous, ill swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. KEEP OUT OF REACH OF CHILDREN. 1, Use genuine HONDA or HONDA-recommended parts and lubricants or their equivalents. Parts that don’t meet HONDA's design specifications may cause damage to the motorcycle. 2. Use the special tools designed for this product to avoid damage and incorrect assembly. 3. Use only metric tools when sen/icing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. lMnstall new gaskets, Orrings, cotter pins, and lock plates when reassembling. 5,When tightening bolts or nuts, begin with the larger diameter or inner bolt first, Then tighten to the specified torque diagonally in incremental steps unless a particular sequence is specified. 6. Clean parts in cleaning solvent upon disassembly, Lubricate any sliding surfaces before reassembly. 7. After reassembly, check all parts for proper installation and operation. 8. Route all cable and harness routing as shown on pages 1-21 through 1—29, Cable and Harness Routing. 1-2 GENERAL INFORMATION MODEL IDENTIFICATION ’977’98: FRAME SERIAL NUMBER II) The frame seriai number is stamped on the right side of the steering head. ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION N UMBER (2) The engine serial number is stamped on the right side of the crankcase below the rear cylinder. (3) The Vehicle Identification Number (VIN) is located on the right side of the frame below the exhaus‘ pipe. CARBU RETOR IDENTIFICATION NUMBER COLOR LABEL (4) The carburetor identification numbers are stamped on the intake side of the carburetor body as shown. (5) The color label is attached on the frame under the seam When ordering coiorAcoded parts, always specify the designa‘ed color code. 1-3 GENERAL INFORMATION MODEL IDENTIFICATION After ’98: ,/ / l , l x/ FRAME SERIAL NUMBER (1i The Irame serial number is stamped on the right side of the steering head. ENGINE SERIAL NUMBER VEHICLE IDENTIFICATION NUMBER (2) The engine serial number is stamped on the right side of the crankcase below the rear cylinder. (iii The Vehicle Identification Number (VlNl is located on the right side of the frame below the exhaust pipe, COLOR LABEL CARBU RETOR IDENTIFICATION N UMBER (A) The carburetor identification numbers are stamped (5) The color label is attached on the frame under the on the fuel tube joint side of the carburetor body as shown. seat. When ordering color-coded partsv always specify the designated color code. 1-4 GENERAL INFORMATION SPECIFICATIONS — GENERAL ITEM SPECIFICATIONS DIMENSIONS Overall length 2,310 mm (90.9 In) Overall width '97 "'98: 890 mm (35.0 in) After '98: 880 mm (34.6 in) Overall height '97fi'98: 1,125 mm (44.3 in) After '98: 1,120 mm (44.1 in) Wheelbase '977'98: 1,605 mm (63.2 in) After '98: 1,600 mm (63.0 in) ‘ Seat height ’97i'98: 690 mm (27.2 in) After '98: 650 mm (25.6 in) Footpeg height '97i'98: 285 mm (11.2 in) After'98: 283 mm(11.1 in) Ground clearance ’97i’98: 140 mm (5.5in) After '98: 135 mm (5.3 in) Dry weight VTGOOC 49 state/Canada type 977/93: 199 kg (439 lbs) 49 state/Canada type After '98: 205 kg (452 lbs) California type ’97i'98: 199 kg (439 lbs) California type After '98: 206 kg (454 lbs) VTSODCD 49 state/Canada type '977’98: 202 kg (445 lbs) 49 stats/Canada type After ’98: 208 kg (459 lbs) California type '97A'98: 203 kg (448 lbs) California type After '98: 209 kg (461 lbsl Curb weight VTSOOC 49 state/Canada type ’97F'98: 213 kg (470 lbs) 49 state/Canada type After '98: 214 kg (472 lbs) California type ’97i'98: 214 kg (472 lbs) California type After '98: 215 kg (474 lbs) VT600CD 49 state/Canada type ’97i’98: 216 kg (476 lbs) 49 state/Canada type After '98: 217 kg (478 lbs) California type '97 i’98: 217 kg (478 lbs) California type After '95: 218 kg (481 lbs) _____ FRAME Frame type Double cradle Front suspension Telescopic fork Front wheel travel 120 mm (4.7 in) Rear suspension Swingarm Rearwheel travel 90 mm (3.5 in) Front tire size 100/9049 57S Reartire size 170/80-15 M/C 77S Tire brand Front 97,93: ERIDGESTONE L309 (DUNLOP F24 After '98: DUNLOP F24 Rear 97,93: ERIDGESTONE 6546 IDUNLOP K555 After '98: DUNLOP D404 Front brake Hydraulic single disc brake Rear brake Internal expanding shoe Caster angle 35° Trail length '97f'98: 164 mm (6.5 in) After '98: 161 mm (6.3 in) Fuel tank capacity Fuel tank reserve capacity 11.0 ll (2.91 US gal , 2.42 Imp gall 3.4 I} (0190 US gal, 0.75 Imp gal) _——————————-————— Revised: Augusl, 2000, ‘97 -'01 VTSDUC/CD @000 American Honda Motor 00., Inc. - All Flights Reserved MSV 8969 (0008) 1-5 N E w GENERAL INFORMATION Displacement Compression ratio Valve train A GENERAL (Cont'dl i ITEM ‘ SPECIFICATIONS ENGiNE Bore and stroke i 75.0 X 56.0 mm i2.95 >< 2.60m) 583 cm3 (35.8 cu—inl 9.2 : 1 Silent, multi-Iink chain drive and OHC with rocker arm Starting system Charging system Regulator/rectifier Lighting system intake valve opens at 1 mm lift '97-’98: 10" BTDC intake valve opens at 1 mm lift After ’98: 0° BTDC Intake valve closes at 1 mm lift '97V’SS: 30° ABDC Intake valve closes at 1 mm lift After ’98: 20° ABDC Exhaust valve opens at 1 mm lll'l '97i'98: 30° BBDC Exhaust valve opens at 1 mm liit After '98: i 30" EBDC Exhaust valve closes at ‘i mm lift ’97a'98: 10” ATDC Exhaust Valve closes at ‘i mm lift After '98: 0" ATDC Lubrication system , Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Paper filter Crankshaft type Unit type, two main journals Engine dry weight VTGOOC '97: 6140 kg i134.5 lbsl After '98: 6240 kg (136.7 lbs) VTGODCD 64,0 kgl141.1lbsl Firing order Front7308"7Rear- 412““Front Cylinder arrangement Two cylinders, 52" V transverse Cylinder number Front: #2, Rear: #1”? . ... . 77777 CARBURETOR Carburetortype ’97~ ’98: CV (Constant Velocity ual carburetorwith fuel pump After ’98: CV (Constant Velocityl single carburetor with accelerator pump Throttle bore ' 34 mm HS in) ., DRIVE TRAIN Clutch system Multirplate, wet Clutch operation system Mechanical type Transmission Constant mesh, 4-speed Primary reduction 1.888 (36/68l i Final reduction 2.750 ”II/16) Gear ratio 1st 2571 i36/14l 2nd 1.700 (34/20) 3rd 1.227 127/22) 11th 0.931 (27/29) . , Gearshift pattern V . Left foot operated return system, 17 N , 2 '37 A ELECTRlCAL Ignition system Full transistor digital ignition Electric starter motor Triple phase output alternator SCR shorted/triple phase, full wave rectification Battew 1-6 GENERAL INFORMATION — LUBRICATION SYSTEM U""' ”‘m ""l ITEM STANDARD SERVICE LIMIT Engine oil capacity At draining 2.1 11(22 US qt, 1.8 Impth , Atdisassembly , 2.811(31] US qt,2.5|mp qt) i At oilfilter change 2.259(238 US qt, 1,98lmp qt) F- 7 Recommended engine oil HONDA 6N4 or HP4 4rstroke oil or k equivalent motor oil API service classification SF or 56 Viscosity: SAE 10W740 7 Oil pressure at oil pressure switch 441 kFa (4.5 kgf/cm‘, 64 psiI at 6,000 rpm J (80 “(3/176 “Fl Oil pump rotor LTip clearance 0.15 (0,006) 0.20 (0.008) Body clearance 0.15*0.22 l0.006*0.009l 0.35 (0.014) Side clearance 0.02*0.07 (0001*0003) l 0.10 (0.004) F FUEL SYSTEM ITEM SPECIFICATIONS 49 state/Canada type i California type Carburetor identification number i '977'98 VDFDA ‘ VDFEA After '98 VESAC l VEEAB Meiniet '97-”98 13115 After '98 1? 125 Slow jet '97 —'98 33 40 TAfrer '93 it 45 Pilot screw Initial/opening See page 5-30 Hight altitude adjustment See page 5—37 Float level i '97 #95 7.0 mm [0.25 in) ( After '98 18.5 mm (0.73 int 7 Base carburetor (Ior synchronization, '971'98 models) Rear cylinder (# 1) Idle speed 1,200 i 100 rpm Throttle gripfree play 2*6 mml1/12*1/4in) Fuel pump flow capacity ('97 v ’98 modelsl Minimum 800 cm3 (27.1 US oz , 28.2 Imp oz) per minute at 13V * COOLING SYSTEM ITEM SPECIFICATIONS l coolant capacity Radiator and engine 1.611(17 US qt, 1.4 Imp qt) Reserve tank 0.4 E (0.11 US qt , 0,4 Imp qt) Radiator cap relief pressure Thermostat I Begin to open 2 Fully open l Valve lift 58» 127 kFa (0.9-1.3 kgf/cm2,12.8718 psi) 80*84"C(176*183 DF) 95 °C(203"FI 8 mm (0.3 in) minimum Standard coolant concentration 50 % mixture with soft water 1-7 GENERAL INFORMATION _ CLUTCH SYSTEM ”""‘ ’"m ""’ ITEM STANDARD SERVICE LIMIT C(utch lever free play 10720 (3/8—3/4) ——~"~ C(utch spring free length 43.2 (1.70) 41.6 (1.64) Clutch disc thickness I A 2.92i3.08(0.115*0.121) 2.6(0.10) B 2.92i3.08(0.115-—0.121) 2.5(D.1DI Clutch pmte warpage _ 0.30 (0.012) Clutch outer guide I.D. 21.991*22.016(O.8655*0.8668) 22.09 (0.87m O.D. 31.959*31.975 (1.2582‘12589) Clutch ouIer |.D. 32.000 7 32.025 (1.2598 — 1.2608) 32:10 (1.264) Oil pump drive sprocket |.D. 32.000 -— 32.025 (1.2598 —1,2608) Mainshafi OD. at clutch outer guide 21.967 —21.980 (0.8648—0.8554) 21.92 (0.863) U 'I: mm (in) ~ ALTERNATOR/STARTER CLUTCH "' ITEM STANDARD SERVICE LIMIT Stanerdriven gear |.D. 31000737325 (14557714577) 37.10(1.461I O.D. 57749757168 (2.2736~2.2743) 57.73 (2.273) Starterclutch ou‘erlD. 74.414~74.440(23297-23307) 74.46 (2.9311 GENERAL INFORMATION Unii: mm Iil’iI 7 CYLINDER HEAD/VALVES ITEM Rocker arm-“Hooker arm shah clearance STANDARD I SERVICE LIMIT Cvllndercompressiun 1,324 i 98 kPa (13.5 t 1.0 kgf/cm‘, I i i 7 32 : 14psi1a1400 rpm If I C linder head warpage 7—? I» 0 (am i VaIve, I VaIve clearance L IN 015100061 ‘ 7 I/I Valve guide I EX 0.20 (0.0081 7 I I Valve stem 0 D IN ‘ 5.4757 5.4901021557021611 545102151 EX 0.5557 6.570 1025817025871 3&102501 I Valve guide I. 0 I IN 550075.5121021057021701 5.50 10.2191 ‘ ‘ EX I 960076.5151025987025041 6.65 10.2521 sre m7m-guide clearance IN I 0.0107043710000470 00 I40 10.7004; I EX 003070.0601000127000241 011100041 VaiVe guide projecxion IN 19.115196 (01670.77) 7 Ijbeve cylinder head Ex 17.197191107070711 4 I Valve sealwidth I lN/EX 09071101003570.0431 , Valve spring Inner IN 38.11 11.5001 I I 304711. 4301 , Iree Iengrh Ex I 38.01 11.5231 LEM 11 4E? Omer IN 4214116591 350115991 7 EX 42.83 11.0051 I $.25 11.6241I Camshaft I Cam iobe IN '977'98 379301149331 , 3 73114051 height 1 After'SB ‘ 37. 1357 37 348114541 1.47041 I 37j/1L63L_ I EX '9 98 37 95011. 49411 37.7511 4001 1 Afler'98 I 37. 0057 37. 75511. 480571. 4063) 3'7- 48015911. Journai 0.0. I 21.9597 21 9801w457036541 ‘ 4&10002147 Runou! I 0.030 (0.00121 005100021 Ijm clearance . I 0 0507 0 111 10 00207 0.00441 I #_ Identification marks I ”F”: Front "R": Rear 717* Rocker arm 1.0. IN/EX I 12. 0007 12. 01a 10. 47247 0 47311); 12.0510.4741:I Rocker arm shaft 0.13. IN/EX 11.966711. 98411047117045.7181 11.91 10.4691 I 007100031 If 0.016 7 0.052 (0.0006 * 0.0020) GENERAL INFORMATION Piston O.D. measuremem point 10 mm (0.4 in) from bottom of skin — CYLINDER/PISTON I Unn. mm (m) ITEM 1 STANDARD SERVICE LIMIT Cylindsr l.D. 75.000i75015(2.9528“2.9533) 75.10 (2.957) Out‘gfwround 0.06 (0.002) Taper 7 0.06 (0.002) Warpage ) 0.10 (0.004) Piston,pis1on Piston mark direction ”IN" markiacing Iowardlha intake side 7 rings Piston OD. 74365774390 (23514729524’ 74.90 (2.049) Piston pin bore LD. 18.002 ~18.008(D.7087 , 0.7090) 18.05 10,711?“ Fis‘on pin O.D. 17.994518.000(0.7OB470.7087) 17.98 (0.708) Piston—to-piston pin clearance 0002—0014(00001-00006) 0.04 (0.002) Piston ring»to»ring Top 001540.045 (00006700018) 0.10 (0.004) groove clearance Second , 0.015'0045(00006—00018) 0.10 (0.004) Piston ring and gap Top 0.107 30 (000470.012) 0.5 (0.02) Second 0.10i0.30(0.004*0.012) 0.5 (0.02) on (side raii) 0.207070 10008700281" 7 0.9 (0.04) Piston ring mark Top/secund "N" mark 7 Cyiinderrlovpiston clearance 0010*0050 (0.0004i00020) 0.10 (0.004) Connecting rod smaH end |.D. 18.016718.034(0.7093*0.7100) 18.07 (0.711)7 7 Connecting rodito—piston pin ciearance 001640.040 (00006700016) 0.06 (0.002) — CRANKSHAFT/TRANSMISSION ”""' mm "”' ITEM STANDARD SERVICE LIMIT Crankshafl Side c)earance 0.05i0.20(0.002*0.005) 0.30 (0.012) Runoul 7 0.05 (0.002) Crank pin ’ glfiarance 0028*0052 (0.0011'00020) 0.07 (0.003) Mainjuurnal oi) clearance 0025*0041 (0.0010i0.0016) 0.06 (0.002) Transmission GeariD. M2, M4, C3 25000728021 (10024710032) 28.04 (1.104) C1 24000724021 (0.96497 .9457) 24.94 (0.982) Bushing O.D. M2, M4, C3 27.959—27.980(1.1007* .1016) 27.94(1.100) C1 1 23.959 ' 23.980 (03433700441) 23.94 (0.943) Bushing |.D. M2 1 25.000~25.021 (0.9843~0.9851) 25.04 (0.986) C1 20.016i20037 (0.7880*O.7889) 20.06 (0.790) Gearrto»bushing M2, M4 1 0020*0062 (0.0008i00024) 0.10 (0.004) clearance C1, CS 0020*0062 (0.0008i00024) 0.10 (0.004) Mainshafi O.D. M2 bushing 24359724330 (0.9826i0.9835) __ 24.94 (0.902) Countershaft OD. C1 bushing 19.980i19393 (0.7865i07871) 19.96 (0.786) _# Eushing-m-shafl M2 002070.062 (00008700024) 0.10 (0.004) c)earance C1 ., 1 0023—0057 (00009700022) 0.10 (0.004) Shift fork,fork Fork LD. ‘ 13.000' 13.015(0.5118*0.5125) 1304 (0.513) shah . Claw thickness 593*600 (0233*0236) 5.60122) Fork shah 0.0. 12.905712.984105105v0511z) 12.90 (0.508) Shiftdrum OD. (atthe lehsidejournai) 11.966*11.984(0.4711*0.4718) 11.94(0.470) 1-10 GENERAL INFORMATION r FRONT WHEEL/SUSPENSION/STEERING ”""' "‘"‘ ""’ ITEM STANDARD l SERVICE LIMIT Minimum lira tread depth 1 1.5 (0.06) Cold lira pressure Up to 90 kg (200 lb) load 200 kPa (2.00 kgf/cm’ , 29 psi) f Up to maximum Weight capaciiy 200 kPa (2.00 kg'icm‘ , 29 psi) Axle runoul P‘ 0.20 (0.008) Wheel rim runout Radial A V 2.0 (0.08) Axial r 2.0 (0.08) Jilvheel hub-io-rim dimnce 777 77777 32.3 t 0.8(117730403) ,, . ., Wheel balance weight Max 70 9 (2.5 01) Fork Spring free length 333.9 (13.15) 327.2 (12.98) Spring direction rignily wound cnils should be aiiheiop Tube runuut ..__ 0.20 (0.008) Recommended fork fluid Pro»Honda Suspension Fluid 5578 Fluid level 111 (4.4) ‘ Fluid capacity 449 1 0.25 Cri"!J (15.2 i’ 0.02 US 01, 15.3 1 0.09 Imp Hz) i Steering head bearing preload 0.9*1.4 kgf(2.0 , 3.1 lhf) l # REAR WHEEL/BRAKEISUSPENSION U““' "‘m ""’ ITEM STANDARD l SERVICE LIMIT Minimum tire tread depth r 2.0 (0.08) Cold (ire pressura Up to 90 kg (200 lb) load 200 kPa (2.00 kgf/sz , 25 psi) .> Up in maximum weight capacity 250 kPa (2.50 kgf/cm‘ , 36 psi) -7 Axle runoul 0.2001003) Wheel rim runout Radial ' 2.0 (0.08) Axial 2.0 (0.03) 7 Wheel hubris-rim distance 32.3 t 0.8 (1.27 i 0.03) Wheel balance Weight Max 70 g (2.5 oz) E Drive Chain link 120L Drive chain slack 20*30 0/4714”) 50 (2.0) Drive Chain sile DID 525 V8 RK ' 525 5M5 Rear brake Drum LD. 160,0*160.3(6.30~6.31) 161 (6.3) Lining thickness 5 (0.2) 2 [0.1) Brake pedal free play 20*30 (3/4‘14/4) Shock absorber sprinq preload adjuster ssning 2nd position . 7* i Revmed Octgbar1999. 1997-2000 v’rsnoclpn 1 _1 1 ©1999 Amellcan Honda Mom 60., inc » All Righis Reserved MSV 8617 (99m) GENERAL INFORMATION ~ HYDRAULIC BRAKE U""' '“m "”’ ITEM STANDARD SERVICE LIMIT Specified brake fluid DOT 4 7"" Brake pad wear indicator g.-." , To groove Brake disc thickness 5.0(0.20l 4.010.16l Brake disc runout 0.30 (0.012I Master Eylinderl.D. 11.000’11043 10.4331“‘D.434E) 11.05(0.435) Master piston O.D. 10.957i10384(0.4314'~D.4324l 10.945lfl.4309l Caliper cylinderlD. Caliper piston O.D. 27.000‘27050 (LOGSOWLOGSOI i 26335—26368l1.0604*1,0617) l 27.06 (1.065) 25.93 (1.06!“ , BATTERV/CHARCIEIIENMG SYSTEM SPECIFICATIONS Battery 3 Capacit 12v-s AH Current leakage 1.3 mA max. Voltage {20 “C/SB “Fl Fullyfiharged 13.0 i 13.2 V Needs charging Below 12.3 V 7 Charging current Normal g 0.8 A/IO h 7",, Quick 4.0 An h max Alternator Capacity 345 W/5,000 rpm Charging coil resistance (20 “C/68“Fl 0.1 7 1.0 $2 Regulator/rectifier regulated voltage 14 7 15 V/4,000 rpm '— IGNITION SYSTEM ITEM SPECIFICATIONS Spark plug Standard DPREEA—S INGKVIV , X24EPR-U9 IDENSO) _Eor cold climate Ibelow 5 ”C/41 °F) DPR7EA~9INGK) X22EPR-U9 IDENSO) I For extended high speed riding DPRSEArWNGK) X27EPR-U9 IDENSOI Spark plug gap 03070.90 mm (0.031 - 0.035 in) Ignition coil primary peak voltage 100V minimum Ignition pulse generator peak voltage 0.7 Vminimum Ignition timing "F” mark 6.5“ BTDC at idle Advance i Start ”(97798 2,000 i 200 rpm . After ’98 1,300 i 200 rpm Stop 6,000 I 200 rpm Full advance BTDC 30° 1-12 GENERAL INFORMATION ___—______———————— ~ ELECTRIC STARTER ”m" '"m ""’ ITEM STANDARD SERVICE LIMIT Starter motor brush length 12‘5I0.49I 6.5 (0.26I — LIGHTS/METERS/SWITCHES l ITEM ‘ SPECIFICA'HONS Bulbs Headlight (High/low beaml _ 12V-60/55W _ Brake/tail light 12V-32/3CP X 2 Front turn signal/running light 12V-21/5W X 2 Rearturn signal light 12V-2‘IW X 2 License light 12Vv4CP Instrument light _ 12v-3.4w Turn signal indicator 12V-1.7W High beam indicamr 12V-1V7W Neutral indicator 12V—1,7W Fuse Main Iuse _ 30A 7 I Subluse , 10A >< 3,15A x1, Fuel pump flow capacity (min/minute) (97* ’98 modrelsl 800 cm3 (271 US oz , 28.2 Imp oz) 7 Fan motor Stanto close IONI , 98 , 'IDT‘C (208 , 216°FI switch _ ,, Startto open (OFF) 93 , 97”C I199 7' 207°Fl Thermosensor resistance (‘97 i’DOI I 50 "C1122 “F 130 *180 £2 1 sow/175% 45 *60 Q , l 120 ”C1248 “F 10 720 52 Thermo switch (After 'OOI Start to close ION) ‘ ‘I 12 7 118°C (259 270’?) IiStart to open (OFFI i Beluw108°C(252°Fi ———_—_———— Revised: August, 2000, ‘97 1m VTfiOOC/CD 1 _1 3 @2000 Amsvlmn Honda Molar Co.. Inc - All Rigth Reserved MSV 8969 (0008) GENERAL INFORMATION TORQUE VALUES TORQUE TORQUE FASTENER TVPE ‘ N-m Ikgf-m, lbI-ft) FASTENER TVPE N-m (kgI-m, lbI-ft) 5 mm hex bolt and nut 5 (0.5, 3.6) 5 mm screw 4 (0.4, 2.9) 6mm hex bolt and nut 10(1.0,7) 6mm screw 9(0.9,6.5) 8 mm hex bolt and nut 22 (2.2, 16) 6 mm flange bolt (8 mm head) 9 (0.9, 6.5) 10 mm hex bolt and nut 35 (3.5, 25) 6mm flange b0|t(1(J mm head) 12(1.2,9) 12 mm hex bolt and nut 54 (5.5, 40) and nut 8mm flange boltand nut 26 (2.7.20) 10 mm flange bolt and nut 39 (4.0, 29) - Torque specifications listed below are for important fasteners. ‘ Others should be tightened to standard torque values listed above. NOTES: 1. Apply sealant to the threads. 2. Apply a locking agent to the threads. 3. Apply molybdenum disulfide mil to the threads and flange surface. 4. Apply grease to the threads, 5. Stake. 6. Apply oil to the threads and flange surface. 7. Apply clean engine oil to the O-ring. 8. Urnut. 9. ALOC bolt: replace with a new one. i ENGINE THREAD TORQUE ”EM 07" DIA. (mm) N-m (kgf-m, 1am) REMARKS MAINTENANCE: Sparkplug 4 12 14(1.4,1D) Crankshaft hole Cap 1 30 15(1.5, 11) NOTE3 Timing hole cap 1 22 1511.5,111 NOTES Valve adjust cover 8 6 12 (1.2, 9) Valve adjusting screw lock nut 6 7 23 (2.3 , 17) NOTE 6 Drain bolt ’97 7 ’98: 1 14 34 (3.5 , 25) After '98: 30 (3.1 , 22) Oilfiltercartridge 1 20 10(1.U,7) NOTEZ Vacuum plug ('97 , '95) 2 5 3 (0.33 , 2.41 LUBRICATION SYSTEM: Oil pressure switch '97i'98: 1 PT1/B 10 (1.0 , 7) NOTE 1 After'QE: 12(1.2,9) Oil pressure switch cord 1 4 2 (0.23 , 1.7) Oil pump driven sprocket bolt 1 6 15115.11) NOTE 2 Oil pump cover bolt (After '98) 3 6 13 (1.3 , 9) ENGINE MOUNTING: Drive sprocket plate bolt 2 10 10 (1.0 , 7) CLUTCH/GEARSHIFT LINKAGE: Hightcrankcase cover bolt 1 13 , 6 12(1.2 ,9) Clutch cable holder bolt l 1 ‘ 6 12 (1.2 , 9) Clutch lifter plate bult § 4 6 12(1.2,9) ‘ Clutch center lock nut ’97—'98: 1 18 127 (13.0 , 94) l NOTE 5 After'SB: 128(13.1,95) Primary drive gear bolt 1 12 83 (9.0 , 65) NOTE 6 Gearshift cam plate bolt 1 8 12 (1.2 , 9) NOTE 2 Left rear cover bolt 1 6 12(1.2,9) Gearshift return spring pin 1 8 23(23, 17) 1-14 GENERAL INFORMATION , ENGINE (Cont'd) . THREAD TORQUE ; ITEM 0,.” DlA. 1mm) N~m tkgt-m. lbf-tt) l REMARKS ALTERNATOR/STARTER CLUTCH: l 1 Left crankcase cover bolt 1 10 6 1211.2 . 9) Flywheel bolt '97 2 '98: 1 1 12 _ 127113.0 , 94-) NOTE 6 After’98: l 1 128113.1,95) Stator mounting socket bolt 4 6 12 11,2 . 9) NOTE 2 Starter one-way clutch socket bolt ’97m’98: 6 8 29 13.0 . 22) NOTE 2 After '98: 3013.1 . 22) Alternator card clamper 2 6 " 1211.2 . 9) NOTE 2 Ignition pulse generator bolt 4 6 ’ 1211.2 , 9) NOTE 2 CVLINDER HEAD: 1 Cylinder head cover bolt 4 6 1011.0,7) Cam sprocket bolt 4 7 2312.3 .17) NOTE 2 Camshaft holders mm bolt 6 8 23123.17) 8mm nut 4 8 . 2312.3,17) Camshaft end holder bolt ’97 , '98: A 6 1 91119.65) After'BB: 1011.0,7) Cam chain tensioner mounting bolt 4 6 10 11.0 . 7) NOTE 2 Cylinder head 8 mm bolt 4 8 . 2312.3 .17) NOTE 6 6mm bolt 1 2 6 12112.9) NOTES 10mm nut 8 1D 4714.8,35) NOTES CRANKSHAFT/THANSMISSION: l Mainshaft bearing set p1ate bolt (’97m’98) l 1 6 1 1211.2 .9) NOTE 2 Countershaft bearing set plate bolt 1'97m'98) l 3 6 910.9 . 55) NOTE 2 Bearing set plate bolt (After '98) 4 6 1211.2 , 9) NOTE 2 Cam chain tensioner set plate bolt 2 6 1211.2 .9) NOTE 2 crankcase 8 mm bolt 13 8 23123.17) 6 mm bolt '97 m'98: 7 6 910.9 , 6.5) After ’98: 12112.9) Connecting rod bearing nut A 8 33 13.4 , 25) NOTE 6 Neutral switch 1 10 1211.2 . 9) NOTE 1 ELECTRIC STARTER: _ Starter motorcable nut 1 6 1011.0.7) 1 — FRAME . THREAD TORQUE . ITEM 07" DlA. 1mm) N-m 1kgi-m,lbf-ft) l REMARKS FRAME/BODY PANELS/EXHAUST SYSTEM: l Exhaust pipe joint nut A a 2512.5,15) ‘: Exhaust cover bolt 3 6 12112.51) Muffler bracket mounting bolt 1 8 20 12.0 . 14) nut 4 8 2012.0 .14) Subrframe mounting bolt 2 6 1211.2.9) nut 2 s 12 (1.2 , 9) ‘. MAINTENANCE: Side stand pivot bolt 1 10 10 11.0 ,7) l nut '97— '95: 1 1o 2913.0.22) 1 After '98: 3013.1 . 22) FUEL SYSTEM: 1 Air cleaner housing cover bolt 1 6 1011.0.7) Air cleaner housing mounting bolt 2 6 1211.2,9) Fuel valve nut ’977’98: 1 22 2312.3 , 17) ‘ After ’98: 35 13.6 . 26) 1 Fuel valve )ever screw 1 5 410.4 , 2.9) 1 Fuel tank mounting bolt 1 8 1911.9.14) ‘ Throttle linkcover screw 1 4 210.21 ,1.5) ) 1-15 GENERAL INFORMATION — FRAME (Cont'dl . . THREAD TORQUE ”EM 0 TV ‘ DIA. (mm) N-m (kgrm, 1mm REMARKS COOLING SYSTEM: 1 Radiator mounting bolt 1 6 ‘ 9 (0.9 , 6.5) Radiator grille mounting screw 1 (I 6 9 (0.8 , 6.5) Thermostat bracket bolt 1 1 6 10 (1.0 , 7) Thermostat housing cover bolt 2 6 10 (1.0 , 7) Thermosensor 97,100. 1 FT 1/8 10 (1.0 , 7) NOTE 1 Thermo switch After '00: 1 PT 1/3 8 (0.0 , 5.8) NOTE 1 Water hose band screw 4 7 7 (0.7 , 5.1) Fan motor switch 1 16 18(1.8,13) NOTE1 ENGINE MOUNTING: Front engine mounting bolt (upper) '977'98: 1 10 54 (5.5 . 40) After '98: 55 (5,6 , 41) (lower) 197., ‘58: 1 10 54 (5.5 , 40) After '98: 55 (5.6 , 41) Rear engine mounting bolt ’97F'98: 1 10 54 (5.5 , 40) After ’98: 55 (5.6 , A1) Engine bracket bolt (front) ’97i’98: 4 8 26 (2.7 , 20) After '98: 27 (2.8 , 20) (rear) '97i'98: 2 B 26(2.7,20) After '98: 27 (2.8 , 20) Gearshift pedal pinch bolt 1 6 12 (1.2 , 9) Footpeg bracket bolt 4 10 39 (4.0 , 29) FRONT WHEEL/SUSPENSION/STEERING: Steering stem nut 1 24 103 (10.5 , 76) , See page1340 Top thread A 1 26 7 E" Top thread El 1 26 Fork top bridge pinch bolt 2 7 11 (1.1 ,8) Fork bottom bridge pinch bolt 2 10 49 (5.0 , 36) Handlebar upper holder 4 8 29 (3.0 , 22) Handlebar lower holder 2 8 23 (2.3 , 17) Handlebar switch screw 4 5 4 (0.4 , 2.9) From axle 1 15 74 (7.5 , 54) . Front ax)e pinch bolt 2 7 22 (2.2, 16) Front brake disc mounting bolt '97i'98: 5 8 39 (4.0 , 29) NOTE 9 After '98: 42 (4.3 , 31) 1 Fork cap 2 34 23 (2.3, 17) ‘ Fork socket bolt 2 10 29 (3.0 , 22) NOTE 2 Spoke 56 4 4 (0.4 , 2.9) REAR WHEEL/BRAKE/SUSPENSION: Rearaxle nut 1 16 88 (9.0 . 65) NOTE 8 Driven sprocket nut 5 10 64 (6.5 , A7) ‘ NOTE 8 Rear shock absorber mounting nut (upper) 1 10 44 (4.5, 33) 1 (lower) 1 1D 44 (4.5, 33) Swingarm pivot nut 1 14 88 (9.0 , 65) ‘ Rear brake stopper arm bolt '977'98: 2 s 2212.2,16) 1 After '98: 21 (2.1 , 15) ‘ Rear brake arm pinch bolt '97 1 '98: 2 B 26 (2.7 , 20) 1 After '98: 21 (2.1 , 15) Rear brake middle rod joint bolt 2 . 6 9 (0.9 , 6.5) Spoke 52 4 4 (0.4 , 2'9) ————_—_ 1 _1 6 Revised: August. 2000, ‘97 :01 VTBODC/CD ©2000 American Honda MotorCo., Inc. - AI) Rights ReseNed MSV 8969 (0008) GENERAL INFORMATION — FRAME (Cont'dl THREAD TORQUE ”EM 0”” DIA. (mm) N-m lkgf-m, lbl-ft) REMARKS HYDRAULIC BRAKE: Brake caliper mounting bolt 2 8 30(3.1, 221 NOTE 9 Caliper pin bolt 1 8 2312.3,17l Bracket pin bolt 1 8 13 (1,3 , 91 Pad pin 1 ; 1O 18(1.8,13l Pad pin plug 1 i 10 2 (0.25, 1.8) Brake caliper bleeder 1 8 6 (0.65 , 4.71 Brake lever pivot bolt 1 6 110.1 ,0.7l Brake laver pivot nut 1 6 6 (0.6 , 4.31 Master cylinder holder bolt ‘ 2 6 12 (1.2 , 9) Master cylinder cover screw , 2 4 1 (0,15,1.1l Front brake light switch screw 1 A 1 (0.12, 0.91 Brake hose oil bolt 2 10 3413.5 , 25) LIGHTS/METERS/SWITCHES: Side stand switch mounting bolt 1 6 9 10.9 , 6.51 NOTE 9 OTHER FASTENERS: Fuel pump stay mounting nut (’97 —'981/ Turn signal relay stay mounting nut (After ’58) 1 6 9 10.9 , 6.5) TOOLS NOTES: 1. Equivalent commercially available in U.S.A. 2. Not available in U.S.A. 3. Alternative tool. 4. Newly provided tool. DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Carburetor float level gauge D7401~0010000 i 5 Pilot screw wrench 07LMA— MT8010A with U7PMA'MZZO11A Vacuum gauge 0740470030000 NOTE 3: 07LMJi001000A 4 Oil pressure gauge D7506i3000000 NOTE 1 4 Oil pressure gauge attachment 0751074220100 ‘ NOTE 1 4 Lock nut wrench 17 X 27 mm 07716i0020300 , NOTE 1 8 Gear holder 0772470010100 1 8 Rotor puller 07733’0020001 ‘ NOTE 3: 07933"3290001 9 Valve guide driver, 5.5 mm 07742‘0010100 10 Valve guide driver, 6.6 mm 07742~OD10200 NOTE 2:07942i6570100 10 Attachment, 32 X 35 mm 07746—0010100 l 14 Attachment, 42 X 47 mm 07746—0010300 ‘ 12, 13, 14 Attachment, 52 X 55 mm D7746i0010400 12,13 Pilot, 15 mm 07746i0040300 ‘ 14 Pilot, 17 mm 077A6i0040400 14 Pilot, 20 mm 077A6i0040500 12, 13 Pilot, 22 mm 07746‘0041000 12,14 Pilot, 25 mm 07746—0040600 12 Bearing remover shaft 07746—0050100 13,111 Bearing remover head, 17 mm 07746i0050500 14 Bearing remover head, 20 mm 07746i0050600 13 Attachment, 28 X 30 mm D7946i1870100 14 Driver 07749—0010000 12,13,14 Main bearing driver attachment , O7HMF—MM90400 , 12 Valve spring compressor 3 07757—0010000 NOTE 3: 0795773290001 l 10 1-17 GENERAL INFORMATION DESCRIPTION TOOL NUMBER REMARKS REF. SEC. Valve seat cutter Seatcutter, 27.5 mm 145“ IN) Seat cutter, 35 mm (45" EX) Flat cutter, 28 mm (32" IN) Flat cutter, 35 mm (32° EX) Interior cutter, 30 mm (60° lNl Interior cutter, 375 mm (60" EXl Cutter holder, 5.5 mm Cutter holder, 6.6 mm Valve adjusting wrench Snap ring pliers Steering stern socket Clutch center holder Bottom holder pipe , Holder attachment , Holder handle Bearing remover set ~ Remover handle A Bearing remover set — Remover weight Flywheel holder Valve guide driver attachment (IN) (EX) Bearing race remover Driver shaft set Steering stern driver Driver shaft Fork seal driver, 39 mm Ball race remover 7 Driver attachment 7 Driver handle Valve guide reamer, 5.5 mm llNl Valve guide reamer, 6.6 mm (EXl Oil filter wrench Peak voltage adapter Main bearing driver attachment Drive chain cutter Spoke wrench Vacuum/Pressure pump 07780 7 0010200 0773070010400 07780i0012100 07780i0012300 07780 7 0014000 07780‘0014100 0778170010101 07781 -0010201 07908iKE90000 07914 7 3230001 0791573710101 07JMBi MN50301 07930-KA50000 07930— KA50100 07930‘KA40200 07936* 3710001 07936* 3710100 07936‘ 3710600 0774170010201 07725’0040000 07943iMF50100 079437MF50200 07946 7 3710500 07946— KA50000 07946 , MBOOOOD D7946iMJ00100 07947i4630100 07953iMJ10000 07953— MJ10100 07953— MJ10200 07984’ 2000001 07984iZE20001 07HAAiPJ70100 07HGJ *0020100 07HMFiMM90400 07HMH7MR10103 07JMA~MR60100 A937X—041iXXXXX NOTE1 NOTE 2: NOTE 1 NOTE 3: NOTE 2 NOTE 2 NOTE 2 NOTE 3: NOTE 1 NOTE 2: NOTE 3: NOTE 3: NOTE 3: NOTE 2 NOTE 3: 07908— KE90100 07HGBi001010A or 07HGB *001010E and 07HGE , 001020A 07HGE , DD1020E 07936i3710200 07953, MJ1000A or 07953iMJ10005 and 0794973710001 or 077A6a0010100 07984’200000D 07984iZE2000D 07HMH7MR1010B STK’AH‘2557MC7 STiAH—ZGOAMC7 10 2,14,15 13 13 12 10 10 17 12 14 1-18 LUBRICATION & SEAL POINTS GENERAL INFORMATION r' ENGINE LOCATION MATERIAL REMARKS Camshaft lobes/journals Valve stem (valve guide sliding surface) Rocker arm slipper surface Rocker arm shaft sliding surface Connecting rod bearing surface Crankshaft journals Clutch outer guide outer surface Crankshaft hole cap threads Timing hole cap threads CZ, M3 shifter gear lshift fork groovesl Transmission collars inner and outer surface Transmission spline collars outer surface Connecting rod small end inner surface Molybdenum disul- fide oil (a mixture of 1/2 engine oil and 1/2 molybdenum disul— fide grease Piston outer surface Piston ring outer surface Piston pin outer surface Primary drive gear bolt threads and seating surface Flywheel bolt threads and seating surface Starter reduction gear shaft outer surface Clutch disc outer surface Clutch center lock nut Cylinder stud bolt threads Cylinder head 8 X 187 mm mounting bolt threads Valve adjusting screw threads and seating surface Connecting rod bolt/nut threads and seating surface Cylinder head mounting bolt seating surface Each bearing rolling area Engine oil Each oil seal lip Multi-purpose grease Oil pressure switch threads 3*4 mm (0,12*0.16in) Right and left crankcase mating surface Fan motor switch threads Thermosensor threads (’97 ’ ’OOl Thermo switch (Afire 'DOl Sealant Revised: August, 2000, ‘97 401 VTGOUC/CD @2000 American Honda Motor 00., Inc - All Rights ReseNed MSV 8969 (0005) 1-19 GENERAL INFORMATION — ENGINE (Cont’d) LOCATION MATERIAL REMARKS R. crankcase cover mating surface (After '98) Fan motor switch threads Thermo sensor threads Sealant , See page (El-21,9-10l Cam sprocket bolt threads Starter onerwav clutch bolt threads oil pump driven sprocket bolt threads Alternator cord clamper bolt threads Gearshift cam plate bolt threads Transmission bearing set plate bolt threads Countershaft oil seal set plate bolt threads Cam chain tensioner set plate bolt threads Stator mounting bolt threads Oil filter boss crankcase inside threads Ignition pulse generator bolt threads Left crankcase cover bolt threads (marked “A"l Locking agent Coating width: 6.5 t 1 mm lllllll 1 -20 GENERAL INFORMATION — FRAME LOCATION MATERIAL REMARKS Steering head bearing sliding surface Steering head dust seal lips Swingarm pivot bearing and dust seal lips Wheel dust seal lips Rear wheel axle sliding surface Side stand pivot sliding area Main and pillion footpeg sliding area Throttle pipe inner sliding surface Throttle pipe rolled up portion Clutch lever pivot bolt sliding surface Rear brake middle arm sliding area Rear brake pivot collar sliding area Brake pedal dust seal rubber Gearshift pedal dust seal rubber Multivpurpose grease Spreading 10 g Spreading 1.0 — 2.0 g Spreading 0,2 7 0.3 g Wheel axle distance collar Swingarm pivot distance collar Steering top threads Steering bottom bridge threads and seating surface Crankcase breather tube entry end Engine oil Brake master cylinder cups Brake master piston Brake caliper piston seals Brake caliper dust seals DOT 4 brake fluid Brake lever pivot and piston tips Brake caliper slide pin surface Silicone grease Final driven flange bolt threads Fork socket bolt threads Locking agent Handle grip rubber inside Honda Bond A or Honda Hand Grip Cement (U.S.A. only) Front fork cap Orring Front fork oil seal lips Front fork spring Front fork rebound spring Pro-Honda Suspen- sion Fluid SS-E Each cable inside Cable lubricant Drive chain Pro Honda Chain Lube or equivalent 1-21 GENERAL INFORMATION CABLE 81 HARNESS ROUTING ’97—’98: THROTTLE CABLES CLUTCH CABLE LEI-‘l' HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE \ ' ~ SPEEDOMETER CABLE FRONT BRAKE HOSE HEADLIGHT CONNECTOR HORN HORN WIRE After ’98: THROTTLE CABLES CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE HORN WIRE SPEEDOMETER CABLE FRONT BRAKE HOSE HEADLIGHT CONNECTOR HORN 1 -22 GENERAL INFORMATION ’97 ~ ’98: HANDLEBAFI SWITCH WIRE BANDS ENGINE BREATHER TUBE WATER HOSE .- STARTER MOTOR E " STARTER MOTOR CABLE CRANKCASE BREATHER SEPARATOFI / ‘ EVAPORANTIVE ‘ EMISSIO F Ir I \ I PURGE CONTROL ,, I ,, ‘ VALVE GROUNDCABLE ‘ , ' (California type only) ‘1 I \ I \ I / sUBrAIR CLEANER \\ 9 / j / CLUTCH CABLE IGNITION PULSE AIR CLEANER HOUSING GENERATOR WIRE After '98: HANDLEBAR SWITCH WIRE BANDS ENGINE BREATHER TUBE WATER HOSE STARTER MOTOR STARTER M OTOR CAB LE CRANKCASE BREATHER SEPARATOR THROTTLE CABLES GROUND CABLE \ CLUTCH CABLE IGNITION PULSE AIR CLEANER HOUSING GENERATOR WIRE 1-23 GENERAL INFORMATION ’97 — ’98: THROTTLE CABLES FRONT IGNITION COIL FUELTANK BREATHER TUBE (California type only) FUELTUBEINLET LINE ALTERNATOR WIRE RIGHT SE VALVE CABLE SPEEDOMETER AIR CLEANER HOUSING FAN MOTOR SWITCH CABLE HOLDER BREATHER TUBE After ’98: WATER HOSE MAIN WIRE HARNESS FUEL TUBE (To carburetorI ‘0. . \ I SIPHON TUBE FUEL TUBE (To fueI tank) BRAKE HOSE ALTERNATOR WIFIE SPEEDOMETER CABLE AIR CLEANER CHAMBER FAN MOTOR SWITCH WIRE SPARK PLUG WIRE BREATHER TU BE 1-24 GENERAL INFORMATION . _, . 97 98- TURNSIGNALRELAY REARIGNITIONCOIL FUEL FILTER STARTE R R ELAY SWITC H MAIN FUSE COOLANT RESERVE TANK SUB FUSE BOX OVERFLOW TUBE After ’98: REAR RI/LI TURN SIGNAL, TAIL/BRAKE LIGHT, LICENSE LIGHT CONNECTORS TURN SIGNAL RELAY STARTER RELAY SWITCH IGNITION COIL CONNECTORS MAIN FUSE EATTERV EVAPORATIVE EMISSION COOLANT RESERVE TANK REAR BRAKE LIGHT SWITCH WIRE CANISTER TUBE OVERFLOW TUBE E Fuel tank to Canister ICaIIforma type onle SUB FUSE BOX 1 ~25 GENERAL INFORMATION ’97 7 ’98: TURN SIGNAL RELAv ERAKE/TAILLIGHT, FUEL PUMP, REAR RIGHTTURN SIGNAL CONNECTORS - REAR LEFT TURN SIGNAL, LICENSE LIGHT CONNECTORS SIDE STAND \4/ 4 2P GREEN C0 ' 7 ' ” L |GN|IION>CONTROL MODULE NNECTOR \ \ REGU LATCH/RECTIFIER 4F BLACK CON NECTOH I FNEU'IIRAL SWITCH 2P BLACK CONNECTOR A “REGULATOR/RECTIFIER m ALTERNATOR 3I§WHITE CONNECTOR <’, IGNITION SWITGH 4P WHITE CONNECTOR NEUTRAL SWITCH OIL PRESSURE SWITCH SIDE STAND SWITCH After '98: TURN SIGNAL RELAY BRAKErrAILLIGHT, LICENSE LIGHT REAR R./L. TURN SIGNAL CONNECTORS (/fl w ‘ IGNITION < CONTROL ’ . MODULE 9 , , I", I 4 . I!” \IIIIIIIIIII'\\I\\\“‘ J / ‘I \ C“ MAIN WIRE HARNESS IGNITION SWITCH 4P WHITE CONNECTOR ALTERNATOR 3P REGULATOR/RECTIFIER WHITE CONNECTOR 4P BLACK CONNECTOR 1 -26 GENERAL INFORMATION '97 7 '98: IGNITION PULSE GENERATOR HORN/FAN MOTOR 4P WHITE CONNECTOR 2P BLACK CONNECTOR FRONT BRAKE HOSE // TURN SIGNAL /\\ I 9PWHITE CONNECTOR bx CLAMP I ‘, R -,‘ ‘1 l/“\ II’ ' O I _ _ E ‘ bi. u L Q I I \ ‘I \ I\\ “ 7 ' INDICATOR PANEL \ 6P GREEN CONNECTOR SPEEDOMETER 6P BLACK CONNECTOR RIGHT HANDLEBAR SWITCH 9P RED CONNECTOR '97 7 '98: After '98: CRANKCASE aREATHER DRAIN TUBE MAIN WIRE WATER HOSE HARNESS EVAPORATIVE EMISSION PUHGE EVAPORATIVE EMISSION PURGE CONTROL VALVE TUBE (California type onin CONTROL VALVE TUBE (California type only) 1-27 GENERAL INFORMATION '97 A '98: ALTERNATOR wIRE NEUTRAL SWITCH SIDE STAND SWITCH OIL PRESSURE SWITCH After ’98: ALTERNATOR WIRE // \ i \1 \ , . \ x , , Q G \M (p‘\% T O NEUTRALSWITCH A» / .’\ . SIDE STAND SWITCH OIL PRESSURE SWITCH 1 -28 GENERAL INFORMATION GROUND POINT GROUND POINT After ’98: '97—’98: THERMOSTATIC SWITCH WIRE CLAMPS THERMOSTATIC SWITCH WIRE CLAMPS ’97 7 '98/After '98: CLAMPS GROMMETS STATOR COIL LEFT CHAN KCASE COVER CRANKCASE IGNITION PULSE GENERATOR 1 -29 GENERAL INFORMATION ’97 7 ’98: BRAKE/TAILLIGHT CASE LICENSE LIGHT WIRE TAILLIGHT WIFIE TURN SIGNAL LIGHTWIRE After '98: BRAKE/TAILLIGHT WIRE REAR RIGHT TURN SIGNAL LIGHTWIRE REAR LEFT / TURN SIGNAL LIGHTWIRE TURN SIGNAL RELAV LICENSE LIGHTWIRE 1-30 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM [CALIFORNIA TYPE ONLY) NOTE: The hoses shown below are numbered as they appear on the Vacuum Hose Routing Diagram Label. ’97 — '98: @TUBE ®TUBE EVAPORATIVE EMISSION EVAPORATIVE EMISSION / FURGE CONTROL VALVE PURGE CONTROL @TUBE VALVE @TUBE TO AIR CLEANER HOUSING ENGINE BREATHER TUBE (FROM REAFI CVLINDER HEAD) @TUBE EVAPORATIVE EMISSION CARBURETOR ©TUBE AIFI VENT CONTROL VALVE EVAPORATIVE EMISSION ®TU BE CARBURETOH AIR VENT TO AIR CLEANER HOUSING GONTROL /\’/ALVE TO EVAPORATIVE EMISSION CANISTER AIR CHAMBER DUCT COOLANT RESERVE TANK DRAIN TUBE EVAPORATIVE EMISSION CANISTER OPEN AIR TUBE EVAPORATIVE EMISSION CANISTEH HEAR SHOCK ABSORBER TUBE 1-31 GENERAL INFORMATION After '98: RETURN TUBE SEPARETOR (TO AIR CLEANER CASE) @TUBE EVAPORATIVE EMISSION CAREURETOR AIR VENT CONTROL VALVE j‘ r / Q ®TUBE ~77 —— R ‘ _ 77/, \ 5" _, \* I EVAPORATIVE EMISSION / , , . PURGE CONTROL VALVE 4 x: " \ ’ - i @TUBE ®Tu BE @TUBE (DTUBE (FROM FUEL TAN KI ENGINE BREATHER TU BE (TO SEPARATORI COOLANT RESERVE TANK DRAIN TUBE EVAPORATIVE EMISSION CANISTEFI OPEN AIR TUBE EVAPORATIVE EMISSION CANISTER ©TUBE EVAPORATIVE EMISSION CANISTER 1 —32 GENERAL INFORMATION EMISSION CONTROL SYSTEMS The U.S. Environmental Protection Agency and California Air Resources Board (CARBl require 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 1,1983 comply with applicable noise emission standards for one year or 6,000 km 13,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided. Compliance with the terms of the Distributor’s Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. SOURCE OF EMISSIONS The combustion process produces carbon monoxide and hydrocarbons control of hydrocarbons is 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 hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The exhaust emission control system is composed of a lean carburetor setting, and no adjustments should be made except idle speed adjustment with the throttle stop screw. The exhaust emission control system is separate from the crankcase emission Control system. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blowiby gas is returned to the combustion chamber through the air cleaner and carburetor. '97 — '98: CRANKCASE BREATHER AIH CLEANER HOUSING SEPARATOR c): FRESH AIR a : BLOW»BY GAS 1 -33 GENERAL INFORMATION After ’98: i 1— SEPARATOR I CARBURETOR AIR CLEANER <2 : FRESH AIR « : ELOW»BY GAS / (or J EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) This model complies with California Air Resources Board evepurative emission requirements. Fuel vapor from the fuel tank and carburetorls) ('97i’98l are routed into the evaporative emission (EVAP) canister where it is absorbed and stored while the engine is stopped. When the engine is running and the evaporativa emission (EVAP) purge control valve is open, fuel vapor in the EVAP canister is drawn into the engine through the carburetor, At the same time, EVAP carburetor air vent (CAV) control valve is open and air is drawn into the carburetorthrough the valve. '97—’98: CAREURETORS EVAP PURGE CONTROL VALVE j DRAIN EVAP CANISTER EVAP CAV / CONTROL VALVE EVAP CAV CONTROL VALVE (ENGINE STOPl i To OPEN AlR :> : FRESH AIR v. : FUEL VAPOR 1 -34 GENERAL INFORMATION After '98: EVAP PURGE CONTROL VALVE CARBURETOH l L I > EVAP CANISTER EVAP cAv CONTROL VALVE V TO OPEN AIR {I Ever/av V5 0N L VAL ED : FRESH AIR (ENGINE STOP, —> : FUEL VAPOR NOISE EMISSION CONTROL SYSTEM TAMPEFIING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Federal law prohibits the following acts or the causing thereof: Hi The removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use; (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conduct exhaust gases. 2. Removal 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. 1-35 GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the inside of the left side cover as shown. The left side cover must be removed to read it. Refer to page 273 for left side cover removal. It gives base tune-up specifications VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL After making a high altitude carburetor adiustment, attach an update label on the inside of the left side cover as shown, The left side cover must be removed to read it. Refer to page 2-3 for left side cover remuval. Instructions for obtaining the update label are given in Service Letter No132. When readjusting the carburetOrIs/’97*’98) back to the low altitude specifications, be sure to remove this update label. ’97i'98: VACUUM HOSE ROUTING DIAGRAM LABEL / EMISSION CONTROL ,. , " T INFORMATION // LABEL /. a /EM|SSION CONTROL LLJAPEEAJE INFORMATION IABEL (Canada type onlyl After '98: VACUUM HOSE ROUTING DIAGRAM LABEL (California type onlyl EMISSION CONTROL INFORMATION LABEL (Canada type only) K EMISSION CONTROL UPDATE INFORMATION LABEL LABEL VEHICLE EMISSION CONTROL INFORMATION UPDATE 41mm Mmon co.,LTn THIS VEHICLE HAS BEEN ADJUSTED TO IIIIFRDVE EMISSION CONTROL FERFORMANCE WHEN OPERATED AT IIIGH ALTITUDE. ALTITUDE PERFORMANCE ADJUSTMENT INSTRUCTIONS ARE AVAILABLE AT YOUR AUTHORIZED HONDA DEALER. 1 -36 VACUUM HOSE ROUTING DIAGRAM LABEL (CALIFORNIA TYPE ONLV) The Vacuum Hose Routing Diagram Label is on Ihe insIde of the left side cover as shown. The left side cover must be removed to read It. Refer to page 2-3 for left side cover removal. GENERAL INFORMATION ’97i’98: VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY E EVAPORATIVE FAMILV CALIFORNIA VEHICLE €70 OPEN AIFI After '98: VACUUM HOSE ROUTING DIAGRAM ENGINE FAMILY-I:| EVAPORATIVE FAMIL‘H—i CALIFORNIA VEHICLE FU EL TA N K EVAP CAV CONTROL VALVE E < z w o o ,_ 1-37 MEMO 2. FRAME/ BODY PANELS/ EXHAUST SYSTEM SERVICE INFORMATION 2-1 SIDE COVER 2-3 TROUBLESHOOTING 2-1 FUEL TANK 2.4 SEAT ('97-'98) 2-2 REAR FENDER/REAR SUB-FRAME 2-8 - SEAT (After ’93) 2-2 EXHAUST PIPE/MUFFLER 2-14 STEERING COVER 2-3 ' SERVICE INFORMATION GENERAL ' Gasoline is extremely flammable and is explosive under certain conditions. Work in a well ventilated area. Smoking or allowing flames or sparks in the work area or where the gasoline is stored can cause a fire or explosion. - Engine and exhaust system parts become very hot and remain hot for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. 0 When 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. O Work in a well ventilated area. Smoking or allowing flames or sparks in the working area or where gasoline is stored can cause a fire or explosion. 0 This section covers removal and installation of the frame body panels, fuel tank and exhaust system. 0 Always replace the exhaust pipe gaskets when removing the exhaust pipe from the engine. ' Always inspect the exhaust system for leaks after installation. TORQUE VALUES Exhaust pipe joint nut 25 N-m (2.5 kgf-m,18lbf-ft) Fuel tank mounting bolt 19 N-m (1.9 kgf‘m ,14lbf-ft) Fual Valve nut '97i'98 23 N>m (2.3 kgf-m ,17Ibf-fti After '98 35 N-m13.6 kgf-m , 26 Ibf-fti Fuel valve lever screw 4 N-m [0.4 kgf-m , 2.9 lbf-ft) Exhaust pipe cover bolt 12 N-m 11.2 kgf‘m , 9 Ibf‘fti Exhaust muffler bracket bolt 20 N-m (2.0 kgf>m , 14 IbIAfii nut 20 N-m 12.0 kgf-m ,14lbf-Iti Sub»frame mounting bolt 12 N-m (1.2 kgf-m , 9 lbffli nut 12 N-ml'l.2 kgf-rn,9|bI-fti TROUBLESHOOTING Excessive exhaust noise - Broken exhaust system - Exhaust gas leak Poor performance - Deformed exhaust system - Exhaust gas leak - Clogged muffler 2-1 FRAME/BODY PANELS/EXHAUST SYSTEM SEAT ('97 — ’98) REMOVAL Remove the two mounting socket bolts. Slide and remove the seat to the back. INSTALLATION Install the seat by inserting the hook of the seat under the raised lip of the frame cross member. lnstell the hooks on the rear fender to the tabs of the seat and push the seat forward. Align the bolt holes and tighten the mounting socket bolts securely. CAUTION: Be earaful not to pinch the wire harness between the seat and the frame. SEAT (AFTER '98) REMOVAL Remove the two mounting socket bolts. Slide and remove the seat toward the back. INSTALLATION install the seat by aligning the holes in the back of the seat with the bosses on the rear fender. Inserting the heck of the seat under the raised lip of the frame cross menber while pushing the seat forward, Tighten the socket bolts securely. CAUTION: Be careful not to pinch the wire harness between the seat and the frame. '97i’98; HOOK SEAT SOCKET BOLTS HOOKS After '98: SOCKET BOLT SEAT BOSSES 2-2 FRAME/BODY PANELS/EXHAUST SYSTEM STEERING COVER REMOVAL CAUTION: Be careful nut to break the steering cover bosses. NOTE. Be careful not to dislodge the grommets in the frame. a Remove the mounting screw. Remove the joint cover. Release the cover bosses from the grommets and steering covers. INSTALLATION NOTE: At installation, align the steering cover bosses on the frame grommets. H Install the steering covers. Install and tighten the screw. Install the joint cover. NOTE' Check that the wire harness does not interfere with handlebar rotation. SIDE COVER 37* ’98. Alter '95: CAUTION: m Be careful not to brook the side cover tabs ('97 7 ’98}. NOTE: E Be careful not to dislodge the grommets in the frame. HE Release the cover bosses from the grommets and the cover tabs from the rear fender. Remove the side cover. Release the cover bosses from the grommets and remove the side cover. Installation is in the reverse order of removal. NOTE: E At installation, align the cover bosses on the frame grommets. a GROMMETS JOINT COVER SIDE COVER 2-3 FRAME/BODY PANELS/EXHAUST SYSTEM FUEL TANK e7=ezam M Gasoline is extremely flammable and is explosive under certain candirian. NOTE Before disconnecting fuel tube, turn the fuel valve "OFF'K REMOVAL Remove the seat lpage 2-2). Remove the fuel valve knob mounting screw and fuel valve knob from the fuel valve body. Remove the fuel tank mounting bolt. Disconnect the fuel tube. Remove the fuel tankfrom the frame. DISASSEMBLYIASSEMBLY Loosen the fuel valve nut and remove the fuel valvet 2-4 FRAME/BODY PANELS/EXHAUST SYSTEM Remove the fuel strainer screen and O-ring. OVRING Check the fuel strainer screen for clogs or damage. FUEL STRAINEH SCREEN Clean by air or replace if necessary. Install the new O-ring to the fuel strainer screen. Anach the fuel strainer screen to the fuel valve and install to the fuel lank. tillzlilglh NOTE R Always replace the Orring with new ones. Tighten the fuel valve nut to the specified torque. TORQUE: '97fi'98: 23 N-m (2.3 kgf-m,17|bf-l't) After '98: 35 N-m (3.6 kgf-m , 26 Ibf-ftl FRAME/BODY PANELS/EXHAUST SYSTEM '97 — '98: FUELTANK 19N-ml'l.9kgf-m,14lbf‘fti FUEL STRAINER SCREEN \'~-\ FUEL FILTER NOT E. The fuel fiiter with its narrow end pointing toward the outside. % 5 T0 FUEL PUMP FUEL VALVE KNOB 291% FUEL PIPE JOINT TO CAHBURETOR NOTE' The fuei pipe joint with its narrow end toward outside. After '98: 19 N-I'TI (1.9 kgf-m ,14Ibf-fl) FUELTANK Q FUEL STRAINER SCREEN @ o.R| NG / ‘ FUEL VALVE BODV FUEL VALVE KNOB ’§D T0 FUEL AUTO VALVE FRAME/BODY PANELS/EXHAUST SYSTEM INSTALLATION Connect the fuel tube to the fuel valve. Install the fuel valve knob to the fuel valve. NOTE: At installation, align the rounded edge on the fuel valve knob with the fuel valve shaft. Tighten the screw to the specified torque. TORQUE: A N-m (0.4 kgfvm , 2.9 Ibf-ftl NOTE' After installation, turn the fuel valve “ON” and check the fuel line for leakage. Tighten the fuel tank mounting bolt to the specified torque (page 2-6). TORQUE: 19 N-rn (1,9 kgfvm , 14 lbf-ftl Install the seat (page 2-2). FRAME] BODY PANELS] EXHAUST SYSTEM REAR FENDER/REAR SU B-FRAME REMOVAL ('97 — '98) Remove the seat (page 2-2). Remove the right and left side covers lpage 2-3l. Remove the fuel tank (page 2-4). Remove the rear fender mounting bolts. Disconnect the taillight connectors. Free the taillight wire harness from the clamps. Remove the taillight mounting nuts, washers and TAILLIGHT taillight. WASHERS Remove the rearfsnder mounting bolt and nut. Remove the rear fender. FRAME/ BODY PANELS] EXHAUST SYSTEM Disconnect the right and left rear turn signal lights and license light connectors, Remove the sub-frame mounting bolts. nuts and sub-frame. REMOVAL (After '98) Remove the seat lpage Z-Zl. Disconnect the brake/taillight, license light and rear turn signal lights connectors. Remove the wires from the clamps. Remove the wires from the clamps. Remove the bolts, collars and grab rail. CONNECTORS CLAMPS FRAME] BODY PANELS] EXHAUST SYSTEM Remove the four bolts, washers, and (we collars. BOLTS REAR FENDER Remove the rear fender. Remove me sub—frame mouming bolts, nuts and BOLTS/NUTS sub»irame. INSTALLATION ('97 — ’98) TAILLIGHT SUBVFRAME MOUNT|NG BOLTS 12 N-m11.2 kgf-m , 9 Ibf-ft) REAR FENDER SUB-FRAME SUBAFRAME MOUNTING NUTS 12 N-m (1.2 kgfm , 9 lbf-ft) 2-10 FRAME/BODY PANELS/EXHAUST SYSTEM Install the sub»frame, bolts and nuts, Tighten the bolts and nuts to the specified torque. TORQUE: 12 Nm (1.2 kgf-m , 9 lbf—ftl Route the right and left rear tum signal light wires and license light wires, Connect the turn signals and license light connectors. NOTE: Route the wire harness properly (page 1-25)i Install the rear fender. install and tighten the mounting bolt and nut securely. lnstall the taillight to the rear fender. NOTE: Install the taillight by aligning the hole on the rear tender with the tab. Install and tighten the mounting nuts securely. FRAME] BODY PANELS] EXHAUST SYSTEM Route khe taillight wire harness. Connect the laillight connectors. LGGNN C ~RS NOTE: Rome the wire harness securely (page 1-30I. Inslall and tighken the rear fender mounting bolts securely. Install the fuel tank (page 277). lnslall the right and left side covers lpage 2*3l. install the seat (page Z-Zl. INSTALLATION (After '98) GRAB RAIL BOLTS COLLARS REAR FENDER GRAB HAIL SUBrFRAME MOUNTING NUTS SUBVFRAME 12 N-m (1‘2 kgf-rn, MOUNTlNG BOLTS SUB~FRAME 9 lbf-ftl 12 N-m (1.2 kngm,9 IbH!) 2-12 FRAME] BODY PANELS] EXHAUST SYSTEM Install the sub-frame, boltsand nuts. Tighten the bolts and nuts to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 Ihf-ftl Install the boss of the rearienderto the hook on the subrframe. Install the washers and collars to the rear fender. Install and tighten the four bolts securely. lnstall the collars and grab rail. lnstall and tighten the bolts. Install the wl res in the clamps. BOLTS BOLTS/N UTS BOLTS REAR FENDER FRAME] BODY PANELS] EXHAUST SYSTEM EXHAUST PIPE/MUFFLER lnstall the wires in the clamps. Connect the brake/taillight, license light and rear CONNECTORS CLAMPS A/ turn Signal lights connectors. 1 I lnstall the seat (page 272l. m_— Do not sen/ice the exhaust system while it is hot. CAUTION, When removing/installing the exhaust pipe/ muffler, be sure to loosen/tighten the exhaust system tastenzrs in the spacified order as follows. REMOVAL Remove the exhaust pipe joint nuts. Remove the muffler mounting bolt, washer and nut. Remove the exhaust pipe/muffler assembly. Remove the front exhaust pvpe joint and collar. GASKETS Remove the front and rear gaskets. 2-14 FRAME] BODY PANELS] EXHAUST SYSTEM Remove the bolts and exhaust covers. EXHAUST COVERS INSTALLATION 20 N-m (2.0 kgf-m , 14 lbl-ft) EXHAUST PIPE COLLAR 25 N-m (2.5 kgf-m , '[8 Ibffl) EXHAUST COVERS 12 N-m (1.2 kgf-m , 9 Ibf-ft) MUFFLER BRACKET 20 N-m (2.0 kgf-m,14tbf—ft) Install the exhaust covers and bolts. Tighten the botts m the specified Torque. TORQUE: 12 Nm (1.2 kgf-m , 9 Ihf-ft) EXHAUST COVERS 2-15 FRAME/ BODY PANELS/ EXHAUST SYSTEM Install the new gaskets. ®§ GASKETS \f NOTE‘ Install the gaskets to the correct position. 7 Front side: Large 0D. 7 Rear side: Small 0. Install the front exhaust pipe collar. Install the muffler assembly. Temporarily install all bolts, washer and nuts. NOTE Do not tighten the bolts and nuts yet. Tighten the muffler mounting bolt and nut to the specified torque. TORQUE: 20 N-m (2.0 kgf-m,14lbf-ft) Tighten the exhaust pipe joint nuts to the specified torque. TORQUE: 26 N-rn (2.5 kgf-m , 18 let) NOTE, Always inspect the exhaust system for leaks after installation. 2-16 3. MAINTENANCE SERVICE INFORMATION 3-1 DRIVE CHAIN 3-20 MAINTENANCE SCHEDULE 3-3 BRAKE FLUID 3-24 FUEL LINE 3-4 BRAKE SHOE/PAD WEAR 3-25 THROTTLE OPERATION 3-4 BRAKE SYSTEM 3-26 B CARBURETOR CHOKE 3-6 BRAKE LIGHT SWITCH 3-27 AIR CLEANER 3-3 HEADLIGHT AIM 3-28 CRANKCASE BREATHER 3-9 CLUTCH SYSTEM 3—28 SPARK PLUG 3—9 SIDE STAND 3-29 VALVE CLEARANCE 3-11 SUSPENSION 3-29 ENGINE OIL/OIL FILTER 3-14 NUTS, BOLTS, FASTENERS 3-30 CARBURETOR SYNCHRONIZATION WHEELS/TIRES 3‘30 ('97 7 '98) 3-17 STEERING HEAD BEARINGS 3‘31 ENGINE IDLE SPEED 3-18 RADIATOR COOLANT 3-19 COOLING SYSTEM 3-19 E¥é¥€filéfifi.=%“l'fifil‘llé°§£ffiL SERVICE INFORMATION GENERAL ' Gasoline is extremely flammable and is explosive under certain conditions, Work in a well ventilated area Smoking or allowing flames or sparks in the work area or where the gasaline is stored can cause a fire or explasian. 0 When 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 paisonous carbon monoxide gas that may cause loss a! tenaciousness and lead ta death Run the engine in an apen area or with an exhaust evacuation system in an enclosed area. 0 Place the motorcycle on a level ground before starting any work‘ SPECIFICATIONS \ ITEM 1 SPECIFICATIONS Throttle grip free play , 276mml1/12*1/4l Spark plug Standard DPB§EA~9 (NGK) ‘ X24EPR-U91DENSOl For cold climate (below 5'C/41'Fl DPFI7EA-9 (NGK) ‘ XZZEPR-US (DENSO) | For extend high speed riding DFRBEA-S lNGKl l X27EPR-U9fllQE4NSO) I Spark plug gap 0.80’030 mm (0.031*0.035‘ml Valve clearance lN ' 0.15 mm (0.006 in) ‘ EX 0.20 mm (0.008 in) 3-1 MAINTENANCE ITEM SPECIFICATIONS Engine oil capacitv At draining“ 2.1 a (2.2 us qr. 1.8 Imp qtl At disassembly “M. 2.8 213.0 us qt, 2.5 Imp qtl i At oil filter change 225 Ii (2.33 us qt, 1.93 Imp qtl Recommended engine oil HONDA GNA or HP4 4-stroke oil or equivalent motor oil API service classification SF or 56 Viscosity: SAE 10W* 40 Engine idle speed 1,200 i 100 rpm Drive chain slack 20*30 mm (3/4 *1r1/4inl Standard links Recommendedbrake fluid 120L Honda DOT 4 Brake Fluid Clutch lever free play 10*20 mm (3/8 7 3/4 in) Tire size Front 100/9049 575 7,7. 7 Hear 170/80-15M/C77S T'Ire brand Front '97‘ '98 BRIDGESTONE L309 / DUNLOFI F24 _ After '98 DUNLOP F24 Rear '977'98 BRIDGESTONE_(3_516__LPUNLQE K5557 After '98 DUNLOP D404 Cold tire pressure Up to 90 kg (200 lbl Front 200 kPa (2.00 kgf/cm’ , 29 psi) load Rear 200 kPa (2.00 kgI/cm’ , 29 psi) Up to maximum Front 200 kPa (2.00 kgf/r:rrr2 , 29 psi) weight capacit Rear 250 kPa (2.50 kgf/cm’ , 36 psil Minimum tire tread depth From 1.5 mm (0.06 in) Rear 2.0 mm (0.08 in) TORQUE VALUES Spark plug Valve adjust cover Valve adiusting screw luck nut Timing hole cap Crankshaft hole cap Oildrain bolt ’97i’98: After ’98: Oil filter cartridge Vacuum plug (’977’98) Rear axle nut Spokes TOOLS Valve adjusting wrench Vacuum gauge Oil filter wrench Drive chain tool set Spoke wrench 14 N-m (1.4 kgf—rrl.10lbf»ft) 12 N-m (1.2 kgf—m , 9 lbf-ft) 23 N-m (2.3 kgfim.17lbf«ft) 15 N-m (1.5 kgf~m,11lbf-fll 15 N-m (1.5 kgf-m,11lbf-ftl Apply oil to the threads and seating surface Apply molybdenum disulfide oil to the threads Apply molybdenum disulfide oil to the threads 34 N-m (3.5 kgf-m , 25 lbf-ftl 30 N-m (3.1 kgf-rn , 22 lbfvftl 10 N-m (1.0 kgf-m , 7 lbf-ftl Apply an engine oil to the threads. 3 N-rn (0.33 kgf-m , 2.4 lbl-ft) B8 Nirn (9.0 kgI-m , 65 lbf-fl) 4 N-m (0.4 kgf—m , 2.9 lbf-fi) 07905‘ KESDOOO or 07908— KE901OU(U.S.A only) 07404—0030000 or 07LMJ— 001000A (USA only) 07HAAi PJ70100 07HMHi MR10103 or 07HMHvMR1010A (USA. only) 07JMAiMFl60100 3-2 MAINTENANCE MAINTENANCE SCHEDULE Perform the Frerride Inspectlon inthe Owner’s Manual at each scheduled maintenance period, I: Inspectand Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and “i may require more technical information and tools. Consult your authorized HONDA dealer. _\7 FREQUENCY NOTE ODOMETER READING (NOTE 1I \\\\7 x 1,000 mi Ice 4 a 12 ‘ 151‘20124 REFER IEMS \\\\ ll x1,oookmé 1 a 12 15 24130 as To PAGE 17» FUELLINE 7 7 l l . I l 7 3-4 R THROTTLE OPERATION I | I l 3,4 g 7y CAREURETOjoQKE 7 7 .. 77 7 l l I I 376 E 7 I AIR CLEANER 7 NOTEZ R . R 378 77 a CRANKCASE BREATHER VVVVV NOTE3 C c c C i c c 379777 :5 SPARK PLUG 7 7 R R 77R R R R are S is VALy7E CLEARANCE I I I I I 311 a ENGINE OIL 77 1 R ‘ R 77 R R 314 g ENGINE OIL FILTER I R R _ R R 3714 g r 1 CARBURETOR SYNCHRONIZATION ’977’98 I I I I 347 g R I ENGINE IDLE SPEED I I I I |_ I I 3-18 m RADIATOR COOLANT 7 NOTE 5 I I R 349 F COOLING SYSTEM I 717 7 I 319 we EVAPORATlVE EMISSION CONTROL SVSTEM I I 3.20 g DRIVE CHAIN 1 a 320 E BRAKE FLUID >' 3724 3 y 7 BRAKE SHOES/PADWEfi 3,25 ,8 BRAKE SVSTEM I 3726 3 7+3; BRAKE LIGHTSWITCH77 3727 7 E K HEADLIGHTAIM ,7 3728 g CLUTCH SYSTEM 7 3728 7 5 SIDE STAND 7 3729 g SUSPENSION 3,29 “.1 * I NUTS, BOLTS,FASTENERS 3-30 5 **‘ WHEELS/TIRES 3.30 2 1* *l STEERING HEAD BEARINGS . 1" 3-31 As Should be serviced by an authorized HONDA dealer, unless the owner has proper tools and service data and is mechanically qualified. * * Inihe interest of safety, we recommend these items be serviced only byan authorized HONDA dealer. NOTES’ . At higher odometer reading, repeat at the frequency interval established here. . Service more frequently when riding in unusually wet. or dusty areas. . California type only. i 2 3. Service more frequently when riding in rain or at full throttle. 4 5 . Replace every 2 years, or at indicated Odometer interval, whichever comes first. Replacement requires mechanical skill. MAINTENANCE FUEL LINE Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Remove the seat (page 2-2l and fuel tank lpage 274). Check the fuel lines for deterioration, damage or leakage. Replace the fuel lines if necessary. Also check the fuel valve vacuum tube for damage and replace the vacuum tube if necessary ('97—'98). FUEL FILTER (’97 m'98l Pull the fuel filler out, clip the inlet line Closed and remove the filter. Replace the fuel filter with new one, if necessary lpage 5-34). THROTTLE OPERATION Check for any deterioration or damage to the throttle cables. Check the throttle grip for smooth operation. Check that the throttle grip returns from the full open to the full closed position smoothly and automatically in all steering positions. lf the throttle grip does not return properly. lubricate the throttle cable, overhaul and lubricate the throttle grip housing. For cable lubrication: Disconnect the throttle cables at their upper ends (page 13-7). Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weightpil. 3-4 MAINTENANCE If the throttle grip still does not return properly, replace the throttle cables, mm—_ Reusing a damaged or abnormally bent or kinked throttle cable can prevent proper throttle side operation and may lead to a loss of throttle control while riding. With the engine idling, turn the handlebar all the way to the right and left to ensure that idle speed does not change. If idle speed increases, check the throttle grip free play and the throttle cable connection. Measure the throttle grip free play at the throttle grip flange. FREE PLAY: 276 mm (1/1271/4 in) Throttle grip free play can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster. Loosen the lock nut and turn the adjuster to obtain the free play. After the adjustment, tighten the lock nut securely and reposition the boot ('97v'98l properly. iii 2mm 1/12717 MAINTENANCE Remove the fuel tank (After '98: page 2-4l, Major adjustments are made wtth the lower adjuster, Loosen the lock nuts and turn the adjusters to obtain the free play. Tighten the lock nuts afterthe adjustment has been made, Recheck the free play. CARBURETOR CHOKE STARTING ENRICHMENT (SE) VALVE The choke system uses a fuel enriching circuit controlled by an SE valve. The SE valve opens the enriching circuit via a cable when the choke knob on the right side of the carburetor is pulled. Check for smooth operation of the choke knob. Check for any deterioration or damage to the choke cable. It the operation is not smooth, lubricate the choke cable and choke knob sliding surface with a commercially available cable lubricant or a light weight oil. To adjust the friction, pull the rubber cover away and turn the adjuster. W=¥Em RUBBER COVER ADJ USTER MAINTENANCE Starting enrichment system operation can be g .SHmWfl checkedbyihewaytheen'inesransandruns: W ‘33 G) N - Difficulty in starting before the engine is warm up ieasy once ii is warmed up): SE valve is not compleieiyopened. -|d|e speed is erraiic even after warm-up (imperfecr combustion): SE valve Is no: completely closed. When the above sympioms occur, inspect the SE valve using the following procedure. NOTE‘ Remove the fuel tank (page 24) when inspecting the SE valve of AFTER '98 models. Loosen rhe SE valve nut(s) and remove (mam) from the carburetoris) ('97—’98). Pull the Choke knob all khe way out to fuliv open position and recheck for smooth operaiion of the choke knob. There should be no free play. Check valve seat on the choke valve for damage. Reinstall the choke valve in the reverse order of removal. After '98 SHOWN 3-7 MAINTENANCE AIR CLEANER NOTE‘ - The visccus paper element type air cleaner cannot be cleaned because the element contains a dust adhesive. 0 If the motorcycle is used in wet or dusty areas, more frequent inspections are required. ’97a‘98' Remove the air cleaner housing cover bolt and Cover. Remove the holder bolts and the air cleaner element. Replace the element accordance with the maintenance schedule (page 3-3). Also, replace the element any time it is excessively dirty or damaged cover. Remove the three bolts and air cleaner case cover. 3-8 MAINTENANCE Remove the air cleaner element. Replace the element accordance with the maintenance schedule (page 3-3l. Also, replace the element any time it is excessively dirty or damaged. CRANKCASE BREATHER NOTE Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposits level can be seen in the transparent section of the breather tube The crankcase drain tube is behind the left frame pipe. Pull the drain tube out ofthe frame clamp, Remove the drain plug from the tube to empty any deposits. Reinstall the drain plug. SPARK PLUG Disconnect the spark plug caps. N OTE Clean around the spark plug bases With compressed air before removing, and be sure that no debris enters the combustion chamber. Remove the spark plugs using the spark plug wrench or an equivalent. inspect or replace as described in the maintenance schedule (page 3-3). MAINTENANCE INSPECTION SPARK PLUG Check the following and replace if necessary (recommended spark plugs: page SM). ~ Insulator for damage - Electrodes for wear - Burning condition, coloration; -dark to light brown indicates good condition. ~excessive lightness indicates malfunctioning ignition system or learn mixture. *wet or black sooty deposit indicates over-rich mixture. REUSING A SPARK PLUG Clean the spark plug electrodes with a wire brush PLUG GAP ;i,i, or spark plug cleaner. 0.80 7 030 mm 1 Check the gap between the center and side (0.031—0.035inl electrodes with a wire-type feeler gauge. If necessary, adjust the gap by bending the side — electrodes carefully. SPARK PLUG GAP: 0.80’030 mm (0331—01335 in) CAUTION: To prevent damage to the cylinder hand, hand tighten the spark plug bafara using a wrench to tighten to the specified torque. Reinstall the spark plug in the cylinder head and hand tighten, then torque to specification. TORQUE: 14 N-m (1,4 kgf-m,10lbf-l‘tl REPLACING A SPARK PLUG Set the plug gap to specification with a wire-type feeler gauge. CAUTION: Do not avertight‘an the spark plug. install and hand tighten the new spark plug, then tighten it about 1/2 of a turn after the sealing washercontacts the seat of the plug hole. 3-10 MAINTENANCE VALVE CLEARANCE INSPECTION NOTE' Inspect and adjust the valve clearance while the engine is cold (below 35 'C/95 'F). Remove khe fuel tank (page 2-4l. Remove ‘he aircleaner housing (page 574). Remove ‘he air cleaner chamber and inlek duct, Remove the crankshaft hole cap and timing hole cap. Remove the bolts and valve adjusting covers from the cylinder head covers. NOTE. Adjust ‘he front cylinder valves first. MAINTENANCE FRONY CYLINDER HEAD Rotate the flywheel counterclockwise to align the “FT” mark with the index notch on the left crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. REAR CVLINDER HEAD 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 (Top Dead Centeri on the compression stroke. Inspect the clearance of all three valve by inserting a feeler gauge between the adjusting screw and the valve. VALVE CLEARANCE: IN: 0.15 mm “3.006 in) EX: 0.20 mm “1.008 in) "FT” MARK % INDEX MARK 3-12 MAINTENANCE ADJUSTMENT Adjust by loosening the lock nut and turning the adjusting screw until there >5 a slight drag on the (ester gauge, Hold the adjusting screw and tighten the lock nut. TORQUE: 23 N-m (2‘3 kgf‘m,17lbf-fl) TOOL: Valve adjusting wrench 07908 7 KESOOOO or 07908 , KE90100 (USA. only) NOTE Apply oil to the nut and bolt threads. Check the Orrings of the valve adjusting covers for damage and replace if necessary. instail the front and rear valve adjusting covers. Tighten the cover bolts to the specified torque. TORQUE: 12 Nm i1.2 kgf-m , 9 Ibf-fti MAINTENANCE Apply molybdenum disulfide grease to the timing hole cap and crankshaft hole cap threads. Install and tighten the caps to the specified torque. TORQUE: Tuning hole cap: 15 N-m 11.5 kgf-m , l1 Ibf-ftl Crankshaft hole cap: 15 N-m 11.5 kgf-m,11 Ibf-ftl ENGINE OIL/OIL FILTER OIL LEVEL INSPECTION _WAFIN|NG 0 When the angina 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. Run the engine in an open area or with an exhaust evacuation system in an anclosa-d area. 0 Engine and exhaust system parts become very hot and remain hot Iar some time after the engine is run, Wear insulafud gloves or wait until the engine and exhaust system have cooled before handling these parts. NOTE: 0Do not screw in the oil filler cap/level gauge when checking oil level. IThe oil level cannot be correctly measured if the motorcycle is not supported perfectly upright on a level surface. - As the oil is gradually consumed, it is necessary to periodically check the oil level and replenish the oil volume to its proper level. .ll the oil level is too high, overall engine performance and the actuation of the clutch may " lilLL ‘ be effected. Too little oil may cause engine ,5] , - overheating as well as premature wearto various parts. I If a difierent brand or grade of oil or low quality oil is mixed when adding oil, the lubricating function deteriorates. Support the motorcycle in an upright and level position usingahoistorajack undertheengine. Stanthe engine and let it idle for a few minutes, Stop the engine and wait 2 » 3 minutes, 3-14 Remove the oil filler cap/dipstick and wipe off the oil from the dipstick with a clean cloth. With the motorcycle upright on level ground. insert the oil filler cap/dipstick into the stick hole without screwing it in, Remove the oil filler cap/dipstick and check the oil level. If the level is below or nearthe lower level mark on the dipstick, iill to the upper level mark with the recommended oil. RECOMMENDED ENGINE OIL: Honda GNA or HP4 4vstr0ke oil or HONDA 4* stroke oil or equivalent motorcycle oil API service classification SF or 56 Viscosity: SAE 10W740 NOTE' Other viscosities shown in the chart may be used when the average temperature in your riding area is within the indicated range. Check the Orring for damage. Reinstall the oil filler cap/dipstick. ENGINE OIL CHANGE _WAFINING I When 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. I Engine and exhaust system parts become very hot and remain hot for some time after the engine is run, Wear insulated gloves or wait until the engine and exhaust system have cooled before handling these parts. NOTE, Change the engine oil with the engine warm and the motorcycle on its side stand to assure complete and rapid draining. Warm upthe engine. Place an oil drain pan underthe engine to catch the oil, then remove the oil drain bolt and oil filler cap/ dipstick. MAINTENANCE MAINTENANCE With the engine stop switch "OFF", push the starter button for a few seconds to drain any ml which may be left in the englne. NOTE Do not operate the motor for more than few seconds. ; After draining the oil completely, check that the sealing washer on the drain bolt IS in good condition and replace it necessary. Tighten the drain boltto the specified torque. TORQUE: '97* '93: 34 N-m (3.5 kgfrm , 25 IbfAIt) After '98: 30 N»m (3.1 kgfvm , 22 lbl-h) Fill the crankcase with the recommended engine oil. OIL CAPACITY: 2.l E (22 US qt , 1.8 Imp qt) at draining 2.8 913.0 US qt , 2.5 Imp qt) at disassembly 2,25 2 {2.38 US qt , 1.98 imp qt) at on filter change lnstall the oil filler cap/dipstick. Stanthe engine and let it idle for 2 or 3 minutes. Stop the engine and weight a few minutes, then check that the oil level is at the Upper level mark with the motorcycle upright. Check that there are no oil leaks. OIL FILTER CHANGE M C When 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. - Engine and exhaust system parts become very hot and remain hat for some time after the engine is run. Wear insulated gloves or wait until the engine and exhaust system have cooled before handling those parts. Drain the engine oil (page 346). Remove the oil filter using the oil filter wrench. TOOL: Oil filter wrench 07HAA> PJ70‘lOO DRAIN BOLT 3-16 MAINTENANCE Apply engine oil to the new oil filter threads and the Owing. Install and tighten the new oil filter to the specified torque. TORQUE: 10 Nm [1.0 kgt-m , 7 lbf-ft) Fill the crankcase with the recommended engine oil (page 3-15l. install the oil tiller cap/dipstick. Startthe engine and recheck the oil level (page 3-15l. Make sure that there are no oil leaks. CARBURETOR SYNCHRONIZATION ('97 — ’98) When 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 puisanous carban manaxide gas that may cause lass af cansciousness and lead to death. Run the engine in an 0P8" area or with an exhaust avacuatinn system in an enclosed area. NOTE Perform this maintenance with the engine at normal operating temperature and transmission In neutral. Place the motorcycle on a level surface. Remove the fuel tank mounting bolt. Carefully raise the tank and support it in the frame using a suitable base. Remove the air cleaner housing lpage 57A). Remove the vacuum plugs and washers from the cylinder head intake ports. Connect the vacuum gauge and attachment. TOOL: Vacuum gauge 07404 , 0030000 or O7LMJ , 001000A (U.S.A. only) Connect the suitable tube between fuel tank and fuel tube. 1.Turn the fuel valve ON. Start the engine and adjust the idle speed to the specification. IDLE SPEED:1,200 : 100 rpm MAINTENANCE 2.Check the difference in vacuum between each carburetor. CARBURETOR VACUUM DIFFERENCE: 27 kPa (20 mmHg, 0.7 In Hg) NOTE: The base carburetor is the Rear (No.1)carburetor. 3. Synchronize to specificativn by turning the adjusting screw. 4. Be sure that the synchronization is stable by snapping the throttle grip several times. 5. Snap the throttle grip several times and recheck the idle speed and difference in vacuum between each carburetor. Disconnect the vacuum gauge and attachment, install the vacuum plugs and washers and tighten the plugs to the specified torque. Install the removed parts. TORQUE: 3 N~m (0.33 kgf-m , 2,4 lbf-ft) ENGINE IDLE SPEED mm When 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 poisanous carban manoxide gas that may cause loss of cansciausness and lead to death, Run the engine in an open area In with an exhaust evacuation system in an enclosed area. NOTE: IPerform this maintenance with the engine at normal operating temperature and transmission in neutral. Place the motorcycle on a level surface, 0 Engine must be warm fur accurate adjustment. Ten minutes of stop-and-go riding is sufficient Warm up the engine and shift the transmission into neutral. Place the motorcycle on its side stand. Check the idle speed and adjust by turning the throttle stop control knob if necessary. IDLE SPEED:1,200 i 100 rpm 3-18 MAINTENANCE RADIATOR COOLANT LEVEL CHECK M 0 Wait until the angina is cool bafore removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. I Radiator coolant is poisonous. Take care to avoid getting coolant in your eyes, on your skin, or on your clothes. I ll coolant gets in your eyes, flush repeatedly with water and contact a doctor immediately. 0 ll coolant is accidentally swallowed, induce vomiting and contact a doctor immediately. ' KEEP OUT REACH OF CHILDREN. Check the coolant level of the reserve tank with the engine running at normal operating temperature. The level should be between the “UPPER" and "LOWER" level lines with the motorcycle in a vertical position on a flat, level surface. If necessary, remove the right side cover lpage 2.3. and reserve tank cap and fill to the “UPPER" level line with a 50-50 mixture of distilled water and antifreeze (coolant mixture preparation: page 6—5). CAUTION: Be sure to use the proper mixture of antifreeze and distilled water to protect the engine, use distilled water. Tap water may cause the engine to rust or corrode. Check to see if there are any coolant leaks when the coolant level decreases very rapidlvt If the reserve tank becomes completely empty. there is a possibility of air getting into the cooling system. Be sure to remove all air from the cooling system as described on page 6-6. COOLING SYSTEM mm To prevent iniury, keep your hands and clothing away from the cooling fan. It may start automatically, without warning. Check the radiator air passage for clogging or damage. MAINTENANCE Straighten bent fins with a small, flat blade screwdriver and remove insects, mud or other obstructions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over more than 20 % of the radiating surface. For radiator replacement, refer to page 6-8. Remove the fuel tank and steering covers (section 2). Check for any coolant leakage from the water pump, water hose and hose joints. Make sure the hoses are in good condition; they should not show any sings of deterioration. Replace any hose that shows any sign of deterioration. Check that all hose clamps are tight, For radiator replacement, refer to page 6-9. EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLY) Check the tank between the fuel tank, EVAF canister, EVAP purge control valve and carburetor for deterioration, damage or loose connections. Check the EVAP canister for cracks or other damage. Refer to the Vacuum Hose Routing Diagram Label and Cable 8t Harness Routing (page 1732, 37) for tube connections. DRIVE CHAIN DRIVE CHAIN SLACK INSPECTION mama— Inspecting the drive chain while the engine is running can result in serious hand or finger injury. Turn the ignition switch OFF, place the motorcycle on its side stand and shift the transmission in neutral. Check the slack in the drive chain lower run, midway between the sprockets. 3-20 MAINTENANCE DRIVE CHAIN SLACK: 20" 30 mm (3/4 , 1-3/16 in) CAUTION Excessive chain slack, 50 mm (2.0 in! ar more, may damage the lrarne. Lubricale the drive chain with Pro Honda Chain Lube designed specificaHv for use With 0-iing chains. Wipe off me excess chain lube. ADJUSTMENT AD“ USTING ao‘rie\ CAUTIO ii the adjustment is not the same on bath sides, the wheel is out ol alignment and can cause excessive tire, sprocket and chain wear. Loosen the real axle nut. Tum both adjusting bolls umiI The correct drive chain slack is obtained, Make sure the index marks an the both adjus‘ers are aligned with me rear end of The swingarm. Tighten the rearaxle nunoxhe specil‘iedtorque TORQUE: 88 Ni" (9.0 kgI-m , 66 lbf-m Recheck the drive chain siack and free wheei lotaiion Lubricate the drive chain with Pro Honda Chain Lube designed speciiicaiiv for use with o~ring chains. Wipe Offthe excess chain mhe, Check the drive chain wear indicator IabeI attached on (he left drive chain adjuster. If the index mark reaches the red zone of (he indicator iahei, replace the drive chain with a new one ipage 3‘22) CLEANING, INSPECTION AND , ‘ LUBRICATION glgixiVEmMMABLE on HIGH FLASH POINT CAUTION CLEAN - chains with o-rings should not be treated ta the Inllawing cleaning and oiling procedure. This treatment will cause degradation of the o-virrgs and loss of grease, thus shortening chain life. - DD not use steam or high pressure water washing. Use a chain spray containing a WIFE AND DRV cleaning agent or use high flash point solvent t0 clean the chain. Revised: OC‘IODeI 1999, 1997 - 2000 VTSDOC/CD @1999 American Honda Motor 00., Inc. - All FIIQMS Reserved MSV 8617 (991m MAINTENANCE Clean the chain with suitable detergent and wipe it dry. Be sure the chain has dried completely before lubricating. Inspect the drive chain for possible damage or wear. Replace any chain that has damaged rollers, loose fitting links, or othenNise appears unserviceable. Installing a new chain on badly worn sprockets will cause the new chain to wear quickly. Inspect and replace sprockets as necessary. Lubricate the drive chain with Pro Honda Chain Lube designed specifically for use with O»ring chains. Wipe offthe excess chain lube. SPROCKET INSPECTION inspect the drive and driven sprocket teeth for damage or wear. Replace if necessary. Never use a new drive chain on worn sprockets. Both chain and sprockets must be in good condition, or the new replacement chain will wear rapidly. Check the attachment bolts and nuts on the drive and driven sprockets. If any are loose, torque them to the proper specification. REPLACEMENT CAUTION: Because a! the drive chain is master link joint pin staking type {the ends of the pins are expanded with the special tool], the specified types of chain and special tool must be used to replace; Do not use clip type chains. This motorcycle uses a drive chain with a staked master link. Loosen the drive chain (page 3721l. Assemble the special tool, TOOL: Drive chain tool set 07HMH MR10103 or 07HMH—MR101DA lU.S.A, only) LUBRICATE WEAR NORMAL DRIVE CHAIN TOOL SET 3-22 MAINTENANCE NOTE When using the special tool, follow the manufac- turer's operating instructions. Locate the drive chain cutter on the staked part of the drive chain and cut the staked pins. TOOL: Drive chain tool set 07HMHiMR10103 or OTHMHiMR1010A (U.S.A. onlvl Remove the drive chain, Remove the excess drive chain links from the new drive chain with the drive chain cutter, NOTE ' One (1i link is indicated as the figure on the right. 0 Include the master link when you count the drive chain links. STANDARD LINKS: 120L REPLACEMENT CHAIN: RK: 525 8M5 DID: 525 V8 Install the new drive chain over the swingarm. CAUTION: Never reuse the old master link, master link plate and D-rirrgs. Install the new Orrings onto the new master link, and insert the master link from the inside of the drive chain taking care to prevent squeezing. install the O-nngs and the link plate with the drive chain cutter. TOOL: Drive chain tool set O7HMH~MR10103 or D7HMH7MR10‘lDA lU.S.A. only) NOTE ' install the link plate with the identification mark facing the outside. ' Take care to prevent squeezing of the O-rings. I Do not remove initially applied grease from the link to lubricate. Remove the special tool and check the master link pin length projected from the plate. STANDARD LENGTH: 1171.4 mm 10.05'006 in) MASTER LINK illilllifl DRIVE CHAIN TOOL SET MASTER LIN K STANDARD LINKS ‘ MASTER LINK DRIVE CHAIN TOOL SET STANDARD LENGTH 41 , fl 3-23 MAINTENANCE Stake the master link pins with the drive chain tool set. TOOL: Drive chain tool set O7HMH — MR10103 or 07HMH-MR1010A lU.S.A. only) NOTE: To prevent over staking, stake gradually checking the diameter ofthe staked area using slide calipers. After staking, check the staked area of the master link using slide calipers. DIAMETER OF THE STAKED AREA: 5.50i5.80 mrn 10.217*0.228 inl NOTE IWhen the measured staked area is over the prescribed value, restake using the new master link, plate and O-rings. 0When the measured staked area is below the prescribed value, reinstall the drive chain cutter and restake. Check the staked area of the master link for cracks and the O~rings for damage. If there is any cracking or damage, replace the master link, plate and O-rings. CAUTION: A drive chain with a clip-type master link must not be used. Check that master link pivots freely on the pins. If the movement is not smooth, restake using the new master link, plate and O-rings. Adjust the drive chain play. BRAKE FLUID CAUTION: - Do not remave the cover or up unless the reservoir is level because fluid may spill nut. 0 Do not mix different types of fluid, as they are not campatible with each other. ' Do nut allow foreign material to enter the system when filling the reservoir. 0 Avoid spilling fluid on painted, plastic or rubber parts. Place a rug over these parts whenever the system is servinezt MASTER LINK DRlVE CHAIN TOOL SET SLIDE CALIPER 3-24 MAINTENANCE NOTE 'When the fluid level is low, check the brake pads for wear (see below]. A low fluid level may be due to wear of the brake pads. If the brake pads are worn, the caliper piston is pushed out, and this accounts for a low resen/olr level. If the brake pads are not worn and the fluid level is low, check entire system for leaks (page 3726). ' DD not remove the level float from the reservoir when filling with brake fluid. Turn the handlebar to the left side so that the reservoir is level and check the front brake reservoir level through the sight glass. it the level liloat edgel is near the lower level mark, remove the cover, set plate and diaphragm and fill the reservoir to the casting ledge with DOT A brake fluidfrom a sealed container. Refer to page 1573 for brake fluid replacement/ bleeding procedures. BRAKE SHOE/ PAD WEAR FRONT BRAKE PADS Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of wear Ilmit groove. Refer to page 15-5 for brake pad replacement. CAUTION: Always replace the brake pads as a set to ensure even disc pressure. REAR BRAKE SHOE Replace the brake shoes if the arrow on the brake arm aligns with the reference mark “A” on full application ofthe rear brake pedal. Refer to page 14-11 for brake pad replacement. MAINTENANCE BRAKE SYSTEM INSPECTION Firmly apply the brake lever or pedal, and check the that no arr has entered the system If the lever or pedal feels soft or spongy when operated, bleed air from the system. Inspect the brake hoses and tittlngs for deterioration, cracks and signs of leakage. Tighten any loose fittings. Replace hoses and fittings as required. Refer to page 15-3 for brake bleeding procedures. BRAKE PEDAL HEIGHT Check the brake pedal height BRAKE PEDAL HEIGHT: 43 mm 11.7 in) above the top ofthe foutpeg To adjust. Loosen the stopper bolt lock nut and turn the stopper bolt. Retlghten the lock nut. NOTE After adjustment the brake pedal herght, check the rear brake light switch and brake pedal free play, adlust if necessary, , l'l LOCK NUT/STOPPERKBOL'T 3-26 MAINTENANCE BRAKE PEDAL FREE PLAY NOTE: Perform brake pedal free play adjustment after adjusting brake pedal height. Check the brake pedal free play. FREE PLAY: 20—30 mm (3/4 7 1-1/4 inl If adjustment is necessaw, use the rear brake adjusting nut. NOTE After adjusting the brake pedal free play, check the rear brake light switch operation and adjust if necessary. BRAKE LIGHT SWITCH Be sure l0 held the switch body 1: Hill y while turning the adjusting nut. CAUTION‘ Alluwing the switch body to turn during adjustment can break the wires in the switch NOTE. IThe brake light switch on the front brake lever cannot be adjusted. if the front brake light switch actuation and brake engagement are off, either replace the switch unit or the malfunctioning parts of the system. I Make all rear brake light switch adjustments aher the height adjustment and the brake pedal free play adjustments have been made. Check the brake light switch operation and adjustment by applying the brakes. Visually inspect for any damage and make sure the reflector plate is clean within the light. Adjust the rear brake light switch so that the brake light comes unjust prior to the brake actually being engaged. If the light fails to come on, adjust the switch so that the light comes on at the proper time. Turn the adjusting nut on the brake light switch and not the switch body and wires to make switch actuation adjustments. After adjustment, recheck to he sure the brake light comes on at the proper time. 3-27 MAINTENANCE HEADLIGHT AIM Adjust the headlight beam as SPEC/fled by late] laws and regulation m—fi An improperly adjusted headlight may blind ancuming drivers, or it may {all to light the road far a safe distance. Place the motorcycle on a level surface. Adjust the headlight beam vertically turning the vertical beam adjusting screw. Aclockwise rotation moves the beam up. Horizontal beam adjustments are made using the horimntal beam adjusting screw. A clockwise rotation moves the beam toward the right side of the rider. CLUTCH SYSTEM Measure the clutch free play at the end of the clutch lever. FREE PLAV: 10*20 rnm (3/8 7 3/4 inl Adjust as follows: Minor adjustments are made at the adjuster near the lever, Loosen the lock nut and turn the adjuster. Tighten the lock nut. CAUTION ‘ The adjuster may be damaged if if is past oned too far out, leaving minimal thread engagement. If the adjuster is threaded out near its limit. and the correct free play cannot be obtained. turn the adjuster all the way in and back out one turn. Tighten the lock nut and make a major adjustment as described below. ‘ ‘JUSTERV 7 3-28 MAINTENANCE Major adjustments are performed at the clutch arm. Loosen the lock nut and turn the adjusting nut to adjust free play. Hold the adjusting nut securely while tightening the luck nut. If properfree play cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch (see section 8). SIDE STAND Supportthe motorcycle on a level surface. Check the side stand spring for damage or loss of tension. Check the side stand assembly for freedom of movement and lubricate the side stand pivot if necessary. Make sure that the side stand is not bent. Check the side stand ignition cutroff system: *Sit astride the motorcycle and raise the side Stand. SIDE STAND *Start the engine with the transmission in neutral, then shift the transmission into gear, with the clutch leversqueezed. *Move the side stand fully down. *The engine should stop as the side stand is lowered. If there Is a problem with the system, check the side stand switch lsection 19L SUSPENSION Mm Loose, worn, or damaged suspension parts impair motorcycle stability and control. Repair or replace any damaged components before riding. Riding a motorcycle with faulty suspension increases your risk of an accident and possible injury, FRONT Check the action of the forks by operating the front brakes and compressing the front suspension several times. Check the entire fork assembly for Signs of leaks, damage or loose fasteners. Replace damaged Components which cannot be repaired. Tighten all nuts and bolts. Refer to section 13 for front fork service. MAINTENANCE REAR Support the motorcycle securely using safety stand or hoist and raise the rearwheel off the ground. Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side to side. Replace the bearings if any looseness is noted lsection 14). Check the action of the shock absorbers by compressing them several times. Check the entire shock absorber assembly for signs of leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. Refer to section 14 for shock absorber service. NUTS, BOLTS, FASTENERS Check that all chassis nuts, bolts and screws are tightened to their correct torque values [page 1714) at the Interval shown in the Maintenance Schedule (page 373). Check that all cotter pins, slip clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES Making sure the fork Is not allowed to move, raise the front wheel and check for play. Turn the wheel and check that it rotates smoothly with no usual noises. If faults are found, inspect the wheel bearings. Support the motorcycle securely and raise the rear Wheel ofithe ground. Check for play in either the wheel or the swingarrn pivot. Turn the wheel and check that it rotates smoothly with no unusual noises. If abnormal conditions are suspected, check the rear wheel bearings, NOTE As the swingarm pivot is included in this check, be sure to confirm the location of the play; i.e. from the wheel bearings or the swingarm pivot. 3-30 MAINTENANCE Inspect the spokes for looseness by tapping them with a screwdriver. Tap on ”is spokes if a spoke does not have a resonant metallic sound, and be sure that or if it sounds different from the other spokes, the clear metallic tighten it to the specified torque. sound or the same resonant metal/i0 TOOL: snund can be Spuke wrench 07JMA! MRED'IOD heard an all spokes TORQUE: 4 N-rn 10A kgf-m . 2.9 lbfvft) NOTE Tire pressure should be checked when tires are COLD. Check the pressure of each tire with a pressure gauge, RECOMMENDED TIRE PRESSURE AND SIZE Front Rear Tire size 100/9049 575 170/8045 M/C 77S UptoQO Coldtrre kngDlel 20012.no,29) zoorz.oo,29i pressures lead kPa 'U’bta lkgf/cm‘, maximum zcorz.oo,29i 25.012.50.36) psl) lweight , l capautv Maximum weightcapauty 161 kg (355 lbsl Tirebrand '97 '95 ERIDGESTONE BRlDGESTONE _ L309 G546 DUNLOP F24 DUNLOP K555 1 After ’98 ] DUNLOP F24 DUNLOP 9404 Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness (refer to section 13 and 14). Measure the tread depth at the center ufthe tires. Replace the tires when the tread depth reaches the following limits. MINIMUM TREAD DEPTH: FRONT: 1.5 mm (0.06 in) HEAR: 2.0 mm (0.08 in) STEERING HEAD BEARINGS NOTE Check that the control cables do not interfere with handlebar rotation Support the motorcycle securely and raise the front wheel off ground check that the handlebar moves freely from side to side. If the handlebar moves unevenly, binds, or has vertical movement, inspect the steering head bearings (section 13). LUBRICATION SYSTEM ROCKER ARM CAMSHAFT PISTON OIL JET CRANKSHAFT COUNTERSHAFT MAINSHAFT OIL PRESSURE SWITCH OIL PUMP OIL FILTER PRESSURE RELIEF VALVE OIL STRAINER 4-0 4. LUBRICATION SYSTEM SERVICE INFORMATION 4—1 OIL PRESSURE CHECK 4—3 TROUBLESHOOTING 4A2 OIL PUMP 4-4 SERVICE INFORMATION GENERAL I When 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 lass of consciousness and lead to death. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. ' Used engine oil may cause skin cancer if repeatedly Ielt in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to thoroughly wash your hands with soap and water as soon as possible after handling used oil. KEEP OUT OF REACH OF CHILDREN. - The engine must be removed from the frame belore servicing the oil pump. I When removing and installing the oil pump use care not to allow dust or dirt to enter the engine. - If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. 0 After the engine has been installed check that there are no oil leaks and that oil pressure is correct. ' For oil pressure indicator inspection, referto section 19 oithis manual. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Engine oil capacity Atdraining ( 2.1R(2.2USqt,1.8Impqtl “’7 At disassembly 280(30 US qt,2.5 Imp qtl 7 At oil filter change 2.25 E (2.38 US qt,1.98lmp qt) 7 Recommended engine oil HONDA GN4 or HP4 A-stroke oil or 7 equivalent motor oil APl service classification SF or SG Viscosity: SAE 10W * 40 Oil pressure at oil pressure switch 441 kPa (4.5 kgf/cm’, 64 psi) at 6,000 ----- rpm (80 ”C/176°Fl Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) ‘ Bod clearance 0.15 70.22‘(0.006*0.009l l 0.35 (0.014) m i Side clearance 0.027007 (000170.003) i 0.10 (0.004) 4-1 LUBRICATION SYSTEM TORQUE VALUES Oil pump cover bolt Oil pump driven sprocket bolt Oil filter Cartridge Oil drain bolt '97.. '98: 34 N-m (3.5 kgf-m , After '98: 30 N»rn (3.1 kgf—m , Oil pressure switch '97i’98: 1D N-m (1.0 kgf-rn, After’98: 12 N-m(1.2 kgi-m, Oil pressure switch cord TOOLS Oil filter wrench Oil pressure gauge Oil pressure gauge attachment 07HAA— PJ70‘I DO 07506—300000!) 0751074220100 TROUBLESHOOTING Oil level low - Oil consumption - External oil leak - Worn piston ring or incorrect piston ring installation - Worn valve guide or sea! Oil contamination lWhite appearance) - From coolant mixing with oil — Faulty water pump mechanical seal 7 Faulty head gasket *Water leak in crankcase No oil pressure ‘ Oil leveltoo low ' Oil pump drive chain or drive sprocket broken -Oil pump damaged (pump sham - Internal oil leak Low oil pressure - Pressure relief valve stuck open - Clogged oil filterand strainer screen - Oil pump worn or damaged ' internal oil leak - Incorrect oil being used - Oil level too low High oil pressure - Pressure relief valve stuck closed - Plugged oil filter, gallery, or metering orifice - Incorrect oil being used 13N-ml1.3kgf-m. 15N-ml1,5kgr.m, 1oN-ml1,o kgf-m, 2 N-m l0.23 kngm, 9 Ibf-ftl 11 lbf-ftl Apply a locking agent to the threads 7 lbf-ftl Apply a engine oil to the threads Apply oil to the O-ring 25 Ibfvftl 22 Ibf-l‘t) 7 |bf>ftl jApply sealant to the threads 9 lbf-ftl 1.7 lbf-ft) Seized engine - No or low oil pressure ~ Clogged oil orifice/passage . Internal oil leak ~ Non-recommended oil used Oil contamination - Deteriorated oil - Faulty oil filter - Worn piston ring (White appearance with water or moisture) —Damaged water pump mechanical seal —Damaged head gasket *Oil relief not frequent enough Oil pressure warning indicator does not work - Faulty oil pressure switch - Short circuit in the indicator wire - Low or no oil pressure - Blown LED 4-2 LUBRICATION SYSTEM OIL PRESSURE CHECK NOTE: If the engine is cold, the pressure reading will be abnormally high. Warm up the engine to normal operating temperature before starting this test. Warm up the engine. Stop the engine. Remove the left rear cover (page 7-4). Remove the screw and disconnect the oil pressure switch wire. Remove the oil pressure switch. Connect the oil pressure gauge attachment and gauge to the pressure switch hole. TOOLS: Oil pressure gauge U7506i3000000 Oil pressure gauge D7510— 4220100 attachment Check the oil level and add the recommended oil if necessary (page 344). Start the engine and check the oil pressure at 6,000 rpm OIL PRESSURE: 441 kPa (4.5 kgf/cml, 64 psil at 6,000 rpm (80 “(3/176 °Fl Stop the engine and remove the oil pressure gauge attachment and gauge from the pressure switch hole. Apply sealant to the oil pressure switch threads as shown and tighten it to the specified torque. J . . TORQUE: 197,33: 10 NM (1.0 kgf-m , 7 Math) fl Afler’98: 12 NJ“ (12 kgf-m , 5 lbf-fll ATTACHMENT Connect the oil pressure switch wire and tighten the screw to specified torque. OIL PRESSURE SWITCH TORQUE: 2 N-m (0.23 kgf-m, 1,7 lbf-ft) —>H‘— NOTE: (page 128). l Start the engine. III Check the oil pressure indicator goes out after one or two seconds. If the oil pressure indicator stays on, stop the engine immediately and determine the cause (page 19-8). Routethe oil pressure switch wire correctly 1 ‘ l 4-3 LUBRICATION SYSTEM OIL PUMP NOTE When removing and installing the oil pump, use care not to allow dust or dirt ta enter the engine. REMOVAL Separate the crankcase (page 1274). Remove the bolt and oil relief pipe. Remove the oil relief valve and O—ring. Remove the oil pump mounting bolts. Remove the oil pump. Remove the collars and Orrings. Remove the dowel pin. L 4-4 LUBRICATION SYSTEM DISASSEMBLY OIL PUMP DISASSEMBLY NOTE‘ if any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly, Remove the oil pipe, oil pipe seals and O-ring, Remove the oil strainer and gasket, Remove the bolts and pump cover from pump body. Remove the dowel pins. Remove the washer, drive shafl, drive pin, inner rotor and outer rotor. LUBRICATION SYSTEM Be careful no! to lose the disassembled parts PRESSURE RELIEF VALVE CHECK M The snap ring is under spring pressure. Use care when removing it and wear eye and face pratection. Check the operation of the pressure relief valve by pushing on the piston. Remove the pressure relief valve snap ring and disassemble the pressure relief valve. Check the piston for wear, sticking or damage Check the valve spring and piston for wear or damage Check the rellei Valve for Clogging or damage. Clean the remaining parts and assemble the relief valve in the reverse urder of disassembly. INSPECTION NOTE - Measure at several places and use the largest reading to Compare to the service limit. ' If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. BODV CLEARANCE Install the inner rotor and outer rotor to the pump body. Install the drive shaft properly. Measure the pump bodyrtoVouter rotor clearance using the ieeier gauge. SERVICE LIMIT: 0.35 mm (0.014 ini TIP CLEARANCE Install the inner rotor and outer rotor to the pump body. Install the drive shaft properly. Measure the outer rutor-to-inner rotor clearance using the feeier gauge. SERVICE LIMIT: 0.20 mm 10.008 inl SNAP RING RELIEF VALVE PISTO N EODV CLEARANCE TIF CLEARANCE ._ , o F , WASHER SPRING 4-6 LUBRICATION SYSTEM SIDE CLEARANCE | CLEARA 6 Install the inner rotor and outer rotor to the pump body. Measure the rotor side-to»pump body clearance using the Veeler gauge and straight edge. SERVICE LIMIT: 0.10 mm (0.004 in) ASSEMBLY NOTE‘ Before assembly, clean all disassembled parts thoroughly with clean engine oil. /, OUTER ROTOR J lNNER ROTOR ‘ DRIVE PIN / DRIVE SHAFT SNAP RING WQHER % PUMP BODY DOWEL PINs PUMP COVER VVXéQER SPRING PISTON RELIEF VALVE OIL PIPE @ PIPE SEALS STRAINER NOTE INNER ROTOR OUTER ROTOR When installing the inner rotor, install it with the groove side facing the pump body. Install the outer rotor and inner rotor to the pump body. PUMP BODNl GROOVE 4-7 LUBRICATION SYSTEM Install the drive shaft and drive pin by aligning the slots in the Inner rotor. Place the washer into the inner rotor groove. Install the dowel pin to the pump cover. install the pump body to the pump cover. install and tighten the bolts to the specified torque. TORQUE: 13 N-m (1.3 kgf-m , 9 Ibf-fll Cleanthe oil strainer. Apply oil to the new O-ring and install the oil strainer. Install the oil strainer to the oil pump aligning it to the groove onthe oil pump. NOTE; Install the oil strainer to the pump body groove securely. LUBRICATION SYSTEM Apply oil to the new oil plpe seal and new O»rmgs, . , § then installzothe oil pipe. ‘ ,, g g , :E ‘ PIPlE EALSM NOTE Install the Orrings with their tapered side facing out. lnstall the oil pipe to the oil pump securely. INSTALLATION COLLAHS Install the dowel pin, \fj/ ' Install the collars. ./’\:// Apply oil to the new Orrlngs and lnstall onto the collars Install the oil pump mm the crankcase securely. @q O’HINGS W NOTE‘ Be careful not to damage the Orrings and pipe seals at oil pump installation. LUBRICATION SYSTEM Install and tighten the bolts securely. Apply oil to the new O-ring and install the pressure relief valve groove, and install the relief valve to the oil pump. Install the oil relief piper Install and tighten the bolt securely. Reassemble the crankcase (page 12-25). Check that there are no oil leaks and that oil pressure is correct. 4-10 MEMO FUEL SYSTEM '977’98: 19N-m(1.9 kgf-m,141bf-ft) 5. FUEL SYSTEM SERVICE INFORMATION TROUBLESHOOTING AIR CLEANER HOUSING SUB-AIR CLEANER ELEMENT ('97 7:93) AIR CLEANER CHAMBER CARBURETOR REMOVAL ('97i'98I CARBURETOR REMOVAL (Afier '98) CARBURETOR SEPARATION (’97 7 '98) CARBURETOR DISASSEMBLY/ ASSEMBLY VACUUM CHAMBER FLOAT CHAMBER AIR CUT-OFF VALVE CARBURETOR BODY CLEANING CARBURETOR REASSEMBLY ('97 i’98) 5-24 CARBURETOR REASSEMBLY (After ’98) 5-26 :sfla Jab-IN mmu’l‘nul <31 gunman u'lu'lu'l .- N «”4qu -1 >1 -1 -2 -2 CARBURETOR INSTALLATION '97 i'98) CARBURETOR INSTALLATION (After ’98) PILOT SCREW ADJUSTMENT ('97 7 '98) PILOT SCREW ADJUSTMENT (After ’98) FUEL PUMP ('97 i'BSI FUEL FILTER ('97i'98) FUEL AUTO VALVE (After ’98) HIGH ALTITUDE ADJUSTMENT (U.S.A. ONLY/’97 ~'93) HIGH ALTITUDE ADJUSTMENT (U.S.A. ONLY/After ‘98) EVAPORATIVE EMISSION PURGE CONTROL VALVE INSPECTION (CALIFORNIA TYPE ONLY) EVAPORATIVE CARBURETOR AIR VENT CONTROL VALVE INSPECTION (CALIFORNIA TYPE ONLYI 5-26 5-27 5-29 5-30 5-32 5-34 5-35 5-37 5-38 a 5-39 5-41 After '98: 12 N-m (1.2 kgf-m , 9 lbf-ft) 2 N-m (0,21 kgf-m , 1.5 (bf~ft) 792: 19 N‘m (1.9 kgf-m,14lbf-fl( ! 5/ 4 N-m (0.4 kgf—m ,2.9 mm) l 5-1 FUEL SYSTEM ’ SERVICE INFORMATION GENERAL 0 Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. I When the angina 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. ' Banding or twisting the control cables will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control, 0 Work in a well ventilated area, Smoking or allowing flames or sparks in the work area or where gasoline is stored can cause a fire or explosion. CAUTION; Be sure to remove the diaphragms before cleaning air and fuel passages with compressed air. The diaphragms might be damaged. 0 For fuel tank removal and installation, refer to Section 2. - Before disassembling the carburetor, place an approved gasoline container under the carburetor drain tube, loosen the carburetor drain screw and drain the carburetor. ‘ When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. C After removing the carburetor, wrap the intake ports of the engine with a shop towel or cover them with a piece of tape to prevent any foreign material from dropping into the engine. Be sure to remove the cover when reinstalling the carburetor. NOTE' If the vehicle is to be stored for more than one month, drain the float bowls. Fuel left in the float bowls may cause clogged jets resulting in hard starting or poor driveability. FUEL SYSTEM ITEM STANDARD ‘ 49 state/Canada type California type Carburetor identification number '97 a ’98 VDFDA VDFEA After '98 VESAC VESAB Mainjet 97,93 #115 After '93 3: 125 Slow jet ’977'93 t: 40 After '98 w. it 45 ., Piot screw Initial/opening See page 5-30 Hight altitude adjustment See page 5-37 Float level 97,93 7.0 mm (0.28 in) After '98 t 18.5 mm 10.73 in) Base carburetor (for synchronization/97 A'SE models only) i Rear cylinder (1: 1i Idle speed l 1,200 :r 100 rpm Throttle gripfreepley Ziemm (1/12i1/4in) Fuel pump flow capacity 1’97 #98 models only) Minimum 800 cm’ (27.1 US 01, 28,2 Imp ozl per minute at 13V 5-2 FUEL SYSTEM TORQUE VALUES Fuel tank mounting bolt Fuel valve nut 19 Nm (1.9 kgf-m,14lbf-ftl '97m'98: 23 N‘m (2.3 kgf-m ,17lbf-ft) After ‘98: 35 N‘m (3.5 kgf-m , 26 lbf-ftl Airclaaner housing mounting bolt Aircleaner housing cover bolt Fuel valve lever screw Throttle link cover screw TOOLS Carburetorfloatlevel gauge 0740143010000 Pilot screw wrench with 07PMA7M22011A A937X7041»XXXXX or STVAHa255-MC7 lU.S.A. onlyl ST-AH-ZGO-MC7 (U.S.A. only) Vacuum/Pressure pump Pressure pump Vacuum pump TROUBLESHOOTING Engine won't to start - No fuel in tank - No fuel to carburetor « Fuel strainer clogged *Fuel filter clogged *Fuel valve stuck *Fuel auto cock malfunction (After '98l * Fuel line clogged *Fuel tank breather clogged 7 Float level faulty AFuel pump malfunction ('97‘ '98) - Too much fuel getting to the engine *Air cleanerclogged *Flcoded carburetor -|ntake air leak ' Fuel contaminated/deteriorated *Jet clogged ' Improper starting enrichment valve operation . Slow circuit or starting enrichment valve circuit clogged . Improper throttle operation - No spark at plug (ignition system faultyl Lean mixture - Fuel jets clogged ' Float valve faulty - Floatleveltoo low - Fuel line restricted > Intake air leak - Throttle valve faulty - Vacuum piston faulty ' Fuel pump malfunction (’97m'98l Rich mixture - Starting enrichment valve open - Float valve faulty - Float level too high - Airjets clogged - Air cleaner element contaminated - Flooded carburetor O7LMA7MT8010A 12 NAm (1.2 kgf-m , 9 Ibf-ftl 10 N-m (1.0 kgf-m,7 lbf-ftl 4 N-m (0.4 kgf‘m , 2.9 lbI-ftl 2 N-m (0.21 kgf-m , 1.5 [bf-ft] j After '98 model Engine stalls, hard to start, rough idling ' Fuel line restricted ' Ignition system malfunction - Fuel mixture too lean/rich ' Fuel ccntamlnated/deteriorated *Jet clogged - Intake air leak - Idle speed misadjusted - Float level misadjusted - Fuel tank breather clogged - Pilot screw misadjusted - Slow circuit or starting enrichment valve circuit clogged - Carburetor synchronization misadjusted (’97m'98l - Fuel pump malfunction (’97 #98) - Fuel auto valve malfunction lAfter’SSl - Valve clearance misadjusted - Cylinder compression too low Afterburn when engine braking is used - Lean mixture in slow circuit - Air cut—off valve malfunction Backfiring or misfiring during acceleration ' Ignition system malfunction (Section 17l - Fuel mixture too lean Poor performance (driveability) and pour fuel acnnomy ' Fuel system clogged - Ignition system malfunction (Section 17l 5-3 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL ('97—'98) Remove the fuel tank (page 274i. Remove the air cleaner housing mounting bolts Loosen the air cleaner housingflrair cleaner chamber band. Disconnect the crankcase breather tube from the aircieaner housing. Remove the air cleaner housing. REMOVAL ('97 " '98) Loosen the connecting band screws. Remove the airciraner housing mounting baits. FUEL SYSTEM Home the tubes correctly (page 1 -22) Disconnect the breather tube from the air cleaner housing, INSTALLATION ('97 7 '98) WA \ Wipe clean the mating surfaces and apply a Honda Bond A or equivalent. Connect the crankcase breather tubes. lnstall the an cleaner housing. Tighten the alr cleaner housing-to-air cleaner cham- ber band. lnstall and tighten the air cleaner housing mounting bolt to the specified torque. TORQUE: 12 N-m (1.2 kgl-m , 9 Ibf-ft) Install the fuel tank lpege 277). INSTALLATION [After'98) Connect the breather tube to the Bll’ cleaner housing. FUEL SYSTEM SU B-AIR CLEANER ELEMENT ('97 v’98) Connect the air cleaner case to the carburetor and air cleanerchamber, Instaii and tighten the air cleaner case moutmg boits to the specified tarque. TORQUE: 12 N-m (1,2 kgf-m , 9 ibi-ft) Tighten the connecting band screws (page 579i. Removethe air cleaner housing (page 5w. A'R HOSE Disconnect the air hose icarburetorsio’subrair cleaner housing cover). Remove the subrair cleaner housing cover screw and cover‘ Remove the eiemeni. ELEMENT Wash the element in non-flammable or high flash point solvent, squeeze out the solvent thoroughly, and allow the element to dry. mm Never use gasoline or low flash point solvents for cleaning the element. A fire or explosion cauld result, Allow the element to dry thoroughly. Soak the element in gear oil (SAE fiBOiQOl and squeeze out the excess. Install the element and cover. Install and tighten the mounting screw securely. Connect the air hose from the carburetors AIR CLEANER CHAMBER REMOVAL ('97 *7 '98) Remove the air cleaner housing and sneak cleaner element (page 574,6). Loosen the intake duct hose bands at the carburetors and unhook the air cleaner chamber draintubefromtheframe. Remove the air cleaner chamber from the frame. REMOVAL lAfter’98) Remove the air cleaner housing lpage 57M Disconnect the spark plug cap (L. front sidel. Remove the air cleaner chamber from the boss. Remove the air Cleaner chamber from the left side of the frame. FUEL SYSTEM -g- ’Q’ l K ‘ WASH lN souEEZE OUT GEAR on. SOLVENT SOLVENT lSAE r50 Sol THOROUGHLV soUEEZE OUT EXCESS OlL FUEL SYSTEM INSTALLATION ('97 i '98) DRAIN TUBE PLUG Qafl/ BRACKET INTAKE DUST HOSES AIR CLEANER HOUSING ELEMENT 10 Nm (1‘0 kgI-m, 7 lbfvftl HOUSING COVER AIR CLEANER CHAMBER AIR CLEANER ELEMENT HOLDER Install the air cleaner chamber in the frame and connect me intake ducts to the carburetors and tighten the band screws. Install the sub-aircleanerelement Ipage 5-7I. Install the air cleaner housing (page 55). 5-8 FUEL SYSTEM INSTALLATION (After ’98) AIR CLEANER CHAMBER AIR CLEANER ELEMENT / AIR CLEANER CASE COVER AIR CLEANER HOUSLNG BANDS CARB‘SIDE 9mm (0.4inD STOPPER SUB AIR CLEANER CASE COVER CHAMBER SIDE InsLaH the air cleaner chamber from the left sxde of BOSS the frame, Insert the air cteaner chamber to the boss‘ Connect the spark plug cap {L from side), InsLal] the aircleaner housmg (page 574?, FUEL SYSTEM CARBURETOR REMOVAL ('977’98) m— Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Loosen the carburetor dram screw and drain the carburetor. Remove the air cleaner chamber (page 5-7). Remove the throttle link cover and disconnect the throttle cables from the carburetor. Loosen the carburetor insulator bands. Disconnect the evaporative emission purge control valve No.5 tubes and evaporative emission carburetor air vent control valve No.6 and 10 tubes from the carburetor (California type only, refer to 1-31). Pull the carburetors the upward and out of the engine. Remove the staning enrichment (SE) valve cable and SE valve from the carburetor by loosening each lock nut. Remove the air tubes icarburetors»to~air cleaner), and fuel tube from the carburetor. 5-10 FUEL SYSTEM CARBURETOR REMOVAL (After ’98) WEE—fl Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Loosen the carburetor drain screw and drain the fuel from the float chamber. Remove the fuel tank (page 2-4). Remove the link cuver {page 5-35) Loosen the nut and remove the choke knob, Remove the throttle stop control knob. Disconnect the fuel tube, Disconnect the forlowrng tubes from the EVAP CAV N°' 10 TU BE CONTROL VALVE (California type only). ~No. embe 1’ See page 1737 , No 10 tube Vacuum hose routing diagram/After '93 Disconnectthe watertube from the‘rnlet manifold, Disconnect the No. 5 tube (Calilornia type only/ After '95: page 1737). Loosen the throme cable adjusters. FUEL SYSTEM Loosen the carburetor msulator band screws and disconnect the carburetor. Disconnect the water tubes. Disconnect the No. 11 tube (Ca‘ifomia type only/ After '98: page 1-37). Remove the adjusters from the stay. Remove the throttle cab‘es from the throttle drum, CARBURETOR SEPARATION (’97 7 '98) The vacuum Loosen the synchronizanon adjusting screw‘ Chamber, H05! chamber and [515 can be sen/med wrmout ssparanng me carburetors. When separarmg the carburewrs, be care/u! nut to /059 the thlusl spring and synchronIZaI/on adjusring spnng 5-12 FUEL SYSTEM Separate the carburetors by removing the two at- taching screws. Remove the thrust spri ng, SPRING CARBURETOR DISASSEMBLY/ ASSEMBLY NOTE 0 Vacuum chamber, float chamber and jets can be serviced without separating the carburetors. ' Note the location of the each Carburetor parts so they can be put back into the original location. I Keep each carburetor’s parts separate from the others so you can install the parts in their original positions - For the following component inspections refer to the applicable pages. *Vacuum chamber (page 5715i *Floatchamber (97498: page 5717) {After '98: page 5-19) *Pilot screw (page 520) *Jets (page 520! 5-13 FUEL SYSTEM ’97 - '98: AIR CUTVOFF VALVE COVER DIAPHRAGM HOLDER CHAMBER COVER / U-RING " \ SPRING . NEEDLE JET HOLDER FLOAT CHAMBER FLOAT VALVE MAIN JET FLOAT After I98 ? I g if I L‘ CARBURETOR BODY \ ¢ 4 a \_ ,I, / ' AIR CUT~OFF VALVE COVER CHAMBER I , , , COVER V v SPRING ® /w® SLOW JET .§ HOLDER \g . SPRING I DEEDLE JET HOLDER/dag MAIN JET/v6 FLOAT VALVE as? FLOAT PISTON FLOAT PIN JET NEEDLE ACCELERATOR PUMP ARM/LIN KAGE ASSEMBLY I DIAPHRAGM/ROD SPRING PILOT SCREW ACCELERATOR PUMP COVER 5-14 FUEL SYSTEM VACUUM CHAMBER DISASSEMBLY Remove the four screws and vacuum chamber COVEI’. Remove the spring, and diaphragm/vacuum piston. inspect the vacuum piston for wear, nicks, scratches or other damage. Make sure the piston moves up and down freely in the chamber. SIBNADIA . Push the jet needle holder in and turn it in 90 degrees counterclockwise. CAUTION: Be careful "at to damage the diaphragm. Remove the jet needle holder, spring and jet needle from the piston. JET NEEDLE HOLDER JET NEEDLE SPFllNG 5-15 FUEL SYSTEM INSPECTION Inspect the needle for excessive wear at the tip, bending or other damage. Inspect the diaphragm for damage, fatigue or pin holes. Inspect the vacuum piston for wear or damage. Replace these parts it necessary. JET NEEDLE HOLDER Air will leak out of the vacuum chamber if the diaphragm is damaged in any wayreven a pin hole. JET NEEDLE SPRING ASSEMBLY Install the iet needle, spring and jet needle holder tothe vacuum piston. Push the jet needle holder in and turn it in 90 degrees clockwise. _ , ”Wig JET NEEDLE HOLDER Install the vacu um piston/diaphragm tn the cavity. Lift the bottom ml the vacuum piston with your finger to set the diaphragm lip in the carburetor body. NOTE Align the tab ofthe diaphragm with thecavity. NOTE Be careful not to pinch the diaphragm, and to keep the spring straight when installing the chamber cover by compressing the spring install the spring and chamber cover while the piston remains in place, Secure the cover with screws before releasing the vacuum piston. 5-16 FUEL SYSTEM lnstall and tighten the screws securely. FLOAT CHAMBER DISASSEMBLY ('97 ~ '98) Remove the screws, float chamber and O-ring. Remove the float pin, float and float valve. CAUTION: Handle alliets with care. Thay can easily be scored ‘ or scratched. Remove the main Jet, needle jet holder, slow jet and valve seat/filter. FUEL SYSTEM NOTE IThe pilot screws are factory pre-set and should not be removed unless the carburetors are over hauled. OThe pilot screw plugs are factory installed to prevent pilot screw misadjustment, Do not re- move the plugs unless the pilot screws are being removed. . Cover all openings with tape to keep metal parti- cles out when the plugs are drilled, Center punch the pilot screw plug. Center the drill point on the pilot screw plug. Drill through the plug with a 4 mm (5/32 inl drill bit. Attach a drill stop to the hit 3 mm 11/8 in) from the end to prevent drilling into the pilot screw. CAUTION: o Be careful not to drill into the pilot screw. - Bath pilot screws must be replaced even if only one requires it, for proper pilot screw adjust- ment lpage 5-29L Force a selfltapping 4 mm screw, lP/N 93903- 35410) into the drilled plug and continue turning the screw driver until the plug rotates with the screw. Pull on the screw head with pliers to remove the plug. Use compressed air to clean the pilot screw area and remove metal shavings. Turn each pilot screw in and carefully count the number of turns until it seats lightly. Make a note of thisto use as a reference 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 screw, spring, washer and O-ring. EA flagen . 5-18 FUEL SYSTEM DISASSEMBLY (After '98) Remove the bolt and disconnect the accelerator pump arm linkage. Remove the screws, float chamber and O-ring. Remove the float pin, flea and float valve. CAUTION, Handle all jet: with care, They can easily be scored at scratched. Remove the main jet, needle jet holder, slow jet and pilot screw. MAIN JET ELSA; PILOT SCREW 5-19 FUEL SYSTEM A worn or contaminated Valve does nol seat properly and will eventually None the carburetor. 0 Install the pilot screw and return it to its original INSPECTION FLOAT VALVE, VALVE SEAT Check the float valve and valve seat for scoring, scratches, clogging or damage. Check the tip of the float valve where it contacts the valve seat, for stepped wear or contamination, JETS Check the each jets for wear or damage. Clean the jets with non-flammable or high flash point solvent and blow open with compressed air. VALVE SEAT! FILTER Check the float valve seat and filter for grooves, nicks or deposits. PILOT SCREW Check the pilot screw for stepped wear or damage. Replace these parts if necessary. MAIN JET . " e/ SL WJET / h “a? O WASHER \ SPRING SPRING PILOT SCREW ASSEMBLY Install the main jet, needle jet holder, slow jet and valve seat/filter. Install the O-ring, washer, spring, pilot screw and new pilot screw plug (’97 ~‘98 models only). NOTE: position as noted during removal, OPerform pilot screw adjustment if new pilot screw is installed (page 5-29). 5-20 FUEL SYSTEM After ’98 SHOWN MAIN JET PILOT SCREW Hang the float valve onto the float arm lip. Install the float valve with the float in the carburetor body, then install the float pin through the body and float‘ FLOAT LEVEL NOTE‘ I Check the float level after checking the float valve and float. 0 Set the float level gauge so that it is perpendicuV lar to the float chamber face and in line with the main jet. Set the carburetor so that the float Valve just con— tacts the float arm lip. Be sure that the float valve tip is securely in Contact with the valve seat. Check the float level with the float level gauge. TOOLS: Carburetorfloat level gauge: 0740143010000 FLOAT LEVEL '97498: 7.0 mm (0.28 in) After '98: 18.5 mm (0.73 lnl If the level is out of specification, replace the float. 5—21 FUEL SYSTEM Inslall the new O-ring Into the float chamber groove. install the float chamber install and tigmen the screw securely. Install the accelerator pump arm linkage and ' "H WN (ightenihe bolt securely lAfier’SSl. A [er 98 5‘0 " AIR CUT-OFF VALVE DISASSEMBLY Remove the two screws, the ser plate and me air cut-off valve cover. NOTE: The air curoff valve cover is under spring pressure. Do n01 lose the spring and screws. 5-22 FUEL SYSTEM INSPECTION Check the diaphragm for deterioration, pin hole or other damage. Check the spring for deterioration or other damage. Check the diaphragm needle for excessive wear at the tip or other damage. Check the air vent orifice for clogging, Check the Urring for damage (’97 7 ’98). Replace the air cut off valve as an assembly, if necessaw. ASSEMBLY Assembly is ln the reverse order of disassembly. NOTE - Install the Urring with its flat side toward the ear- buretor body as shown (’977’98l. - Be careful not pinch the diaphragm. CARBURETOR BODY CLEANING CAUTION. - Cleaning the air and fuel passages with a piece of wire will damage the carburetarbody. 0 Remove the diaphragms to prevent damage ta than! befare using air to blow open passage. Disassembled the carburetor (page 5714i. Blow open all air and fuel passages in the carburer tor body with compressed air. Clean the fuel strainer in the float valve using come pressed air from the float valve seat side. 5-23 FUEL SYSTEM CARBURETOR REASSEMBLY ('97—'98) AIR TUBES JOINT SCREW \N JOINT PIPE FRONT CARBURETOR FUELTUBES JOINT PIPE 0 SUBVAIR CLEANER TUBE SVNCHRONIZATiON ADJUSTING SPRING Loosen the synchronization adjusting screw until there IS no spring tension. Instali the thrust spring between the ihronle links. Secure the carburetors tugether with the iwo screws, 5-24 FUELSVSTEN Install the synchronization spring and synchronize» SYNCHhONIZATION.’ tion adjusting screw. ‘ [)st ‘ ' INSPECT THROTI'LE OPERATION AS DESCRIBED BELOW: Open the throttle slightly by rotating the throttle valve, then release the throttle. Make sure that there is no drag when opening and closing the throttle. Turn the throttle stop control knob to align the rear cylinder carburetor throttle valve with the edge of the byrpass hole. Align the front cylinder carburetor throttle valve with the by—pass hole edge by turning the synchroV nization adjusting screw. SYNc Make sure the throttle returns smoothly. 5-25 FUEL SYSTEM CARBURETOR REASSEMBLY (After ’98) lCaIifornialype) T0 EVAP CAV CONTROL VALVE TO FUEL AUTO VALVE TO RADIATOR WATER TUBE All? VENTTUBE CARBURETOR INSTALLATION ('97 ~'98) Flame the wrres Install the starting enrichment (SE) valve and cable. and tubes properly (page 7-22) Install the fuel and alrtubes as shown. 5-26 lnstall the carburetor to the insulator. Tighten the insulator band screws securely. Connect the throttle cables to the throttle drumt install the throttle Imk cover and screw. TORQUE: 2 N-m (0.21 kgf-m,1.5lbf-ftl Install the followrng parts: 7A” cleaner chamber (page 5-15) iAir cleaner housing (page 5-5l iFueltaanage 277l Perform the following inspections and adjustment. 7 Pilot screw (page 5~25l *Carburetor synchronization (page 3-17) *Throttle grip free play (page 374) AEngine idle speed (page 3718) ACarburetor choke (page 376) After installation, turn the ignition switch ON and check the fuel line (or leakage. CARBURETOR INSTALLATION (After '98) NOTE Homer/re Wl/BS At the carburetor insulator installation, install the and WDES WOPBFIY insulator with the "CARE” mark facing the (page 1724). carburetor. Install the carburetor Insulator onto the carburetor by aligning its groove with the lug of the carburetor. Install the throttle cables to the throttle drum. lnstall the adjusters to the stay. FUEL SYSTEM 135,155 mm (0.53 D 61 inl “CARE” MARK FUEL SYSTEM Connect the water tubes. Connect the No. 11 tube lCalifornia type only/ After ’98: page 1-37l. Install the carburetor on to the inlet manifold by aligning the insulator groove with the lug of the inlet manifold, Tighten the insulator band screws. INLET MANIFOLD ALlGN iNSULATOR Adjust the throttle grip free play by tightening the adjusters lpage 36), Connect the water tube to the inlet manifold. Connect the No.5 tube (California type only/ After '98: page 1-37). 5-28 FUEL SYSTEM Connect the fuel tube. Connect the following tubes to the EVAP CAV N°’ ”TUBE CONTROL VALVE (California type only). 7 No. 6 tube v See page 1737 7N0. 10 tube Vacuum hose routing diagram/After ’98 Install the choke knob and tighten the nut. Install the throttle stcp control knob. Install the fuel tank (page 27). Install the link cover lpage 5-35). Perform the following inspections and adjustments *Pilot screw lpage 549) *Engine idle speed (page 3-I8I *Carburetor choke (page 3-6) After installation, check the fuel and water lines for leakage. PILOT SCREW ADJUSTMENT (’97 —'98I IDLE DROP PROCEDURE M I if the engine must be running to do some work, make sure the are: is well-ventilated. Never run the engine in an enclosed area. 0 The exhaust contains poisonous carbon monox- ide gas that may cause loss a! consciousness and may lead to death. _____-_____———( NOTE‘ _______l__————— 'Make sure the carburetor synchronization is withln specification before pilot screw adjust ment (97,95 only: page 3717). OThe pilot screw factory prerset and no adjust ment can be done unless it is replaced. - Use a tachometer with graduations of 50 rpm or smaller that will accurately Indicate a 50 rpm change. ._______.____—’ 1.Remove the pilot screw plugs lpage 5713). 2 Turn each pilot screw clockwise until it seats lightr Iy, then back it out to specification given. INITIAL OPENING: ‘I 1/4 turns out 5-29 FUEL SYSTEM CAUTlON: Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. 3. Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient. 4. Attach a tachometer according to its manufac- tures instructions. 5. Start the engine and adjust the engine idle speed to the specified rpm with the throttle stop control knob. IDLE SPEED: 1,200 : 100 rpm 6.Turn each pilot screw 1/2 turn out from the initial setting. 7.lf the engine speed increase by 50 rpm or more, turn each pilot screw out by successive 1/2 turn increments until engine speed does not increase. 8. Adjust the idle speed with the throttle stop screw, 9. Turn the rear cylinder carburetor pilot screw in until the engine speed drops 50 rpm. 10.Turn the rear cylinder carburetor pilot screw counterclockwise to the final opening from the position in step 9. FINAL OPENING: 1 turn out 11.Adjust the idle speed with the throttle stop screw. 12.Perform steps 9, 10 and 11 for the front cylinder carburetor pilot screw. 13.Drive new pilot screw plugs into the pilot screw bores with a 7 mm valve guide driver (P/N 079427 8230000l. When fully seated, the plug surfaces Will be recessed 1 mm. PILOT SCREW ADJUSTMENT (After ’98) IDLE DROP PROCEDURE M I I! the engine must be running some work, make sure the area is well-Ventilated. Never run the engine in an enclosed area. 0 The exhaust contains poisonous carbon monox- ide gas that may cause loss of consciousness and may lead to death. NOTE ~The pilot screw is factory prevset. Adjustment is not necessary unless the carburetor is overhauled or a new pilot screw is installed. - Use a tachometer with graduations of 50 rpm or smaller that will accuratery indicate a 50 rpm change. 5-30 FUEL SYSTEM .Turn the pilot screw With the pilot screw wrench clockwise until II seats lightly, and then back it out to the specification given. This is an intial setting prior to the final pilot screw adjustment. TOOL: Pilot screw wrench O7 LMA—MT8010A with 07PMA7M2201 ‘lA CAUTION: Damage to the pilot screw seat will occur if the pilot screw is tightened against the seat. INITIAL OPENING: 49 state/Canada type: 3 turns out Cariiomia type: 2 3/4 turns out 2. Warm the engine up to operating temperature. Stop and go riding for 10 minutes is sufficient. 3.Stop the engine and connect a tachometer according to the tachometer manufacturer’s instructions. 4. Start the engine and adjust the idle speed with the throttle stop control knob. IDLE SPEED: 1,200 i 100 rpm 5.Turn the pilot screw in or out slowly to obtain the highest engine speed. 6.Readjust the idle speed with the throttle stop control knob. 7.Turn the pilot screw In until the engine speed drops 50 rpm. 8.Turn the pilot screw conterclockwise to the final opening from the position in step 7. FINAL OPENING: 3/11 turns out 9.Readjust the idle speed with the throttle stop screw. PILOT SCREW 5-31 FUEL SYSTEM FUEL PUMP ('977’98) WW Gasnline is extremely flammable and is explosive under certain conditions. KEEP OUT OF HEACH OF CHILDREN. SYSTEM INSPECTION Remove the seat lpage 272). Turnthe lgnition switch OFF. Disconnect the fuel cut relay 3P connectér and connect the voltmeter at the 3P connector wire harness side. CONNECTION: Black I‘ l - body ground (7) Turn the ignition switch ON. There should be battery voltage: If there is no voltage, check for an open Circuit or loose connection in Black wire. If there is battery voltage, check for continuity in the Black/Blue wlre. Check for continuity between the Black/Blue wire and ground at the 3P connector wire harness side. CONNECTION: Black/Blue , body ground STANDARD: No continuity If there is continuity, replace the fuel cut relay. If there is no continuity, short the termlnals of the 3P connector wire harness side wlth the suitable jumperwire. SHORT TERMINALS: Black/Blue » Black 3F CONNECTOR (*l: GROUND BLACK/BLUE GROUND 3P CONNECTOR JUMPER WIRE 5—32 Disconnect the fuel pump 2P (White) connector and connect the voltmeter at the 2P (Whitel connector wrre harness side. CONNECTION: Black/Blue (+l - Green l“) Turn the ignition switch ON and measure the voltage at the 2P (Whitel connector. STANDARD: Battery voltage If there is no voltage, check for an open circuit or loose connection in Black/Blue and Green wires. If there is battery voltage, replace the fuel pump. DISCHARGE VOLUME INSPECTION Remove the seat (page 2A2l. Disconnect the fuel cut relay 3F connector. Short the Black and Black/Blue terminals with a suitable jumperwire. Disconnect the fuel pump outlet tube from the tube joint. Hold a graduated beaker under the fuel pump outlet tube. Turn the ignition switch ON and let the fuel flow into the beakerfor 5 seconds, then turn the ignition switch OFF. Multiply the amount in the beaker by 12 to determine the fuel pump flow capacity per minute. FUEL PUMP FLOW CAPACITY: 800 cm“ (27.1 US 02 , 28.2 Imp oz) min/minute REMOVAL Remove the fuel tank (page z-Al. Disconnect the fuel pump 2P (white) connector and remove the fuel pump wire from the clamps. FUEL SYSTEM 2P (WHITE) CON NECTOR FUEL SYSTEM Disconnect the fuel tubes (pump»to-fllter, pump-to- carburetor). Disconnect the fuel pump tube. Remove the fuel pump from the pump bracket. INSTALLATION NOTE: Route the wire harness and tubes properly lpage ‘l-ZSl. Connect the fuel pump tube to the fuel pump. Install the fuel pump to the pump bracket. Connect the fuel tubes lpumprtonilter, pumprtoV carburetor). NOTE‘ Connect the fuel tubes lpump»to»filter) to fuel pump ”IN" markside. Connect the fuel pump 2P (white) connector and install the fuel pump wire to the clamps. Install the seat lpage 2»2l. FUEL FILTER ('97 7'98) REMOVAL Remove the seat (page 2-2). Disconnect the fuel tube (pumprtovfilterlu Remove the fuel filter and rubber cushion from the filter bracket. Disconnect the fuel tubes from the fuel filter. Remove the rubber cushion from the fuel filter. Check the fuel filter for damage or contamination. Replace the fuel filter if necessary. F PUMPTUBE UELTUBES F PUMPTUBE UELTUEES 2P (WHITE) CONNECTOR 5-34 FUEL SYSTEM INSTALLATION lnstallation is in the reverse order of removal. NOTE. At fuel filter and rubber cushion installation, install the filterwith the “a” mark facing thefuel pump. lnstall the seat (page 2~2i. FUEL AUTO VALVE (After '98) INSPECTION Wm— Gasoline is extremely flammable and is explosive under certain conditions. KEEP OUT OF REACH OF CHILDREN. Remove the fuel tank mount bolt (page 24). Disconnect the air tube and fuel (fuel auto valvertoV carburetor) tube. Connect the vacuum pump to the air tube joint. Apply the vacuum pump and inspect the fuel flow from the fuel tube. REMOVAL Remove the fuel tank (page 273). Remove the screw and the cover. Remove the choke knob and throttle stop control knob (page 5711). Disconnect the fuel tube and air tube. Remove the two bolts and washer. Remove the fuel auto valve. FUEL SYSTEM DISASSEMBLY Remove the screws' clamp and the diaphragm cover. NOTE, The diaphragm cover is under spring pressure, Do not lose the spring and screws. Remove the diaphragms and spring Check the diaphragms for damage or pin holes. NOTE: Be careful not to damage the diaphragms. ASSEMBLY Install the diaphragms and spring. install the diaphragm cover and damp, Tighten the screws, 5-36 FUEL SYSTEM INSTALLATION mummmé .. BdL/TswA-SHER . Install the fuel auto valve to the inlet manifold. Install the washer and tighten the two bolts. Connect the air tube and fuel tube. Install the choke knob and throttle stop control knob (page 5729). Install the cover and tighten the screw to the specified torque, TORQUE: 2 N-m (0.21 kgf-m , 1.5 Ibf-fll Install the fuel tank (page 277). HIGH ALTITUDE ADJUSTMENT IU.S.A. ONLY/'97 V '98) NOT When the vehicle Is to be operated continuously above 2,000 m (6,500 Ieetl the carburetors must he readjusted as follows to improve driveability and decrease exhaust emissions. Remove each pilot screw plug (page 5713). Warm up the engine to operatlng temperature. Stop and go driving for 10 minutes is sufficient, ,’ Turn each pilot screw to the specification shown PILOT SCREW below. HIGH ALTITUDE SETTING: 1/2 turn in from low altitude setting Adjust the idle speed to 1,200 : 100 rpm, with the throttle stop control knob. Drive new pilot screw plugs into the pilot screw bores (page 5721). NOTE This adjustment must be made at high altitude to ensure proper high altitude operation. 5-37 FUEL SYSTEM Do not attach ms label to ally part that can be easily removed rrom the vehicle. Attach a vehicle Emissron Control Information update Label onto the inside 01 the Ian side cover as shown. Sea SLfi 132 for information on obtaining the label. mm Sustained aparatinn n! In .Itlludu lower then 1500 m {5,000 [ml with the carburetors ldiustad for high lkirude m.y emu the engine to idle roughly nnd angina nuy cull in traffic and may clusa enginn damage due to overheating. When the vehicle is to be operated continuously below 1,500 m (5,000 feeti, turn each pilot screw to the specification below, its original, low altitude, position. LOW ALTITUDE SETTING: 1/2 turn out from hlgh altitude setting Adjust the idle speed to 1,200 i 100 rpm with the throttle stop control knob. Drive new pilot screw plugs into the pilot screw bares (page 5-21). Be sure to make these adiustments at low aItitucIe. Remove the VehicIe Emission Control Update Labei that attached to the inside or the left side cover after adjusting Ior the Iow altitude. HIGH ALTITUDE ADJUSTMENT IU.S.A. ONLY/After '98) NOTE when the vehicle is to be operated continuously above 2,000 m (6,500 feet) the carburetor must be readjusted as follows to improve driveability and decrease exhaust emissions. Warm up the engine to operating temperature. Stop and go driving for 10 minutes Is sufficient. Turn the pilot screw to the specification shown below. TOOLS: Pilot screw wrench 07LMA-MTBD’IOA with F'MA-MZZO1 1A HIGH ALTITUDE SETTING: 1/2 turn in from low altitude setting Adjust the idle speed to 1,200 i 100 rpm, with the throttle stop control knob. '977'93 SHOWN: VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL VENICLE EMISSION convent lurORIIArluII UPDAIE rItOIIDA Moron cairn ms VEHICLE NAs IEEII ANUS'IED ro IMPROVE :ulsstou CONTROL PERFORMANCE WHEN oPEaAtED AT mutt ALYITIIDE, ALTIrUI'IE PERFORMANCE AnJustlle IIIs'rnucrloNs ARE AVAILABLE AT YOUR AanoItIzED IIaltnA DEALER. PILOT SCREW “fifty-mi ‘v‘ ‘h r PILOT SCREWWHENCH '99 SHOWN: VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL 5-38 Revised October 1999, lee? - 2mm stoochD @1999 Amencan Honda Motor Co . Inc VAII Rights Resemed Msv 8617 (9910i Do not attach the label to any part that can be easily removed from the vehicle NOTE This adjustment must be made at high altitude to ensure proper high altitude operation. Attach a Vehicle Emissian Control lnformation update Label as shown. See SL3 132 for information on obtaining the label. m— Susm‘ned opsratian at an altitude lower than 1,500 m (5,000 feet] with the carburetor adjusted for high nltiluda may cause the engine to idle roughly and engine mny stnll in traffic and may cause angina damage due in overheating. When the vehicle is to be operated continuously below 1,500 m 15,000 teetl, turn the pilot screw to the specification below, its original, low altitude, position. LOW ALTITUDE SETTING: 49 state/Canada type: 2 1/2 turns out Calilornia type: 2 1/4 turns nut from high altitude setting. Adjust the idle speed to 1,200 1 100 rpm with the throttle stop control knob. Be sure to make these adjustments at low altitude. Remuve the Vehicle Emission Control Update Label that attached to the inside of the left side cover after adjusting Ior the low altltude. EVAPORATIVE EMISSION PURGE CONTROL VALVE INSPECTION (CALIFORNIA TYPE ONLY) rhe evaporairve emission purge cumrol valve should be inspected 1/ ho! restart ls dllllcult The E VAP PUHGE CONTROL VAL V5 is located under the fuel tank. m w . '99 m Alter '99 Check all fuel tank, Evaporatlve Emission Purge Control Valve (EVA? PURGE CONTROL VALVE), and evaporative emission canister hoses to be sure they are not kinked and are securely connected. Replace any hose that shows signs of damage or deterioration. Disconnect the EVAP FURGE CONTROL VALVE hoses from their connections and remove the EVAF PURGE CONTROL VALVE from its mount. Refer to the routing label on the inside of the leftside cover for hose connections Refer to the routing label on the inside uI the left side cover Iur hose connection Refer to the routing iebei on the frame pipe under the fuel tank for hose connection. FUEL SVSTEM After ’99 VEHICLE EMISSlON CONTROL INFORMATION UPDATE LABEL VEHICLE Eutsslou CONTROL insanumuu watts -NDNDA ua‘ron co..LrD this VEHICLE ms BEEN Autumn to IIIPnavE Eulsslou CONTROL PERFORMANCE VINE" UPERATEU Ar HIGN thrunE. Aumm: PERFORMANOE ADJUSTMENT INSTRUCTIONS ARE AVAILAELE tr Inuit Aurnohlztn haunt DEALER. VICWII NOSE Mllllllli‘ DIAGRAM mm ”mum l ’97i'98: EItIflIAlllt min __4 LAIIFMIIA vtlim l l i l “l \ “mm x X r m 1 \sm mm; W VACUUM HOSE IIDUIIIIG I'llIGlIAI min: Hlltl 7.4;, Eltlattviv: rlliti uwnmt mine FUEL rm guwoummvé After ’98: i l RBVlSSd‘ Octnber 1999. 1957 .2000 Weave/CD @1999 American Honda MaiarCa inc -All Rights Reserved msv 55w (99in) 5-39 FUEL SYSTEM Connect the vacuum pump to the No. 10 hose that goes to the right carburetor body ('97—’98i/goes to the 3rway joint (After '98i, Connect the pressure pump to the air vent port of the EVAP CAV CONTROL VALVEV While applying the vacuum to the EVAP CAV CONr TROL VALVE No. 10 hose that goes to the right carburetor body ('977'98i/goes to the (£7an joint (After '98), pump air through the EVAP CAV CON» TROL VALVE and out the hose that goes to the carburetor air joint pipe i’97i’98)/goes to the carburetor body [After '95). TOOL: Vacuum/pressure pump A937-041-XXXXX or Vacuum pump ST»AH»260-MC7 Pressure pump ST-AH-255vMC7 Plug the hose that goes to the carburetor air joint pipe ('977’98ilgoes to the carburetor body (After 'SSi White applying vacuum to the EVAP CAV CON- TROL VALVE No. 10 hose that goes to the right carburetor body ('97v '98)/goes to the 37way joint (After ’58), apply air pressure. Remove the pumps, instaii the EVA? CAV CONv TROL VALVE on its mount, route and reconnect the hoses according to the routing iabel. TOOL: Vacuum/pressure pump A937-04‘i-XXXXX or Vacuum pump ST-AH-ZBOVMC7 Pressure pump STVAHVZSSVMU BLOCKED TUBE 5-42 NOTE COOLING SYSTEM SYSTEM FLOW PATTERN '97"98: 6-0 6. UUULINU 5Y5 I thI SERVICE INFORMATION 6-2 THERMOSTAT 6-7 TROUBLESHOOTING 6-3 RADIATOR/COOLING FAN 6-9 SYSTEM TESTING 6-4 WATER PUMP 6-15 COOLANT 6—5 RADIATOR RESERVE TANK 6-18 After ’98: 6-1 COOLING SYSTEM SERVICE INFORMATION GENERAL “WARNING 0 Wait until the engine is cool before slowly removing the radiator cap. Removing the cap while the engine is hot and the coolant is under pressure may cause serious scalding. - Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. , If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. 7 If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. 7 If any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. 0 KEEP OUT OF REACH OF CHILDREN. 0 Use only distilled water and ethylene glycol in the cooling system, A 50—50 mixture is recommended for maximum corrosion protection. Do not use alcoholrbased antifreeze or an antifreeze with self sealmg properties. 0 Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. 0 All cooling system services can be done with the engIne In the frame. 0 AVOId spilling coolant on painted surfaces U After servicing the system, check for leaks with a cooling system tester. - Refer to Section 19 for fan motor sztch and thermosensor ('97 "'DOl/thermo swrtch (Alter '00) Inspection. SPECIFICATIONS ITEM SPECIFICATIONS .4 Impqt) Coofig capacity I‘ladiator and engIne Reserve tank 7,7,, Radiator cap relief pressure Thermostat 88* 127 kPa (0. 9*13 kgf/Cm’, 12. 8 , 18 psi) 80 84 "C (176*183 ”F) ’ 95 “C (203 °Fi 8 mm (0.3m) I'I'Ill’llmum 50 "/n mixture with soft water Begin to open > Fully open Valve lift Standard coolant concentratIon TORQUE VALUES Radiator mounting bolt 9 N-m (0.9 kgf‘m,6.51bf-lt) Radiator grille mounting screw Thermostat bracket bolt Thermostat housing cover bolt Thermo sensor (’97 7’00) Thermo switch (After ’ODl Water hose band screw Fan motor switch TOOLS Pressure pump 9 N-m (0.9 kgfvm , 6.5 (bf-ft) 10 N-rrt (1.0 kgf-m , 7 Ibfrfl) 10 N-m (1.0 kgf-m,7 lbfvtt) 10 N-m (1.0 kgf-m , 7 |bf~ft) 8 N~m (0.8 kgf-m , 5.8 (bf-fl) 7 N«m (0.7 kgf-m , 5.1 [bf-It) 18 N-m (1.8 kgI-m ,13lbf-i‘t) Apply sealant to the threads NEW Apply sealant to the threads _ Apply sealant to the threads Equivalent commercially available —-———_——_— 6-2 0". Revised: August. 2000, '97 -'01 VTSDOC/CD ©2000 Amstican Honda Motor C0,. (no. - All Rights ReseNed MSV 5969 (0008) COOLING SYSTEM TROUBLESHOOTING Engine temperature too high - Faulty tern perature gauge or thermo sensor (Section 19) ' Faulty radiator cap - lnsufficient coolant - Passages blocked in radiator, hoses or waterjacket -Air in system - Faulty waterpump - Thermostat stuck closed - Faulty cooling fan motor ‘ Faulty fan motor switch Engine temperature too low - Faulty temperature gauge or thermo sensor Section 19) ‘ Thermostat stuck open - Faulty cooling fan motor switch Coolant leaks - Faulty water pump mechanical seal . Deteriorated Orring - Damaged or deteriorated gasket - Loose hose connection or clamp > Damaged or deteriorated hose ‘ Faulty radiatorcap COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) “NE—.— 59 sure the engine is cool before remaving the cap or yau may be severely scalded. Remove the steering covers (page 2-3). Remove the radiator cap. Check the coolant gravity using a hydrometer. STANDARD COOLANT CONCENTRATION: 50 % Look for contamination and replace the coolant if necessary. Coolant specific gravity chart Coolanttemperamre “C 1°F1 ‘ 1 ‘ 1 ‘ 1 1 * ’— 0 5 10 15 20 25 30 35 . 40 45 50 Cooiamragio We”? \ 1321.141) 1501.039) 168) 1771 (861 (95) (10411113110221 fl 5 100911.009 1.008 @9071th 1.006. 005 10034001 0. 10 1.018 1017 1.0171015 1.015713014111313 1.011 1.003 1.0071005 15 1,028 1.02711.02§ 102511.024 1.022 1.020 101811.016 1.0141012 20 1.036 1.035‘1034 1.033 1.031 1.029 1.027 1.9275 17.023 1.021 1.019 25 1.045 1.044 1.043 1.042 1.040 1.038 1.035 1.034 1.031 1.023 1.025 30 1.053 1.052 1.051 1.049 1.047 1.045 1.043 1341:1038 1.035 1.032 35 1.063 1.062 1.050 1.058 1.055 1054 1.05201045 104611.043‘1040 407 . 107211.070 1.058 1.066 1.054 1.062 10591105611053 105011.047 ,ii 45 7 1.0801078 1.076 1.074 1.072 1.069 1.0601063‘1060 105710534 50 1.036 1.054 1.082 L080 1.07Zl074 1.071 1.068 1.005 52 1.059 . 55 11.095 109311.091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.067 60 11.100 139511.0951.0521108910361083 1.080 1.077 1.074 1.071 Before installing the sap In the tester, wet the sealing surlace. COOLANT RADIATOR CAP/SYSTEM PRESSURE INSPECTION M The engine must be cool before removing the radiator cap, or severe scalding may result. Remove the steering covers (page 2-3). Remove the radiator cap. Pressure test the radiator cap. Replace the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. it must hold specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: 88—127 kPa 103*13 kgf/cm2,12.8718 psi) Pressure the radiator, engine and hoses, and check for leaks. CAUTION: Excessive pressure can damage the cooling system components. De not exceed 127 kPa {1.3 kgf/cm’, 18.512517. Check the following components if the system will not hold specified pressure for at least 6 seconds. *AII hose and connections *Water pump installation *Water pump seal lfor leakage) , Deformed radiator filler neck m___ 0 Radiator coolant is toxic. Keep it away from eyes, mouth, skin and clothes. - If any coolant gets in your eyes, rinse them with water and consult a doctor immediately. 7 If any coolant is swallowed, induce vomiting, gargle and consult a physician immediately. 7 if any coolant gets on your skin or clothes, rinse thoroughly with plenty of water. I KEEP OUT OF REACH OF CHILDREN. COOLING SYSTEM QQGLING SYSTEM TESTEFb LVA [WELE ' BASE SOLUTIONl LOW MINERAL OR DlSTlLLED WATER ANTIFREEZE SOLUTION /' lETHYLENE GLYCOL‘ / COOLANT 6-5 COOLING SYSTEM NOTE - The effectiveness of coolant decreases With the accumulation of rust or if there is a change in the mixing proportion during usage. Therefore, for best performance change the coolant regularly as specified In the maintenance schedule. 0 Mix only distilled, low mineral water with the antifreeze. RECOMMENDED MIXTURE: 50*50 (Distilled water and antifreeze) REPLACEMENT/AIR BLEEDING M The engine must be cool before removing the radiator cap, or severe scalding may result. NOTE When filling the system or reserve tank with a coolant (checking the coolant levell, place the motorcycle in a vertical position on a flat, level surface. Remove the steering covers (page 273). Remove the radiator cap. Dram the coolant from the system by removing the drain bolt and sealing washer on the water pump cover. Remove the rear cylinder coolant drain bolt and drain the coolant using a funnel as shown. Reinstall and tighten the drain bolt securely with a new sealing washer. Remove the reserve tank (page 648). Remove the reserve tank cap from the reserve tank and drain the reserve coolant. Empty the coolant and rinse the inside of the reserve tank with water. 6-6 COOLING SYSTEM Install the reserve tank (page 6-1Bi. Usrng the filler opening, fill the system with the recommended coolant upto filler neck. Remove the reserve tank cap and fill the reserve tank to the upper level line. Bleed air from the system as follows: 1, Shift the transmission into neutral. Stan the engine and let it idle for 2 7 3 minutes. 2. Snap the throttle 3 7 4 times to bleed air from the system. 3. Stop the engine and add coolant up to the filler neck. Reinstall the radiator cap. 4. Check the level of coolant in the reserve tank and fill to the upper level if it is low. THERMOSTAT REMOVAL Remove the followrng: , Fuel tank ipage 274) *Air cleaner housing (page 574) 7 Drain the coolant ipage 6~6). Remove the thermostat housing and radiator filler mounting bolts. Disconnect the siphon tube from the radiator filler. Disconnect the upper radiator hose at the radiator and remove the filler and radiator hose from the frame. Remove the bolts and thermostat housing cover. lit-flit COOLING SYSTEM Remove the thermostat from the I’lDUSlI’Ig. Coolant temperature, thermosensor inspection and removal (page 19-13). INSPECTION 'Wear insulated gloves and adequate eye protection. IKeep flammable materials away from the electric heating element. NOTE: I Do not let the thermostat or thermometer touch the pan, or you will get false readings, I Replace the thermostat it valve stays open at room temperature, or if it responds at tempera tures other than those specified. Visually inspect the thermostat for damage. Heat the water with an electric heating element to operating temperature for 5 minutes. Suspended the thermostat in heated water to check its operation. THERMOSTAT BEGINS TO OPEN: 80 ' 84 “C l’l76" 183 ”Fl VALVE LIFT: 8 mm l0.3 in) minimum at 95 ”C1203 ”Fl INSTALLATION Install the thermostat into the housing. NOTE‘ Install the thermostat with its hole facing up and fit it properly In the housing. THERMOSTAT THERMOMETER COOLING SYSTEM Install a new O-ring on the housing cover and install the housing cover onto the housing Be sure to secure install and tighten the thermostat housing Cover the theimustal mounting bolts to the specified torque. gmund wlre with the cover TORQUE: 10 N-m l‘l.0 kgfim , 7 Ibf-ft) mounting ball as shown Install a new Orring on the radiator filler, and connect the upper radiator hose and siphon tube to the radiator filler. Install the radiator iiller onto the thermostat housing, Tighten the filler and thermostat housing mounting bolts. Install the following: *Air cleaner housing lpage 575) *Fuel tank (page 2»7l Fill and bleed the cooling system (page 6-7l. RADIATOR/ COOLING FAN CAUTION: Ba caraful nut to damage the radiator fins. REMOVAL Drain the coolant {page 676). Remove the fuel tnak lpage 2-4). Disconnect the fan motor 2P lblackl connector. COOLING SYSTEM Disconnect the horn wires and remove the horn mounting bolt and horn 1'97498)‘ Remove the radiator mounting bolt. Loosen the hose band and disconnect the iower radiator hose from the radiator. '977 '98. Unhook the radiator mount rubbers from the frame stays. Unclamp the hose band and disconnect the upper radiator hose from the radiator‘ Remove the radiator. After‘QB :thhook the radiator mount rubbers fromthe frame fl VS- J \ Loosen the hose band and disconnect the upper radiator hose, Unclamp the tube band and disconnect the water tube. Remove the radiator. 6-10 COOLING SYSTEM DISASSEMBLY Remove the radiator grille mounting screw and radiatorshroud GRILLE Discunnect the fan motor switch connector. . CONNECTOR Remove the Wire: from the clamp. ' Remove the bolts and ground terminal. Remove the cooling fan assembly from the radiator. Remove the nut and cooling fan‘ 6-11 COOLING SYSTEM Remove the nuts and fan mutorfrom the shroud. The fan motor switch removal and inspecfion procedure is described an page 19-12. ASSEMBLV RADIATOR GRILLE FAN MOTOR SHROUD RADIATOR Insta/l {he ran InstaH the fan momma the shroud. motor to the shroud wrrh (he dram tube d/rec- tron as shown MAINTUBE 6-12 COOLING SYSTEM install and lighten the nuts securely. lnsiall the caniing fan onto the motor shaft by aligning the ilaisuriaces. Tighten the nut securely. install the cooling fan assembly to the radiamr. Tighxen the bolts securely with the ground terminal. TERMINAL COOLING SYSTEM Connect the fan motor swnch connector. ‘ ' " 1 CONNECTOR Route the ground wire and fan motor switch wire properiy, clamp the wires. Install the radiator grilie. install and tighten the screw to the specified torque. TORQUE: 9 N-m (0.9 kgf:m , 6.5 lbf-ftl INSTALLATION 977'98' Connect the upper radiator hose and clamp the radiator hose band to the radiator. Hook the radiator mount rubbers to the frame stays. After 98. Connect the upper radiator hose and tighten the radiator hose band screw. Connect the water tube and clamp the water tube band Hook the radiator mount rubbers to the frame stays. 6-14 COOLING SYSTEM Coonect the lower radiator hose and tighten the radiator hose band screwto the specified torque. TORQUE: 7 N-m (0.7 kgfvm , 5.1 lbf-ttl Install and tighten the radiator mounting bolt to the specified torque. TORQUE: 9 N-m (0.9 kgfvm , 6.5 lbf-Ftl |nsta(l the horn and tighten the mounting bolt to the specified torque. TORQUE: 26 N-m (2.7 kgl-m , 20 lbf-ft) Connect the horn wires. Connect the fan motor 2P (blackl connector. install the steering covers (page 2-3). Install the fuel tank (page 24). Fill and bleed the cooling system (page 6—7l. WATER PUMP MECHANICAL SEAL INSPECTION NOTE: The water pump cover and O-ring can be removed with engine in the frame. Inspect the telltale hole for signs of coolant leakage. If there is leakage, the mechanical seal is defective and the water pump assembly must be replaced. COOLING SYSTEM REMOVAL Remove the englne from the frame (section 7). Remove the water pump caver mounting bolts and cover. Remove the Orring and dowel pins from the water pump assembly and disconnect the water hose. Do not Remove the water pump and Orrlng from the crank disassemble (he case, water pump Rep/acemepump INSPECTION as an assembly if n /5 damaged, Check the water pump for mechanical seal leakage and bearing deterioration. Replace the water pump as an assembly ii necessary. 6-16 COOLING SYSTEM INSTALLATION @‘5 §p O-RING i , Q121@ WATER PUMP COVER Alter ’98 WATER PUMP Apply a coat of clean engine oil to a new Orring and install it in the water pumpshaft housing groove, Align the water pump shaft groove with the oil pump shaft and insert the water pump into the crankcase. Connect the water hose to the water pump assembly and clampthe hose band securely. Apply a coat of clean engine oil to a new Orring and install it around the impeller housing. Install the duwel pins, Install the water pump coverto the water pump. COOLING SYSTEM Install and tighten the cover bolts securely. Install the engine in the frame (section 7!. Fill and bleed the cooling system (page 6-7). Fill the engine with the recommended engine oil lpage 344). Check the cooling system for leakage, RADIATOR RESERVE TANK REMOVAL/INSTALLATION The radiator Raise and support the motorcycle rear frame using reserve tank can a hoist or jack under the engine. be serviced with the rear wheel in CAUTION: the swingarm. Do not suppart the motorcycle using oil filter. Remove the evaporative emission canister (California type only). Piace a suitable container under the siphon tube ioint of the reserve tank. Disconnect the radiator siphon tube and overflow tube at the reserve tank. Remove the reserve tank mounting bolt, filler mounting nut and reserve tank, Installation is in the reverse order of removal. Fill the reserve tank with coolant (page 677l. 6-18 MEMO ENGINE REMOVAL/INSTALLATION ’97 7 ’98: 54 N~m (5.5 mm , 4o lbf-fil 54 N-m15.5 kgfvm,401bf‘m 26 N-m (2.7 kgf‘m , 20 Ibflft) 1o N-m (1.0 kgflm, 7 [bf-ft) 12 N-m11.2 kgf-m, 39 N-m (4.0 kgfvm , 29 lbf-fl) 9 Ibf-fi) 7-0 7. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION 7-3 ENGINE INSTALLATION 7-9 DRIVE SPROCKET REMOVAL 7-4 DRIVE SPROCKET INSTALLATION 7-14 I ENGINE REMOVAL 7-5 I After ’ 98: 27 N-m (2.8 kgf-m , 20 Ibf-fth 55 N1m15.6 kgf‘m,41lbi-ft) 10 N-m (1.0 kgf-m. 7‘bf-h) I 12N-m(1.2kgf-m, W/ 9mm) ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL - A floor jack or other adjustable support is required to support and maneuver the engine, CAUTION: Do not support the engine using the oil filter. 0 When removing/installing the engine, cover the frame around the engine with tape beforehand for frame protection. 0 The following components can be serviced with the engine installed in the frame. sAlternator (Section 9) *Camshaft (Section 10) ACarburetor (Section 5) ' Clutch/gearshift linkage (Section 8) —-Front cylinder (Section 1 I) “From cylinder head (Section 10) *lgnition pulse generator (Section 17) 7 Starter motor/starter clutch (Section 18) I The following components require engine removal for service. 7Cylinder/piston (Section 11) *Crankshafl (Section 12) *Oil pump (Section 4) *Rear cylinder (Section 11) *Rear cylinder head (Section 10) — Shift fork, shift drum and gearshift spindle (Section 12) *Transmission (Section 12) *Watev pump body (Section 6) ' After engine installation, adjust the following. *Clutch cable (page 348) 7 Drive chain (page 3-20) *Throttle cable (page 3-4) SPECIFICATION 7.. ITEM SPECIFICATIONS Engine dry weight VTSODC ’97 61.0 kg (134.5 lbs) After '98 62.0 kg (136.7 lbs) VT600CD 64.0 kg (141.1 lbs) Engine oil capacity , , , _ W 3.? 053.0 US qt, 2.5 Imp qt) Coolant capacity 1.612(1.7 USot,1.4|moqt) 7-2 ENGINE REMOVAL/INSTALLATION TORQUE VALUES Len rear cover bolt Drive sprocket setting plate boli Clutch cable holder bolt Gearshift pedal pinch bolt Fompeg bracket bolt Swingarm pivot nut Front engine mounting boil (upperi 97,93. Rear engine mounting boi: Engme bracket butt (front) (reari Afler '93: 12 Nm (1.2 kgf-m , 9 lbf-ft) 10 N«m (1.0 kgf-m , 7 lbf-fi) 12 N‘m (1.2 kgf-m , 9 lbf-ft) 12 N-m (1.2 kgf-m , 9 ibf-fzi 39 N«m (4.0 kgf-m , 29 Ibf-ft) 88 Nm (9.0 kgf-m , 65 Ibfvfl) 5A N-m (5.5 kgf-m , 40 lbf-fli 55 N-m (5.6 ka-m , 41 ibV-fli 54 N-m (5.5 kgf-m, 401bf-fli 55 Nvm (5.6 kgf—m,41lbf-fti 54 N-m (5.5 kgf‘m , 40 Ibf-ft) 55 N-m (5.6 kgf-m , A1 Ibf-ft) 26 N-m (2.7 kgf-m , 20 Ibf-ft) 27 NW! (2.8 kgf-m , 20 |bf>ft) 26 N-m (2.7 kgf-m , 20 Ibf-fli 27 N-m (2.8 kgf:m , 20 |bf~fti 7-3 ENGINE REMOVAL/INSTALLATION DRIVE SPROCKET REMOVAL Loosen the rear axle nut, Loosen both look nuts and turn both adjusting balls as necessary. Push the rear wheel forward fully, creating maximum drive chain slack. Remove the bolt, clip, washer and left rear cover. Remove the drive sprocket setting plate bolts. Align the drive sprocket setting plate teeth and countershaft teeth, then remove the drive sproket setting plate. ENGINE REMOVAL/INSTALLATION Remove the drive sprocket. ENGINE REMOVAL CAUTION: Do not support the engine using the oil filter. NOTE. - Support the motorcycle safety stand or a hoist. OTurn the ignition switch OFF and disconnect the battery ground (*(cable (page 165). t A floor jack or adjustable support is required to support and maneuver the engine. The jack height must be continually adjusted to relieve stress for ease of bo(t removal. Drain the engine oil (page 344i and the radiator coolant (page 6-6(. Disconnect the battery negative cable from the batteryterminal. Remove the following: *Fuel tank (page 2-4) *Air cleaner housing (page 5-4) ~Air cleaner chamber (page 5-7) >Carburetor [page 5710) iExhaust pipe/muffler (page 271“ 7 Drive sprocket (page 7-4) Disconnect the oil pressure and neutral switch Wires from the switch terminals and free the switch wire harness from the engine and frame. 7-5 ENGINE REMOVAL/INSTALLATION Remove the nuts and diseonnec! the starter mokor cable and ground cabie from the staner motor. Remove the clutch cable holder bolt and disconnec‘ (he dutch cable from the clutch lifter arm. Remove the right footpeg bracket bolls. Remove the right ioo‘peg and rear brake pedal. Disconnect the ignixion pu‘se generator wire 4P (Wni‘eD connector and free the wire harness from the engine and frame, , :fl 7-6 ENGINE REMOVAL/INSTALLATION Disconnectthealternatorwire3P(White)connector . WGEWNE R and free the wire harness from the engine and frame. Loosen the radiator hose band screw and remove the lower radiator hose (radiatorrtorwater pumpl. Remove the radiator mounting bolt. ’97’983 Disconnect the water hoses [thermostat housing to»cy|inder heads) from the cylinder heads (page 1075). Place a floor jack or other adjustable support under the engine. CAUTION' Du nut suppnrt the engine using the oil filter. This may break the oil filter mount resulting in crankcase replacement, NOTE The jack height must be continually adjusted to relieve stress for ease of bolt removal. ENGINE REMOVAL/INSTALLATION After '93: Remove the water tube from the rear cylinder. Remove the bolts and the inlet manifold Unclamp the hose bands and disconnect the water hoses. Disconnect the engine breather tube. Place a floor jack or other adjustable support under the engine. CAUTION: Do not support the engine using the oil filter. This may break the ail filter mount resulting in crankcase replacement. NOTE‘ The jack height must be continually adjusted to relieve stress for ease of bolt removal. Remove the from upper engine mounting bolt/nut (10 mm) and collar. Remove the front upper engine bracket bolts (5 mm) and bracket. Remove the from lower engine mounting bolt/nut (10 mml. Remove the from lower engine bracket bolts (8 mml and bracket. 7-8 ENGINE REMOVAL/INSTALLATION Remove the rear engine mounting bolt/nut 110 mm). Remove the rear engine bracket bolts (8 mm) and bracket. Remove the swingerm pivot bolt caps. Remove the swingarm pivot bolt, nut and collars. CAUTION: During engine removal, hold the engine securely and be careful not to damage the frame, engine and radiator finst Remove the engine from the right side of the frame. ENGINE INSTALLATION CAUTION: Carefully align the mounting paints with the jack to prevent damage to engine, frame, wires and cables. NOTE' - Loosely install all the engine mounting bolts and nuts, then tighten the bolts and nuts to the specified torque. IAt engine installation, temporarily install the drive chain to the gearshift spindle. OBe sure to install the mounting collars and swingarm dust seals in their correct positions. Use a floor jack or other adjustable support to carefully maneuverthe engine in to place. Carefully align the bolt holes in the frame and engine. ENGINE REMOVAL/lNSTALLATlON Install the swingarm pivot collars, bolt and nut. install the rear engine bracket and bracket bolts (8 mml. Install the rear engine mounting bolt/nut (10 mml, Install the front lower engine bracket and bracket bolts (8 mm). Install the front lower engine mounting bolt/nut (10 mm). install the front upper engine bracket and bracket bolts (8 mm]. Install the Collar and front upper engine mounting bolt/nutHD rnrnl. Tighten the engine bracket and mounting bolt/nut to the speclfied torque. TORQUE: Engine bracket bolt (upper/lower] '97i'98: 26 N-rn (2.7 kgf-m , 20 lbf-ft) After '98: 27 N-m l2.8 kgf-m , 20 lbf-ft) Front engine mounting bolt (upper/lower) 197,3 : 54 N-m (5.5 kgf-m , 4O Ibf‘fl) Afler'SS: 55 N-m (5.6 kgfvm , 4‘l lbf‘f‘t) Rear engine mounting bolt '97498: 54 N-rn (5,5 kgi-m , 40 lbf—ftl After '98: 55 N‘m [5.6 kgf-m , 41 lbf-ftl 7-10 ENGINE REMOVAL/INSTALLATION Tighten the swingarm prOI nut to the specified torque, TORQUE: 88 N-m19.0 kgf-m , 65 letl Install the swingarm pivot bolt caps. ’977 98' Connect the water hoses (thermostat housing-to» cylinder headsl to the cylinder heads. Arts: ‘98' Connect the water hoses (thermostat housing-to- cylinder heads) tothe cylinder heads and clampthe hose bands. Connect the engine breather tube. Alter '98 SHOWN Apply engll’le oil to the new Orrings, than Install to "‘ W, , the inlet manifold. mrs SH®WN lNLEW/MANJFOLB ENGINE REMOVAL/lNSTALLATION Install the inlet manifold and tighten the bolts. Connect the water tube to the rear cylinder. Install the following: *Carburetor lpage 5726) *Fuel auto valve (page 5*35l Install and tighten the radiator mount bolt to the specified torque. TORQUE: 9 N-m 10.9 kgf~m , 6.5 lbl-ftl Connect the lower radiator hose (radiatontcrwater pumpl to the water pump. Tighten the band screw to the specified torque. TORQUE: 7 Nut (0.7 kgf-m , 5.1 lbf-ft) Route the alternator wire harness properly lrefer to section 1). Connect the alternator wire 3P lWhite) connector. 7-12 ENGINE REMOVAL/INSTALLATION Route the ignition pulse generator wire harness 0' ‘ ' m gfimafifl properly (refer to section 2). i v . Connect the ignition pulse generator wire 2? (White) connector. Install the rear brake pedal and right footpeg, Install and tighten the bracket bolt to the specified torque. TORQUE: 39 NM {4.0 kgf-m , 29 lbt-ft) Connect the clutch cable to the clutch lifter arm. Install the clutch cable holder and bolt. Tighten the holder bolt to the specified torque. TORQUE: 12 N-rn (1.2 kgr-m , 9 [hf-rt) Connect the starter motor cable and ground cable to the starter motor. Install and tighten the cable nut to the specified torque. TORQUE: 10 N-m (1.0 kgf‘m , 7 [bf-rt) Route the neutral switch and oil pressure switch wire harness properly lreferto section 2), Connect the wire terminals. Install and tighten the oil pressure switch terminal screw to the specified torque. TORQUE: 2 N-m (0.23 kgflm , 1.7 lbfvftl ENGINE REMOVAL/INSTALLATION DRIVE SPROCKET INSTALLATION Install the following: 7 Drive sprocket lpage 7714) , Gearshift arm (page 8-16) *Exhaust pipe/muffler lpage 2715) *Carburetor lpage 526i *Air cleaner chamber (page 577) *Air cleaner housing (page 575) *Fuel tank [page 2*7l Fill the engine oil lpage 3-14l. Fill and bleed the cooling system lpage 645i Connect the battery negative cable to the battery terminal, NEUTRAL SWITCH Install the drive chain tothe drive sprocket. Install the drive sprocket to the countershaft with its marking side facing out. Install the drive sprocket setting plate onto the Countershaft and align the bolt holes on the plate with the holes ofthe sprocket. Install and tighten the drive sprocket setting plate [WW WOLTS bolts to the specified torque. TORQUE: 10 NJ" (1.0 kgiim , 7 lbf‘fi) 7-14 ENGINE REMOVAL/INSTALLATION Install the lefl rear cover, washer and clip to Me securely. Install and ligh‘en the left rear cover bolt to the specified torque. TORQUE: 12 N‘m (1.2 kgf-m , 9 Ibf-fl.) Adjust the drive chain slack lpage 340). 7-15 CLUTCH/GEARSHIFT LINKAGE 23 N-m (2.3 kgf-m, 17 mm 12 N-m (1,2 kgf-m , 9 {bf-ft) 88 N-m (9.0 kgf-m , 65 Ibf‘fi) '97 '98: 127 Nm (13.0 kgf—m , 94 (bf-m After’BB: 128 N-m 113,1 kgf-m,95 Ibf-m 12 N-m11.2 kgf-m , 9 lbf-fu 8-0 8. CLUTCH/GEARSHIFT LINKAGE SERVICE INFORMATION 3-1 PRIMARY DRIVE GEAR 8-9 TROUBLESHOOTING 3-2 GEARSHIFI' LINKAGE 8-12 RIGHT CRANKCASE COVER CLUTCH INSTALLATION 8-16 REMOVAL 5-3 RIGHT CRANKCASE COVER CLUTCH REMOVAL s-s INSTALLATION 8-20 SERVICE INFORMATION GENERAL IThe clutch and gearshift linkage maintenance can be done with the engine In the frame. I Engine oil viscosity and level, and the use of Oil additives have an effect on clutch disengagement. Oil additives of kind are not recommended. When the clutch does not disengage Or the motorcycle creeps with the clutch disengaged, inspect the engine Oil VIscOsity and level before servicing the clutch system. ' Clean off any gasket material from the right crankcase cover surface. I Be careful not to damage the crankcase cover mating surface when SerVIcing. I When removing Or servicing the clutch and gearshift linkage, use care not to allow dust or dIrt to enter the engine. I The crankcase must be separated when the transmission requires Service1Section12i. I Refer to section 17 for Ignition pulse generator inspection SPECIFICATIONS UNIT: mm (inl ITEM STANDARD SERVICE LIMIT Clutch lever free play ’ 1072013/873/11 ' ’ ' ' 'T 7 Clutch spring free length 7H _‘ 43211.70) ‘ 111.611.6111 Clutch disc thickness A 2.92ar3.0810.115*0.121l ‘_ _ a, . V .. 2,92 3.0810.11570.121l Clutch plate warpage ___ g » "—7 0301001217 7 Clutch Outer guide |.D, , 21991f22.01610.8558 T118668) 22.0910.870i .. O.D. ., _ 31375112582 1.2559) 1 31.9811.259l "W Clutch outer |.D 32.000’32025112598' 112608] 321011.264) Oil pump drive sprocket LD. 32.000m32.92§11.2598*1.2608] 321011.264) Mainshaft CD. at clutch Outerguide 21.967m21.98010.8648v0.8654) 219210.863) TORQUE VALUES Right crankcase cover bolt 12 N-rn11.2 kgfvm , 9 lbfrftl Clutch cab1e holder bolt 12 N»m11.2 kgf-m , 9 lbf-ft) Clutch lifter plate bolt 12 N-m11.2 kgf-m , 9 lbf-ftl Clutch center lock nut ’977’98; 127 N-m113.0 kgf-m , 94 lbf-ft) Stake After'QB: 128 N-m113.1 kgt-m , 95 lbf-ft) Primary drive gear bolt 88 N-m19.0 kgf-m , 65 lbf-ft) UBS bolt Apply Oil tO the threads and seating surface Gearshift cam plate bolt 12 N-m 11.2 kgf-m , 9 lbfrftl Apply a locking agent tothethreads Gearshift pedal pinch bolt 12 N-m11.2 kgf-m , 9 IbH‘tl Gearshift return spring pin 23 N-m 12.3 kgf-m, 17 lbf-ft) Oil pump driven sprocket bolt 15 N-m 11.5 kgf-m, 11 lbf-Itl Apply a locking agent tothethreads CLUTCH/GEARSHIFT LINKAGE TOOLS Lock nut wrench, 17 >< 27 mm 07716—0020300 Gear holder «177244010100 Clutch center holder TROUBLESHOOTING Clutch lever too hard - Damaged, klnked or dirty clutch cable - Faullv clutch lifter plate bearing - Damaged clutch lifter mechanism ~ Improperly routed clutch cable Clutch will not disengage or motorcycle creeps with clutch disengaged - Too much clutch lever free play - Warped clutch plates - Loose clutch center lock nut . Engine oil too high, improper oil viscosity Clutch slips - Clutch lifter Sticking V Worn clutch discs v Weak clutch springs - No clutch leverfree play Hard to shift - Improper clutch operation or incorrect clutch adjustment - Bent or damaged shift forks lSection 12) ' Bent shift fork shaft lSection 12) - Bentordamaged gearshift spindle - Damaged shift drum cam grooves Transmission jumps out of gear - Worn gear dogs or slots - Bent shift fork shaft (Section 12l - Broken shift drum stopper arm - Worn or bent shift forks (Section i2) - Broken gearshift linkage return spring 07JMB *MN503010r07HGE*001010A or or equivalent commercially available in U,S.A. if (U,S.A. only) 07HGBi0010105 and 07HGB*001020A 07HGBiOOiOZOE 8-2 97* '98. Allel '98' Be Careful no! to damage the mar/rig surface. Drain the engine oil (page 3714). Disconnect the clutch cable from the clutch lifter arm. Remove the right crankcase bolts and never, Remove the dowel pins and gasket. NOTE' After 98 modeis have sealant instead of a paper gasket. Remove the dowei pins and clean off the sealant from the mating surface. DISASSEMBLY Remove the clutch iifter piece. CLUTCH/GEARSHIFT LINKAGE 1r B@L'|'[S.i CLUTCH/GEARSHIFT LINKAGE Remove the snap ring and return spring from the right crankcase cover. Remove the clutch lifter arm. INSPECTION Check the dust seal fatigue or damage. Check the needle bearing for wear, damage or loose fit. Replace these parts If necessary. NOTE If the dust seal replacement is required, press the dust seal to the case surface. DUST SEAL - '9» E Check the clutch lifter arm for damage or bending. Check the spring for fatigue or damage. Replace these parts if necessary. Apply grease to the clutch lifter arm sliding surface. Apply grease to the dust seal lips and needle bearing. LIFTER ARM 8-4 CLUTCH/GEARSHIFT LINKAGE CLUTCH REMOVAL 1' ”19 OllPUWP Remove the right crankcase cover (page 8-3l. driven sprocket WW [78 remained, loosen {he driven sprocket bolt wnn "75 clutch IS still installed. Loosen the clutch lifter plate bolts in a crisscross pattern in 2 or 3 steps. Remove the lifter plate/bearing and clutch springs. Unstake the clutch center lock nut. CAUTION Be careful not to damage the mainshah threads. Hold the pressure plate with the clutch center holder and loosen the clutch center lock nut. TOOL: Clutch center holder O7JMB , MN50301 or O7HGE‘OD‘IO10A0r 07HGB—00101OBand D7HGB'001020A 07HGBi00102OB (U.5.A, onlvl Lock nut wrench 07716i0020300 Equivalent commerclallv available in USA. CLUTCH/GEARSHIFI' LINKAGE Remove the clutch center lock nut and washer. Remove Khe clutch cemer‘ Remove the judder spr'rng, spring seat, clutch discs and dumb plales as a set Remove the pressure plane. _ .35 /« UIDIDER SBBING‘XSPRIN‘G SEAT/DISCS/ , LAT'ES, PRESSURE‘F’LAIE W “ 4 I ‘ ' PE 43 » V Remove the washer and clutch outer. Remove the 0H pump driven sprocket bait and L washer. k 8-6 Hep/ace (he alutch sprlngs as a set Replace the discs and plales as a set, CLUTCH/GEARSHIFT LINKAGE Remove the oil pump drive sprocket, driven sprocket and oil pump drive chain as a set. Remove the clutch outer guide. INSPECTION LIFTER PLATE BEARING Check the lifter plate bearing for damage. Turn the bearing inner race with your finger. The bearing should turn smoothly and quietly without play. Also check that the bearing outer race fits in the plate. Replace the hearing if necessaw, CLUTCH SPRING Measure the clutch spring free length. SERVICE LIMIT: 41.6 mm (1.64 in) CLUTCH DISC Check the clutch discs for signs of scoring or discoloration. Measure the thickness of the discs. SERVICE LIMITS: Disk A: 2.6 mm 10.10 in) Disk B: 2.6 mm (0.10 in) CLUTCH/GEARSHIFI' LINKAGE Replace the discs and plales as a sat CLUTCH PLATE Check the plate for excesswe warpage or discoloration. Check the plate warpage on a surface plate uslng a healer gauge. SERVICE LIMIT: 0.30 mm (0.012 in) CLUTCH CENTER Check the clutch center for nicks, indentations or abnormal wear made bythe clutch plates. CLUTCH OUTER Check the slots in the clutch outer for nlcks or mdentations made by clutch discs. Measure the ID. ml the clutch outer. SERVICE LIMIT: 32.10 mm (1.264 in) CLUTCH OUTER GUIDE Measure the clutch outer guide. SERVICE LIMITS: O.D.: 31.98 mm 11.259 inl l.D.: 22.09 mm 10.870 inl CLUTCH CENTER CLUTCH/GEARSHIFI' LINKAGE OIL PUMP DRIVE SPROCKET Check ihe oil pump drive sprocket for damage. Measure the LD. of the drive sprocket. SERVICE LIMIT: 32.10 mm (1.264 in) MAINSHAFI' Measure the mainshaft CD. at the clutch outer guide. SERVICE LIMIT: 21.92 mm (0.863 in) JUDDER SPRING, SPRING SEAT SPRiNG SEAT Check the spring sea! and judder spring for distonion, wear of damage. PRIMARY DRIVE GEAR REMOVAL Remove the clutch (page Best, Remove the ignition puise generator mounting bolts and ignition pulse generators. ,, o. f eULs’E G_EI)IERATORS§ 8-9 AiGNI‘FI‘ON CLUTCH/GEARSHIFT LINKAGE The primary drrve gear wr/l only go on My one positron because at the extra Wrda a/rgm‘ng splme Temporarily Install the clutch outer onto the mainshaft‘ Hold the primary drive gear With the gear holder and remove the primary drive gear bolt. TOOL: Gear holder 0772470010100 Remove the clutch outer and gear holder. Remove the ignition pulse generator rotor and primary drive gear INSPECTION Check the serrated teeth of the primary drive gear for wear or damage. Check the serrated teeth of the sub gear for wear or damage. INSTALLATION lnstall the primary drive gear with the ”OUT" mark facing out, 8-10 CLUTCH/GEARSHIFT LINKAGE The ignition pulse Install the ignition pulse generator rotor. generator IanI wlll only go an in one paslllan because of the extra Wlde align/rig spline. Apply engine oil to the primary drive gear bolt threads and seating surface. Install the washer and primary drive gear bolt. Temporarily install the clutch outer onto the mainshaft. Hold the primary drive gearwith the gear holder. TOOL: Gear holder 07724—0010100 Tighten the primary drive gear bolt to the specified torque, TORQUE: B8 N-rn (9.0 kgf-m , 65 lbf-fll Remove the gear holder, Clutch outer and clutch outer guide. Apply a locking agent to the ignition pulse generator bolt threads. Install the ignition pulse generators and tighten the bolts to the specified torque. TORQUE: 12 Nm 11.2 kgf-m , 9 lbfrft) CLUTCH/GEARSHIFI' LINKAGE Install the clutch lpage 8-16). NOTE' if the ignition pulse genelaror wire grommets were removed from the case groove, reinstall them securely. GEARSHIFT LINKAGE REMOVAL Remove the left rear cover lpage 741). Remove the gearshift arm pinch bolt and gearshift arm from the gearshift spindle. Remove the bolts and gearshift pedal/arm from the left footpeg. Remove the following: ”Right crankcase cover (page 873) *Clutch (page 875) *Oil pump drive chain (page B-Gl GEARSHIFT PEDAL Remove the oil pipe stay mourning bolrand oil pipe mounting bolt. Pull the oil pipe out ofthe stay and oil pump. 8-12 CLUTCH/GEARSHIFT LINKAGE Remove the O-nng from the oil pipe. Remove the gearshift spindle from the crankcase while unhooklng the shifter arm from the gearshlfl cam plate. Remove the bolt, washer, gearshift drum stopper, collar and spring. Remove the bolt and gearshift cam plate, CLUTCH/GEARSHII—‘l’ LINKAGE INSPECTION Checkthe gearshift spindleiorwear or damage. If Check the return spring for fatigue or damage. SPINDLE lnspect the gearshift pedal shaft for damage or LOCK NUTS loose lock nuts Replace the shaft if necessary. SHAFT Inspect the dust seals and pivot collar for wear or damage. ,@ DUST SEALS COLLAR Replace if necessary, Apply grease to the dust seal lips and pivot collar. Install them into the pedal shaft INSTALLATION Install the gearshift cam plate to the shift drum. NOTE, Install the gearshift cam plate aligning the hole on the cam plate with (he dowel pin, 8-14 CLUTCH/GEARSHIFT LINKAGE Clean and apply a locking agent to the gearshift cam plate bolt threads, Install and tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 lbflftl Install the collar. spring, gearshift drum stopper, washer and bolt as a set. Tighten the bolt securely. Install the gearshift spindle by aligning the return spring ends with the pin in the case. Apply oil to the new Orring. Install the oil pipe with a new O-ring onto the oil pipe stay and oil pump. CLUTCH/GEARSHIFT LINKAGE lnstall and tighten the bolt securely. Install the following: -Oil pump drive chain/Clutch lsee belowl ~Right crankcase cover lpage B»20l install the gearshift pedal and gearshift pedal mounting bolt. Tighten the mounting bolt securely. Install the gearshift arm to the gearshift spindle aligning the punch mark on the spindle with the punch mark of the gearshift arm. Install and tighten the gearshift arm pinch bolt to the specified torque. TORQUE: 12 N-m 11.2 kgf-m , 9 lbf-ftl Install the left rearcover (page 7715). CLUTCH INSTALLATION Install the on pump drive sprocket with its labs side facrng out. NOTE, if the oil pump driven sprocket is removed, tighten the driven sprocket bolt to the specified torque after clutch installation Apply molybdenum disulfide oil to the clutch outer guide outersurface. install the clutch outer guide to the mainshaft. install the oil pump drive sprocket to the clutch outer guide. GEARSHlFT PEDAL 8-16 CLUTCH/GEARSHIFI' LINKAGE Install the oil pump drive chain to the oil pump "VB I” 3.»: drive and driven sprocket. DE“ EN SPRQGKET Install the oil pump driven sprocket with the ”W” mark on the driven sprocket lacing inside. Align the flat surfaces of the driven sprocket hole and oil pump shaft end. Clean and apply a locking agent to the oil pump driven sprocket bolt threads. Install the oil pump driven sprocket bolt. NOTE If the oil pump driven sprocket is removed, tighten the driven sprocket belt to the specified terque after clutch installation. Align thecut-outs in the clutch outer with the tabs f flaws on the OII pump drive sprocket while turning the V sprocket With the chain and pushing the clutch -' outer on to the shaft. install the thrust washer onto the mainshait. CLUTCH/GEAHSHIFT LINKAGE CLUTCH CENTER Coat the clutch discs and clutch plates with clean engine oil. Install the clutch disc B, spring seat and judder spring on the clutch center as shown, Install the six clutch plates and six clutch discs A alternately, starting with a clutch plate to the clutch center Install the washer, pressure plate, clutch discs, clutch plates, judder spring, spring seat and clutch centeras a set tothe clutch cuter. CLUTCH PLATE JUDDER SPRING SPRING SEAT CLUTCH DISC B JUDDER SPRING ’ 4’4 ”””” SPRING SEAT CLUTCH OUTER PHESSU RE PLATE CLUTCH DISC B CLUTCH DlSC A Install the clutch assemblyto the mainshaft. Install the new spring washer with its “OUT SIDE” mark facing out. Apply engine oil to new clutch center lock nut threads. install the new clutch center lock nut. 8-18 CLUTCH/GEARSHIFI' LINKAGE Hold the clutch center with the clutch center holder. TOOLS: Clutch center holder 07JMBi MN50301 or 07HGBi00‘lO1DA or 07HGB'00101DB and 07HGBi001OZDA U7HGBiUO’lO2DB (U.S.A.onlyl Tighten the look not to the specified torque. TORQUE: '97i'98: 127 N-m (13.0 kgf‘m,941bt-fll After '93: 128 N-m (13.1 kgf-m,95 (bf-ft) Remove the special tools and stake the lock nut into ’ the mainshaft groove. ' CAUTION: Be careful not to damage the mainshah threads. Install the clutch springs and litter plate/bearing. Install and tighten the clutch lifter plate bolts in a crisscross pattern in several steps, TORQUE: 12 N-m (1.2 kgf~m , 9 lbf-ftl If the oil pump driven sprocket Is removed, tighten the driven sprocket bolt to the specified torque. TORQUE: 15 NH! (1.5 kgi-m , 11 |bf~ftl install the right crankcase cover (see next page). SPROCKET BOLT 8-19 CLUTCH/GEARSHIFI' LINKAGE RIGHT CRANKCASE COVER INSTALLATION ASSEMBLY Apply grease to the ciutch lifter arm pivot needle bearings and dust seal lips, Apply gvease to the clutch lifter arm siiding surfaces and slit, install the ciutch lifter arm. install the return spring and snap ring. Hook the spring end in the cover tap securely, and mm the shaft. Appiy grease in the clutch lifter piece, Instaii the clutch lifter plece, aligning the piece and with the groove in the clutch iifter arm 8-20 '97 ' '35. After ’98 Be careful not to damage the mating surface INSTALLATION Install the dowel pins and new gasket. Clean the right crankcase cover mating surface. Apply sealant well to the right crankcase cover mating surface as shown. CAUTION: Du nat wipe off the excessive sealant by using the nrganil: solvent. install the dowel pins. install the right crankcase cover. install and tighten the right crankcase cover bolts in a cvisscross pattern in several steps. TORQUE: 12 N-m (1.2 kgf—m , 9 lbf-ftl Connect the clutch cable and install the cable holder and bolt. TORQUE: 12 N!" (1.2 kgf-m , 9 lbf-ft) Fill the engine oil (page 3-14). Perform the clutch adjustment lpage 3728i CLUTCH/GEARSHIFI' LINKAGE ALTERNATOR/STARTER CLUTCH 12 N-m (1.2 kgf-m , 9 lbfrfl) '97 V '98: 29 N~m (3.0 kgf-m , 22 IN“) Aher '98: 3D N~m(3.1kgf~m,22|bf-ft) '97i'98: 127 N-m (13D kgi-m , 94 Ibf-fl) After'SB: 128 Nvm(13.1kgf‘m,95lbf-fl) 12 N-m (1,2 kgf-m , 9 Ibfvft) 97,93 12 N-m (1.2 kgf-m , 9 [bf-m ’97 *‘98 9-0 9. ALTERNATOR] STARTER CLUTCH SERVICE INFORMATION 9-1 FLYWHEEL, STARTER CLUTCH 9-3 l TROUBLESHOOTING 9-1 STATOR INSTALLATION 9-9 E STATOR REMOVAL 9‘: l SERVICE INFORMATION GENERAL 0 The alternator and Sta rter clutch maintenance can be done with the engine in the frame. - Refer to section 16 for alternator inspection. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT StaFtig'driyen gear W ‘I.D. 3700073702511,4567*1,4577l T“ 57.30 {1.461) N“ 0.1). 57.74% 57.76812; 55‘ 77131 > 57 73 (2.273) Starter clutch outerl.D. 7A.414*74.440 (2.9297’2l9307l 74.46 (2.931) TORQUE VALUES Left crankcase cover bolt 12 N~m l1.2 kgiAm , 9 lbf-l‘t) Flywheel bolt ’97—'98: 127 Nm (13.0 kgfvm , 94 lbf-ftl Left hand threads After '98: 128 N-m (13,1 kgf-m , 95 lbrlfll Apply oil to the threads and seating surface Starter onerway clutch torx bolt ’97 7 '98: 29 N-m (340 kgf-rn , 22 lbf-ft) Apply a locking agent to the threads After '98: 30 N-ml3,1kgt-m , 22 Ibf-ft) Stator mounting socket bolt 12 N-m (1.2 kgf-m , 9 Ibf-ft) Apply a locking agent to the threads Alternator cord clamper 12 Nnm (1.2 kgf-m , 9 Ibf-l‘tl Apply a locking agent to the threads Ignition pulse generator bolt 12 N>m l‘l.2 kgfim , S lbf-ftl Apply a locking agent to the threads TOOLS Flywheel holder 07725'0040000 Rotor puller 07733i00200010r 0793373290001 lU.S.A. only) TROUBLESHOOTING Starter motor turns, but angina does nut turn - Faulty starter clutch - Damaged reduction gear - Damaged starter idle gear ALTERNATOR/ STARTER CLUTCH STATOR REMOVAL ' ‘ afimfififim Referlopage16-7 Remove the left side cover lpage 2*3l and for alternator disconnect the alternator 3P (White) connector. (charging coll) fnspactran, Remove the left rear cover (page 7~4lv Place a container under the left crankcase cover to catch the engine Oil. Loosen the Is" Remove the eleven left crankcase cover belts and crankcase cover cover. balls in a crisscross pattern CAUTION' rn several steps. The left crankcase cave! {stator} is magnetically attached to the flywheel, be careful to removal. ’977 ’98‘ Remove the gasket and dowel pins, NOTE, After ’98 models have sealant instead of a paper gasket. After ’95' Remove the dowel pins and clean off the sealant Be carelulnal to from the mating surface. damage the manng surrace, Remove the socket bolts and wire clamp from the left crankcase cover. 9-2 ALTERNATOR/STARTER CLUTCH Remove the stamr grommets from the left crankcase cover. Remove the socket bolts and stator from the left crankcase cover FLYWHEEL, STARTER CLUTCH Fla/er to page 16-7 Remove the left crankcase cover {page 9~2). f0! alternator {Chafglllg coil) Remove the starter idle gear and shaft. mspectlon. Remove the staner reduction gear and shaft. CAUTION The flywheel bah has left hand threads. Remove the flywheel bolt and washer while holding the flywheel wirh a flywheel holder. TOOL: Flywheel hnldar 0772570040000 Equlvalenr cammercially avallable in U.S.A, ALTERNATOR/STARTER CLUTCH Remove the flywheel using the rotor puller. TOOL: Rotor puller 07733A0020001 or 07933 7 3290007 lU.S.A. onlyl Remove the needle bearing and woodruff key from the crankshaft. NOTE 0 During wuodruh‘ key removal, be careful not to damage the key groove or crankshaft. 0 Do not lose the woodruff key. STARTER DRIVEN GEAR, STARTER CLUTCH REMOVAL Check that the driven gear turns smoothly in one direction and locks up in the other direction. Remove the starter driven gear from the flywheel while turning the driven gearcounterelockwise. Remove the starter one-way clutch torx bolts while holding the flywheel with a flywheel holder. TOOL: Flywheel holder 07725- 0040000 Equivalent commercially available in U.S,A‘ BOLTS FLYWHEEL HO DER 9-4 ALTERNATOR/STARTER CLUTCH Remove the clutch housing and one-way clutch from the flywheel, Remove the washer, STARTER CLUTCH INSPECTION NEEDLE BEARING Check the needle bearing clutch sprag for abnormal wear, damage. ONE-WAV CLUTCH Check the one-way clutch sprag for abnormal wear, damage or irregular movement. CLUTCH HOUSING Check the clutch inner contact surface of the housing for damage. ONE»WAV CLUTCH STARTER DRIVEN GEAR Check the roller contact surface for damage Measure the driven gear OD. SERVICE LIMIT: 57.73 mm [2.273 inl Measure the driven gear I.D. SERVICE LIMIT: 37.10 mm (1.661 in) 9-5 ALTERNATOR/STARTER CLUTCH STARTER DRIVEN GEAR, STARTER CLUTCH INSTALLATION CLUTCH HOUSING STARTER ONE-WAV CLUTCH TORX BOLT 97493: 29 Nlm13.0 kgfm , 22 lbf-ftl After’QE: 30 N-m13.1kgf.m,22lbf-ftl STARTER DRIVE N GEAR ONE-WAY CLUTCH FLVWHEEL Clean the oneway clutch and apply engine oil to the sprag. Install the one-way clutch into the clutch housing with its flange side facing flywheel. install the washer. Install the clutch housing/onerway clutch to the flywheel HDUSlNG/G E—WAVCLUTCH ALTERNATOR/STARTER CLUTCH Hold the flywheel using the flywheel hulder. TOOL: m BOLTS Flywheel holder 077257 0040000 Clean and apply a locking agent to the starter one way clutch torx bolt threads. Install and tighten the starter one-way clutch torx bolts to the specified torque. TORQUE: '97i'98: 29 N»m (3.0 kgf-m , 22 lbf-ft) After '99: 30 N~m (3.1 kgf-rn , 22 lbf-ft) install the starter driven gear to the flywheel while turning the driven gear counterclockwise. FLYWHEEL INSTALLATION When waodruff Apply engine oil to the needle bearing and install it Key Installation, be onto the crankshaft. carefu/nalto Wipe any oil off the mating surface of the damage the key crankshaft. grout/em Install the wuodruff key to the key groove of crankshaft crankshaft. Wipe any oil off the mating surface of the flywheel. install the flywheel to the crankshaft aligning the key groove of the flywheel with the woodruff key on the crankshaft. ALTERNATOR/STARTER CLUTCH Hold the flywheel using the flywheel holder. TOOL: Flywheel holder 0772570040000 Equivalent commercially available in USA, Install the washer. C AUTIO N : The flywheel bolt has left hand threads. Apply englne oil to the flywheel bult threads and seating surface. |nstall and tighten the flywheel bolt to the specified torque. TORQUE: '97493: 127 N-m (13,0 kgf-m , 94 [bf-ft) After ’98: 128 N-ml13.1kgf-m,95lbf-ft) Check the starter reduction gear, shaft and journal for wear or damage. Check the starter idle gear, shaft and journal for wear or damage. Apply engine oil to the starter reduction gear, starter idle gear and shafts. install the starter reduction gear, starter idle gear and shafts to the left crankcase as assembly. NOTE Install the starter reduction gear with its "OUT” mark facing out. Install the stator and left crankcase cover (page 98). 9-8 ALTERNATOR/STARTER CLUTCH STATOR INSTALLATION WlRE CLAMPS LEFT CRANKCASE COVER GROMMET STATOR MOUNTING SOCKET BOLTS 12 N-m (1.2 kgflm ,9 let) STATOR Install the stator to the left crankcase cover. Clean and apply a locking agent to the stator mounting socket bolt threads. Install and tighten the stator mounting socket bolts to the specified torque‘ TORQUE: 12 N-m (1.2 kgf-m , 9 le’t) Clean and apply sealant to the wire grommets seating surface and install the grommets into the grooves in the left crankcase cover. ALTERNATOR/STARTER CLUTCH Clean and apply a locking agent to the cord clamp socket bolt threads. install the cord clamp to the left crankcase cover. Install and tighten the socket bolt to the specified torque TORQUE: 12 N-m (1.2 kgfm , 9 Ibf-ftl '9714 ’98 Install the dowel pins and new gasket. After ’95 Clean off the sealant from the left crankcase cover Be carelu/ not to mating surface damage the Apply sealant well to the left crankcase cover mating surface mating surface CAUTION. Do not wipe aff the excessive sealant by using the organic solvent, Install the dowel pins. install the left crankcase cover, NOTE The left crankcase cover (stator) is magnetically attached to the flywheel, so be careful during installation. Install and tighten the left crankcase cover bolts to the specified torque in a crisscross pattern in several steps. TORQUE: 12 N-m (1.2 kgf-m ,9 lbf-ft) 9-10 ALTERNATOR/STARTER CLUTCH NOTE Route the wire harness proper1y1page1»24,28), Mstafl the clamps ontc the wires‘ Connect the alternator 3P 1White) connector. lnstaH the left rearcuver (page 745). Install the left side cover {page 273), Check the engine oil level (page 3714). 9-11 CYLINDER HEAD/VALVES 23 N-m (2,3 kgf-m,17|bf~m g1!) N-m11.D kgf-m , 7 le-fll 23 N-m12V3 kgf-m,17|bf-m 's7v'93: 9N-m(D.9 kgf.m,e.51bi-m @ After ’98: 1O N-m (1,0 kgbm , 7 Ibf-ft) 10-0 10. CYLINDER HEAD/VALVES SERVICE INFORMATION TROUBLESHOOTING CYLINDER COMPRESSION CYLINDER HEAD COVER REMOVAL CAMSHAFT REMOVAL CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLV 10-1 10-3 10-4 10—5 10-7 10-13 10-14 VALVE GUIDE REPLACEMENT VALVE SEAT lNSPECTlON/REFA CYLINDER HEAD ASSEMBLY CYLINDER HEAD INSTALLATION CAMSHAFT INSTALLTION CYLINDER HEAD COVER INSTALLATION 10-17 CING 10-19 10-21 10-23 10-25 10-31 SERVICE INFORMATION GENERAL 0 The engine must be removed from the frame before servicing the rear cylinder head. - The front and rear cylinder head cover and front cylinder head can be serviced with the engine in the frame. - The camshaft can be serviced with the engine in the frame. ' Be careful notto damage the mating surfaces when removing the cylinder head cover and cylinder head. 0 When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. m - Clean all disassembled parts with clean solvent and dry them using compressed air before inspection. - During assembly apply molybdenum disulfied oil to the camshaft holders, camshafljournals of the cylinder head, rocker arm shafts, rocker arm slipperfaces and valve stems to provide initial lubrication. SPECIFICATIONS Unit: mm linl ITEM STANDARD SERVICE LIMIT Cylinder compression ‘ 1,324 L 98 kPa (13.5 i 1.0 kgf/cm’, 7 _ , a, 192 i 14 psilat400 rpm Cylinder head warpage _. .-,. ,, 0.10 (o 004) Valve, Valve clearance W 0.15 (0.0061 7,, fl ._. Valve guide _. EX 0.20 (0.0081 7 Valve stem 0.0. W l 5.475i5.490(0.2156"'0.2161) 5.45(0.2151 w ‘ EX 6555*6570(0.2581j0.2587l 6.55 {0.258l Valve gulde LD. lN 5_50075_512(0_215570 2170) 556(0219) ex 1 660076.615 (0.2598 41» 6.6510162l Stem-to-gulde clearance 1N 001070.037 (000047000151 _ ._ 0.10 (0.0041 ,7 1;): 0.030 70.060100012701102“ .., 011(90g117 3 Valve guide projection lN . . 19.4*~19.5l0.7670.77l above cylinder head EX 7 7 , (0.70 , 0.711 . Valve seat width lN/EX 0.907 0 (0.035 0.0431 1.5 (0.0017 7 7 Valve Inner IN 38.11 (1.500) 354711.436) spring , EX 38.81 (1.528) 37.51 (1.477l free length Outer IN 42.14 (1.659) 40.58l1.598l 7.. EX{ 428311.686) 412511.624l Camshaft Cam lobe helght IN ’97498 37.930(1.49331 __7§77.73(1.4351 After ’98 37.188s737348(146417147041 l 37.16 (1.4031 EX ’97i'98 37350114941) 377511486) _ 77 After '98 37 605*37765l71.4_805*1.48651 37.58 (1 .480) Journal O.D 21.959i21380 (0.8545j03654l 213010.862) . Runout , _ 0.030 (0.0012) 0.0510002) Oil clearance 0:050 0.1111110020700044) 1 01310005) 1 Identificatio‘nimarks ”F”: Front, “R": Rear l A 7 Rocker arm l.D. IN/EX 12.000’12018 (0.4724i0.4731l l 12.0510474) Rockerarm shaft O.D. lN/EX 11.966711.984(0.4711 0.47151 11.91(0.4691 Rocker armrtoVrocker arm shaft clearance 0.016701352100006 . 020) 00710003) 10-1 CYLINDER HEAD/VALVES TORQUE VALUES Spark plug 14 N-m(1.4kgf:m,10lbf>ft) Cylinder head cover bolt 10 N-m (1.0 kgf-m , 7 Ibf-ft) Valve adjust cover bolt 12 N-m (1.2 kgfvm , 9 lbf-ft) Valve adjusting screw lock nut 23 N-m (2.3 kgfrm,17|bf‘ft) Apply oil to the threads and seating surface Cam sprocket bolt 23 N-m (2,3 kgf-m ,17Ibf-ft) Apply a locking agent to the threads Camshaft holder 8 mm bolt 23 N-m (2,3 kgI-m,17|bIAftI 8mm nut 23N-m(2.3kgf-m,17|bf-ft) Camshaft end holder bolt ’97 '7’ ‘ 9 N-m (0.9 kgf-m , 6.5 Ibf-ft) After '98: 10 N-m (1.0 kgf-m , 7 Ibfrft) Cam chain tensioner mounting bolt 10 N-m (1.0 kgf-m , 7 Ibf-ft) Apply a locking agent to the threads Cylinder head 8 mm bolt 23 N-m (2.3 kgf-m,17lbf-ft) j, Apply oil to the threads and seating 6 mm bolt 12 Nm (1.2 kgf-m , 9 [bf-ft) 1 surface 10 mm nut 47 N-m (4.8 kgf-m , 35 Ibtrft) ~J TOOLS Valve guide driver, 55 mm (IN) Valve guide driver. 6,6 mm (EX) Valve spring compressor Valve seat cutter (Commercially available in U.S.A.) *Seat cutter IN 27.5 mm (45") EX 35 mm (45°) *Flat Cutter IN 28 mm (32°) EX35 mm (32°) Interior Cutter IN 30 mm (60°) EX37.5 mm (60°) *Cutter holder IN 5.5 mm EX6.6 mm Valve guide driver attachment (IN) Valve guide driver attachment (EX) Valve guide reamer (IN) Valve guide reamer (EX) 0774270010100 07742, 0010200 Not available in U.S.A. or 079427 6570100 0775770010000 or07957i3290001 07780 7 0010200 07780 7 0010400 07780i0012100 07780 ,. 0012300 07780 ' 0014000 0773070014100 0773170010101 0773170010201 07943, MF50100 07943, MF50200 07984 7 2000001 or 07984 *ZOUUOOD 07934 ”-ZE20001 or 07984 *ZEZOOOD 10-2 TROUBLESHOOTING CYLINDER HEAD/VALVES 0 Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracking noises to the top-end. 0 If performance is poor at low speeds, checkfor white smoke in the crankcase breathertube, If the tube is smoky, check for a seized piston ring. Compression too low, hard starting or poor per'ormance at low speed - Valves *lncorrect valve adjustment *Bumad or bent valves *lncorrect valve timing *Bruken valve spring 7 Uneven valve seating - Cylinder head iLeaking or damaged cylinder head gasket *Warped or cracked cylinder head - Loose spark plug - Faulty cylinder, piston (Section 11l Compression too high - Excessive carbon build-up in cylinder head or on top of piston Excessive smoke 'Worn valve stem or valve guide - Damaged stem seal - Faulty cylinder, piston (Section 11l Excessive noise ' Incorrect valve adlustment ' Sticking valve or broken valve spring - Damaged or worn camshaft 4 Loose or worn cam chain -Wurn or damaged cam chain tensioner , Worn cam sprocket teeth - Faulty cylinder, piston (Section 1‘1) Rough idle - Low cylinder compression 10-3 CYLINDER HEAD/VALVES CYLINDER COMPRESSION M I! the engine must be running to do some work, make sure the area is wall-ventilated. Never run the engine in an enclosed area, Warm up the engine to normal operating temperature. Stop the engine, disconnect the spark plug caps and remove one spark plug cap ata time. NOTE To measure the cylinder compression of each cylinder, remove only one plug at a time. Shift the transmission into neutral. Install the compression gauge attachment in a spark plug hole. Connect the compression gauge to the attachment, Open the throttle all the way and crank the engine withthe starter motor, NOTE Crank the engine until the gauge reading stops rising. The maximum reading is usually reached Within 4*7 seconds. STANDARD:1,324 1 98 kPa (13.5 i 1.0 kgf/cm‘, 192 t M psii at 400 rpm If compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or the piston crown. If compression is low, pour 3*5 cc (0.1"01 Ozl of clean engine oil into the cylinder throuh the spark plug hole and recheck the compression if the compression increases from the previous value, check the cylinder, piston and piston rings. , Leaking cylinder head gasket - Worn piston ring - Worn cylinder and piston If compression is the same as the previous value, check the valves for leakage. 10-4 CYLINDER HEAD/VALVES CYLINDER HEAD COVER REMOVAL FRONT Drain the coolant (page 6-6l. Remove the steering covers (page 2-3). Remove the fuel tank ipage 2»4li Remove the air cleaner housing (page 54). Remove the carburetors l’97i’98: page 5710). Disconnect the spark plug caps‘ Remove the water pipe mounting bolt, front water pipe and Grim. NOTE. i If coolant drips cm the engine, wipe it off immediately. Remove the cylinder head cover bolts, washers and rubber seals. Be careful not to Remove the cylinder head cover and gaskett damage the wire harness and mating surfaces when removing the Cylinder head cove: CYLINDER HEAD/VALVES REAR Drain the coolant (page B-Bl. Remove the steering covers (page 273). Remove the fuel tank (page 2-4). Remove the air cleaner housing (page 574). Remove the carburetor(s) (’97 7 '98: page 5-10, After ’98: page 5-1 ‘ll. Remove the inlet manifold (After ’98: page 778). Remove the socket bolts and Valve adjusting cover. Disconnect the spark plug caps and crankcase breather tube. Remove the water pipe mounting bolt, rear water pipe and O-ring. NOTE' If coolant drips on the engine, wipe it off immediately. Remove the cylinder head cover bolts, washers and rubber seals. 10-6 Be careful nm 20 damage me we harness and mating surraees when remcvmg the cylinder head cover CAMSHAFT REMOVAL CYLINDER HEAD/VALVES Align the wire harness with the valve adjusting REAR CYLINDER HEAD COVER hole, then remove the rear cylinder head cover to \\ - A, #7 ~ \_ forward. NOTE - The camshaft can be serviced with the engine In the frame. 0 The rear cylinder camshaft service procedure is the same as the front cylinder camshaft service procedure. Remove the front cylinder head cover (page 10—5). Remove the crankshaft hoie cap and timing hole cap from the ieft crankcase cover. Remove the camshaft end holder bolts and camshaft and holder. Remove the dowei pins. CYLINDER HEAD/VALVES Turn the crankshaft coumerclockwise and align the “FT” mark (rear cylinder: “RT” markl wixh the index mark on rhe lefr crankcase cover. Make sure the rear cylinder is at TDC (top dead center). Measure the cam Chain (ensicner wedge 8 length as shown SERVICE LIMIT: 6 mm (0.2 inl When the service Iimir is exceeded, replace the cam chain. The cam chain can be replaced after removing the following parts Front: 7 Front camshaft Flywheel lSection 9) Rear: *Rear camshafl *Primary drive gear (Section 8) Pull the cam Chain tensioner wedge A slraighi up while holding wedge B down. Secure wedge Awnh a 2 mm pin as shown. NOTE Be careiul not re ler the 2 mm pin fall into the crankcase, Remove Ihe cam sprocket bolr, turn the crankshaft counterclockwise one full lurn (360°l and remove the other Cam sprocket bolt. NOTE Be careful nm m let the cam sprocket bolts fall into the crankcase, WEDGE B 6 mm (0.2 in) WEDGE A 10-8 CYLINDER HEAD/VALVES Remove the cam sprocket from the camshaft flange suriace. Remove the camshaft holder nms (8 mmD/washer, Remove the camshaft holder bolts (8 mm and 0H guide plate. Remove the camshafi holder assembly. Removeme dowel pinsr Remove the camshaft CYLINDER HEAD/VALVES Remove the cam sprocket from cam chain, Attach a piece of mechanic’s wire to the cam chain to pvevent it form being dropped into the crankcase CAM CHAlN CAMSHAFI' HOLDER DISASSEMBLY (EXHAUST) SHAFT NOTE ROCKER ARM The rear cylinder camshaft holder sen/ice uses the same procedure as the front cylinder camshaft holder. Remove the exhaust rocker arm shaft, exhaust rocker arm and wave washer tram the camshaft holder WAVE WASHER Remove the intake rocker arm shaft, intake rocker arms and wave washers from the camshaft holder. SHAFT ROCKER ARM WAVE WASHER Remove the valve adjuster lock nut and valve . . ADJUSTING SCREW adjusting screw. LOCK NUT 10-10 CYLINDER HEAD/VALVES INSPECTION CAMSHAFTRUNOUT Support both ends of the camshaft with V-blocks and check the camshaft ru nout with a dial indicator. Actual runout is 1/2 the total indicator reading SERVICE LIMIT: 0.05 mm (0.002 inl CAM LOBE HEIGHT inspect the cam lobe surfaces for scoring or evidence of insufficient lubrication. Measure the height of each cam lobe using a micrometer. SERVICE LIMITS: IN: ’977'98: 37.73 mm [1.485in) After ’93: 37.16 mm (1.463 in) EX: ’977’ . 37.75 mm (1.486 inl After '98: 37.58 mm (1.480 in) NOTE. Inspect the rocker arm if the cam lobe is worn or damaged. CAMSHAFI' JOURNAL Inspect the camshaft journal surfaces for scoring or evidence of insufficient lubrication. Measure the OD. of each camshaft journal. SERVICE LIMIT: 2130 mm (0.862 ml NDTE' Inspect the oil passages and camshaft holder for wear or damage if the journal surface is worn or damaged. 10-11 CYLINDER HEAD/VALVES CAMSHAFI OIL CLEARANCE ‘CAIVISHAFT Clean off any oil from the journals of the camshaft holders, head and Camshafts. Put the camshaft onto the cylinder head and lay a strip of plastigauge lengthwise on the top of each camshaft journal. NOTE, ' Do not block any oil holes with the plastigauge. 0 Do not rotate the camshaft during inspection. install the camshaft holder and camshaft end holder. Install and tighten the camshaft holder bolts/nuts (8 mm) to the specified torque in 273 steps. TORQUE: 23 N-m (2.3 kgf-m,17lbf-ft) Install and tighten the camshaft holder bolts (6 mml to the specified torque in 2 , 3 steps. TORQUE: 10 Nm l1.D kgf-m , 7 lbf-ftl Remove the camshaft holder and measure the width of each plastlgauge. The widest thickness determines the oil clearance. SERVICE LIMIT: 013 mm (0.005 in) When the service limit is exceeded, replace the camshaft and recheck the oil clearance. Replace the cylinder head and camshaft holders if the clearance still exceeds the service limit. ROCKER ARM, ROCKER ARM SHAFI' Inspect the sliding surface of the rocker arms for wear or damage where they contact the camshaft, or forclogged oil holes. Inspect the contact surface of the valve adjuster screw for wear or damage. Measure the ID. of each rocker a rm. SERVICE LIMIT: 12.05 mm (0,474 in) 10-12 CYLINDER HEAD/VALVES Measure the each rocker arm shaft (1D, SERVICE LIMIT: 1191 mm 10.459 inl Inspect Ihe shaft for wear or damage and calculate the shaftto rocker arm clearance. SERVICE LIMIT: 0.07 mm (0.003 ml Replace the rocker arm and/or shaft if necessary. CYLINDER HEAD REMOVAL NOTE‘ 'The engine must be removed from the frame before servicing the rear cylinder head, 'The from cylinder head and rear cylinder head cover can be serviced with the engine in the frame. IThe rear cylinder head servme uses the same procedure as the front cylinder head. Remove the engine from the frame (rear cylinder only/Section 7). Remavethe cylinder head cover (page 1075). Remove the camshaft (page 1077i. Remove the cam chain lensioner mounting bolts and sealing washers. Remove the cam chain tensioner. Loosen the bolls Remove the following cylinder head bolts and nuts: and nuts In a 78 mm bolts/washers crisscross parrsm a 6 mm bolt in several times ~10 mm nuts/washers Be careful rim to Remove the cylinder head. damage me mating surfaces when remaving the cylinder head, CYLINDER HEAD/VALVES Remove the gasket and dowel pins. Remove the cam Chain guide. '977’95. Loosen the screw and remove the carburetor insulator, KNSUIZELQ CYLINDER HEAD DISASSEMBLY ‘_ 2 'vzstspm'fimeRESSOHi Mark all pans instaii the valve spring compressor onto the valve during and compress the valve spring. disassemb/y so they can be placed TOOL: back in may; Valve spring compressor 07757 0010000 or original position 07957 73290001 4n 1‘ CYLINDER HEAD/VALVES CAUTION: ALVE STEM SEAL Compressing the valve springs more than necessary will cause loss of valve spring tension. ‘SPRINGS Remove the valve cotters and valve spring compressor, then remove the retainers, springs and valves. Remove the stem seals and spring seats. ‘ ' COTTERS NOTE Do not reuse a removed stem seais, Remove carbon deposits from the combustion chamber and clean off the head gasket surface CAUTIONV Avoid damaging the gasket and valve seat surface Check the spark ping hole and valve areas for cracks, INSPECTION CVLINDER HEAD Check the cylinder head for warpage with a straight edge and feeier gauge. SERVICE LIMIT: 010 mm (0004 in) VALVE SPRING Check the valve spring for fatigue or damage. Measure the free length of inner and outer valve springs. SERVICE LIMIT: Inner [IN]: 36.47 mm (1.436 ini (EX): 37,51mm11.477ini Outer [IN]: 4058 mm H.598 ini (EX): 4125 mm (1.624in) CYLINDER HEAD/VALVES VALVE STEM. VALVE GUIDE lnspect each valve Ior bending, burning, scratches or abnormal wear. insert the valves in their original positions in the clyinder head. Check that each valve moves up and down smoothly, without binding. Measurethe each Valve stern OD. and record it. SERVICE LIMITS: IN: 5.45 mm (0.215 In) EX: 6.55 mm (0.255 in) Ream the valve guide to remove any carbon build- up before measuring the guide, Insert the reamer from the combustion chamber side of the head and always rotate the reamer clockwise. NOTE 'Take care not to tilt or lean the reamer in the guide while reaming, 'If the valve guides are not reamed correctly, oil will leak past the valve stern seal. This could cause improper seat contact that cannot be corrected by reiacing. 0 Rotate the reamer clockwise, never counterclock- wise, when Inserting and removing. TOOLS: Valve guide reamer IN: 07954 2000001 or 07984i200000D EX: 07984iZE20001 or U7984’ZE2000D Measure each valve guide LB. and record it. SERVICE LIMITS: IN: 5.56 mm 10.219 inl EX: 6.65 rum l0,262inl Subtract each valve stem OD. from the corresponding guide l.D. to obtain the stemrtoV guideclearance. SERVICE LIMITS: IN: 010 mm (0004 IN EX: 0.11 mm l0.004 inl It the stemrtorguide clearance exceeds the service limit, determine if a new guide with standard dimensions would bring the clearance within tolerance. Ii so. replace any guides as necessary and ream to fit. If the stemetoeguide clearance exceeds the service limit with new guide, also replace the valve. NOTE, Inspect and reface the Valve seats whenever the valve guides are replaced lsee after page). VALVE GUIDE REAMER 10-16 CYLINDER HEAD/VALVES CAM CHAIN GUIDE CHAIN GUIDE Checkthe carn chain guide for wear ur damage. Replace the cam chain guide if necessary. CAM CHAIN TENSIONER CHAIN TENSIONER Checkthe cam chain iensionerforwearor damage. Replace the cam chain lensioner if necessary. VALVE GUIDE REPLACEMENT NOTE Refinish the valve seats whenever the valve guides are replaced in prevent uneven seating. Chill the valve guides in the freezer section of refrigerator for abom an hour. M Wear insulared gloves to avoid burns when handling the heated cylinder hand. Heal the cylinder head to 130* 140 DC1275*290 "Fl with a hot plaie or oven Do not heat the cylinder head beyond 150 ”C (300 ”Fl, Use iemperature indi- caiur sticks, available from welding supply stores, to be sure the cylinder head is heated to propertemr peramre. CAUTION. Using a torch to heat the cylinder head may cause warping. 10-17 CVLINDER HEAD/VALVES Support the cylrnder head and drlve out the old guides lrom the combustion chamber Slde of the cvlmder head VALVE GUIDE DRIVER TOOLS: Valve guide driver 5.5 mm (IN) 07742’ 0010700 - _ ‘ 6.6 mm (EX) 07742 oolozoo Not ‘ ' , *W’ available in us A or ‘ ‘ 07942 '6570700 CAUTIUNV Be careful nut m damage the cylinder head, Drlve the new guides in from (he Camshafl slde of ' ' IDE DRIVER the cylinder head to me valve gulde helgm whlle VALVE GU lhe cylinder head is still healed TOOLS: Valve guide driver 55 mm (IN) 07742 uommo 5.6 mm (EX) 07742 0010200 Not available .n u s A or 07942i6570100 Attachment 5.5 mm [IN] 07943 , MFSOWOD 6.6 mm {EX} 079M! MFSOZUO VALVE GUIDE PROJECTION: IN: 19.4i19.6 mm10V7fii 0 77 in) EX: 17.9 1B.1mm{0.70' 0.71 IN Let the cylinder head cool to room temperature, then ream the new valve guldes. TOOLS: Valve guide reamer IN: 079811 2000001 or 07934 2000000 EX: 07984’ ZE200010r 07984 ZEZOODD NOTE ‘Take Care Um K) ‘III or lean [he reamer In the gulde whlle reamlrlg. OtherWlse, the valves wlll be lnstalled slanted, causmg all leaks from the stem seal and improper valve seat Contact ”this occurs, valve seat refacing cannot be performed 'Insen lhe reamer from the combustion chamber 5lde of the head and always rotate the veamer clockwlsc. Clean the oylinder head thoroughly to remove any rnetal oartleles aher reaming and refacing the valve seat. 1 0'18 Hevlsed‘ Odober 1999, 1997 ~ 2000 VTSOOCICD @1999 Amerlcan Honda M010! Co.‘ Inc. - All Rights Reserved MSV 861719910) CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING INSPECTION Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coating of Prussian Blue to each valve face. Tap the valve against the valve seat several tlmes using a handvlapping tool, without rotating valve, to make a clear pattern. DAMAGED FACE UNEVEN SEAT Remove the valve and inspect the valve seat face WIDTH NOTE. The valve cannot be ground. If the valve face is burned ur badly worn or it it contacts the seat unevenly, replace the valve. inspect the valve seat lace for: ‘ Uneven seat width: * Bent or collapsed valve stem: Replace the valve and reface the valve seat - Damaged face: 7 Replace the Valve and reface the valve seat. - Centact area (too high or too lowarea): , Reface the Valve seat. TOO LOW TOO HIGH Inspect the width of the valve seat. The valve seat contact width should be within the specified dimension and uniform all around the circumference. STANDARD: 0.90A1.10 mm (0035,0043 in) SERVlCE LIMIT: 1.5 mm (0.06 in) T lf valve seat width is not Wlthin specification, reface the valve seat. ’\ L VALVE SEAT CONTACT WIDTH VALVE SEAT REFAClNG NOTE /\ - Follow the refacer manufacture’s Operating ’ A5“ instruction. A I Heface the valve seat whenever the valve guide — ' ’W has been replaced. 0 Be careful not to grind the seat more than , / \60” necessary, \ 10-19 CYLINDER HEAD/VALVES if the Contact area is too high on the valve, the seat must be lowered using a 32“ flat Cutter. If the cuntact area is too low on the valve, the seat must be raised using a 60° innercutter. Refinish the seatto specifications, using a 45” finish cutter. Using a 45" cutter, remove any roughness or irregularities from the seat. Using a 32“ Cutter, remove 1/4 of the existing valve seat material. Using a 60“ Cutter, remove the bottom 1/13 of the old seat. CONTACT Too HIGH OLD SEAT #NMDTH 32” CONTACT TOO LOW OLD SEAT WIDTH ’ , 60” .L ROUGHNESS OLD SEAT WIDTH OLD SEAT WIDTH 10-20 CYLINDER HEAD/VALVES ,' N1 mm 40mm) Using a 45° cutter, cut the seat to the proper width Make sure that all pitting and irregularities are removed. CAUTION 0 Excessive lapping pressure may deform of damage the seat. ' Change the angle of lapping taal frequently to prevent uneven seat wean 0 Lapping compound can cause damage if it enters between the valve stem and guide. After cutting the seat, applv lapping compound to the valve face, and lap the valve using light pressure. After lapping, wash any residual Compound off the cylinder head and Valve. Recheck the seat contact after lapping. CYILINDER HEAD ASSEMBLY COTTERS RETAINER a; 9 £3 a INNER VALVE SPRING ® %/~4 STEM SEAL g OUTER VALVE SPRING , . g 5;, ' ®@ , ® SPRING SEAT gs /’ -/ VALVE GUIDE CYLINDER HEAD VALVE 10-21 CYLINDER HEAD/VALVES Install the spring seals and new stem seals. Lubricate each valve stems and valve guide inner surfaces wtth malybdenum oil solution, lnstall the valvesinto the valve guides. VALVE NOTE' To avoid damage to the stem seal, turn the valve Slowly when valve installing. Install the Inner, outer valve springs with tightly would coils Slde facing the combustion chamber. Install the retainers. Install the valve spring compressor onto the valve and compress the valve springs, TOOL: Valve spring compressor 07757 *OO'lOOOO or 07957 * 3290001 CAUTION: Cumpressing the valve springs more than necessary will cause loss of valve spring tension. To ease install the valve cutters. installation of the callers, grease NOTE them first. M Support the cylinder head so that the valve heads will not Contact anything that causes damage. Set the cotters firmly uslng two soft hammers as shown. Hold one hammer on the valve stem and gently tap it with the other hammer. 10-22 CYLINDER HEAD/VALVES CYLINDER HEAD INSTALLATION 49 state, Canada ('977 '95) type. NOTE ‘The rear cylinder head uses the same service procedure as the front cylinder head. 'Be careful not to damage the mating surfaces when cleaning the cylinder mating surface. 0 When cleaning the cylinder mating surface, place the shop towel civer the cylinder opening to prevent dust or dirt from entering the engine. Clean any gasket material from the cylinder mating surfaces. Install the cam chain guide aligning its tab with the groove on the cylinder. Make sure that the end of the guide is inserted into place in the crankcase. Install the dowel pins and new gasket. install the insulator, aligning the boss on the cylinder head With the slot in the insulator as shown. Install the insulator bands and tighten the screws securely. ;, , ”’iNsutATOR 10-23 CYLINDER HEAD/ VALVES California Install the insulator bands aligning the pins on the ('97‘ '93) type. insulator bands with the Sluts on the insulators as shown. Tighten the band screws securely. Install the cylinder head to the cylinder. NOTE The cylinder heads are identified by marks on its camshaft side. “F": Front cylinder head “R": Rear cylinder head Apply oil to the cylinder head 10 mm nut threads and flange surfaces. Install and tighten the cylinder head bolts and nuts to the specified torque: TOHOUE: 10 mm nut: 47 N-m (4‘8 kgf-m , 35 Ibf-ftl 8 mm bolt: 23 N-m 12.3 kgf-m ,17lbf-fll 6 mm bolt: 12 N-m (1.2 kgf-m , 9 lbf-ft) NOTE' . Tighten all handrtight, then torque the big fasteners before little fasteners. 0 Tighten the bolts and nuts in a crisscross pattern in several times. Install the earn chain tensioner by aligning its end with the groove on the crankcase. 10-24 CYLINDER HEAD/VALVES Install the new sealing washers. Clean and apply a locking agent to the cam chain tensioner bolt threads. install and tighten the cam chain tensioner mounting bolt to the specified torque. TORQUE: 10 N-m 11.0 kngm , 7 Ibf-ft) install the engine to the frame (rear cylinder only/ Section 7i. Install the camshaft (see below). Install the Cylinder head cover (page 1031i. CAMSHAFI' INSTALLATION CAMSHAFT HOLDER ASSEMBLY VALVE ADJ USTI NG SCREW g(/ LOCK NUT l &\ \« VALVE ADJUSTING SCREW \ @\ lNTAKE ROCKER ARM l \ WAVE WASHER INTAKE ROCKER ARM SHAFT ‘5 EXHAUST ROCKER ARM SHAFT CAMSHAFT HOLDER EXHAUST ROCKER ARM NOTE: SHAFTS Camshaft lubricating oil is fed through oil passages in the cylinder head and camshaft holder. Clean the oil passages before assembling the cylinder head and camshaft holder. Lubricate each rocker arm shaft outer sliding surfaces with molybdenum oil solution. CYLINDER HEAD/VALVES lnstall the valve adjusting screw and lock nut. NOTE 'The exhaust rocker arm has larger slipper face than the intake rocker arm 0 The intake rocker arm shaft has two holes on each end. 0 The exhaust rocker arm shaft has two grooves on each end. Install the wave washer, intake rocker arm and intake rocker arm shaft to the camshaft holder. install the wave washer to the “A” mark side on the camshaft holder, install the exhaust rocker arm and exhaust rocker arm shaft to the camshaft holder. Position the grooves and holes in the rocker arm shafts vertically, aligning the bolt holes of the holder. ADJ USTI NG SCREW LOCK NUT SHAFT ROCKER ARM WAVE WASHER (EXHAUST) “A" MARK ROCKER ARM as WAVE WASHER SHAFT ”A” MARK 10-26 VALVE TIMING CYLINDER HEAD/VALVES CAMSHAFI' INSTALLATION , ”R M‘AVRKV’T' NOTE‘ 'The camshafts are identified by marks on the theirflanges: "F”: Front cylinder camshaft “R": Rear cylinder camshaft ”Index notch” : TDC [Top Dead Centerl mark I If both (front and rear) Camshafts are removed, Install the front cylinder camshaft first, then install the rear cylinder camshaft. 0 If the rear cylinder head was not serviced, remove the rear cylinder head cover to check the camshaft position. - If the front cylinder head was not serviced, remove the front cylinder head cover to check the camshaft position. OF THE MPRESSION STROKE TDC OF THE EXHAUST STROKE TDC OF THE COMPRESSION STROKE TDC OF THE EXHAUST STROKE CAMSHAFT SERVICE FOR BOTH CYLINDER ”FT” MARK Remove the timing hole cap, Turn the crankshaft counterclockwise and align the “FT" mark on the flywheel with the index mark on the left crankcase cover, then check the front cylinder piston is “TDC (Top Dead Centerl”. Install the front cylinder camshaft (page 10-29). CYLINDER HEAD/VALVES Then turn the crankshaft counterclockwise 308° and “RT" M align the "RT" mark on the flywheel with the index mark on the left crankcase cover, then install the rear camshaft (see after pagel. REAR CYLINDER CAMSHAFT SERVICE ONLY (FRONT CVLINDER CAMSHAFT WAS NOT SERVICED) If the front cylinder head was not serviced, remove the front cylinder head cover (page 1075) and check the camshaft position as follows: Remove the front cylinder head camshaft end holder (page 1077l. Remove the timing hole cap and crankshaft hole cap. Turn the crankshaft counterclockwise and align the "FT" mark on the flywheel with the index mark on the left crankcase cover, then check that the camshaft “TDC (Top Dead Center)" mark is facing up. If the ”TDC (Top Dead Center)" mark .5 facing up, turn the crankshaft counterclockwise 308” and align the ”RT” mark on the flywheel with the index mark on the left crankcase cover, then install the rear camshaft (see after pagel. lfthe “TDC (Top Dead Center)" mark is facing down, turn the crankshaft counterclockwise 668° (360° + 308“ l and align the "RT” mark on the flywheel with the index mark on the left crankcase cover, then install the rearcamshaft (see after pagel. FRONT CVLINDER CAMSHAFT SERVICE ONLY (REAR CYLINDER CAMSHAFT WAS NOT SERVICEDI if the rear cylinder head was not serviced, remove the rear cylinder head cover (page 10-6) and check the camshaft position as follows: Remove the front cylinder head camshaft end holder (page 10.7)_ Remove the timing hole cap. Turn the crankshaft counterclockwise and align the ”RT" mark on the flywheel with the index mark on the left crankcase cover, then check that the camshaft "TDC (Top Dead Center)" mark is facing up. 1 0-28 CYLINDER HEAD/VALVES If the "TDC (Top Dead Center)" mark is facing up, “FT“ MAR turn the crankshaft counterclockwrse 412“ lSBDUr 52° ) and align the "FT" mark on the flywheel With the index mark on the left crankcase cover, then install the front camshaft (page 10-30l lf the ”TDC (Top Dead Centerl” mark is facing down, turn the crankshaft counterclockWise 52° and align the ”FT“ mark on the flywheel with the index mark on the left crankcase cuver, then install the front camshaft (page 10*30l. CAMSHAFT INSTALLATION Remove the timing hole cap. Turn the crankshaft counterclockwise and align the “FT" mark irear cylinder: "RT" markl on the flywheel with the index mark on the left crankcase cover Install the cam sprocket to the cam chain with the ”W" mark facing the inside and align the timing marks (index line) on the cam sprocket and the upper surface of the cylinder head. Install the camshaft through the cam chain and cam sprocket with the camshaft "TDC" mark is facing up, NOTE The Camshafts are identified by marks on the their flanges: HF": Front cylinder camshaft ”R”: Rear cylinder camshaft ”index notch”: TDC (Top Dead Center) mark CYLINDER HEAD/VALVES install the dowel pins. Lubricate each rocker arm slipper surfaces with molybdenum oilsolution. NOTE Before camshaft holder installation, loosen the valve adjusting screw and lock nut fully. install the camshaft holder assembly. Install the oil guide plate. install the camshaft holder bolts (8 mm), nuts and washerts mml. Tighten the bolts (8 mm) and nuts 18 mm) to the specified torque. TORQUE: 8 mm bolt: 23 N-ml2.3kgf-m,17lbf-ftl 8 mm nut: 23 N-m (2.3 kgf-m ,17lbfvfi) lnstall the cam sprocket on the camshaft flange and recheck that the timing marks align with the upper surlace ofthe cylinder head. Clean and apply a locking agent to the cam sprocket bolt threads. NOTE Be careful not to let the cam sprocket bolts fall into the crankcase. Align the cam sprocket bolt holes in the cam sprocket and camshaft. Temporarily install the Cam sprocket bolt. Turn the crankshaft counterclockwose 360” and tighten other sprocket bolt to the specified torque. TORQUE: 23 N«m12t3 kgf-m, ‘l7 lbf-l‘t) 10-30 CYLINDER HEAD/VALVES Turn the crankshaft counterclockwise 360“ and tighten other sprocket bolt to the Specified torque. Remove the 2 mm pin holding cam chain tensioner wedge A. NOTE: 0 Be careful not to let the 2 mm pm fall into the crankcase. IDo not forget to remove the 2 mm pin before installing the cylinder head cover. lnstallthe dowel pins. Install the camshaft end holder with it’s flat surface on the holderfacmg in Install and tighten the camshaft and holder bolts to the specified torque. TORQUE: ’97i’98: 9 N-m (0.9 kgf‘m , 6.5 Ihf-t'tl After '98: 10 N~m11.0 kgf-m , 7 lbf-ftl Adjust the valve clearance (page CH 1 ). CYLlNDER HEAD COVER INSTALLATION Fill the oil pockets inthe head with the engine oil. CYLINDER HEAD/VALVES Clean the gasket groove of the cylinder head cover. Apply Honda Bond A or equtvalent to the gasket groove of the cylinder head cover, then install the new gasket into the groove. FRONT Install the front cylinder head cover to the front cylinder Install the rubber seals and washers. Install and tighten the cylinder head cover bolts to the specified torque. TORQUE: 10 N-rn I‘LD kgf‘m , 7 Ibf-ft) Install the new O-rlng to the water pipe with the small diameter side facing the cylinder head. Install the water pipe to thefront cylinder head. Install and tighten the bolt securely. Connect the spark plug caps. Install the inlet manifold (After ’98: page 7-11). Install the carburetors ('97 7'98: page 5-26). Install the air cleaner housing lpage 55). Install the fuel tank lpage 2-7). Install the steering covers (page 273). Replace the coolant (page 676). 10-32 CYLINDER HEAD/VALVES REAR Install the rear cyllnder head cover to the rear cylinder. Install the rubber seals and washers. Install and tighten the cvllnder head cover bolts to the specified torque TORQUE: 10 N-m (1,0 kgi-m ,7 lbfrft) lnstall the new Orrmg to the water pipe with the small dlameter side facing the cylinder head. lnstall the water pipe to the rear cylinder head. lnstall and tighten the bolt securely, Connect the spark plug caps. CYLINDER HEAD/VALVES install the valve adjusting cover and socket bolt. Tighten the socket bolt to the specified toruque TORQUE: 12 N-m (1.2 kgf-m , 9 |bf~ftl Install the inlet manifold (After ’58: page 7,1“ Install the Carburet0r(s) (’97‘498: page 5-26, After ’98: page 5-27). install the air cleaner housing (page 5-5). Install the fuel tank (page 277l, Install the steering covers (page 273). Replace the coolant (page 5-6l. 10-34 MEMO CYLINDER/PISTON 11-0 11. CYLINDER/PISTON SERVICE INFORMATION 11-1 CRANKCASE STUD BOLT INSPECTION 11-71 TROUBLESHOOTING 11-2 PISTON INSTALLATION 11.3 CYLINDER REMOVAL 11-3 CYLINDER INSTALLATION 11.9 PwTONREMOVAL 115 SERVICE INFORMATION GENERAL - The engine must be remuved from the frame before servicing the cylinder and piston. 0 Take care not to damage the cvlinderwall and piston. - Be careful not to damage the mating surfaces by using a screwdriverwhen disassembling the cylinder. ‘ Clean all disassembled parts with clean solvent and dry them using compressed air before inspection I When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their Original locations. SPECIFICATIONS Unit: mm lin) ITEM STANDARD ‘ SERVICE LIMIT Cylinder |.D, , 75000775015 l2.9528*2.9533) 75.10l2,9_5:/l Out of round . W ‘ 0.06 (0.002) _ i Taper 7m 7 0.06 (0.002I 7 7 i Warpage ‘ A 7 7 0.10 (0.0041 . Piston, i Piston mark direction ,, W ’UPF.‘I‘E.‘2"_V?"’ the intake side 7 . , piston rings . Piston O.D. . 74.905740901205147 295241 7400120401 !7 Piston O.D. measurement point 10 mm 1 .4 In) from bottom Of skIrt _M "V A '11 Piston pin bore |.D. 18.002i18.00810.7087*0.7090) 18.05l0.711l ,. _nwp_i‘n 0,0. 17.995.718.00010.7084*0,7087I 17.93 l0.708l PistO pistOn pin clearance 000270.014 (00001700006) 0.04 (DDUZI Piston ringrtoVring TOp 0.015~D.045 l0.0006*0.0018l 0.10 (0.004) groove clearance Second 0.015‘ 0.045 (0.0006i0.0018l 0.10 (0.004} Pistun ring end gap Tap 0.10 0.3010.004~0.012> 0.5 (0-021. Second 010*030 ID.DO4>0.012I 0.5 (0.02) Oil lside [ailiii 02 70701000070028) 0.0 (0.04) W Piston ring mark Top/second ”N mark Cylinderrtonistqn plearance 001070.050 (00004103201 ‘ 0.10 (0.004) Cunnectingrod smallend |.D. 18.016m18.03410.7093*0.7J>00l, ,__ 133.07 l0.711l Connecting rodrtoniston pin clearance 0315,0040 l0.0006*0.0016i 0.06 (0.002) 11-1 CYLINDER/PISTON TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed - Leaking Cylinder head gasket , Worn, stuck or broken piston rings -Worn or damaged cylinder and piston - Loose spark plug Compression too high, over heating or knocking 'EXCeSSIVE carbon buildup in cylinder head oron top of piston Abnormal noise ' Worn cylinder and piston 'Worn piston pin or piston pm hoie -Worn connecting rod smaH end Excessive smoke - Worn cylinder, piston and piston rings - Improper instaiiauon of piston rings - Scored or scratched piston orcylinderwali 11-2 CYLINDER/PISTON CYLINDER REMOVAL NOTE The from cylinder service uses the same procedure as the rear cylinder. Remove the cylinder head (page 1042). Remove the joint collar clips. Slide the cylinder joint collar toward eilher lhe from or rear cylinder. Remuve the bolls, water hose joim and O—rlng (frontcvlinderonlyl. Remove the cylinder. NOTE IArtach a piece of mechanic's wire ‘0 the cam chain to prevem ii from being dropped imo lhe crankcase. ' Be careful not to damage the mating surfaces by using a screwdriver when disassembling the cylinder i CYLINDER/PISTON Remove the O-ring. Remove the gasket and dowel pins. Clean of! any gasket maternal from the cylinder uppersurface, NOTE Be careful not to damage the gasket surface. INSPECTION inspect the cylinder wall for scratches and wear. Measure and record the cylinder ID. at three levels in both the X and Y axes. Take the maximum reading to determine the cylinder wear. SERVICE LIMIT: 75.10 mm l2t957 inl Measure the cylinder tor out of round at the three levels in an X and V axis. Take the maximum reading to determine the out of round. SERVICE LIMIT: 0136 mm (0.002 in) Measure the cylinder for taper at three levels in an X and Y axis. Take the maximum reading to determine the taper. SERVICE LIMIT: 0.06 mm l0.002 in) The cylinder must be rebored and an oversize piston fitted if the service limits are exceeded. The following oversize pistons are available: 0.25 mm (0.010 in), 0.50 mm (0.020 in). The cylinder must be rebored so that the clearance for an oversize piston is 0,020i0.060 mm (0.0008* 0.0024 in). 11-4 CYLINDER/PISTON Check the cylinder for warpage by placing a straight edge and a feeler gauge. SERVICE LIMIT: 0.10 mm (0.004 inl PSTONREMOVAL NOTE - Place a shop towel over the crankcase opening to prevent piston pin clips from falling into the crankcase. I The rear piston service using the same procedure as for the front piston. Remove the piston pin clip, piston pin and piston. Spread each piston ring and remove it by lifting it up at a point just opposite the gap. CAUTION: I Do not damage the piston ring by spreading the ends too far. I Be careful not to damage the piston when the piston ring removal. Clean carbon deposits from the piston NOTE' Clean carbon deposits from the piston ring grooves with a ring that will be discarded. Never use a wire brush; it will scratch the grooves. 11-5 CYLINDER/PISTON INSPECTION Inspect the piston for cracks or other damage. Inspect the ring grooves for excessrve wear and carbon build-up. Measure each piston O.D.. NOTE Take measurements 10 mm (0.4 in) from the bottom, and 90" to the piston pin hole. SERVICE LIMIT: 74.90 mm 12.949 ini Calculate the piston-to~cylinder clearance. Take the maximum reading to determine the clearance lelinder ID; 1174). SERVICE LIMIT: 0.10 mm 10.004- lni Measure each piston pin hole ID. in an X and Y axis. Take the maximum reading to determine |.D,. SERVICE LIMIT: 18.05 mm 10.711 inl Measure the piston pin CD. at three points. SERVICE LIMIT: 17.98 mm (0.708 inl Calculate the pistonrwrpislon pin clearance. SERVICE LIMIT: 0.04 mm (0.002 in) Measure the connecting rod small end |. .. SERVICE LIMIT: 18.07 mm (0.711 ml Calculate the connecting rod small endrtoniston pin clearance. SERVICE LIMIT: 0% mm (0.002 ml 10mm (0.4 in) 11-6 CYLINDER] PISTON Always replace the Inspect the piston ring, and replace them if they are pistan rings as a worn. sex. Reinstall the piston rings (page 11»8l intothe piston grooves. Push in the ring until the outer surface of the piston ring is nearly flush with the piston and measure the clearance using a feeler gauge. SERVICE LIMIT: Tap: 0.10 mml0.004inl Second: 0.10 mm (0.004 inl Using a piston, push the ring securely into the cylinder and measure the end gap using a feeler gauge. SERVICE LIMIT: Top: 0.5 mm (0.02 inl Sncand: 0.5 mm (0.02 in) Oil: 0.9 mm (0.04 in) CRANKCASE STUD BOLT INSPECTION Check the stud bolts for looseness. lf the stud bolts are loose, remove the stud bolts and apply engine oil to the threads and tighten the stud bolt securely or replace the stud bolt and clean and apply a locking agent to the new stud bolt threads and tightenthe stud bolt securely. NOTE E Install the stud bolts with its tah side facing to the cylinder head side. After installing, be sure to measure the length from the top uf each stud to crankcase surface. STANDARD LENGTH: 8 X 189 mm: 186 mm (7.3 in) 10 X 177 mm: 169 mm (6.6inl 12 X 177 mm: 169 mm 16.6inl PISTON STUD BOLT TAB 8X189mm 10X177 mm. 12 X177 mm 186 mm (7.3 inl 169 mm 15.6 in) xl/lr’r , CYLINDER/PISTON PISTON INSTALLATION NOTE The rear piston service uses the same procedure as the front piston. Clean the piston heads, ring lands and skins, Carefully install the piston rings onto the piston with their markings facing up. CAUTION: - Do nut damage the pistan ring by spreading the ends too far. - Be carelul not to damage the piston when the piston ring installation. NOTE, - Do not confuse the top and second rings: The top ring is chromeicoated and second ring is not coated (black). 0 After installing the rings they should rotate freely, without sticking. 0 Space the ring end gaps 180 degrees apart, TOP RING SECOND RING SIDE RAIL SPACER PISTON TOP RING 4—— m/ 4— W—SECOND RING 4.___ SIDE HAIL SPACER 11-8 NOTE When cleaning the cylinder mating surface, place a shop towel over the cylinder opening to prevent dust or dirt enter the engine. Clean any gasket material from the cylinder mating surfaces ofthe crankcase. NOTE' Place a shop towel over the crankcase opening to prevent piston pin clips from falling into the crankcase. Apply molybdenum solution to the piston pin outer surfaces. Apply engine oil to the connecting rod small end and piston pin hole. Install the piston with its “IN” mark facing the intake side. Install the piston pin. Install the new piston pin clips. CAUTION: Always use new piston pin clips. Reinstalling used piston pin clips may lead to serious engine damage. NOTE - Set the piston pin clip in the groove properly. I Do not align the clip’s end gap with the piston cut-out. CYLINDER INSTALLATION NOTE O The rear cylinder service using the same procedure as for the front cylinder. 0 When cleaning the cylinder mating surface, place a shop towel over the cylinder opening to prevent dust or dirt enter the engine. Install the dowel pins and new gasket. CYLINDER/PISTON PISTON % PISTON PIN I A» Lfi; GASKET w». ,V ._ , CYLINDER/PISTON Apply coolant to the new O»ring and install it to the walker iolnt of the cylinder. w—vv . @OVHING Apply engine oil to the cylinder wall and piston outer surfaces and piston rings. CAUTION: Be careful nut to damage the piston rings and cylinder walls. Rome the cam chain thruugh the cylinderv install the cylinder over the piston rings by hand while compressing xhe pismn rings. Slide the cylinder joint collar to the its original position. install the joint collar clips to the groove on the water joint of the cylinder, 11-10 CVLlNDER/PISTON Apply coolant to the new O-ring and install it to the groove on the water hose joint of the front cylinder liront cylinder onlyi. Install and tighten the hose iolnt bolts securely (front cylinder only). install the cylinder head (page 10*23i. 11-11 CRANKSHAFFITRANSMISSION 12 N-m (1.2 kgf‘m , 9 Ibf-flh 23 N-m12.3 kgf-m,17lbf-fl| 33 N-m [3.4 kgf-m , 25 lbf-fi) 9 N-m10‘9 kgf-m , 5.5 lbflh) 23 Nm (2.3 kgi-m,17|bf-ft) 12-0 12. CRANKSHAFT/TRANSMISSION SERVICE INFORMATION 12-2 TRANSMISSION TROUBLESHOOTING 12-3 CRANKCASE BEARING REPLACEMENT CRANKCASE SEPARATION 12-4 CRANKCASE ASSEMBLY CRANKSHAFr/CONNECTING ROD 12—6 1244 12-23 12-25 9 N-m 10.9 kgi-m , 6.5 Inf-fl) \~\\ / , @ \ fi f 23 N-m (2.3 kgf-m , ’I7 Ibf-ft) (5 23 N-m (2.3 kgf-m, 9 N-m (0.9 kgf-m , 6.5 IbI-m 7 lbf-fi) r, . r, \ 'r (V 12 N-m (1.2 kgf-m , 9 lbf-ft) 23 N-rn 12.3 kgf-m,17|bf-m 9 N-m (0.9 kgf—m , 6.5 Ibf-ft) 10 N-m11.0 kgfvm, 17 Ibf-ft) 12-1 CRANKSHAFr/TRANSMISSION SERVICE INFORMATION GENERAL OThe crankcase halves must be separated to service the crankshaft, connecting rod and transmission (including the shift fork and shift drum). Tc service these parts, the engine must be removed from the engine (Section 7i. 0 The following parts must be removed before separating the crankcase: *Water pump (Section SI *Cvlinder head (Sectlon 1UI *Cylinder, piston (Section 11) *Clutch, gearshift linkage and primary drive gear (Section 8) *Alternator, flywheel (Section 9) "Starter motor (Section 18! _ Neutral switch, oil pressure switch lSection 19I t Be careful notto damage the crankcase mating surface. U When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. 0 Connecting rod and crankshaft bearing Inserts are select fitted and are identified by color code. Select the replacement bearings using the selection tables, After installing new bearings, recheck them with plastigauge to verify correct clearance. I Clean and apply sealant tothe crankcase mating surfaces. Wipe off excess sealant thoroughly. SPECIFICATIONS Unit: mm (in) ITEM STANDARD SERVICE LIMIT Crankshaft Side clearance 0.05’020 (0.002‘0008) ‘ D.30(0.012I Runout 9.05l0.002l Crank pin oil clearance ooze—0.05210,0011vocozol No.07 (usual .7 Mainjournal oil clearance 50 dia.” 0,025” 0.041 l0.0010*0.0016l ‘ 0.06 (0.002I Transmission Gear |.D. M2, M4, C3 28000-28021(1.1024*I.10321 28.04 (1. Of“ M c1 < 24.0007 24.021 (0.944970345“ ‘ 24.94 (0. 32) Bushing OD. M2,M4, C3 ‘ 27.959i27.950(1.1007i1.1016) 27.94l1.100l ‘ . c1 23.9597 23.930 (03433703441) 23.94 (0.94m . Bushing |.D. M2 , 25000725021 I0.9843*0.9851) w { 25.04 (0.986I C1 20.016i20.037 (0.7880~O.7889) 20.06 (0.79m , GearrtoVbushing M2, M4 D,020*0.052 (0.0008 11.0024) , (0,004) 3 clearance c1,c3 . 0.0204062 l0.0008*0.0024l . u (o,oo4l I Mainshaft 00. M2 bushing 24.959 24.980 (0.9826i03835) 24.94 (0.982l Countershaft O.D. CI bushing 19.980' 19.993l0.7866*0.7871) 19.96ID.785I ,7 Bushing—to-shaft 77 M2 D.020*0.06210.0008*0.0024l 0.10 10-004! . ___ clearance C1 “023,00‘57 [0.0009*0.0022l w 01100100“ Shiftfork, Fork l.D. 13.000*13.013(0,5118*0.5125) . ,. 13,04ID.513I fork shaft Clawthickness 5.93m6.0010,233“0.236) 5.61012) w Fork shaft OD. 12.966i12.98410.5105" 0.5112) 1230 (0.508) Shift drum CD. (at leftsidejournal) 11.966i11.98410.4711“ 0.4718) 11.94I0.470) 12-2 TORQUE VALUES Mainshafl bearing set plate bolt Countershal‘t bearing set plate bolt Cam chain tensioner set plate bolt Crankcase 8 mm bolt 6 mm bolt Connecting rod bearing cap nut TOOLS Attachment, 42 X 47 mm Attachment, 52 X 55 mm Pilot, 20 mm Pilot, 25 mm Pilot, 22 mm Driver Main bearing driver attachment Bearing remover set A Remover weight s Remover handle ,, Bearing remover head TROUBLESHOOTING Excessive noise - Worn connecting rod big end bearing ~ Bent connecting rod - Worn crankshaft main bearing - Worn transmission gear Hard to shift ' Improper clutch adjustment ' Improper clutch operation ' Bent shift fork ' Bent shift fork shaft - Bent shift spindle - Damaged shift drum cam grooves - Incorrect engine oil weight Transmission jumps out of gear ‘ Worn gear dogs or slots - Bent fork shaft - Broken shift drum stopper - Worn or bent shift forks . Broken gearshift linkage return spring ’97 *'98: After ’98: 12 Nm (1.2 kgf-m,9 (bf-ft) 9 N-m (0.9 kgf-m , 6.5 lbf-ftl 12 N-rn (1.2 kgf-m , 9 lbf-lt) 23 N-m (2.3 kgf-m,17lbl‘-ftl 9 N-m (0.9 kgf-m , 6.5 lbf-ftl 12 N-m (1.2 kgfrm,9 |bf>ftl 33 N-m (3.4 kgf-rn , 25 lbf-ftl 07746* 0010300 07746'0010400 07746i0040500 07745 7 0040600 07746 7 00A1000 07749 7 0010000 07HMF7MM90400 07936i3710001 07741 *OO'lUZO’I 07936—3710100 07936 7 3710600 CRANKSHAFI'ITRANSMISSION Apply a locking agent to the threads Apply a locking agent to the threads Apply a locking agent to the threads Apply oil to the threads and seating surface Not available in U.S.A. or 07936 7 3710200 12-3 CRANKSHAFI'ITRANSMISSION CRANKCASE SEPARATION Remove the engine from the frame (Section 7). Refer to Service information (page 12-1) for removal of necessary parts before disassembling the crankcase. Remove the bolts and countershah bearing set plate. Remove the engine sub harness. Remove the bolt and front cam chain tensioner set plate Remove the front cam chain from the crankshaft. Remove the bolt and rear cam chain tensioner set plate. Remove the rear cam chain and cam chain drive sprocket. Remove the mainshaft bearing set plate by removing the bolts. 12-4 CRANKSHAFT/TRANSMISSION Remove the bolt and gearshift cam plate Remove the left crankcase bolts. NOTE - Loosen the 6 mm bolts first, then 8 mm bolts. - Loosen the left crankcase bolts in a crlsscross pattern in several steps. Remove the right crankcase bolts. 8 mm‘BOLTS‘X if»; NOTE, ‘3 .jé 7 {5‘3 5. gc; ‘ " I Loosen the 6 mm bolts first, then 8 mm bolts. XV” -- ’ : I Loosen the nght crankcase belts in a crisscross pattern in several steps. Place the crankcase with the left crankcase down RIGHT CHANKCASE and remove the right crankcase. 12-5 CRANKSHAFTITRANSMISSION NOTE i RIGHiCRA’NKCAS’Ei- , -Separate the right crankcase from the left crankcase Whlle prying at the points as shown. OSeparate the right crankcase from the left crankcase while tapping them at several locations with a soft hammer. Remove the dowel pins. Clean off the sealant from [he left and right crankcase mating surfaces. CRANKSHAFT/CONNECTING ROD CAUTION: Be careful not (a damage the crankshaft main bearing and connecting rad bearing while servicing the crankshaft/connecting rod. REMOVAL Separate the crankcase (page 1274). Remove the crankshaft/connecting rod from left crankcase. INSPECTION Inspect the connecting rod big end side clearance. Measure the Side clearance by inserting the feeler gauge between the crankshaft and connecting rod large end as shown. STANDARD: 0.30 mm (0.012 in) 12-6 CRANKSHAFT/TRANSMISSION Place the crankshaft on Veblocks. Rotate the crankshaft two revolutions and read the runout with a dial indicator. Divide the total indicator reading In half to get the actual runout. SERVICE LIMIT: 005 mm 10.002 In) Remove the connecting rod bearing cap nuts, bearing caps and cannecting rod. NOTE Tap the side of the cap lightly if the bearing cap is hard to remove. Mark the bearing caps, bearings and connecting rod as you remove them to indicate the correct cvlinder and pusrtion on the crankpins for reassembly. Connecting rod small end Inspection (page 11~6l CONNECTING ROD BEARING INSPECTION Inspect the bearing inserts for unusual wear, damage or peeling and replace If necessary. 12-7 CRANKSHAFI'ITRANSMISSION CRANKPIN OIL CLEARANCE PLASTIGAUGE Da not rotate the Clean off any oil from the connecting rod bearing crankshall during inserts and crankpln. inspectmnv Put a strip of plastigauge on each crank pin avoiding oil hole. Install the connecting rod bearing and bearing cap to the Original location Install and tighten the connecting rod bearing cap nuts In a crisscross pattern in several steps. TORQUE: 33 N-m13.A kgfvm , 25 "film Remove the connecting rod bearing cap nuts, _ PLASTIGAUGE bearing cap and bearing. Measure the compressed plastigauge at its widest point on each crank pin to determine the oil clearance. SERVICE LIMIT: 007 mm (0.003 in) If the clearance exceeds the service limit, select the correct replacement bearings as follows. CONNECTING ROD BEARING SELECTION Determine the connecting rod ID. number, The code will be either a number 1 or 2 located on the rod inthe area shown. 12-8 CRANKSHAFT/TRANSMISSION Determine the corresponding crankpin OD. code lor measure the crankpin 0D,). The code will be either a letter A or B on the crank weight. Cross reference the crankpin and connecting rod codes to determine the replacement bearing collar. Unit1rnrnlinl Crankpin 0.0. A B ‘ 39.982 7 39.590 39 576 7 39.881 Connecting rod (1.5738 *157“) l.D code (1574171574Al ‘ , 1 ‘ 43.000 7 43.007 C B H 6929 7 1.6932) lBrown) (Blackl 43 one B i A 11.5932 (Blackl (Blue) BEARING INSERT THICKNESS: A lBluel: 1.495 7 1.499 mm (0.0589 7 0.0590 in) B (Blackl: 1.491 7 1.495 mm (0.0587 m 0.0589 in) C (Brown): 1.487 7 1.491 mm 10.0585 7 0.0587 inl CONNECTING ROD/CRANKSHAFT SELECTION Connecting red and crankshaft are select fitted. Record the connecting rod weight code (A, B or Cl. Record the crankshaft weight code (L, H or No code). if the connecting rod and/or crankshaft are replaced, select them with the following fitting table. NOTE' The “O” mark in the table indicates that mating is possible in the crossed codes. CRANK PIN O.D. CODE BEARING CONNECTlNG ROD WEIGHT CODE 12-9 CRANKSHAFT/TRANSMISSION Um“ mm “m CRANKSHAFTWEIGHT CODE ‘ \_ From connecting rod ‘\ weight code %\ A B c Hearconnecting rod weight code “ A O i O ‘ t t i CAUTION: For selecting crankshaft weight. ' Select ”L” crankshaft weight, if the Iran! rod and rear rad have cade A I * l. ' Select ”H" crankshaft Weight, if the front rod and rear rad have EDdB C ( * *1. 0 Select crankshaft weight with no code, nthsr than the above two cases. CRANKSHAFT/CRANKCASE SELECTION Crankcase and crankshaft are select fitted. Record the main journal O‘D. code number“ or 2). Record the main bearing LD. code (A or B). if the crankcase end/or crankshaft are replaced, select them with the foliowmg fitting table. NOTE‘ The "0" mark in the table indicates that mating is possible in the crossed codes. Mainiournal , O.D. code Main bearing \_\ LD. code L\\ A B i i 12-10 CRANKSHAFI'ITRANSMISSION MAIN BEARING INSPECTION Inspect the bearing inserts for unusual wear, damage or peeling and replace if necessaryv MAIN BEARING OIL CLEARANCE Clean off any oil from the main bearing insens and crankshaft journals. Measure and record the Crankshaft main journal O.D.. Measure and record the main bearing l.D.. Calculate the oil clearance by subtracting the journal CD. from bearing I,D.. SERVICE LIMIT: 006 mm (0.002 inl Replace the bearing if the service limit is exceeded. Select the replacement bearing lsee below). CRANKSHAFT/ TRANSMISSION MAIN BEARING SELECTION Record the main journal O.D. code number l1 or 2). Press out the main bearing using the speclal tools and hydraulic press: CAUTION: When remaving bearings, always use a hydraulic press and special faols to prevent crankcase damage. TOOLS: Driver 07749—0010000 Main bearing driver O7HMF * MM90400 attachment Measure and record the crankcase ID. (A or B). CrossVreference the crankcase and main journal codes to determine the replacemenl bearing color. Unit: mm lin) \ Main journal 1 2 O.D. code Crankcase \ 44,992 7 45.000 ”.9811 — “.991 (17713 17717l (1.7710 17713) |.D. code A 48.990 7 49.000 C B 111.9287 7 1.9291) lBrownl (Black) B 48.000 7 49.010 B A (1.9291 ' 1.8295)‘ (Black) lBIUe) BEARING INSERT THICKNESS: AlEluEB) 2.003 7 2.013 mm 10.0789 7 0.0793 inl E lBlackl: 1.998 ' 2.008 mm 10,0787 7 0.0791 inl C lBrownl: 1.993 7 2,003 mm (0.0785 7 0.0789 inl DRIVER ATTACHMENT MAIN BEARING 12-12 CRANKSHAFT/TRANSMISSION A! installation. align me hearing all hole with the crankcase an hale Apply molybdenum disulfide oil to the outer surface of the new main bearing. Place the bearing in the crankcase by aligning the tab With the crankcase groove. Press the main bearing into the crankcase. CAUTION: Be careful not to damage the bearing. TOOLS: Driver 07749iDO‘IUOOD DRIVER Main bearing driver O7HMFiMM90400 attachment NOTE If the main bearing is replaced, record the new main bearing LD. code letter on the crankcase. INSTALLATION BEARINGS n f Clean off any oil from the main bearing inserts and connecting rod bearing cap Install the main bearing to the connecting rod and bearing cap by aligning the tab on the bearing with the groove on the connecting rod and bearing cap. TAB/GROOVES install the connecting rods and bearing caps on the CRANK PIN CONNECTING ROD crankpin. Be sure the each part is installed in its original position. NOTE. Align the ID. code on the bearing cap and connecting rod. CRANKSHAFI'ITRANSMISSION Apply oil to the connecting rod bearing cap nut threads and flange surface. :9 NUTS lnstall and tighten the connecting rod bearing cap \ nuts to the specified torque in several steps. TORQUE: 33 N-m (3.4 kgf-rn , 25 |bf~ftl After tightening, check that the connecting rods CRANKSHAFT/CON move freely Without binding. Apply molybdenum disulfide all to the main bearing sliding surfaces and install the crankshaft into the (aft crankcase. Assemble the crankcase (page 12-24l. TRANSMISSION Do not target [0 1m Slall the transmis sion end washer. FORK SHAFT REMOVAL Separate the crankcase (page 7241i. Remove the shift fork shaft from the Shift forks. Remove the shift drum and shift forks. Remove the mainshaft and countershaft from the left crankcase as assembly, MAl NSHAFT/COUNTERSHAFT 12-14 CRANKSHAFT/TRANSMISSION DISASSEMBLY MAINSHAFT NOTE, OKeep track of the disassembled parts (gears, bushings, washers, and snap rings) by stacking them on a tool or slipping them onto a piece of wlre I Do not expand the snap ring more than necessary for removal. To remove a snap ring, expand the snap ring and pull it off usrng the gear behind it. COUNTERSHAFT Disassemble the mainshaft and countershaft. INSPECTION GEAR Check the gear dogs, dog holders and teeth for damage or excessive wear. Measure the ID. of each gears. SERVICE LIMITS‘ M2, M4, C3: 28.04 mm (1.104 in) C1: 24.94mm10382in) BUSHING Check the bushings for damage or excessive wear. Measure the OD. oI each bushings. SERVICE LIMITS: M2, M4, C3: 27.94 mm (1.100 inl (:1: 23.94 mm (0.943 in) Measure the ID. of each bushings. SERVICE LIMITS: M2: 25.04 mm10.986in) C‘I: 20.06 mm 10.790 In) MAINSHAFT/COUNTERSHAFT Check the spline grooves and sliding surfaces for I damage or abnormal wear. _, Measure the CD. of the mainshaft and counterr shaft at the gear and bushing sliding areas. SERVICE LIMITS: Mainshaft: M2 gear bushing: 24,94 mm (0.982 in) Countershaft: (:1 gear bushing: 19.95 mm (0.786 in) Calculate the clearance by subtracting mainshaft and countershaft CD. from gear bushing |.D.. CRANKSHAFT/TRANSMISSION SERVICE LIMITS: M2, 01: 0.10 mm (0.004 ml Calculate the clearance by subtracting gear bushingO.D,fromgearl.D.. SERVICE LIMITS: M2, MA, 01, 03: 010 mm 10,004 ln) SHIFI' DRUM/SHIFT DRUM BEARING Remove the dowel pm. Inspect the shlft drum for scoring, scratches or evidence of insufficient lubllcakion. Check the shift drum grooves for abnormal wear or damage. Turn the inner race of bearing with your finger. The bearing should turn smoothly and quletly. Measure the shift drum shaft CD. at the left side journal SERVICE LIMIT: 1194 mm (0.470 in) DOWEL PIN DFlUM BEARING \ 12-16 CRANKSHAFI'ITRANSMISSION Install ‘he dowel pin mm the shift drum. SHIFI' FORK. SHIFT FORK SHAFT Check for abnormal wear or deformation Measure the shifl fork LB. and claw thickness. SERVICE LIMITS: I.D.: 13.04 mm (0.513 in) Clnw thickness: 5.6 mm (022 in) Check for abnormal wear, damage or straightness. Measure the shift fork shaft 0D,. SERVICE LIMIT: 1230 mm (0.508 in) SHIFI‘ DRUM JOURNAL, SHIFI' FORK SHAFI' JOURNAL Check the right and left crankcase shifl fork shaft journal for wear crdamage, Check the left crankcase shift drum journal for wear or damage DRUM JBUR 12-17 CRANKSHAFI'ITRANSMISSION OIL JET Remove the oil jets from the from cylinder bore of the right and lefl crankcase. Check the Orring for fakigue and damage. O-RING 12-18 MAINSHAFT ASSEMBLY Clean all pans in solvent, Apply molybdenum oil solution to the gear and bushing sliding surface and shift fork grooves to ensure initial lubrication, Assemble all parts into their original positions. NOTE 0 Check the gears for freedom of movement or rotation on the shaft. - Install the washers and snap rings with the chamfered edges facmg the thrust load side. 0 Do not reuse worn snap rings which could easily spin in the grooves. 0 Check that the snap rings are seated in the grooves. Align their and gaps with the grooves of the spline. MAl NSHAFT/Ml GEAR (1 Ni M2 (20T) M3 lZZTl CRANKSHAFI'ITRANSMISSION M4 (259T) 12-19 CRANKSHAFT/TRANSMISSION COU NTERSHAFT Ci i35T) C2 (BAT) C3 (27T) LOCKWASHER C4 (27T) COUNTERSHAFT INSTALLATION install the C4 gear onto the countershaft. Install the lock washer and stop washer, aligning bigger tabs of the lock washer with bigger grooves of the stop washer in the countershaft groove. Turn the washers as shown to lock them on the nearest spiine. 12-20 C4 GEAR LOCK WASHER STOP WASHER CRANKSHAFr/TRANSMISSION Install the stopper ring ontothe countershaft. STOPPER RING Install the stop washer first, and then the lock washerforthe C3 gear. Align and lock the washers using the procedure above LOCK WASHER STOP WASHER Assemble the countershaft and mainshaft. Check the gears for freedom of movement or rotation on the shaft. Check thatthe snap rings are seated in the grooves and align their end gaps with the lands of the splines. Apply engine oil to the following parts. , Mainshaft *Countershaft *Each gears 7 Mainshaft bearing > Cuuntershaft bearing > Shiftdrum bearing MAINSHAFT COUNTERSHAFT install the mainshaft and countershaft to the left MAINSHAFT/COU NTEHSHAFT crankcase as assembly. NOTE: - Do nut forget ta install the transmission end washer, 0 When mainshal‘t and countershaft installation, be careful not to damage the countershaft oil seal. CRANKSHAFT/TRANSMISSION NOTE "R" MARK Each shift forks has an identification mark, "R is for the right shift fork and “C” is for the center shift fork. lnstall the shift forks to the grooves of the shifter gear With their marks facing up lright crankcase side). install the shift drum aligning the guide pins on the shift forks with the guide grooves of the shift drum. Apply molybdenum all solution to the shift fork shaft, Install the shift fork shafl with its Stepped and side facing up lright crankcase side). STEPPED END , .9 After installing, check for smooth transmission operation. Assemble the crankcase lpage 12725). 12-22 CRANKCASE BEARING REPLACEMENT Drive in me new bearing square/y with we marking sine racing up. Remove the followings: 7 Crankshaft (page 1243). "Transmission lpage 12-14). *Oil pump (page 4-4). 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 in the crankcase. Replace the bearings ii the races does not turn smoothly and quietly, or if they fit loosely ln the crankcase, LEFI' CRANKCASE BEARING REPLACEMENT NOTE The oil pump must be removed before replacing the crankcase bearing. Remove the left marnshaft bearing using the specialtools, TOOLS: Bearing remover set 07936 7 3710001 Not available in U. S. A. Afiemover handle 07936i3710100 - Bearing remover head 0793573710500 *Remover sliding weight 0774170010201 or O7936i3710200 Remove the mainshaft bearing oil guide plate. Remove the left countershaft bearing and oil seal. Install the mainshaft bearing oil guide plate. Install the new hearings to the left crankcase using the following special tools. TOOLS: Mainshaft bearing: Driver 07749‘0010000 Attachment, 42 X 47 mm 07746‘0010300 CRANKSHAFr/TRANSMISSION BEARlNG 12-23 CRANKSHAFTITRANSMISSION TOOLS: Countershafl bearing: Driver 07749‘0010000 Attachment, 52 X 55 mm 07746~0010400 Film, 25 mm 07746 W 0040600 BEARING Apply the grease to the new countershafl oil seal Up Install the new countershaft oil seal. 5 El biL SEAL Check the gearshift spindle oil seal for damage. Replace the gearshift spindle oil seal if necessary, SHIFT SPINDLE . 5 AL RIGHT CRANKCASE BEARING REPLACEMENT Drive out the right mainshaft bearing and right countershaft bearing. Dnvemme new Install the new hearings to the right crankcase bearwgs squaraly using the following spemal tools‘ with the marking Slde /acmg up TOOLS: Mainshah bearing: Driver 07749 -- 0010000 Attachment, 52 X 55 mm 07746—0010400 Pilot, 25 mm 07746’ 0040600 BEARING 12-24 TOOLS: Countershafl bearing: Driver D7749’0010000 Attachment, 42 X 47 mm D7746i0010300 Pilot, 20 mm D7746i0040500 CRANKCASE ASSEM BLY Clean the right and left crankcase mating surfaces thoroughly, being careful not to damage them. install the followings: —Crankshaftlpage12»13l —Transmission (page lZ-ZUl ‘Oil pump (page 4-9) Install the dowel pins. Apply a light but thorough coating of sealant to all crankcase mating surfaces except the oil passage area. install the right crankcase to the left crankcase. CRANKSHAFT/TRANSMISSION ATTACHMENT/PlLOT ‘ BEARING DOWEL PINS 12-25 CRANKSHAFT/TRANSMISSION lnstall and tighten the right crankcase bolts in a crisscross pattern in several steps. TORQUE: 8 mm bolt: 23 N-m l2.3 kgf«m,17lbf-ft) 6 mm bolt: 9 N-m (0.9 kgl‘m , 6.5 lbf-ft) rm- 6 mm Install and tighten the left crankcase bolts in a crisscross pattern in several steps. TORQUE: 8 mm bolt: 23 N-m (2.3 kgfim ,17lbf-fi) 6mm bolt: 9 N-m (0.9 kgfm , 6.5 lbf-ft) Clean and apply a locking agent to the gearshift cam plate bolt threads. Install the 953,. lnstall the gearshift cam plate and bolt to the shift shift cam plate drum by sllgnlng the hole on the cam plate Tighten the bolt to the specified torque. with the dowel pin. TORQUE: ’IZ N-m (1.2 kgf-m , S lbf-fll Clean and apply a locking agent to the melnshafl bearing set plate bult threads. lnstall the malnshaft bearing set plate. lnstall and tighten the malnshaft bearing sat plate bolts to the specified torque. TORQUE: 12 N-m (1.2 kgf:m , 9 WM“ 12-26 CRANKSHAFT/TRANSMISSION Clean and apply a locking agent to the rear cam chain tensioner set plate bolt threads. Install the rear cam chain tensioner set platei lnstall and tighten the rear cam chain tensioner set plate bolt to the specified torque. TORQUE: 12 N-m (1.2 kgf-m , 9 lbf-ftl Install the rear cam chatn drive sprocket to the crankshaft, aligning the extra wide splines in the sprocket and crankshaft. Install the rear cam chain tn the cam chain drive sprocket tooth. Install the front cam chain to the cam chain drive sprocket tooth, Clean and apply a locking agent to the front cam chain tensioner set plate bolt threads, Install the front cam chain tensioner set plate. Install and tighten the front cam chain tensioner set plate bolt to the specified torque, TORQUE: 12 N-m 11.2 kgf-m , 9 lbf-ftl CRANKSHAFI'ITRANSMISSION Install the engine sub harness, NOTE: Route the engine sub harness correctly lpage 1728l‘ Clean and apply a locking agent to the ceuntershaft set plate bolt threads. Install the countershaft bearing set plate and bolts. Tighten the countershaft bearing set plate bolts to specified torque. TORQUE: 9 N-m (0.9 kgi-m , 65 Ibflf‘t) Install the engine to the frame (Section 7)t 12-28 MEMO FRONT WHEEL/SUSPENSION/STEERING 29 N-m13.0 kgfm,22lbfvf11 103 N-m (10.5 kgf-m , 76 lbf-m 23 N-m12.3 kgfrm, 17 le-m 11 Nm (1.1 kgi-m , 8 Ibf-fl) 49 N-m15.0 kgf—m, 36 IbHfi 74 N-m (7.5 kgf-m , 54 Ibf-fi) 22 N-m12.2 kgf-m,16lbf-fl1 30 N-m13.1 kgf-m , 22 Ibfvft) 13-0 13. FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION 134 FRONT WHEEL 13-13 TROUBLESHOOTING 13-3 FORK 13—22 HANDLEBAR 13-4 STEERING STEM 13—34 SERVICE INFORMATION GENERAL AWARNING 0 A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent, 0 Riding on damaged rims or spokes impairs safe operation a! the vehicle. ' Wheel balance directly affects the stability, handling and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel. CAUTION: ' Do not jack up the motorcycle using oil filter. ' To avoid damaging the rim when using the tire lever, always use rim protectors. I When servicing the front wheel, support the motorcycle securely with a jack or other support under the engine. I Do not operate the brake lever after removing the caliper and front wheel To do so will cause difficulty in fitting the brake disc between the brake pads, ' Refer to Section 15 for brake system information. a SPECIFICATIONS Unit: mm Iin) ITEM STANDARD i SERVICE LIMIT r Minimum tire thread depth 7 ’l.5(0.06l Cold tire pressure Up to so kg (200 lbl load l 200 kPa (2.00 kgr/cm1,2ggsii “ . i Upto_rn>agrr\ (3.0 kgl-m , 22! 197,193: After '93: Fork cap Fork socket bolt Clutch lever holder bolt Brake master cylinder holder bolt Spokes TOOLS Attachment, 42 X 47 mm Attachment, 52 X 55 mm Pilot, 20 mm Bearing remover shaft Bearing remover head, 20 mm Driver Steering stem socket Bottom holder pipe —Holder handle —Bottom holder attachment Bearing race remover Steering stem driver Fork seal driver, 39 mm Ball race remover *Driver attachment ‘Driver handle Spoke wrench 07746*0010300 07746i0010400 07746i0040500 07746i0050100 07746i0050600 07749 7 0010000 07916‘3710101 07930— KA50000 07930'KA50100 J 07946i3710500 07946iMBOOOOU 07947i4630100 07953iMJ10000 7 07953iMJ10100 7 07953‘MJ10200 h 07JMA—MR60100 07930 ’ KA40200 *7 6 lbf-ft) 3* See page 1340 11 N-m(1.1kgf-m,8lbf-ftl hf~ftl bf~ftl bf~ftl 4 N-m (0.4 kgf-m , 2.9 lbf-ftl bH‘tl bf-ftl bf-ftl bf-ftl bf-ftl bf-ftl ALOC bolt: with a new one Apply a locking agent to the threads 12 N-m (1.2 kgf-m , 9 letl 12 N-m (1.2 kgf-m,91bf‘ftl 4 N«m (0.4 kgfvm ,23 lbf-ftl Not available in U.S.A. Equivalent commercially available in U.S.A. 7 Not available in U.S.A. or 07953 , MJ1000A or 07953 7 MJ 1 0005 07949>3710001 or 07746‘0010100 or equivalent commercially available in USA. 13-2 TROUBLESHOOTING Hard steering - Steering top thread too tight v Faulty steering head bearings - Damaged steering head bearings - Faulty tire - lnsufficienttire pressure Steers to one side or does not track straight - Bent fork - Faulty steering head bearings - Damaged steering head bearings - Bent frame - Worn wheel bearings - Bent front axle ~ Worn swingarm pivot component Front wheel wobbling ' Bent rim - Worn wheel bearings ‘ Faulty tire - Unbalanced tire and wheel FRONT WHEELISUSPENSION/STEERING Soft suspension - Weak fork spring ' Low fluid level infork ' insufficient fluid in fork , Low tire pressure Hard suspension - Hightire pressure ‘ Bent fork - High fluid level in fork - Incorrect fluid weight - Clogged fluid passage Front suspension noisy - Loose fork fasteners - insufficient fluid infork Wheel turns hard - Faulty wheel bearings ' Bent front axle - Brake drug - Faulty speedometer gear 13-3 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR GRIP REPLACEMENT Remove the throttle grip from the handlebar (page lB-Bl. Remove the grip from the throttle pipe. Apply Honda Bond A or Honda Grip Cemment (U.$.A. only) to the inside surface of the throttle grip to the Clean surface of the throttle pipe. Wait 375 minutes and install the grip. Rotate the grip for even application of the adhesive. Install the throttle grip to the handlebar lpage 13-10). Remove the left handlebar grip from the handlebar. Apply Honda Bond A or Honda Grip Cemment lU.S.A. onlyl to the inside surface of the left handle grip to the clean surface of the handlebar. Wait 3*5 minutes and install the grip. Rotate the grip foreven application ofthe adhesive. NOTE’ Allow the adhesive to dry for an hour before using. Check for smooth throttle operation after the throttle grip is installed, THROTTOLE GRIP HONDA BONDA THROTTOLE GRlP HANDLEBAR GRIP HONDA BONDA LEFT HAN DLE GRlP 13-4 FRONT WHEEL/SUSPENSIONISTEERING REMOVAL REAR VIEW MIRRORS Remove the right and left rearview mrrrors. Loosen the clutch cable lower and upper ADJUSTING NUT BOLT/NUT adjusting nuts, and disconnect the clutch cable V V ,’ from the dutch lever. Remove the bolt/nut and clutch lever from the clutch lever bracket. LEVER Disconneet the dutch switch chnectors from the CONNECTORS clutch swuch. Remove the socket bolts, clutch lever ho‘der and BRACKET bracket. FRONT WHEEL/SUSPENSIONISTEERING Remove the clu‘ch swimh from the dutch holder. Remove the screws and Iefi handlebar switch. Remove the left handiebar grip and adapter. Dwsconnect the from brake Iighl switch connectors from me switch‘ CLUTCH SWITCH SCERWS HANDLEBAH GRIP ADAPTER 13-6 FRONT WHEEL/SUSPENSION/STEERING Remove the socket boils, master cylinder holder and master cylinder. Remove the right handiebar switch screws. Loosen the throttle cable iower adjusting nuts at the carburetors and disconnect the throttle Cables from the throttle cable guide. Remove the right handiebar switch from the handlebar‘ Remove the thronie grip from the handlebarv THROTTOLE GRIP 13-7 FRONT WHEEL/SUSPENSlON/STEERING ll the handlebar Loosenthe handlebar lower holder nutsv luWEr holders Wl/I be rsmaved, NOTE, loose/l [he lower holder nuts before Do nor remove the lower holder nuts yet. remuvmg the upper holders Remove the handlebar upper holder bolt caps‘ Remove lhe sockel bolts, upper holders and handlebar Remove the nuxs, washers and handlebar lower holders, 13-8 FRONT WHEEL/SUSPENSION/STEERING Check the bushings for wear or damage. Replace the bushings if necessary. INSTALLATION Install the handlebar lower holders, washers and nuts. NOTE Do not tighten the lower holder nuts yet. Install the handlebar and upper holders with their punch marks facing forward. Temporarily tighten the upper holder socket bolts. /‘ Tighten the lower holder nuts to the specified torque. TORQUE: 23 NM (2.3 kgf-rn , 17 |bf~ftl Loosen the upper holder socket bolts and align the punch marks on the handleberwith the splits of the handlebar holders, Tighten the forward bolts first, then tighten the rear bolts. TORQUE: 29 N«m 13.0 kgf-m , 22 lbf-l‘tl FRONT WHEEL/SUSPENSION/STEERING Install the upper holder bolt caps. Apply grease to the throttle grip Inner surface and throttle cable Contact point Install the throttle grip to the handlebar. THROTTOLE GRIP Connect the throttle cables to the throttle cable HANDLEBAR SWITCH guide. Install the right handlebar switch housing onto the handlebar, aligning the lucating pin with the hole in the handlebar. CABLE GUIDE Install the attaching screws and tighten the forward SCREWS screw first, then tighten the rear screw. 13-10 FRONT WHEEL/SUSPENSION/STEERING Install the master cylinder and holder with the “UP" mark facing up Align the end of the master cylinderwith the punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt to the specified torque MASTER CVLlN DER HOLDER TORQUE: 12 N-m l1t2 kgf‘m , 9 lbfrftl Connect the front brake light switch connectors to the swrtch. lnstall the adapter and left handlebar grip onto the HANDLEBAR GRIP m handlebarlreferto page 1374l. ,/ ' ADAPTER Install the left handlebar switch housing onto the handlebar, aligning the locating pin with the hole in the handlebar. HANDLEBAR SWITCH 13-11 FRONT WHEEL/SUSPENSION/STEERING Install the attaching screws and tighten the forward SCREWS screw then tighten the rear screw. \nstall the clutch switch into the dutch lever bracket. CLUTCH SWITCH \nstal‘ the clutch Iever bracket and holder with the BRACKET ALIGN "UP" mark facing up. Align the end of the clutch lever bracket with the HOLDER punch mark on the handlebar and tighten the upper \J butt then tighten the lower bolt to the specified ‘ torque. TORQUE: 12 N-m (1,2 kgi-m , 8 let) Connect the clutch switch connectors to the dutch switch. 13-12 FRONT WHEEL/SUSPENSION/STEERING lnslall the clurch lever to the clulch lever bracket Install and tighten ihe boll and nut securely. Connem (he cluich cable to (he leverv install the right and la“ rearview mirrors. NOTE: Home the cables, Wires and harness properly (page 1722). Adjust the followings: *Throttle opera‘ion free play lpage 375i *C|ulch lever free play (page 3728i FRONT WHEEL M.“ A contaminutad brake dis: Dr pad radutas stopping power. Discard contaminated pads and clean a cantaminated dis: with a high quality brake degreasing agent. REMOVAL Raise and supper! the motorcycle using a hoist or jack underthe engine. CAUTION: Da notieck up the mommycle using oil filter. Remove the screw and disconnect the speedometer cable from the speedometer gear. Remove the axle pinch bull caps. FRONT WHEEL/5USPENSIONISTEERING Loosen the axle pinch bolts. Remove the axle and front wheel. NOTE Do not operate the from brake lever after removing the from wheel. To do so will cause diflicully in fitting the brake disc between the brake padst Removethesldecollar - ' ‘ ~ : COLLAR Remove the speedometer gear box‘ INSPECTION m AXLE AXLE Set the front axle in V-blocks and measure the runout. Turn the front axle and measure the runout uslng s dial indicator. Actual runout is 1/2 the total lndlcator reading. SERVICE LIMIT: 0.20 mm (0008 inl 13-14 Replace the wheel bearings m pairs FRONT WHEEL/SUSPENSION/STEERING WHELL BEARING Turn the inner race of each bearing with yourfinger. The hearings should turn smoothly and quietly. Also check that the bearing outer race iits tightly In the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, if they fit loosely in the hub. WHEEL RIM Check the rim runout by placing the wheel in a truing stand. Spin the wheel slowly and read the runout uslng a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.05 inl Axial: 2.0 mm (0.03 in) Check the spokes for looseness or damage. DISASSEMBLY Remove the brake disc mounting bolts and brake disc, Remove the right and left dust seals from the each side of the front wheel. WHEEL BEARING FRONT WHEEL/SUSPENSION/STEERING Remove the speedometer gear retainer. Replace the wheel Install the bearing remover head into the bearing. beanngs m pairs From opposne side install (he bearing remover Do not reuse UId shaft and drive the bearing out of the wheel hub. bearmgs Remove the distance coIIar and drive out the other bearing. TOOLS: Bearing remover shaft 07746 0050100 Bearing remover head D7746’ 0050600 ASSEMBLY DISTANCE COLLAR BEARING SIDE COLLAF/ § 4°? DUST SEAL fl DUST SEAL @ ’97i'98: 39 N-m (4,0 kgf-m , 29 Ibf-h) Aher'98: 42 N-m (4,3 kgf-m,31lbf-ft) BEARING RETAINER ' SPEEDOMETER V GEAR BOX SFEEDOMETER GEAR WASHERS 13-16 FRONT WHEEL/SUSPENSION/STEERING Drive in a new right bearing squarely With the marking sidefacing up until it is fully seated. Install the distance collar. Drive in a new left bearing squarely with the marking side facing up until it is fully seated. DRIVER TOOLS: Driver 0774970010000 Attachment, 42 X 47 mm 0774370010300 PUBLZO mm 0774570040500 Assemble the wheel as follows it the wheel has been disassembled. Clean the spoke nipple threads. Adlust the hub position so that the distance from the hut] left end surface to the Side of rim is as shown. STANDARD: 32.3 i 0.8 mm l1.27i0.03 in) Torque the spokes in 2 or 3 prugressrve steps. TOOL: Spoke wrench 07JMA* MRSO‘IOU or equivalent commercialr Iy available in U.S.A. TORQUE: A N-m l0.A kgf~m , 2.9 lbf-ft) i Install the brake disc with the ”MIN.TH.4MM” marked side facing out. H We FRONT WHEEL/SUSPENSlON/STEERING install and tighten the new brake disc bolts to the specified torque. NOTE, Tighten the bolts in a crisscross pattern in 2 or 3 steps. TORQUE: '97i'98: 39 N-m (4.0 kgf~m , 29 lbf-ftl After '98: 42 N-m (4.3 kgl‘m , 31 lbf-ftl WHEEL BALANCE M Wheel balance directly affects the stability, handling and overall safety a! the motorcycle. Carefully check balance before reinstalling the wheel. NOTE ' The wheel balance must be checked when the tire is remounted, 'For optimum balance, the tire balance mark (apaint dot on the side wall) must be located next to the valve stem. Remount the tire it necessary. Mount the wheel, tire and brake disc assembly on an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviest) part olthe wheel with chalk. Do this two or three times to verify the heaviest area. ltthe wheel is balanced, it will not stop consistently in the same position. To balance the wheel, install balance weights on the lightest side of rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 70 g (2.5 ozl to the front wheel. 13-18 FRONT WHEEL/SUSPENSION/STEERING Install the speedometer gear retainer to the wheel hub aligning lhe tangs on the retainer with the slots on the hub. IlHIIflEEl_____________A‘s________ Du nut get grease an the brake disc or stopping power will be reduced. Apply grease to the new right dusl seal lip. lnstall the right dusx seal \olhe right wheel hub. Apply grease to me new lefl dust seal lip, Install the lehdust seal lip to lhe lefl wheel hub. INSTALLATION Apply grease to the inside of speedometer gear box and gear‘ Install the speedometer gear and washers into the gear box. ALIGN RETAINER / / ‘PUSJSEAL‘ , z 3% / FRONT WHEEL/SUSPENSION/STEERING Install the speedometer gear box into the left wheel ALIG W-SPEEDEMETER GEAR BOX hub, aligningthetangs withthe sluts. r Install the side collar into the right wheel huh. COLLAR install the front wheel between the fork legs so that the brake disc is positioned between the pads, being careful not to damage the pads Apply thin coat of grease to the front axle‘ Install the front axle Position the lug on the speedometer gear bux againsed the back of stopper on the fork leg. Tighten the front axle to the specified torque. TORQUE: 74 N-m (7.5 kgfrm , 541mm 13-20 FRONT WHEEL/SUSPENSION/STEERING With the front brake applied, pump the front suspension up and down several times to seat the axle and check front brake operation. Tighten the axle pinch bolts to the specified torque. TORQUE: 22 N-m (2.2 kgf-m,16|bf-ttl Install the axle pinch bolt caps, install the speedometer cable and tighten the screw securely. FRONT WHEEL/SUSPENSION/STEERING FORK REMOVAL Remove the front wheel (page 13-13). Pull the speedometer cable out of the cable holder on the front fender. Unhook the brake hose from the hook on the front fender. Remove the front fender mounting bolts and front fender. 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 brake caliper mounting bolts and brake caliper, CAUTION 0 Do not suspend the brake caliper from the brake hose. - Do not twist the brake hose. Remove the bolt, collar and tum signal light assembly from the fork tube. BRAKE HOSE fl FRONT FENDER CALlPER TURN SIGNéL L 13-22 FRONT WHEELISUSPENSION/STEERING Remove the fork top bridge pinch bolt caps. Loosen the fork top bridge pinch bolts. When the fork is ready to be disassembled, loosen the fork cap, but do not remove it. Remove the fork bottom bridge pinch boltcaps. Loosen the fork bottom bridge pinch boits while holding the fork, Remove the fork from the top bridge and steering stem. FRONT WHEEL/SUSPENSION/STEERING DISASSEMBLY FORK CAP The fork cap is under spring pressure. Use care when ramaving it and wear eye and lace pratsctian. Remove the {ark cap and O-ring from the fork tube. .V ovRI'NGWWW; i Remove the spring spacer from the fork tube. SPACER Removethe washer. WASHER Remove the fork spying. SPRING 13-24 FRONT WHEEL/SUSPENSION/STEERING Pour the fork oil from the fork leg by pumping the 10118710 times. CAUTION: ‘ BOTTOM HOLDER PIPE Do not over tighten the [ark slider. Hold the axle holder in a vise with a piece of wood or soft jaws to avoid damage. install the special tool into the fork tube and hold ‘ N the piston, then remove the socket bolt and sealing washer. TOOLS: 1 Bottom holder pipe 07930, KA50000 FORK TUBE l Not availablein U.S.A. ’ 'Halder attachment 07930A KASO’IOO Equ‘vé'en‘ 9°”‘me'cia" SOKET BOLT/SEALING WASHER ly available m U.S.A. ,__ Bottom holder handle 07930— KA40200 Equivalent commercialr ly available in USA Remove the fork piston and rebound spring. FORK PISTON NOTE Do not remove the fork piston ring, unless it is necessary to replace with a new one. REBOUND SPRING 13-25 FRONT WHEEL/SUSPENSION/STEERING Remove the dusk seal from the fork slider Remove lhe stopper ring from the groove of (he fork slider. CAUTION: Do nut scratch the fork tube sh ng surface. NOTE Check that the fork tube moves smomhiv in the fork slider. if dues not, check the fork tube for bending or damage, and bushings for wear or damage. Using quick successive motions, puii the fork tube out ofthe fork slider. Remove the oil lock plece from the fork siider, OIL LOCK PIECE SLIDER 13-26 FRONT WHEEL/SUSPENSION/STEERING Remove the oil seal, backrup ring and slider bushing from the fork tube. OIL SEAL SLIDER BUSHING BACK-UP RING NOTE Do not remove the fork tube bushing unless it is necessary to replace it with a new one. Carefully remove the fork tube bushing by plying the slot with a screwdriver until the bushing can be pulled off by hand. FORK TUBE BUSHING INSPECTION FORK SPRING Measure the fork spring free length by placing the spring on a flat surface. SERVICE LIMIT: 327.2 mm l‘lz.88 inl ,IIMMIWH NW MINI! if 3-! V V? FORK TUBE/SLIDER/FORK PISTON Check the fork tube, slider and fork piston for score FORK TUBE marks, and excessive or abnormal wear. Replace the component if necessary. 13-27 FRONT WHEE L/SUSPENSIONISTEERING Check the fork piston ring for wear or damage. Check the rebound spring forlatigue or damage Replace the component if necessary Set the Fork tube in Vrblocks and measure the fork tube runout rotating it with a dial indicator, Actual runout is 1/2 the total Indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) Replace if the service limit is exceeded. or there are scratches or nicks that will allow fork oil to leak past the seals. NOTE: Do not reuse the fork tube if it cannot be perfectly straightened with mlnlmal effort. FORK TUBE BUSHING Visually inspect the slider and fork tube bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more 3/4 of the entire surface. Check the backup ring; replace it if there is any distortion at the point shown FORK PISTON SPRING BUSHING BACKVUF RING COPPER SU RFACES CHECK POINTS 13-28 FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY FORK CAP Before assembly, wash all parts with a high flash 23 N»rn (2,3 kgflm ( 17 lbfm point or nun-flammable solvent and wipe them off corn letel . P V DUST SEAL W SPACER ~‘ PISTON RING STOPPER RING I 9}” OIL SEAL BACK-UP RING SLIDER BUSHING ‘, FORK TUBE BUSHIN OIL LOCK PIECE an? it SEALING WASHER l I / § I I , [fl REBOUND / SPRING , FORK SPRING I j FORK TUBE WW“ FORK SOCKET BOLT 29 Nm (3.0 kgf-m , 22 Ibi-fll Install a new fork tube bushing if the tube bushing ; has been removed. SCREW DRIVER\ ‘ CAUTION: - Be careful not to damage the {ark tube bushing coating. 0 Do not opgn the fark tuba bushing more than necessary. NOTE Remove the burrs from the bushing mating surface, ~fi FORKTUEE BUSHING being careful not to peel off the coating. forktube Apply fork oil to the new oil seal lip. Install the new oil seal to the fork tube with the marking side facing up. OIL SEAL Install the slider bushing and back-up ring to the w? fl , SLIDER BUSHING BACKUP RING FRONT WHEEL/SUSPENSION/STEERING Ins‘all lhe all look piece onto the fork piston and. Coat the fork tube bushing with lhe fork oil and install lhe fork into the fork slider. OlL LOCK PIECE SLIDEH Install the rebound spring to the fork pismn. FORK PISTON Install the fork pislon into the fork tube. FORK PISTON FORK TUBE ;‘ & Install the special tools into the fork tube to hold the BOTTOM HOLDER PIPE piston. TOOLS: Bonom holder pipe 07930 , KASOOOO Not available in USA. *Holder attachment O7930iKA50100 Equivalent commercial- ly available in U.S.A. ABonom holder D7930— KA40200 handle Equivalem commercial ly availablein USA. FORK TUBE 13-30 FRONT WHEEL/SUSPENSIONISTEERING CAUTION' ——‘——‘——— ‘: Wt% Du not overtighten the fork slider. SOCKET BOLT m, Hold the axle holder of the fork slider in a vise with a piece of wood or soft laws to avoid damage. Replace the sealing washer with a new one Clean and apply a locking agent to the fork socket bolt threads and install the fork socket bolt with the new sealing washer into the fork piston. Tighten the fork socket bolt to the specified torque, TORQUE: 29 Nm (3,0 kgf-m , 22 |bf«ft) Drive in the new oil seal into the fork tube until the stop ring groove is visible, using the special tool, DUST SEAL TOOLS Fork seal driver, 39 mm 07947 ~4830100 STOPPER RING —————OlL SEAL i BACK-UP Install the stopper ring into the groove in the fork sliderv FRONT WHEEL/SUSPENSION/STEERING Apply fork oil to the lip a new dust seal and install the dust seal. Pour half the required amount of the recommended fork oil in the fork tube. RECOMMENDED FORK OIL: Honda Suspension Fluid 85-5 or equivalent OIL CAPACITY: A49 Cm3 (16.9 US 01.15.8lrnp oz) SPECIFIED Slowly pump the fork tube several times to remove LEVEL trapped air. Pour additional oil up to the specified capacity and repeat the above step. Compress the furk leg fully. Measure the oil level from the top of the fork tube. OIL LEVEL: 111 mm 14.4 ml Install the fork spring with the tightly wound end facing up. ‘Hlllllllllfllllllllfulfill/Vi! \l' lf V V i] FACING UF‘ Install the washer. WASHER 13-32 FRONT WHEELISUSPENSION/STEERING Installthe spring spacer. SPACER Apply fork oil to the new O»ring and install to the fork cap. Install the fork cap into the fork tube. NOTE: Tighten the fork cap after installing the fork tube into the fovk bridge. FORK CAP INSTALLATION Install the fork into the bottom and top bridge. Align the top of fork tube with the upper surface of rhetop bridge. Tighten the bottom bridge pinch bolts to the specified torque. TORQUE: 49 Nm (5.0 kgf‘m , 36 lbf-ftl FRONT WHEEL/SUSPENSlON/STEERING install the bottom bridge pinch bolt caps. Tighten the fork cap to the specified torque. TORQUE: 23 N-m (2.3 kgf~m , 17 lbf-it) Tighten the top bridge pinch bolts to the specified torque. TORQUE: 11 Nm (1.1 kgf m . 8 lbf—ftl install the top bridge pinch bolt caps. install the turn signal light assembly and collar. install and tightenthe mounting bolt securely. NOTE. At installation, turn the signal stay with its tab into the bottom bridge cut-out. 13-34 FRONT WHEEL/SUSPENSION/STEERING Install the brake caliper to the left front fork. Install and tighten the new front caliper mounting bolts to the specified torque. TORQUE: 30 Nm (3.1 kgfm , 22 lbf-ftl Install the front fender and tighten the mounting bolts securely. Hook the brake hose onto the hose hook. Install the speedometer cable through the cable holder. I SPEgtioiviETER CABLE STEERING STEM SPEEDOMETER CONNECTOR REMOVAL Remove the handlebar (page 135). Raise and support the motorcycle using a hoist. Remove the steering cover lpage 2-3) and disconnect the speedometer 6P (Blackl connector. 13-35 FRONT WHEEL/SUSPENSION/STEERING Disconnect the speedometer cable from the SPEEDOMETER speedometer. Remova the bolt, nut and speedometerv BOLT/N UT Remove the nuts and headlight/stay as assembly. Remove the steering stem nut. Remove the washer, WASHER 13-36 FRONT WHEEL/SUSPENSION/STEERING Remove the front forks (page 13-22). TOP BRIDGE Remove the top bridge. Remove the screws and indicator panel from the (up bridge. SCREWS Remove the bolts and speedometer stay from the top bridge. Straighten the lock washer tabs. 13-37 FRONT WHEEL/SUSPENSION/STEERING Remove ihe lock nut using followingtoai. TOOL: ’ Steering s‘em socke‘ 07916 73710100 STEERING STEM SOCKET Remove the lock washer, Remove the steering top thread using ihe foilowing moi. STEERING STEM SOCKET TOOL: Steering stem socks! 07916 *3710100 Hold the steering stem by hand and remove the TOPTHREAD steering top thread, dust seal, upper bearing inner ‘ race and upper bearing. INNER RACE DUST SEAL . j UPPER . BEARING Remove the steering stem from the sieering head. Check the steering bearings, inner and auier races BEARING forwear or damage. STEERING STEM 13-38 FRONT WHEELISUSPENSION/STEERING STEERING BEARING REPLACEMENT Always replace the Remove the lower bearing outer race using the bearings and following tool and suitable shaftt races as a set OUTER RACE TOOL: Bearing race remover 07946-3710500 Remove the upper bearing outer race using the following tools‘ TOOLS: Ball race remover 07953iMJ10000 Not available in U,S.A. *Attachment 07953iMJ10100 Not available in USA. *Driver handle 07953iMJ102DU Not available in U.S,A. or Race remover attach- 07953— MJ1000A or ment O7953'MJ10008 Driver O7949E37‘10001 or Attachment, 32 X 35 mm 07746*0010100 Install the stem nut onto the stem to prevent the threads from being damage when removing the lower bearing inner race from the stem Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the stem Remove the dust seal. STEM NUT STEERING STEM 17 Apply grease to the new dust seal lip and install it to the steering stem. install the new lower bearing inner race using the following tool and hydraulic press. TOOL: Steering stem driver 07946? MBOUOOO FRONT WHEEL/SUSPENSION/STEERING Drive the new upper bearing outer race imo the A H N head pipe using me foIIowingtools. “T 0 ME T TOOLS: Driver 0774970010000 Attachment, 42 X 47 mm 07746i0010300 DRIVER OUTER RACE Drive the new Iower bearmg omer race into the head pIpe using the foIIow'mg tools. TOOLS: Driver 0774970010000 Attachment, 52 X 55 mm 07745’0010400 INSTALLATION LOCK NUT N LOCK WASHER BEARING ‘m ADJUSTMENT NUT DUST SEAL %‘— UPPER BEARING INNER RACE UPPER BEARING M UPPER BEARING OUTER RACE $4— LOWER BEARING OUTER RACE \\ LOWER BEARING LOWER BEARING INNER RACE M DUST SEAL 13-40 FRONT WHEEL/SUSPENSION/STEERING Apply grease to the new lower bearing. Install the new lower bearing onto the steering stern. install the steering stem into the head pipe. STEERING STEM Apply grease to the new upper bearing. Install the upper bearing, upper bearing inner race, dust seal and steering top thread. TOP THREAD INNER RACE Tighten the top thread to the specified torque. TOOL: STEERlNG STEM SOCKET Steering stem socket O7916i3710100 TORQUE: 25 Nm (2.5 kgf-m.18|bf-ftl Turn the steering stem right and left, lock-to-loek at least five timesto seat bearings. STEERING STEM Make sure that the steering stem moves smoothly, without play er binding. FRONT WHEELISUSPENSION/STEERING Retighten the topthread to the specified torque. ST “E STEM SOCKET TOOL: Steering stem socket O7916’37101D‘l TORQUE: 25 N-m (2.5 kgf-m,18|bf-ftl Install the new look washer and bend the two opposite tabs down into the grooves in the adjustment nut. Install and finger tighten the lock nut all the way. Hold the steering top thread and further tighten the TOP THREAD lock nut, within 90 degrees, to align its grooves with the tabs of the lock washer. Bend up the luck washer tabs into the grooves of the lock nut. Install the speedometer stay and bolts to the top bridge. Tighten the bolts securely. 13-42 FRONT WHEELISUSPENSION/STEERING Install the indicator panel and screws Tighten the screws securelyv y »|ND|CATOR PANEL f SCREWS Install the top bridge. Install the fork legs (page 13r33lv Installthe washer. WASHER Install and tighten the steering stem nut to the specified torque. TORQUE: 103 Mm (105 kgf-m , 76 lbf-ftl Install the headlight stay and head light with bolt Install and tighten the nuts securely. FRONT WHEE L/SUSPENSIONISTEERING install the speedometer stay and speedometer. Install and tighten the boil and nut. Connect the speedometer cable to the speedome- ter. Connect the speedometer 6? (Black) connector. Install the steering cover (page 2-3). Install the handlebar (page 13-9). STEERING BEARING PRELOAD Raise the front wheel off the ground. Position the steering stem to the straight ahead position. Hook 3 spring scale to the fork tube between the fork tube between the fork top and bottom bridges. Make sure that there is no cable or wire harness interference, Pull the spring scale keeping the scale at a right angleto the steering stem. Read the scale at the point where the steering stem just starts to move. STEERING BEARING PRELOAD; 0.9i1.4 kgf (2.0 , 3.1Ibfl If the readings do not fall within the limits, readjust the steering top thread. Install the removed parts in the reverse order of removal. NOTE Route the cables and wire harness properly (page 2-20). 13-44 MEMO REAR WHEEL/BRAKE/SUSPENSION 44 N-m (4,5 kgf-m , 33 lbf-flb 14-0 14. REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 14-1 BRAKE PEDAL 14-14 TROUBLESHOOTING 14-2 SHOCK ABSORBER 14—13 REAR WHEEL 14.3 smeARM 14.22 REAR BRAKE 1441 SERVICE INFORMATION GENERAL 'WARNIN" - A ccnrnminand broke orunr l7! shoe mduces stopping power, Discnrd cnm‘aminlted shoes and than - connml'nated drum with a high quality brake oegrusing agent. . Riding on damaged rims or spokes impairs sale operation orthe vehicle. - Wheel balance diuctly affects the stability, handling and overall safety a! the motorcycle, Cereiully cheek balance bolero reinstalling the wheel, CAUTION: - To .void dlmnging the rim when using the tire lever, always use rim protectors, - Do an! jack up the motorcycla using the oil filter. - When servicing the rear wheel, swingarm or shock absorber, support the motorcycle using a safety stand or hoist. - Use only genuine Handa replacement bolts and nuts for all suspension pivot and mounting points. SPECIFICATIONS ITEM “ STANDARD 3 SERVIOE LIMIT I Minimum tire thread depth , ,7 , 2,010.08) Cold tire \ Upto so kg (200 lb) load 200 kPa (goo kgI/cm’ , 29 psii pressure ‘ Up to maximum weight capacity 250 kPa (2‘50 kgI/crrn2 , Stipsi) Axle runout 7 ,7 U , 0.20 (0.00m wneel rim runeut Radlal , , 74 2.0 loloai Axial ; *7 N 2131008) Wheel hub-\O-rim distance , 32.3 x 0.2mm : anal , w Wheel balance welght , ,, Max70 g (2.5 oz) 7, 7 Drive chain slack , 20730 (3/477 171/“ 50 (2.0) Drive chain link 9sz 7 , Drivechainsiza DID H , i 525 vs _ , i 7 r RKV ‘ 525 5M5 , , _ Rearhrake i Drum LD. 7 160.0i1803(63075.31IM V ,, 161(63) Liningthickness H 5(0.2) i 210.1) J Brake pedal free play 20-30 (3/471-‘1/4) 1 , Shock absorber spring preload adjuster setting 2nd position , Revised: chber1999 1997 - 2000 VTSOOCICD 14_1 ©1999 Amencari Honda Molar Co ‘ In: 7 All Rigms Reserved MSV 8617(9910) 14 'I REAR WHEEL/BRAKE/SUSPENSION TORQUE VALUES Rear axle nut Driven sprocket nut Rear shock absorber mounting nut (upper) llowerl Swingarm pivot bolt Rear brake stopper arm bolt '97* Rear brake arm pinch bolt Rear brake middle rod joint bolt Spokes Fuel pump stay mountlng nut ('97m'98l/ Turn signal relay stay mounting nut (After ’98) TOOLS Attachment, 32 x 35 mm Attachment, 42 >’ 47 mm Pilot, 15 mm Pilot, 17 mm Pilot, 22 rum Bearing remover shaft Bearing remover head, 17 mm Attachment, 28 X 30 mm Driver Snap ring pliers Driver shaft set Driver shaft Spoke wrench TROUBLESHOOTING Rear wheel wobbles - Bent rim ' Worn rearwheel bearings - Loose or bent spokes - Faulty tire - Unbalanced tire or wheel - Low tire pressure - Axle not tightened properly - Chain adjusters not adusted equally - Faulty swingarm pivot bearings and bushings - Bent frame or swingarm Wheel turns hard ' Faulty wheel bearings - Bent rear axle - Brake drug Rear suspension noisy - Faulty rear shock absorber - Loose fasteners Soft suspension - Weak spring - Improper shock absorber spring preload - Oil and gas leakage from damper unit ~ Low tire pressure After '98. 88 N-m (9‘0 kgf-m , 65 Ibf‘ft) Urnut 64 N-m (6‘5 kgt-m , 47 [bf-ft) Urnut 44 N-m (4.5 kgf-m , 33 lbi‘ft) 44 N-m (4.5 kgf-m , 33 lbf‘ft) 88 N-m (9‘0 kgt-m ,65 Math) : 22 N-rn (2‘2 kgf-m , 16 lbf-ft) 1N-m(2.‘lkgt-m,15lbfvft) 6 N-m (2.7 kgf‘m , 20 Ibf-ft) 21N:m(2.‘lkgf‘m,15|bf-ftl 9 N-m l0 9 kgi-m , 6.5 Ibfvtt) 4 N-m (0,4 kgl-m , 2.9 Ibf-tt) 9 N»m (0,9 kgf-rn , 6.6 lbf-ftl 0774570010100 07746i0010300 07746 0040300 07746‘s0040400 07745’0041000 07746 ‘ 0050100 07746 ' 0050500 07946’ 1570100 0774970010000 07914, 3230001 07946iKA50000 07946iMJ00100 Not available in U.S.A. or 0794973710001 or 07746* 0040500 07J MA W MR50100 or equivalent commercially available in U.S.A. Hard suspension - Improper shock absorber spring preload - Bent damper rod - High tire pressure ‘ Damaged swingarm pivot bearings and bushings ‘ Bent frame or swingarrn Poor brake perlormance - 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 4—2 REAR WHEEL/BRAKE/SUSPENSION REAR WHEEL REMOVAL CAUTION: Do not jack up the molarcycle using the oil filter. Support the motorcycle using a hoist or a jack underthe engine. Loosen the axle nut Loosen the drive chain adjusters on both sides of the swingarm, Disconnect the brake rod from the brake arm. Remove the cotter pin, nut, washers and bolt from the stopper arm on the brake panel Remove the drive chain from the driven sprocket. Remove the axle nut, adjuster collars, side collar and rear axle. Remove the rear wheel. INSPECTION AXLE Place the axle in V-blocks and measure the runout. Actual runout is 1/2 the total indicator reading. SERVICE LIMIT: 0.20 mm (0.008 in) REAR WHEEL/BRAKE/SUSPENSION WHEEL Check the rim runout by placing the wheel in a turning stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 the total indicator reading. SERVICE LIMITS: Radial: 2.0 mm (0.03 inl Axial: 2.0 mm (0.08 inl WHEEL BEARING Turn the inner race of each bearings with your finger. Bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub, HEP/1996‘ ”79 Wheel Remove and discard the bearings if the races do [Jammy/"pa“ not turn smoothly and quietly, or if they fit loosely in the hub. WHEELE BEARING DRIVEN SPROCKET Check the condition of the final driven sprocket OK NO GOOD teeth. Replace the sprocket if worn or damaged. 0 X NOTE ~ It the final driven sprocket requires replacement, inspect the drive chain and drive sprocket. /_\ A ' Never install a new drive chain on a worn sprocket or a worn chain on new sprockets. Both chain and sprocket must be in good Condition or the replacement chain or sprocket will wear rapidly. BRAKE PANEL DISASSEMBLY Remove the brake panel assembly from the right wheel hub. 1 4-4 REAR WHEEL/BRAKE/SUSPENSION Remove the col lar. COLLAR Remove the driven flange from the left wheel hub. NOTE: if you will be disassembling the driven flange, loosen the driven sprocket nuts before removing the driven flange from the wheel hub, Remove the damper rubbers and O»ring. DRIVEN FLANGE BEARING REMOVAL DUST SEAL N UTS Remove the dust seal, Remove the driven sprocket nuts and driven sprocket. * DRIVENSPROCKET 14-5 REAR WHEEL/BRAKE/SUSPENSION Remove the driven flange collar‘ COLLAR Remove the driven flange bearing, WHEEL BEARING REMOVAL Install the bearing remover head into the bearing. From the opposite side install the heaving remover shaft and drive the bearing om of khe wheel hub. Remove me distance collar and drive out the other bearing. TOOLS: Bearing remover shaft 07746i0050100 Bearing remover head, D7746i 0050500 17 mm REMOVER HEN ASSEMBLY BEARlNG O-RING DRIVEN SPROCKET 64 N-m (6.5 kgf:m , 47 lbf>ft) BEARXNG DAMPER RUBBER COLLAR DRIVEN FHANGE BEARING DUSTSEAL 1 4-6 REAR WHEEL/BRAKE/SUSPENSION WHEEL BEARING INSTALLATION DRIVER Pack all bearing cavities with grease CAUTION‘ Never install an old hearing has been Iamnved, the bearing must be replaced with a new one. Drive a new left bearing squarely with its sealed side facrng out, Install the distance collar, then drive in the right side bearing with its sealed side facing out. TOOLS: Driver 07749 *0010000 Attachment, 42 X 47 mm O7746’001U300 Pilot, 17 mm 077AS’00A0400 DRIVEN FLANGE BEARING INSTALLATION DRIVER Drive a new driven flange bearing into the driven flange using the special tools. TOOLS: Driver 077A970010000 Attachment, 42 X 47 mm U7746i0010300 Pilot, 17 mm 07746‘0040400 BEARING Place the rim on the work bench. Place the hub with the left side down and begin Iacmg with new spokes. Adiusl the hub position so that the distance from the hub right end surface to the side of rim as Shown. STANDARD: 23.5 : 0.8 mm (0.93 i 0.03 in) 1 4-7 REAR WHEEL/BRAKE/SUSPENSION TOOLS: Spoke wrench 07JMAiMR60100 or equivalent commer- cially availabie in U.S.A. Torque the spokes in 2 or 3 progressive steps. TORQUE: 4 N-m (0.4 kgf-m , 2‘9 Ibf-ft] Checkthe rim runout (page 1AA). Appiy grease to the new dust sear lips, then install SEAL itlntothe driven flange, @ r-fili DUST Instail the driven flange collar. COLLAR Insiaii me wheel damper rubbers and Orring into $3 the wheel hub. 1 4-8 REAR WHEEL/BRAKE/SUSPENSION W— 00 not get grease on the brake drum or stopping power will be reduced. Install the driven llange assembly into the left wheelhub. If the driven sprocket was removed, install the driven sprocket and tighten the nuts. TORQUE: 64 N-m (6,5 kgt-rn , 47 Ibf-ltl WHEEL BALANCE m— Wheel balance directly alfects the stability, handling and overall safety of the motorcycle. Carefully check balance before reinstalling the wheel NOTE' OThe wheel balance must be checked when the tire is remounted. O For optimum balance, the tire balance mark (a paint dot on the side walll must be located next to the valve stem. Remount the tire if necessary. Mount the wheel, and tire assembly on an inspection stand. Spin the wheel, allow it to stop, and mark the lowest (heaviestl partof the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position, To balance the wheel, install balance weights on the lightest side of rim, the side opposite the chalk marks. Add just enough weight so the wheel will no longer stop in the same position when it is spun. Do not add more than 70 g l2.5 oz) to the rear wheel. BALANGE 1 4-9 REAR WHEEL/BRAKE/SUSPENSION lnstall the left slde collar. COLLAR Install the brake panel assembly mm the right wheelhub. INSTALLATION Fuslt‘ron the rear wheel in the sw‘mgarm. Install the left side adjuster collar onto the rear axle and insert the axle (from the left side) through the swingarm, wheel hub and rlght side collar. Install the drive Chall’l overthe drlven sprocket, lnstall the rightside adjuster collar and axle nut. 14-10 REAR WHEEL/BRAKE/SUSPENSION Connect the stopper arm to the brake panel with bolt, seat washer, washer and nut. Tighten the nut to the specified torque, TORQUE: ’97,:95: 22 N-m l2.2 kgf-m,16|bf-ftl Afler'SE: 21N-m12.1kgf-m,15|bfvftl Install the new cotter pin and bend it back securely. Connect the brake rod to the brake arm. Adjust the drive chain (page 3721) and rear brake pedal free play lpage 346). Tlghten the axle nut. TORQUE: 88 N-m (9.0 kgfrm , 65 lbf-ftl REAR BRAKE REMOVAL Remove the rearwheellpage14v3). Remove the brake panel from the rear wheel (page 1474). INSPECTION Measure the brake drum |.D. SERVICE LIMIT: 161 mm (6.3m) Measure the brake lining thickness. SERVICE LIMIT: 2 mm (0.1 inl REAR WHEEL/BRAKE/SUSPENSION DISASSEMBLY Remove ihe cotter pins and set piate. Remove the brake shoes and springs. NOTE. Mark the shoes 10 indicate their original positions before removing them. Remove the boil and brake arm. Remove the indicator plate and felt seai, Removethe brake cam. COTTER PINS SHOES SET PLATE 14-12 REAR WHEEL/BRAKEISUSPENSION ASSEMBLY BOLT INDICATOR PLATE SPRINGS BRAKE SHOES FELT SEAL BRAKE CAM BRAKE ARM _ '9‘“ § BRAKE PANEL 4%“ CUTTER PINS SET PLATE Apply grease to me anchor pins and brake cam. ANCHOR PINS Install Ihe brake cam into me brake panel. ,@ BRAKE CAM Apply oil to (he felt seal and install it onto the brake panel. lnslall the wear indicator plate on the brake cam aligning Its wide tooth wikh The wide groove on the brake cam. REAR WHEEL/BRAKE/SUSPENSION install the brake arm aligning the punch marks of the arm and the brake cam. Install and tighten the brake arm pinch bolt securely. Install the brake shoes and springs. Install the set plate and new cotter pins. INSTALLATION Install the brake panel into the wheel hub lpage 1440). Install the rear wheel (page 14710). BRAKE PEDAL REMOVAL NOTE 0 if the middle brake rod will be serviced, remove the muffler (page 2714i. 0" the brake rod will be serviced, remove the swingarm lpage 14721). Remove the cutter pin/washer (’97"98), nut and middle brake rod from pivot bolt. Remove the brake pedal assembly from the middle brake rod. 14—14 REAR WHEEL/BRAKE/SUSPENSION Remove the right footpeg bracket mount bolts, washers and bracket. Remove the prUl collarv Inspect the brake pedal pivot dust seals wear a! damage. Replace it if necessayy. / "K J: \ 0 BRAKE PEDAL COLLAR Remove the rear brake light swrtch return spring. Remove the rear brake rod return sprlng, Remove the middle brake arm joint bolt. Remove the middle brake arm/brake rod from the brake shaft arm. Remove the brake shaft arm and middle brake rod from the frame. BRAKE SHAFT ARM REAR WHEEL/BRAKE/SUSPENSION Remove the cotter pIn/washer l'977'98), nut and ‘ ~ 'ID‘DLE‘BRAKE ROD middle brake rod rear pivot bolt. * ’ Remove the middle brake rod from the brake shaft arm. INSTALLATlON BRAKE SHAFT ARM COW—FER FIN ~t ('97 - ’98l WASHER (97* '95l I!» MIDDLE BRAKE ROD Q; ‘F‘ BRAKE PEDAL ADJUSTER BOLT (,1. “m , DUST SEALS BRAKE ROD BRAKE PEDAL 26 N-m (2,7 kgf-m , 20 Ibf-ftl PIVOT COLLAR ~’ COTI’ER FlN ('97 7'98) MIDDLE BRAKE ARM Install the middle brake rod to the brake shaftarm Install the middle brake rod rear pivot belt, washer l'97i'98l and nut, Tighten the nut securely l’977'98l. Tighten the nut to the specified torque (After 'BSl. BRAKE ROD TORQUE: 9 N-m 10.9 kgf-m , 6.5 lbf-fil Install the new cotter pin securely to the nut (’97i'98l. 14-16 REAR WHEEL/BRAKE/SUSPENSION Apply grease to the brake shaft arm DlVOL Install the brake shaft arm/middle brake rod into the frame. Install the middle brake arm aligning the punch mark on the brake shaft arm with the slit of the middle brake arm. Install and tighten the middle brake arm joint bolt. TORQUE: '97‘98: 26 Nlm (2.7 kgfvm , 20 Ibf-ft) After ‘53: 21 N«m (2.1 kgf-m, 15 lbf-ftl Install the rear brake rod return spring. lnstall the brake light switch spring. RETURN SPRING Apply grease to the pivot collarand dust seal lips. Install the pivot Collar and dust seal into the brake @ pedal pivot. DUST SEALS BRAKE PEDAL COLLAR 14-17 REAR WHEEL/BRAKE/SUSPENSION SHOCK ABSORBER 97* '95‘ A/ter '92? Install the right tootpeg, washers and bolts. Tighten the bolts to the specified torque. TORQUE: 39 N»m (4.0 kgf-m , 29 Ibf-fll Install the middle brake rod front pivot bolt, washer l’97 7’98l and nut, Tighten the nut securely (’97 #98). Tighten the nut to the specified torque {After '98l. TORQUE: 9 N-m (0.9 kgf-m , 6.5 lbf-ft) Install the new cotter pin securely to the nut ('97’ '98). After installation, adjust the rear brake pedal free play (page 3726). BOLT/WASHER (’97 7 'SSl/N UT ”mew . . l v REMOVAL Support the motorcyole securely using a hoist or equivalent. Remove the following: *Seat (page 2-2) *Right and left side cover lpage 273l *Rear ignition coil mounting bolts (page 1778) Disconnect the fuel pump and fuel pump relay connector. Remove the turn signal relay from the fuel pump stay. fl CUTTER PIN ('97 '98l Disconnect the turn signal relay 3P connector. Remove the turn signal relay from the stay. 14-18 REAR WHEEL/BRAKE/SUSPENSION Remove the rear ignition coil stay from side mounting bolt. Remove the fuel pump stay (’97 498mm signal relay stay (After ’98) mounting nut. Remove the fuel pump stay1’97i'98), Remove the turn signal relay stay [After '98’. Any 98. Remove the side cover upper mount bolt and stay, After ’98' 14-19 REAR WHEEL/BRAKE/SUSPENSION After ’98‘ Remove the upper and lower shock absorber mounting bolts and nuts, and remove the shock absorber. INSPECTION Visually inspect the shock absorber for damage. Check the following: *Damper rod for bend or damage 7 Damper unit for deformation or oil leaks 7 Upper and lower §o|nt bushings for wear or damage Check smooth damper operation. CAUTION: Do not disassemble the shock absorber, Replace the shock absorber if any component is damaged. INSTALLATION Install and tighten the upper and lower mounting bolts and nuts to the specified torque. TORQUE: 44 N~m (4.5 kgflm , 33 Ibf-ttl Install the side cover upper mount stay and tighten the bolt securely. After '98: 14-20 REAR WHEEL/BRAKE/SUSPENSION Install the fuel pump stay (’97 #98). Install the turn signal relay stay (After ’98). Install the fuel pump stay ('977’38l/tum signal relay slay lAfter '98) mounting nut to the specifed torque. TORQUE: 9 N-m l0.9 kgf-m , 6.5 lbf-ft) install and tighten the ignition coil stay front side mounting bolt securely. ’977’98' Connect the turn Signal relay and fuel pump relay connectors. Install the fuel pump onto the fuel pump stay‘ REAR WHEEL/BRAKE/SUSPENSION After '95' Install the turn signal relay to the stay and connect After ’98: the turn signal relay 3P connector. Install the following: *Hear ignition coil (page 17-El W Right and left side cover (page 273i *Seat (page 272) SWINGARM REMOVAL Remove the followings: *Rearwheel (page 143i 7 Drive sprocket (page 773) *Gearshift arm from the gearshift spindle (page EriZl —Evaporative emission canister (California type only) *Radiator coolant reserve tank (page 6716) Remove the shock absorber lower mounting bolt and nut, Remove the swmgarm pivot bolt caps. Remove the swingarm pivot bolt and nut, then remove the swingarm from the frame. 14—22 REAR WHEEL/BRAKE/SUSPENSION DiSASSEMBLY V DRIVE CHAIN inspect lhe drive chain slider for wear or damage. Replace ii if necessary. Inspect the drive chain for din or damage Clean or replace it if necessarv lpage 3v21). Remove ihe nu‘s, boils, collars and drive chain MTé/BOLTS/COLLARS slider. " Remove the bolts and drive chain cover. Remove the cotter pin, nut, washers, bolt and stopperarm. STOPPER ARM 14-23 REAR WHEEL/BRAKE/SUSPENSION Remove the collars and dust seals from the right DUST SEALS side pivot. Remove the collar and dust seais from the \eit side pivot. COLLAR INSPECTION Inspect the swingarm for deformation or cracks, Check the pivot bearings, collars and dust seals for wear or damage. Disassemble the drive chain cover and inspect the chain protector for wear or damage. Replace if necessary. 14-24 REAR WHEEL/BRAKE/SUSPENSION PIVOT BEARING REPLACEMENT Remove the dust seals from the right and left swmgarm pivots. Remove the snap ring from the right pivot. TOOL: Snap ring pliers 07914, 3230001 Drive the righl pivot ball bearing out of the swingarm using a hydraulic press and drivershah. TOOL: Driver shah 07946 7 MJ00100 Not available in U.S.A. or 07949 * 3710001 or 07746 7 0040500 Drive the left needle bearing cm of the swingarm. TOOL: Driver shall see: 07946— KASOODD Install me Carefully press new beanngs into the swingarm bearings with (he pivots. marks facing am. RIGHT SIDE BALL BEARING: TOOL: Drivar 07749’0010000 Attachment, 32 X 35 mm 07746i0010100 Pilot, 15 mm 07746*0040300 SNA‘P RlNG DRlVER SHAFT “ BEAHlN mm... DRlVER SHAFT ‘ ‘BEARlNG ' DRIVER REAR WHEEL/BRAKEISUSPENSION LEFT SIDE NEEDLE BEARING: TOOL: Driver 0774970010000 Attachmant,23 X. 30 mm 07946 1870100 NE I Film, 22 mm 07746 0041000 lnstaH me newsnap Hng mm the ngm pwm TOOL. Snap ring pliers 07914 3230001 ASSEMBLY App‘y grease w the new dust gem Hps. App‘y an to me plvm sonar outer and shding surface. \nsta“ the dust See’s and pivol coHar to the swmgarm fen Side pwol Apply grease to the new dust seal hps 927,463+ Apply 0H m the pwm muars outer and stmg surface. \ns‘all the dust 556‘s and pwm collars m the swingarm ngm side pivm N I“ i \ \ a CDLLARS 14-26 Revised Combs! 1999, 1997 - 2000 VTGUOC/CD ©1959 American Honda Mmm 00., Inc. - AH Rxghts Reserved MSV 561719910) REAR WHEEL/BRAKE/SUSPENSION Install the stopper arm, bolt, washers and nut. Tighten the nut securely. Install the new cotter pin to secure the nut. ‘ STOPPER ARM Install the drlve chain cover and bolts‘ Tlghten the bolts securely, Install the drive chain Slider by allgning the hole an the chaln sliderto the pin on the swingarm. ALIG Install the collars, bolts and nuts. M _B LT Tighten the nuts securely. 0 /NUTS/COLLARS 14-27 REAR WHEEL/BRAKE/SUSPENSION INSTALLATION Install the swingarm in the frame. Install the swingarm pivot bolt and nut. Tighten the nut to the specified torque. TORQUE: EB N-m (9.0 kgf-m .65 lbf-ftl Install the swingarm pivot caps. Install the shock absorber lower mounting bolt and nut. Tighten the nut to the specified torque. TORQUE: 44 N-m (4.5 kgf-m , 33 (bf-m Install the followings: 7 Radiator coolant reserve tank (page 6-18). 7 Evaporative emission canister (Carifornia type only). 7 Gearshift arm to the gearshift spindle (page 8-16). 7Drive sprocket (page 744). 'Rear wheel (page 14710). Adjust the drive chain (page 3721). Adjust the rear brake pedal free play (page 376). 1 4-28 MEMO HYDRAULIC BRAKE 1 N-m10.15kgf-m,1.1|bf-ffl 1N-m(0.1kgi‘m,0.7lbf~m 12 N-m (1.2 kgf-m , 9 lbf-ffl 34 N-m13.5 kgf—m , 25 Ibf-ft) 6 N-m (0.6 kgf-m , 11.3 \bfrfl) 1Nrm (0.12 kgf‘m. Delhi-m 23 N-m12.3 kgf-m, 17 (bf-m 13 N-m(1.3 kgf-m,9|bfvft) 34 N-m13.5 kgf-m, 25 lbf-fU wm (1.8 kgf-m,13|bf-ft) @ \ 2 N-m (0.25 kgfvm , 1.8 mm 15-0 1 5. HYDRAULIC BRAKE SERVICE INFORMATION 15-1 TROUBLESHOOTING 15-2 BRAKE FLUID REPLACEMENT] AIR BLEEDING 15-3 BRAKE PAD/DISC MASTER CYLINDER BRAKE CALIPER 15-5 15-7 15-13 SERVICE INFORMATION GENERAL AWAHNING A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. CAUTION. I Support the brake caliper with a piece of wire so that it does not hang from the brake hose. Do not twist the brake hose. I Reusing drained fluids can impair braking efficiency. I Avoid spilling brake fluid on painted, plastic or rubber parts. Place a rag or shop towel over these parts whenever the system is serviced. I Never allow contaminants (dirt, water, etc.) to get into an open reservoir. I Always use fresh DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of fluid as they may not be compatible. I Spilled brake fluid will severally damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap: make sure the from reservoir is horizontal first. I Do not reuse the sealing washers. Replace with new ones. I Once the hydraulic system has been opened, or ifthe brake feel spongy, the system must be bled. I Always check brake operation before riding the motorcycle, I Always replace the brake pads is pairs to ensure even disc pressure. SPECIFICATIONS Unit: mm fin) ITEM STANDARD SERVICE LIMIT Specified brake fluid n . Honda DOT 4 Brake Fluid . ~ Brake pad wear indicator ’ 77777 ‘ 77 To groove Brake disc thickness 5.0 mm W _ 4.0 (0.16) Brake disc runout . . ‘ 0.30 (0.012i Master cylinder |.D. 11000711043 (0,4331- 0.4348) 1105170395), Master piston GD, 7 10.957i10.984(0.4314 "0,4324) 10.945 (0.4309i ,, Caliper cylinder Lo 27.0007 27.050 (1.063077130650)” 27.05 (1.065) Caliper piston O.D. 26.935* 25.968 (10504710 ) l 26.93 (1.060) 15-1 HYDRAULIC BRAKE TORQUE VALUES Brake caliper mounting bolt Caliper pin bolt Bracket pin bolt Pad pin Pad pin plug Brake caliper bleeder Brake lever pivot bolt Brake lever pivot nut Master cylinder holder bolt Master cylinder cover screw Front brake light switch screw Brake hose 0” bolt TOOLS Snap ring pliers TROUBLESHOOTING Brake lever soft or spongy - Air in the hydraulic system - Leaking hydraulic system - Contaminated brake disc/pad - Worn caliper piston seal - Worn mastercylinder piston cup - Worn brake pad/disc - Contaminated caliper ' Caliper notsliding properly - Low fluid level - Clogged fluid passage -Warped/deformed brake disc - Sticking/worn caliper piston - Sticking/worn master cylinder piston - Contaminated mastercylinder - Bent brake lever Brake lever hard - Sticking/worn caliper piston - Caliper not sliding properly - Clogged/restricted (luid passage ~ Worn caliper piston seal - Sticking/worn master cylinder piston - Bent brake lever 30 Nm (3.1 kgf‘m , 22 lbl-ftl ALOC bolt: replace with a new one 23 N-m [2.3 kgf»m, 17 Ibf-ft) 13 N-m (1.3 kgf»m , 9 Ibl-ft) 18 N-m (1.8 kgfm , 13 (bf~ftl 2 N-m (0.25 kgf-m , 1.8 (bl-ft) 6 N-m (0.65 kgf-m , 4.7 lbf-ftl 1 N«m(D.1kgf-m , 0.7 lbflfil 6 N-m (0.6 kgf-m . 4.3 lbf-fi) 12 N-m (1.2 kgftm , 9 lbflft) ‘lem (0.15 kgf«m,1.1|bf-ftl lem (0.12 kgfrm , 0.9 Ibf-ftl 34 N-m (3.5 kgf-m , 25 lbfvft) 0791473230001 or equivalent commercially available in U.S.A. Brake grab or pull to one side ‘ Contaminated brake pad/disc - Misaligned wheel - Clogged/restricted brake hose joint - Warped/deformed brake disc - Caliper not sliding properly Brakes drag . Contaminated brake disc/pad - Warped/deformed brake disc ' Caliper not sliding properly - Misaligned wheel 15-2 HYDRAULIC BRAKE BRAKE FLUID REPLACEMENT/AIR RESERVOIR r" BLEEDING mm A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean contaminated disc with a high quality brake degreasing agent. CAUTION. 0 Do not allow foreign material to enter the system when filling the reservoir. I Avoid spilling fluid on painted, plastic or rubber parts. Place a rag over these parts whenever the system is serviced. t Use only DOT 4 brake fluid from a sealed container. - Do not mix different types of fluid. They are not compatilzlet BRAKE FLUID DRAINING For the front brake, turn the handlebar to the left until the reservoir is level Remove the screws, reservoir cover, set plate and diaphragm. Connect the bleed tube to the bleed valve. RESERVOIR Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. BRAKE FLUID FILLING/BLEEDING Close the bleed valve. Fill the reservoir with DOT 4 brake fluid from a sealed container. Connect a commercially available brake bleeder to the bleed Valve Pumpthe brake bleeder and loosen the bleed valve. Add brake fluid when the fluid level in the reservoir IS low. NOTE OCheck the fluid level often while bleeding the brake to prevent air from being pumped into the system. IWhen using a brake bleeding tool, follow the manufacturer’s operating instructions. _ BRAKE BLEEDER- HYDRAULIC BRAKE Repeat the above procedures until air bubbles do not appear ll'l the plastic hose. NOTE If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon taper Close the bleed valve and operate the brake lever, If it still feels spongy, bleed the system again. lfa brake bleeder is not available, use the lollowing ‘Mwfi procedure: ‘ , Pump up the system pressure with the brake lever 59‘ until lever resistance is felt, Connect a bleed hose to the bleed valve and bleed the system as follows: 1. Squeeze the brake lever, Open the bleed valve 1/2 turn and close it NOTE' Do not release the brake lever until the bleed valve has been closed. 2. Release the brake lever slowly and wait several seconds after It stops moving. Repeat steps 1 and 2 until air bubbles do not appear in the bleed valve. Tighten the bleed valve. TORQUE: 5 N‘m (0.55 kgi~m , 4.0 lbfrfi) Fill the reservoir tothe upper level mark with DOT 4 UPPER LEVEL MARK brake fluid from a sealed container. 15-4 Install the diaphragm, set plate and reservoir cover, Tighten the screws to the specified torque, TORQUE: lN-ml0.15kgf~m,1.1lbf-ftl BRAKE PAD/DISC Always replace the brake pads in pairs to ensure even disc pressure _W ARNING A contaminated brake dis: or pad reduces stopping power. Discard contaminated pads and clean contaminated disc with a high quality brake degassing agent. BRAKE PAD REPLACEMENT Push the Caliper pistons all the way in by pushing the caliper body inward to allow installatiun of new brake pads. NOTE' Check the brake fluid level in the brake master cylinder reservoir as this operation causes the level to rise, Remove the pad pin plug and loosenthe pad pint Remove the pad pin and the brake pads. Install the new pads so that their ends rest on the pad retainer on the bracket properly, HYDRAULIC BRAKE COVER SET PLATE DIAPHRAGM t B VA“K_E PADS 1 5-5 HYDRAULIC BRAKE Install the pad pin by pushing the pads against the pad spring to align the pad pin holes in the pads and caliper. Tighten the pad pin to the specified torque. TORQUE: 18 N-m ll 8 kgf-m,13lbf-ftl Install and tighten the pad pin plug ta the specified torque. TORQUE: 2 N-m (0.25 kgf-rn,1,8lbftft) MW After replacement, operate the brake lever to seat the caliper pistons against the pads. BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Measure the brake dlSC thickness at several points, SERVICE LIMIT: 4.0 mm (0.16 In) Replace the brake disc if the smallest measurement is less than the service limit. Check me brake disc forwzrpage. SERVICE LIMIT; 0.30 mm (0.012 in) Check the wheel bearings for excessive play, if the warpage exceeds the service limit, Replace the brake disc if the wheel bearings are normal. 1 5-6 HYDRAULIC BRAKE MASTER CYLINDER HEARVIEW MIRROR CAUTIONt . Avoid spilling brake fluid on painted, plastic izr rubber parts. Place a rag or shop towel aver these parts whenever the system is serviced. 0 When removing the oil hose, cover the end of the hose to prevent contamination, REMOVAL Drain the brake fluid (page 15-3). Remove the right rearview mirror. Disconnect the brake hose by removing the oii butt and sealing washers. Remove the master cylinder holder bolts, holder and master cylinder. Disconnect the brake light switch connectors. HYDRAULIC BRAKE DISASSEMBLY LEVER Remove the brake lever pivot nur, bolt and brake lever. Remove the screw and brake light switch, SWITCH Remove the book from the master cylinder and master piston. BOOT “emc’ve‘hemaprmg' SNAP RING PLIERS SNAP RING TOOL: Snap ring pliers 07914~3230001 or equivalent commercially available in U.S.A. 15-8 Remove the master piston and spring from the master cylinder. Clean the master cylinder, reservoir and master piston with clean brake fluid. NOTE: - Replace the master piston, spring, cups and snap ring as a set whenever they are disassembled. - Be sure that each part is free from the dust or dirt before reassembiy. - Never ailow contammants (dirt. water, etc.) to get into an open reSErVQtr. INSPECTION Check the piston cups for wear, deterioration or damage. Check the master cyiinder and piston for scoring, scratches or damage. Measure the master cylinder LD SERVICE LIMIT: 11.05 mm (0.435 in) Measure the master piston O.D. SERVICE LIMIT: 10.945 mm (0.4309 ini HYDRAULIC BRAKE MASTER CYLINDER PISTON CUPS PISTON MASTER CVLINDER 1 5-9 HYDRAULlC BRAKE ASSEMBLY SNAP RING BRAKE LEVER 1N-m (0.15 kgf-m,1.1lbf-ftl 1N-m (0.1 kgf-m,0.7 lbf-ft) MASTER PISTON BOOT RESERVOIR COVER SET PLATE \ DIAPHRAGM MASTER CVLINDER é BRAKE LIGHT SWITCH S N-m10.$ kgi-m , 4.3 lbfvft) 1N-m (0.12 kngm , 0.9 Ibf-ft) SPRING NOTE 0 Replace the master piston, spring, cups and snap ring as a set. 0 Replace the boot if it shows wear, deterioration urdamage. 0 Apply silicone grease to the boot Inner surface. I Be sure that each part is free from the dust or dirt before reassembly. MASTER CYLINDER Coat the master piston, spring, and piston cups with clean DOT4 brake fluid. Install the spring onto the master piston end. Install the master plston/spring and washer into the master cylinder. a PISTON CAUTION: Do not allow the piston cup lips to tum inside out. Install the snap ring into the groove in the master SNAP RING PLIEHS SNAP RING cylinder. ~ TOOL: Snap ring pliers 0797477 3230001 or equivalent Commercially available in U.S.A. CAUTION. Be curtain the snap ring is firmly seated in the groove. 15-10 HYDRAULIC BRAKE lnstall the boot into the master cylinder and the groove in the master piston. Apply silicone grease to the brake lever contacting surface of the master cylinder. Install the brake light switch to the master cylinder by aligning the brake light switch boss and master cylinder hole. SWITCH Install and tighten the screw to the specified torque. TORQUE: 1 N-ml0.12 kng , 0.9 lblvft) SCREW Apply grease to the brake lever pivot bolt. Install the brake lever to the mastercylinder. 'fi" BOLT Install and tighten the brake lever pivot bolt and nut. TORQUE: Bolt: 1 N-m 10.1 kgf-m , 0.7 lbl-fl) Nut: 6 N-m 10.6 kgf-m , 4.3 lbf-l‘t) LEVER \ HYDRAULIC BRAKE INSTALLATION CONNECTORS Connect the brake light switch connectors. Install the master cylinder and the master cylinder “UP" MARK holder with the "UP” mark facing up. Align the end of the mastercylinder with the punch ALlGN MASTER CYLINDER mark on the handlebar Install the front master cylinder bolts and tighten the upper bolt first, then tighten the lower bolt to the specified torque TORQUE: 12 N-rn (1.2 kgf-m , 9 lbf-ft) Be carelul not to Connect the brake hose eyelet with the oil bolt and (ms: the brake new sealing washers, hose Tighten the brake hose oil bolt to the specified torque. TORQUE: 34 N-m13.5 kgf-m , 25 lbfvftl NOTE, While tightening the brake hose oil bolt, align the brake hose end with the stopperr 15-12 HYDRAULIC BRAKE Instali the right rearview mirror. Hefiii the brake fluid (page 1573), REARViEW MIRROR BRAKE CALIPER CAUTION: 0 Avaid spilling brake fluid on painted, plastic or rubber parts. Place a my a! shop towel over these parts whenever the system is serviczd. 0 When removing the oil hose halt, cover the end of the hose to prevent contamination, REMOVAL Drain the brake fluid (page 1573). Remove the brake hose oil bait and seaiing washers, and disconnect the brake hose from the front brake oaiiper. Remove the front brake caiiper mounting bolts and front brake caliper. Remove the brake pad (page 1575i. DISASSEMBLY BRACKET NOTE: Do not remove the caliper and bracket pins uniess replacement is necessary. Remove the caliper bracket from the caliper body. CALIPER BODY 15-13 HYDRAULIC BRAKE Remove the caliper pIn boot and pad retainer from RETAlNER the caliper bracket BOOT BRACKET Remove the pad spring and bracket pin boot from the caliper body. BOOT \‘~ RETAINER CALIPER Place a shop towel over the pistons Position the caliper body with the pistons down and apply small squirts of air pressure to the fluid inlet to remove the pistons. MEL—“m Do not use high pressure air or bring the nozzle too close to the inlet, Push the dust seals and plston seals in and lift them out. CAUTION: Be careful not ta damage the piston sliding surlace. Clean the seal grooves, caliper pistons and caliper piston sliding surfaces with clean brake fluid. 15-14 HYDRAULIC BRAKE INSPECTION Check the caliper cylinder and pistons Ior scoring, scratches or damage. Measure the caliper cylinder LD. SERVICE LIMIT: 27.06 mm (1.065 inI Measure the cahper piston O.D. SERVICE LIMIT: 26.93 mm (1.0601n) A EMB SS LY CALIPER BRACKET CALIPEFI PIN BOOT CALIPER PISTONS CALIPER PIN BOLT 23 N-m 12.3 kgf—m,17|bf»fl) CALIPER BLEED VALVE 6 N-m (0.65 kgf-m, 4.7 Ibf-ftI PAD RETAINER BRACKET PIN BOLT CALIFER 13 N-rn (1,3 kgfvm, SIM-III 18 Nm (1.8 kgf‘m,13|bflft) K BRACKET PIN BOOT 2 N-m (0.25 kgf-m, 1.81bfft) @ PISTON SEALS 33;, DUST SEALS PAD SPRING 15-15 HYDRAULIC BRAKE ' Replace the dust seals and piston seals with a new ones. ' Replace the caliper and bracket pin boots if it is wear, deterioration or damage. I Apply silicone grease to the boot inner surface. 0 Be sure that each part is free from the dust or dirt before reassembly. NOTE a PISTON SEALS sea DUST SEALS Coat new piston seals with clean brake fluid and install them in the seal grooves in the caliper. Coat new dust seals with silicone grease and install them inthe seal grooves in the caliper, Coat the caliper piston with clean brake fluid and install it Into the caliper cylinder with the opening RETAl toward the pads m NER Install the pad spring to the caliper body. Replace the bracket pin boot with a new ones if it is wear, deterioration or damage. Install the bracket pin boot to the caliper body. CALIPER Replace the caliper pin boot with a new ones if it is RETAINER wear, deterioration or damage. lnstali the caliper pin boot and pad retainer to the caliper bracket. m BOOT BRACKET Apply silicone grease to the caliper and bracket pins. install the caliper bracket over the caliper. BRACKET CALIFER BODY 15-16 HYDRAULIC BRAKE INSTALLATION Install the front brake caliper to the front fork. Install and tighten the new front caliper mounting bolts to the specified torque. TORQUE: 3D N-m 13.1 kgf-m , 22 lbf-ftl Be careful/mm: Connect the brake hose to the brake caliper with twist the brake new sealing washers. hase Install and tighten the brake hose oil bolt to the specified torque. TORQUE: 34 N-m (3.5 kgf-m ,25 lbf-ftl NOTE. While tightening the brake huse oil bolt, align the brake hose end with the stopper. \« on" Refill the brake fluid (page 1573). Install the brake pads (page 15»5l, 15-17 BATTERY/CHARGING SYSTEM ’97 7 '98: ALTERNATOR (‘3 , , REGULATOR/RECTIFIER Am" 93' MAIN FUSE \ BATTERY V v—-—— MAIN FUSE 30A Y G— Y 2 Yellow G '. Green R ‘. Red w : White ALTERNATOR REGULATOR/RECTIFIER 1 6-0 Revised: August, 2000. ‘97 301 VTGOUC/CD ©2000 American Honda Motor 00., Inc. A All Rigms Reserved MSV 8969 (0008} luv 16. BATTERY/CHARGING SYSTEM i SYSTEM DIAGRAM 16-0 BATTERY 16-5 SERVICE INFORMATION 16-1 CHARGING SYSTEM INSPECTION 16-7 TROUBLESHOOTING 16-3 REGULATOR/RECTIFIER 16-9 SERVICE INFORMATION GENERAL AW ARNING - The battery gives of! explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. . The battery contains sulfuric acid lelactrolytel. Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield 7 If electrolyte gets on your skin, flush with water. i If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physician immediately 0 Electrolyte is poisonous, * If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a ph ysicien. KEEP OUT OF REACH OF CHILDREN. 0 Always turn off the Ignition SWitch before disconnecting any electrical components. CAUTION: Some electrical components may be damaged if terminals or connectors are connected or disconnect while the ignition switch is ON and a current is present. 0 For extended storage, remove the battery, give it a full charge and store it in a cool, dry space. For maximum service life, charge the stored battery every two weeks. 0 For battery remaining in a stored motorcycle, disconnect the negative battery cable from the battery terminal. 'The battery can be damaged it overcharged or undercharged, or if left to discharge for long periods. These same conditions contribute to shortening the lifespan of the battery. Even under normal use, the performance ol the battery deteriorates after 23 years. I Battery voltage may recover after battery charging, but under a heavy load, battery voltage will drop quickly and eventually the battery Will be completely discharged. For this reason, the charging system is often suspected to be the problem. Battery overcharge often results in problems in the battery itself, which may appear to be an overcharge symptom. If one of the battery cells is shorted and the battery voltage does not increase, the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level drops quickly. 0 Before troubleshooting the charging system, checkfor proper use and maintenance of the battery. Check it the battery is frequently under a heavy load, such as having the headlight and taillight ON for long periods of time without riding the motorcycle. OTl're battery will self»discharge when the motorcycle rs not use. For this reason, charge the battery every two weeks to prevent sulfation from forming. o Filling a new battery with electrolyte will produce some voltage, but in order to achieve maximum performance, always charge the battery. Also, the battery life is lengthened when it is initial-charged. 0 When checking the charge system, always follow the steps in the troubleshooting flow chart ipage 16~3). I Alternator servicing may be done with the engine in the frame, 16-1 BATTERY/CHARGING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Banery 1 Capacity 12VAEAH ‘ Current leakage 1.3 mA max. 7 Voltage 1 Full charged 13.0 ~ 1312 V .. (20“C/68”F) ‘ Needs chargmg Eelow12.3V , Charging current Nurmai (ISA/jgh , 4 , . ,7 . ,,__ ‘ Quick 4.0 A/1 h max I Alternator CapathL ”mm 345 W/5,000 rpm Charging cqil rgsigtanqe QuicflgiIELWAhW", < , 0.1 7 1.0 52 1 Regmamr/recflfier regulated voltage 15 V/4,000 rpm 1 6-2 BATTERY] CHARGING SYSTEM TROUBLESHOOTING Battery undercharging (voltage not raised to regulated voltage). Measure the ch ng voltage w h the battery Correct fully charged and in good condltlon (page 16 6 , Check the battery current leakage (leak test, page 16-8l4 Correct lncorrect - Faulty battery Disconnect the regulator/rectifier 4P connector and recheck the battery current leakage, Standard regulated voltage is not reached when the engine speed increases. Correct Incorrect - Shorted wire harness ‘ Faulty ignition switch - Faulty regulator/rectifier Check the voltage between the battery line and ground line of the regulator/rectifier 4P connector (page 16-9). Incorrect —> . shorted wire harness - Poorly connected connectors Correct Check the resistance of the charging coil at the charging coil line of the alternator 3F connector Incorrect A- Shorted wire harness (page 16-9). - Faulty charging coil Correct - Faulty regulator/rectifier 16-3 BATTERY/CHARGING SYSTEM Battery overcharging (regulated voltage too highlt Measure the charging voltage with the battery w Correct —— - Faulty battery fully charged and in good condition (page 16—6). Regulated voltage greatly exceeds the standard value Check the continuity between the ground line and frame of the regulator/rectifier AP connector v Incorrect —> - Open circuit in wire harness (page 16-9). ‘ Poorly connected connectors Correct M < Faulty regulator/rectifier - Poorly connected connectors 16-4 BATTERY REMOVAL NOTE. Always turn the ignition switch OFF before removing or installing the battery. Remove the right side cover (page 2-3). Remove the rubber cover and unhook the fuse box from the battery case cover. Remove the battery case cover by removing the bolts. Remove the left side cover (page 2-3). NOTE ’______H Disconnect the battery negative cable first, then positive cable from the battery. _______.___—— Remove the negative cable cover. Remove the bolt and battery negative cable. Remove the positive cable cover. Remove the bolt and battery positive cable. Pull the battery out of the battery case. INSTALLATION Place the battery into the case and connect the battery positive cable to the battery first from the right side, then connect the negative cable from the left side. Coat the battery terminal with clean grease. Install the battery case cover by hooking the tab on the cover to the hook on the case. Install and tighten the cover mounting bolts. Install the fuse box onto the battery case cover. Install the rubber cover in the sequence as shown. Install the right and left side covers (page 24%|. Route the battery cables as shown on the battery caution label. NOTE _____________—— Pull the cover over the positive terminal, ‘_________— BATTERY] CHARGING SYSTEM OVER WIRING AS SHOWN BELOW NEGAVIVE LEFMJM POSl‘IVE rumuu BHTEIV susmuroa CABLE 16-5 BATTERY/CHARGING SYSTEM INSPECTION Measure the battery voltage using a commercially available digital multimeter. VOLTAGE: Fully charged: 13.0 7 13.2 V Under charged: Below 12.3 V BATTERY CHARGING Wm . The battery gives of! explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilatian when charging. a The battery contains sulluric acid lelsctrolyte). Contact with skin or eyes may cause severe burns. Wear protective clathing and a face shield ,” electrolyte gets on yaur skin, flush with water. 7” electrolyte gets in yaur eyes, flush with water for at least 15 minutes and call a physician immediately. 'Electrolyte is paisonaus. ll swallowed drink large quantities a! water or milk and [allow with milk of magnesia nr vegetable oil and call a physician. 0 Turn puwer ON/OFF at the charger, not at the battery terminals. Remove the battery (page 1675), Connect the charger positive (+l cable to the battery positive l- l terminal. Connect the charger negative iii cable to the battery negative 1* ) terminal. CHARGING CURRENT/TIME Standard: 0.8 A/10 h Quick: 4 0 N1 h max CAUTION: 0 Quick-charging should only be done in an emergency; slow charging is preferred. 0 For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or extending the charging time may damage the battery. BATTERY BATTERV 16-6 BATTERY/CHARGING SYSTEM CHARGING SYSTEM INSPECTION NOTE. I Measuring circuits with a large capacity that exceeds the capacity of the tester may cause damage to the tester. Before starting each test, set the tester at the high capacity range first, then gradually down to low capacity ranges in order to ensure that you have the correct range and do not damage the tester. I When measuring small capacity circuits, keep the ignition switch off. if the swrtch is suddenly turned on during a test, the tester fuse may blow. j BATTERY REGULATED VOLTAGE INSPECTION W_______ 0 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. 0 The exhaust contains poisonous carbon manuxide gas that may cause loss a! cansciousness and may lead to death. Remove the battery (page 1675) and install the fully charged battew. Start the engine and warm it up to the operating temperature; stop the engine. Connect the multimeter between the positive and negative terminals of the battery. CAUTION: 0 To prevent short, make absnlutely certain which are the pasitive and negative terminals or cable. I Do not disconnect the battery or any cable in the charging system withaut first switching off the ignition switch. Failure to Iallaw this precaution can damage the test" or electrical components. With the headlight to L0 beam, restartthe engine Measure the Voltage on the multitester when the engine runs at 5,000 rpm. REGULATED VOLTAGE: 115*140 V/5,000 rpm The battery is normal it the voltage reads the regulated voltage on the tester. NOTE The speed at which voltage starts to rise cannot be checked as it varies with the temperature and loads on the generator. 16-7 BATTERY/CHARGING SYSTEM A frequently discharged battery is an Indication that it is deteriorated even if it proves normal in the regulated voltage inspection. The charging circuit may be abnormal if any of the following symptoms is encountered: 1. Voltage not raised to regulated voltage [page 16-3) - Open or shorted circuit in the charging system wire harness or poorly connected connector - Open or shorted of the alternator - Faulty regulator/rectifier 2. Regulated voltage too high (page 16-4) - Poorly grounded voltage regulator/rectifier - Faulty battery ' Faulty regulator/rectifier CURRENT LEAKAGE TEST Remove the battery cover lpage 15-5). Turn the Ignition switch off, and disconnect the negative 1» ) cable from the battery Connect the ammeter 1+) probe to the battery negative cable and the ammeter (i) probe to the batteryklterminal. With the ignition switch off, check for current leakage, NOTE 0 When measuring current using a tester, set it to a high range, and then bring the range down to an appropriate level. Current flow higher than the range selected may blow out the fuse in the tester 0 While measuring current, do not turn the ignition on. A sudden surge of current may blow out the fuse in the tester SPECIFIED CURRENT LEAKAGE: 1,3 mA max. It current leakage exceeds the specified value, a shorted circuit is likely. Locate the short by disconnecting connections one by one and measuring the current. NORMAL CHARGING VOLTAGE . CONTROL —/— VOLTAGE T BATTERY e VOLTAGE V 0 L _ T A- G E T—f—V—l—I—_‘l—l V ENGINE SPEED ——> ABNORMAL CHARGING VOLTAGE e 4 @ v L o L _ T A V G E -—T_“‘l—T*’T’w—‘l—_l ’V‘ ENGINE SPEED —> BATTERY NEGATIVE TERMlNAL BATTERY NEGATIVE CABLE 1 6-8 BATTERY/CHARGING SYSTEM REGULATOR/RECTIFIER WIRE HARNESS INSPECTION Remove the left side cover (page 23) Disconnect the regulator/rectifier 3P and 4P connectors. Check the connectors for loose or corroded terminals. BATTERY LINE Make sure the battery voltage between Red/White (+) and Green (ii, if there is no voltage, measure the following; rite/m Terminals Specification Battery Red/White H») Battery charging and ground l-l voltage should line register Ground Green and Continuity line ground exists CHARGING LINE NOTE' It is not necessary to remove the stator coil to complete this test. Measure the resistance between the connector terminals and ground. CONNECTION: Yellow and Yellow STANDARD: 0.1 W 1.0 Q (20”C/68"Fl If the charging coil reading is out of specification, replace the stator lpage 9~2l. Check for continuity between the connector terminals and ground. There should be no continuity. If the there is continuity between the connector and ground, replace the stator (page B~2). BATrERY/CHARGING SYSTEM REMOVAL] INSTALLATION m .5 Remove the left side cover (page 23). Disconnect the regulator/rectifier 3F and AP conneuors. Remove the nuts and regulator/recnfier unit. \nstallakion is in the reverse order of removal‘ NOTE. Route the wire harness properly (page 146?. REGULATQR/ / RECTI‘HEfi r 16-10 MEMO IGNITION SYSTEM ENGINE STOP SWITCH IGNITION SWITCH IGNITION COILS IG NITION CONTROL MODULE SPARK PLUGS NEUTRAL SWITCH ENGINE STOP SWITCH SIDE STAND SWITCH IGNITION PULSE GENERATORS IGNITION SWITCH IGNITION Alter '98: CLUTCH SWITCH IGNITION PULSE GENERATORS ’ BATTERY NEUTRAL SWITCH SIDE STAND SWITCH ENGINE sua IGNITION mm STOP SWITCH FusE 10A sercI-I FUSE mu - avw -c\o-aI aim «>—0\o— a —BI NEuTFALfi‘ sua aAI'TEnv INDICATOR ‘ FUSE 15A IzvuI-I e e IszJw “’5" currcu SWITCH DIODE We” “N ;W gum“ GM‘ 1' WW _a._— 5"“ G—_I_ Mm» 5"" T smE S’I’AND F“ ““IE‘E‘E‘I’” wan IGNITION & I! 3H COIL M W IuNmoN an: sI-ck I :3ng v 2 ‘é’."°“ a u. FRONT REAR 6" GM“ Li _I_t a m i i w WM: 7 ~ IGNITION PULSE GENERATOR Lg : mm Gm" 1 7-0 Revised: August, 2000, ‘97 -'0I VTGDOC/CD @000 Amsncan Honda Motor (30., Inc. - AII FIIghIS Reserved MSV 8969 (0008) 17. IGNITION SYSTEM SYSTEM DIAGRAM 17.0 IGNITION CONTROL MODULE (ICMl 17-7 SERVICE INFORMATION 17-1 IGNITION COIL 17-8 TROUBLESHOOTING 17-3 IGNITION TIMING 17<9 IGNITION SYSTEM INSPECTION 174 SERVICE INFORMATION GENERAL AWARNING When 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. Run the engine in an open area or with an exhaust evacuation system in an enclosed area. CAUTION: Some electrical components may be damaged it terminals or connectors are connected or disconnected while the ignition switch is ON and a current is present. - When checking the ignition system, always follow the steps in the troubleshooting (page 17-3l, ' Ignition timing cannot be adjusted since the Ignition Control Module (ICM) is non-adjustable. It ignition timing is incorrect, check the system components and replace any faulty parts. 'The [CM may be damaged it dropped. Also, if the connector is disconnected when current is flowmg, the resulting excessive voltage may damage the unit. Always turn oh‘ the ignition switch before servicing, 0 A faulty ignition system is often related to poorly connected or corroded connectors. Check those connections before proceeding. Make sure the battery is adequately charged. Using the starter motor with a week battery results in a slower engine cranking speed as well as no spark at the spark plugs. ' Use spark plugs of the correct heat range. Using a spark plug of an incorrect heat range can damage the engine. - For neutral switch and side stand switch inspection and removal/installation see section 19. I For engine stop switch and ignition switch inspection and removal/installation see section 19. SPECIFICATIONS ITEM SPECIFICATIONS Spark plug . Standard DPRSEA-S iNGKl l X24EPRVU9 (oansoi ‘ For cold climate (below 5 ”C/41°Fl DPR7EA-91NGKI X22EPR-U9 (DENSO) i For extended high speed riding DPR9EA-9 lNGKl . X27EPR-U9 lDENSO) Sgark glug gaL _____ _ 77777 , 77 77 7 7 7 7 77 7 7989*0 i 0 031j0073flnl77 7 7 ,7 Ignition coilprimary peak voltage 100Vminim 7 7 Ignition pulse generator Eeakygltjggfi 7,, ‘7 M . W 0.7 v minimum 7 7777“ Ignition timing ”F” mark 6.5” BTDC at idle Advance l Start '977'98 2,000 + 200 rpm 7 l After '98 1,800 : 200 rpm l Stop ; 6,000 L 200 rpm Full advance ] BTDC 30u 17-1 IGNITION SYSTEM TORQUE VALUES Timing hole cap TOOLS Peak voltage (ester or Peak voltage adapter 15 N-m 11.5 kgI-m,11lbf-fll Apply molybdenum disulfide oil to the threads 07HGJ’OOZO‘IOO with Commevcially available digital multimeter limpedance 10 MEZ/DCV minimum) 17-2 IGNITION SYSTEM TROUBLESHOOTING . Inspect thefollowrng before diagnosing the system. * Faulty spark plug * Loose spark plug cap or spark plug wire connections *Water got into the spark plug cap lLeakIng to the ignition coil secondary voltage) - If there is no spark at either cylinders, temporarily exchange the ignition coil with the other good one and perform the spark test. If there is a spark, the exchanged ignition coil is faulty. ' "Initial voltage” of the ignition primary coil is the battery voltage with the ignition switch ON and engine stop switch at RUN (The engine is not cranked by the starter motor). No spark at all plugs Unusual condition Probable cause (Check in numerical order] Ignition coil No initial voltage with ignition and 1.B|own Sub fuse (10 AI. primary engine stop switches ON. (Other 2.An open circuit in Black wrre between the sub fuse voltage electrical components are normal) (10 A) and ICM. 3. Faulty engine stop switch. 4. An open circuit In Black/White Wire between the ignition coil and engine stop switch. 5. Loose primaryterrnmal or an open circuit in primary coil. 6. Faulty ICM lin case when the initial Voltage Is normal i > , 7 while disconnecting ICM connectors). g Initial voltage is normal, but it drops 1. Incorrect peak voltage adapter connections. 5 down to 2 ,, 4 v while cranking the 2.Undercharged battery. I engine. 3. No voltage between the Black/White (H and Body l ground ii) at the ICM connector or loose ICM connection. 4. An open circuit or loose connection in Green wire. 5.An open circuit or loose connection in Vellow/Blue and Blue/Yellow wires between the Ignition coils and ICM. , 6. Short circuit in ignition primary coil. l 7. Faulty side stand swrtch or neutral switch. i 8,An open circuit or loose connection in No. 7 related Circuit Wires. - Side stand swnch line: Green/White wire - Neutral switch line' Light Green/Red wire 9. Faulty ignition pulse generator (measure the peak voltage). 10. Faulty ICM lin case when above No.1 W 9 are normall. Initial voltage is normal, but no peak l 1.Faulty peak voltage adapterconnections, voltage while cranking the engine. 2. Faulty peak voltage adapter, ,, _ _ Sifauiltylglifln case when above No. ‘l, 2 are normall. Initial voltage is normal, but peak 1,T e multimeter impedance IS too low‘ below 10 M9/ voltage is lower than standard value. DCV. 2. Cranking speed is too low (battery underchargedl. 3. The sampling timing of the tester and measured pulse were not synchronized (system is normal it measured voltage is over the standard voltage at least oncel, 4. Fault ICM (in case when above No. ‘l 7 3 are normall, Initial and peak voltage are normal, but 1.Faulty spark plug or leaking ignition coil secondary does not spark. current ampere. 2, [aiulty ignition coil. ignition Peak voltage is lower than standard 1.The multimeter impedance is too low: below 10 M9/ pulse value. DCV. generator 2. Cranking speed is too low lbattery underchargedl. 3. The sampling timing of the tester and measured pulse were not synchronized (system is normal it measured voltage is over the standard voltage at least oncel. 4. Faulty ICM (in case when above No.1 7 3 are normal). "No peak voltage. 1. Faulty peak voltage adapter. 2. Feulty ignition pulse generator. 17-3 IGNITION SYSTEM IGNITION SYSTEM INSPECTION NOTE -If there IS no spark at either pulg, check all connections for loose or poor Contact beiore measuring each peak Voltage. ‘Use the recommended di 'tal multimeter or commercially available digital multimeter with an lmpedance of '10 MEL/DCV minimum. 'The display value differs depending upon the internal impedance ofthe multimeter. Oil using an lmrie diagnostic tester (model 625), follow the manufacture’s instructions. Connect the peak voltage adapter to the digital multimeter, or use the lmrie diagnostic tester, TOOLS: Peak voltage tester or Peak voltage adaptor 07HGJ70020100 with Commercially available digital multimeter (impedance 10 MSJIDCV mlnimum) IGNITION PRIMARY VOLTAGE INSPECTION NOTE 'Check all system connections before the inspections if the system is disconnected, an incorrect peak voltage will register. 0 Check cylinder compression at each cylinder and check that the spark plugs are installed Correctly In each cylinder. Support the motorcycle using the SldE stand. Dlsconnect the spark plug caps from the spark plugs on the cylinder head, Connect a good known spark plug to each spark plug cap and ground the spark plugs to the cylinder as done in a spark test. DlGlTAL MULTlMETER PEAK VOLTAGE / ADAPTOR 17-4 IGNITION SYSTEM When servrcing the front Ignition coil as following: , Remove the fuel tank (page 274). , Remove the crankcase breather tank with bolt (page 17-8). When servrcing the rear ignition coil as Iollowmg: Remove the right side cover lpage ZrAl Connect the peak voltage adaptor or peak voltage tester to the ignition coil primary terminal. NOTE. Do not disconnect the ignition coil primary wires. TOOLS: Peak voltage tester or Peak voltage adaptor D7HGJiODZO’IDO with Commercially availabi digital multimeter [impedance 10 M £2 IDCV mi mum) CONNECTION: Front ignition coil: Elue/Yellow(+) '7 Body ground l'nl Rear ignition coil: Vellow/Blue (+l , Body ground iii Turn the ignition swrtch ”0N” and engine stop swrtch to "RUN". Check for initial battery voltage. Ii battery voltage is not present, follow the checks described in the troubleshooting on page 1773. Shiftthe transmission into neutral. Crank the engine with the starter motor and read each ignition :oil primary voltage. PEAK VOLTAGE: 100 V minimum M; Avoid touching the spark plugs and tester probes to prevent electric shock. NOTE‘ Although measured values are different for each ignition coil, they are normal as long as the voltage is higherthan the standard value. if the peak voltage is lower than the standard value, follow the checks described in the troubleshooting on page 17-3. 17-5 IGNITION SYSTEM IGNITION PULSE GENERATOR PEAK VOLTAGE INSPECTION NOTE ‘ Check all system connection before the inspection. If the system is disconnected, an incorrect peak voltage will register. - Check cylinder compression at each cylinder and check that the spark plugs are installed correctly in each cylinder. Remove the ignition control module (lCM) lpage 1777i, Disconnect the Ignition control module (ICM) 4P connector. Connect the peak voltage adaptor to the 4P connector wire harness side. TOOLS: Peak voltage tester or Peak voltage adaptor 07HGJ 70020100 with CommerciaIIv available di 'tal multimeter (impedance 10 M £2 IDCV minimum) CONNECTION: Front cylinder: White/Blue (+) , Bluel ) Rear cylinder: White/Vellowl+l , Vellowifl Turn the ignition switch "ON” and engine stop switch to “RUN“ Shift the transmission into neutral Crank the engine With the starter motor and read the ignition pulse generator peak voltage. PEAK VOLTAGE: 0.7 V minimum mm Avoid touching the spark plugs and tester probes to prevent electric shock. 1f the peak voltage is lower than standard value, perform the following procedure. Remove the left steering cover (page 22). Disconnect the ignition pulse generator 4P connector. Turn the ignition switch "ON” and engine stop switchto”RUN”. Shift the transmisSion into neutral. Crank the engine with the starter motor and measure the peak voltage at the 4P connector ignition pulse generatorside and record it. CONNECTION: Front cylinder: White/Blue (+) 7 Blue ‘7) Rear cylinder: White/Yellow H l ~ Yellow ‘7) PEAK VOLTAGE: 0.7 V minimum 4P CON NECTOR PEAK VOLTAGE ADAPTER PEAK VOLTAGE ADAPTER 17-6 IGNITION SYSTEM Compare their values at the ignition control module (ICMl 4P connector and the ignition pulse generator 4P connector. lithe value at the ignition pulse generator is normal, but abnormal at the ignition control module llCM): ‘ Open circuit inthe ignition pulse generator wires ‘ Loosen connection in the ignition pulse generator connector if both values are abnormal: - The ignition pulse generator is likely to be faulty. Check and perform troubleshooting on page 17»3. - For ignition pulse generator replacement, referto section 8. IGNITION CONTROL MODULE (ICM) REMOVAL/INSTALLATION Remove the left side cover (page Z3). Remove the connector mounting plate. Remove the rubber band, nuts andtool tray. Remove the ignition control module (lCMi from the mounting stay. Disconnect the GP and AP connectors. Installation is in the reverse order of removal. IGNITION SYSTEM IGNITION COIL REMOVAL/INSTALLATION FRONT: Disconnect the spark plug cap from the spark plug. Remove the fuel tank (page 273i Remove the crankcase breather separator wilh bolt. Disconnect the ignition coil primary Wires from the terminals Remove the bolts and ground wire eyelet. Remove the ignition coil. Installation is in the reverse order of removal. in . . l'i “WEE REAR: Remove the rightside cover lpage 22). Disconnect the spark plug caps from the spark plugs. Remove the bolts. Disconnect the Ignition coil primary wires from the terminals and remove the ignition coil. Installation is in the reverse order of removal. NOTE nRoute the spark plug wires properly (page 1-22, Z3l. 0Connect the primary wires to the original position, Front: Black terminal: Black/White wrre Green terminal: Blue/Vellow wire Rear‘ Black terminal: Black/White wire Green terminal: Yellow/Blue Wire BREATHER SEPARATOR 17-8 IGNITION SYSTEM IGNITION TIMING m____ If the engine must be running to do some work, make sure the area is well ventilated. Neva! run the engine in an enclosed area. The exhaust contains poisonous carbon monoxide gas that may cause lass of consciousness and may lead to death. Run the engine in an open area or with an exhaust evacuation system in enclosed area. NOTE Read the manufacture’s instructions for the timing light before operating, Warm up the engine. Stop the engine. Remove the timing hole cap, Connect a timing light to the rear (#1) cylinder spark plug Wire. Startthe engine and let it idle. IDLE SPEED: 1,200 1’ 100 rpm The timing Is correct if the ”F” mark on the flywheel aligns with the index mark on the left crankcase cover. Increase the engine speed by rotating the throttle stop control knob. The timing is correct if the advance marks on the flywheel aligns With the index mark on the left crankcase cover. Stop the engine and connect the timing light to the from (it 2i cylinder spark plug Wire. Recheck the ignition timing at the front cylinder. Coat the new O-ring with engine oil and install it in the timing hole cap groove, Apply molybdenum disulfide oil to the timing hole cap threads and flange surface. Install and tighten the timing hole cap to the specified torque. TORQUE: 15 NM l1.5 kgf-m,11|bf-ftl ELECTRIC STARTER '9'] 7 ’98: STARTER SWITCH CLUTCH SWITCH STARTER RELAY SWITCH/ MAIN FUSE 30 A STARTER MOTOR STARTER SWITCH NEUTRAL SWITCH SIDE STAND SWITCH STARTER RELAY SWITCH/ MAIN FUSE 30 A IGNITION SWITCH //j\ / Altar '98: . \ TR DIODE V NEU AL SWITCH / BATTERY SIDE STAND SWITCH STARTER BATTERY RELAV SWITCH IZVIAN 9 e Iaumogl j MODULE MAIN FUSE I I I. GIW GIW [:oN—mn—I w: CLUTCR SWITCH STARTER MOTOR SIDE STAND SWITCH FUSg‘lIllA mil ‘ RIBI lN’aICATOR SIEEIEEE'E Izv1.7w Bl—O IGNI'HOM SWITCH SUI FUSE "IA 1 8-0 RvasedzAugusl, 2000. 97 -'DI VTSOOC/CD ©2000 AmerIcan Honda MW)! 00.. Inc. - AII Rigms Reserved NI SV 5959 (0005) 18. I:LI:UIHIU SIAHItH SYSTEM DIAGRAM 18-0 STARTER MOTOR 18-4 SERVICE INFORMATION 18-1 STARTER RELAY SWICTH 18-13 TROUBLESHOOTING 18-2 CLUTCH DIODE 13—14 SERVICE INFORMATION GENERAL AWARNING Always turn the ignition switch OFF before servicing the starter motor. The motor could suddenly start, causing serious injury. - When checking the starter system, always follow the steps in the troubleshooting flow chartlpage1B-2). I A weak battery may be unable to turn the starter motor quickly enough, or supply adequate ignition current. - II current continues to flow through the starter motor while the engine is not cranking over, the starter motor may be damaged. 0 Always turn off the ignition switch before disconnecting any electrical components. I Forfollowing components inspections, refer to the following pages:for the parts locations, see page 1870 of this manual *Side stand switch (Section 19) *NeutralswitohlSection19) *lgnition switch lSection 19l , Starter switch (Section 19l Clutch switch (Section 19) SPECIFICATIONS Unit: mm (Inl [ ITEM STANDARD SERVICE LIMIT Starter motor brush length 12.5 (0,49) ’ 6.5 (0.26) 18-1 ELECTRIC STARTER TROUBLESHOOTING ' Check for the following before troubleshooting the system. *Blown main fuse l30 A) or sub fuse (10A, 15A). ‘ Loose battery and starter motor cable. Discharged battery. - The sta rter motor should turn when the transmission is in neutral. - The starter motor should turn when transmission is in any gear as indicated the chart below. Gear Position Side Stand Clutch Lever Starter Motor _ Up yvfulledin Turn Any Gear Released Does not turn Down Pulled in Does not turn Released Does not turn Starter motor will not turn Check for loose or poorly connected battery terminals, and opened or shorted battery cable. iAbnormal —> . Normal Check for loose or poorly connected starter relay switch terminals and AP connector. —Abnormal‘>- Normal Check for loose or poorly connected starter motor cable, or opened cable. —Abnormal—>- Normal Poorly connected battery terminals - Open or short circuit in battery cable Poorly connected terminals or 4P connector Poorly connected motor cable ‘ Open circuit in starter motor cable With the ignition switch ON, push the starter switch and check for a “Click" sound from the starter relay switch. — Clicks —> No click To page: 1873 Connect the starter motor terminal directly to the battery positive terminal lbecause a large amount of current flows, do not use thin wires). Starter motor does not turn Starter motor turns - Faulty starter motor Loose or disconnected starter motor cable Faulty starter relay switch 18-2 L—hhvllllvulr‘lllhll From page: 1872 Check the starter relay coil ground wire lines lpage18-13). Continuity Check the starter relay voltage at the starter relay switch 4P connector (page 1843), l Voltage l Check the starter relay switch operation lpage18-13i. Abnormal L_____w_wa. The starter motor only turns when the transmission The side stand is up and the clutch lever is pulled in. is in neutral. Check that the side stand indicator operates properly withthe ignition switch ON (’97400)‘ Normal Check the clutch switch operation (page 1940). Normal Check the side stand switch (page 1915). l Normal Starter motor turns slowly - Poorly connected battery terminal cable - Poorly connected starter motor cable ' Faulty starter motor - Worn or damaged starter motor brush Starter motor turns, but engine does not turn - Starter motor is running backwards ' Case assembled improperly *Terminals connected improperly - Faulty starter clutch R No continuity + a % No voltage)!" Normal —> ' iAbnorrnal + - — Abnormal —> - W Abnormal 4* - Faulty neutral switch - Faulty clutch swttch diode ‘ Faulty side stand switch - Loose or poor contact of connector - Open Circuit in wire harness Faulty ignition switch - Faulty starter switch ‘ Loose or poor contact of connector - Open circuit in wire harness Loose or poor contact of the starter relay switch 4P connector Faulty starter relay switch Faulty side stand switch - Eurntbulb - Open circuit in wire harness Faulty clutch switch Faulty side stand swttch - Open circuit in wire harness - Loose or poor contact of connector Starter relay switch "clicks”, but engine does not turn over - Crankshaft does not turn due to engine problem - Faulty starter reduction gear - Faulty starter idle gear —_—_——_ Revised: August. 2000, ‘97 :01 VT600C/CD ©2000 American Honda Motor 50., inc. - All Rights Reserved MSV 8969 (0003) 18-3 ELECTRIC STARTER STARTER MOTOR REMOVAL Always turn the ignition switch OFF beiare servicing the starter motor. The motor nould suddenly start, causing serious injury, Remove the rubber cap and starter motor cable nut. Disconnect the staner motor cable. Remove the baits and ground cable. Remove the starter motor, Remove the Orring, O-RING DISASSEMBLY O-RING Record the Remove the bolts, rear cover and O-rrng. location and number of shims and washers REAR COVER 18-4 ELECTRIC STARTER Remove the thrust washers. Remove the from cover. Remove the O-rlng and thrust washers. Remove the armalu re, THRUST WASHERS FRONT COVER O’RING THRUSTWASHERS ARMATU RE 18—5 ELECTRIC STARTER Remove the ‘erminal nuL Remove the washer, shims and Orring. Remove me brush holder assembly‘ BRUSH HOLDER DISASSEMBLV Remove the ‘erminal boll stopper, ‘erminal bolt, motor brushes and brush springs. O’RING BRUSH HOLDER ASSEMBLY SHIMS SPRINGS BRUSHES STOPPER 18-6 INSPECTION Measure the each brush length. SERVICE LIMIT: 6.5 mm (0.26 inl Check for continuity between starter motor terminal and positive brush. There should be continuity. Check for continuity between starter motor terminal and starter motor case. There should be no continuity. Check for continuity between positive and negative terminals. There should be no continuity. Check the commutator for damage or abnormal wear. Replace the armature with a new one if necessary. Chock the commutator for metallic debris between commutator bars. Clean the metallic debris off between commutator bars. NOTE, Do not use emery or sand paper on the commutator. Check the commutator for discolorration of the commutator bar. Replace the armature with a new one if necessary. ARMATURE ELECTRIC STARTER 18-7 ELECTRIC STARTER Check for continuity between pairs of commutator bars, There should be continuity. Replace the armature with a new one if necessary. COM MUTATOR BARS Check for continuity between each individual _ ‘ COMMUTATDR BARS commutator barand the armature shaft There should be no continuity. Replace the armature with a new one if necessary. Remove the lock washer from the front cover. E NEEDLE BEARlNG Check the dust seal and needle bearing for wear or damage. Check the needle hearing rotates smoothly. Apply grease to the seal lips and needle bearing. install the lock washer to the front cover. 4&4 DUST SEAL L6ch WASHER Remove the starter idle gear, reduction gear and shafts (page S-Sl. Check the starter idle gear and shaft for wear or damage. SHAFT / lDLE GEAR 18-8 ELECTRIC STARTER Check the starter reduction gear and shaft for wear or damage. Instal‘ the starter idle gear, reduckion gear and shafis (page 978). SHAFT REDUCTION GEAR ASSEMBLY WASHERES ARMATURE BRUSH HOLDER WASHERES @@_ BRUSH SPRINGS WASHER TERMINAL NUT k. m rm“ O-RING ‘ 69) @ O’RING REAR COVER STOPPEH TERMINAL Nfifi ED: O'R'NG BOLT FRONT COVER STARTER MOTOR CASE NEEDLE BEARING DUST SEAL LOCK WASHER ‘r , 9} ORING BRUSH HOLDER ASSEMBLV BOLT SPRINGS Install the brush spring, momr brush and terminal bolt. NOTE Setthe brush spring as shown. BRUSHES STOPPER 18-9 ELECTRIC STARTER , Install the terminal bolt-stopper with its tab side BOLT STOPPER TAB facing to the vear cover Slde. , Install the terminal bolt and brush holder to the starter motor case aligning the terminal bolt and hole on the starter motor case. Align the starter motor case notch With the brush holdertab BRUSH HOLDER ASSEMBLY Installthe new O»ring. 0»R|NG lnstall the same number of shims in the same 'w locations as when disassembled. install the washer and terminal nutl WASHER yr‘ui SHIMS NUT Tighten the terminal nut securely Push and hold the brush inside the brush holder, and install the armature through the brush holder. When Installing the armature Into the stater motor BRUSH SPRlNGS case, hold the armature tightly to keep the magnet from pulling the armature against the starter motor case. CAUTION' - The coil may be damaged i! the magnet pulls the armature against the case. - The sliding surfaces at the brushes can be damaged if they are not installed properly Set the brush springs. ARMATUHE 18-10 ELECTRIC STARTER instaii the new Owing, Insiall the same number of ihrust washers in (he same locations as when disassembledv WASHERS instaii the from cover FRONT COVER CAUTION: _.________#— When installing the front cover, take care to prevent damaging the ail seal lip with the armature shaft instaii the same number of thrust washers in the same iocations aswhen disassembied. WASHERS Insxall the new Orring. Appiy thin coa‘ ofgrease to the armature shaftend. install the rear cover aligning its groove with the / brush haidenab. ’ ALIGN REAR COVER ELECTRIC STARTER Align the index marks on the starter motor case and front cover. Install and tighten the bolts securely. INSTALLATION NOTE. Route the starter motor cable and ground cable properly (page 1»25l. Apply oil to the new 0an and install it to the starter motor groove. Install the starter motor onto the crankcase. Install the ground cable, Install and tighten the bolts securely. 18-12 ELECTRIC STARTER Connect the starter motor cable. lnstall and tighten the starter motor cable nut securely. TORQUE: 10 N»m (1.0 kgf-m , 7 lbf-ft) install the rubber cap securely. STARTER RELAY SWITCH INSPECTION NOTE: Before checking the starter relay switch, check for battery condition. Remove the right side cover lpage Zral. Shift the transmission into neutral. Turn the ignition switch ON and engine stop switch to RUN, Depress the starter switch button. The coil is normal if the starter relay switch clicks. if you don't hear the switch “CLICK”, inspect the relay switch using the procedure below. GROUND LINE Disconnect the starter relay switch 4P connector. Check for continuity between the Green/Red wire (ground linel and ground. If there is continuity when the transmission is in neutral or when the clutch Is disengaged and the side stand switch is up, the ground circuit is normal [In neutral, there is a slight resistance due to the diode), STARTER RELAV VOLTAGE Connect the starter relay switch 4P connector. Shift the transmission into neutral. Measure the voltage between the Yellow/Red l'l Wire and ground at the starter relay switch 4P connector. If the battery voltage appears only when the starter switch is pressed with the ignition switch 0N, it is normal, BODY GROUND STARTER RELAV SWlTCH 18-13 ELECTRIC STARTER OPERATION CHECK Disconnect the starter relay switch 4P connector and cables. Connect a fully charged 12 V battery positive wire to the relay switch Yellow/Red wire terminal and negative wrre to the Green/Red wire terminal There should be continuity between the large terminals while the battery is connected, and no continuity when the battery is disconnected. REMOVAL/INSTALLATION Remove the right side cover (page 272). Disconnect the starter relay 4P connector. Remove the socket bolts and cables. Remove the starter relay switch. Installation is in the reverse order of removal. CLUTCH DIODE INSPECTION Remove the left side cover (page 273i. Remove the tape and diode 18-14 Check for cominuitv between the diode terminais. When there is continuny, a smail resistance vaiue will ragisier. If there 15 continuity in one direcnon, the diode is normal. DIODE ELECTRIC STARTER 18-15 LlGHTS/METERS/SWITCHES ’977’98: ENGINE STOP SWITCH STARTER SWITCH I A TURN SIGNAL RELAV FRONT BRAKE LIGHT SWITCH ( FUEL PUMP FUEL CUT RELAV CLUTCH SWITCH REAR BRAKE LIGHT SWITCH HORN FAN MOTOR SWITCH N EUTRAL SWITCH OIL PRESSURE SWITCH SIDE STAND SWITCH BATTERY After '98: STARTER SWITCH fl ENGINE STOP SWITCH FRONT BRAKE LIGHT SWITCH IGNITION TURN SIGNAL RELAY CLUTCH SWITCH , HORN FAN MOTOR SWITCH NEUTRAL SWITCH REAR BRAKE OIL PRESSURE SWITCH SIDE STAND SWITCH BATTERY LIGHT SWITCH 19-0 19. LIUH I SIWII: I tHS/SWI I UHtS i SYSTEM DIAGRAM 19-0 HANDLEBAR SWITCH 19-10 I SERVICE INFORMATION 19-1 IGNITION SWITCH 19-11 BULB REPLACEMENT 19-3 FAN MOTOR SWITCH 19-12 SPEEDOMETER 19-6 COOLANT TEMPERATURE INDICATOR, THERMOSENSOR 19-13 OIL PRESSURE INDICATOR/SWITCH INSPECTION 19-8 HORN 19-14 NEUTRAL INDICATOR/SWITCH 19-9 TURN SIGNAL RELAY 19-15 FRONT BRAKE LIGHT SWITCH 19-9 SIDE STAND SWITCH 19-15 REAR BRAKE LIGHT SWITCH 19-10 CLUTCH SWITCH 19-10 SERVICE INFORMATION GENERAL ' A halogen headlight bulb becomes very hot While the headlight is ON, and remains hot for a while after it is turned OFF. Be sure to let it cool down before servicing. I Use an electric heating element to heat the water/coolant mixture far the thermnsensar inspection, Keep all flammable materials away from the electric heating element. Wear protective clothing, insulated gloves and eye pmtectian. 0 Note the following when replacing the halogen headlight bulb, *Wear clean gloves while replacing the bulb. Do not put finger prints on the headlight bulb, as they may create hot spots on the bulb and cause it to break. *If you touch the bulb with your bare hands, clean it with a cloth moistened with alcohol to prevent its early failure. 7 Be sure to install the dust cover after replacing the bulb. 0 All plastic connectors have locking tabs that must be released before disconnecting, and must be aligned when reconnecting, 0 Always turn off the ignition switch before disconnecting any electrical components. ' A continuity test can be made with switches installed on the motorcycle. . Check the battery condition before performing any inspection that requires proper battery voltage. 0 The following color codes used are indicated throughout this section. Bu: Blue G: Green Lg: Light Green R: Red Bl: Black Gr: Gray 0: Orange w: White Br: Brown Lb: Light Blue P: Pink Y: Vellow 19-1 LIGHTS/METERS/SWITCHES ITEM SPECIFICATIONS Bulbs ‘ Headlight (High/low beam! 12V-60/55W ‘ Brake/tail light 12V732/SCP ><2 l Front turn signal/running light 12V-21/5W><2 Rearturn signal light 12V-21WX2 License light IZV-ACP Instrument light 77 12Vr3.4W 7T_urn Signal Indicator 12Vrl.7W . ingh beam indicator L 12V—1.7W N Val indicator 12V»1.7W Fuse M 5e 30A Subruéq 10AX3,15AX1 Fuel hump flaw capacity (Wm/minute) 800 cm1(27.1US oz , 28.2 Imp oz) l Fan motor Startto clp§9 (ON) l 98 - 102m (203 , 216°F) switch p Startto open ( 93 , 97 “C (199 . 207 “F1 Thermosensor resistance 50 “9/122 “F r 130- 130 (2 eye/176 “F 120 °C/248 “F TORQUE VALUES Oil pressure switch Neutral switch Handlebar switch 5 Fan motor switch Thermosensor Side stand switch mounting bolt '977’98: 10 N-rn (1.0 kgfvm , 7 letl After '98: 12 Nam (1.2 kgf-m , 9 thtl 12 Nm (1.2 kgf-m ,9 lbI-ftl 4 N-m (0.4 kgf‘m , 2.9 lbf-ftl c rew Apply sealant to the threads Apnly sealant to the threads 18 N-m (1.8 kgf-m,13lbf-ftl Apply sealant to the threads 10 N~m (1.0 kgf-m , 7 lbf-ftl 9 N-m (0.9 kgf-m , 6.5 lbf-ftl Apply sealant to the threads ALOC bolt: replace with a new one 19-2 LIGHTS/METERS/SWITCHES BULB REPLACEMENT ' ' ’ , HEADLIGHT HEADLIGHT ‘ ' M A halogen headlight bulb becomes very hot while the headlight is ON, and remain hot for a while after it is turned OFF. Be sure to let it we! dawn befare servicingt CAUTION: I Wear clean glaves While replacing the bulb. D0 nut put linger prints on the headlight bulb, as they may create hot Spats on the bulb and cause it ta break. - If you much the bulb with yuur bare hands, clean it with a ninth mais‘tened with alcohol ta prevent its early failure. - Be sure to install the dust cover after replacing the bulb. Remove the screws and headlight. Disconnect the headlight bulb socket and remove the dust cover Unhook the bulb retainer and remove the headlight RETAINER bulb. lnstallation is in the reverse urder of removal. NOTE lnstall the dust cover with its “TOP" mark facing up. LIG HTS/METERS/SWITCHES '97 7 '98. Do not damage the WI re harness TURN SIGNAL LIGHT Remove the screwtsl (’97i'98l and turn signal light lens. While pushing In, turn the bulb cuunterclockwrse to remove it and replace with a new one. Installation is in the reverse order of removal NOTE ° When turn signal light lens installation, align the tab on the lens with the groove on the turn signal light case SCR‘EWS’ - Seatthe rubber packing properly. After '98. // LENS TAIL/BRAKE LIGHT Remove the screws and tail/brake light lens. While pushlng in, turn the bulb counterclockwise to remove it and replace with a new one, installation IS in the reverse order of removal. NOTE Seat the rubber packing properly. LICENSE LIGHT Remove the two bolts, three nuts and license plate bracket from the rear Fender. Remove the license light lens attaching nuts on the reverse side ol the license plate bracket and remove the license light lens. 19-4 After ’98 Remove the two screws, washers, nuts and license Do not damage the plate bracket from the rear fender. wire harness Remove the license light lens attaching nuts on the reverse side of the license plate bracket and remove the license light lens. While pushing in, turn the bulb counterclockwise to remove it and replace with a new one. installation is in the reverse order of removal. NOTE: Seat the rubber packing properly. HIBEAM/NEUTRALITU RN INDICATOR BU LB Remove the bulb socket from the indicator box: Remove the indicator bulb from the bulb socket. Replace a new bulb and install it in the reverse order of removal. SPEEDOMETER LIGHT Disconnect the speedometer cable from the speedometer. LlGHTS/METERS/SWITCHES After '98: SCREWS N UTS NUTS/WASHERS BRACKET BULB / NUTS LENS lENDICATOR‘BE) l " f mtmli’" . "W‘ ‘ SOCKET LlGHTS/METERSISWITCHES Remove the speedometer cover mount'mg screws and cover. Remove the bulb socket from the speedometer. Remove the speedometer bulb from the bulb socket. Replace a new hub and instal‘ rt in the reverse order of removal. EULB t (12 V’3,4 W4) SPEEDOMETER REMOVAL/INSTALLATION Remove the steering covers (page 22). Disconnect the speedometer 6P (Black) connector. Disconnect the speedometer cable from the speedometer. 19-6 LlGHTS/METERS/SWITCHES Remove the speedometer mounting nut/bolt meter from the speedometer stay. installation is in the reverse order of removal. DISASSEMBLY Remove the speedometer (see abovel. Remove the screws and speedometer rear cover. Remove the speedometer stay. Remove the clamp and speedometer light from the speedometer. Remove the wi re harness from the speedometer. ASSEMBLY Assembly is in the reverse order of disassembly. NOTE: Route the combination meter harness properly (see belowl‘ _ WIRE HARNESS 19-7 LlGHTS/METERS/SWITCHES '977'00 METER BULB (3 AW) SPEEDOMETER CABLE STAV O-RING f SCREWS 9 SPEEDOMETER COVER OIL PRESSURE INDICATOR/SWITCH INSPECTION NOTE The oil pressure switch removal/installation is on page 4—3. Make sure that the Oil pressure warning indicator comes on with the ignition switch “ON". If the indicator does not come on, inspect as follows: Remove the left rear cover (page 773l, Disconnect the oil pressure switch wire from the switch by removrng the terminal screw. Short it to ground using a jumper Wire. Turn the ignition switch ”ON". The oil pressure warning Indicator should come on. If the indicator does not come on, check the sub- fuse (70 A) and wires for a loose connection or an open circuit, Start the engine and make sure that the indicator goes out. If the indicator does not go out, check the oil pressure (page 473l. if the oil pressure is normal, replace the oil pressure switch (page 7~3)‘ 6? BLACK CON NECTOR SPEEDOMETER 19-8 Revised: August, 2000, ‘87 301 VTSOOC/CD ©2000 American Honda Mote! 00.. inc. - All Rights Reserved MSV B969 (0005) NEUTRAL INDICATOR/SWITCH INSPECTION Make sure that the neutral indicator comes on with the ignition switCh "0N" and neutral position. if the indicator does not come on, inspect as foiiows: Remove the left rear cover (page 73). Disconnect the neutral switch connector Short it to ground using a jumper wire. Turn the Ignition switch "ON“. The neutral indicator should come on. If the indicator does not come on, check the sub fuse (10 A) and wires for a loose connection or an open circuit. REMOVAL/INSTALLATION Remove the left rear cover (page 773i, Disconnect the neutral switch connector. Remove the neutral switch. Clean and apply sealant to the neutral switch threads. install and tighten the neutral switch to the specified torque. TORQUE: ’12 N-m (1.2 kgi-m , 9 ibi-fli Connect the neutral switch connector. FRONT BRAKE LIGHT SWITCH NOTE For front brake light switch removal/installation refer to page 15-8. LlGHTS/METERS/SWITCHES Disconnect the Iront brake light sw1tch connectors and check for continuity, There should be continuity with the front brake applied and no continuity with it released. LlGHTS/METERS/SWITCHES REAR BRAKE LIGHT SWITCH Remove the right side cover (page 2-3l Disconnect the rear brake light switch 2F connector and check for continuity at the switch side connector There should be continuity with the rear brake applied and no continuity with It released. mew CLUTCH SWITCH CLUTCH S‘WITCH For clutch switch removal/installation refer to page 135. Disconnect the clutch switch connectors and check for continuity. There Should be Continuity wlth the clutch applied and no continuity With it released. HANDLEBAR SWITCH NOTE For handlebar switches removal/installation refer to page 1375. Remove the left steering cover (page 273). Check for continuity between the terminals. Continuity should exist between the color coded wires as shown in each chart. RIGHT HANDLEBAR SWlTCH Disconnect the right handlebar switch 9P connector. STARTER swncn "* \ Bi/W V/R Free _ Push v r L, ,, ENGINE sror swncn " t ‘ Ell/G ‘ BMW on . > Run RlGHT HANDLEBAR SWITCH QPCONNECTOR 19-10 LIGHTS/METERS/SWITCHES LEFT HANDLEBAR SWITCH Disconnect the left handlebar 9P swutch connector. DIMMER SWITCH \\\ Bu/VV Bu w Lo , ~ 7' J (N) 1 Hi TURN SIGNAL SWITCH " rec; Gr Lb o lBr/Bl LbNV‘O/W Right . 7 2 ,,,i O :l O N E .. ,iQ:{}r* 0 Let! A O l O J . IGNITION SWITCH Remove the left Side cover (page 23) Disconnect the ignition switch 4? iWhitel connector. Check for continuity between the ignition switch connector terminals in each sWItch position. Continuity should exist between the color coded wires in each chart below. IGNITION SWITCH ' R 0. 0,, Off REPLACEMENT Remove the ignition swttch cover by removing the screw. Remove the break-off bolt heads using a drill then remove the ignition switch. Install the new swnch and new break—off bolts. Tighten the breakroff bolts until the heads twist off. LlGHTS/METERS/SWITCHES FAN MOTOR SWITCH INSPECTlON FAN MOTOR DOES NOT STOP Turn the ignition swttch OFF, disconnect the fan motor switch connector from the tan motor switch and turn the ignition switch ON again. If the fan motor does not stop, check for a shorted wire between the fan motor and switch It the fan motor stops, replacethe tan motorswttch. FAN MOTOR DOES NOT START Before testing, warm up the engine to operating temperature. Disconnect the connector from the fan motor switch and ground the connectorto the body with a jumper wire. Turn the ignition switch ON and check the fan motor. If the motor starts, check the connection at the fan motor switch terminal. If it is OK, replace the fan motor swttch. If the motor does not start, check for voltage between the fan motor switch connector and ground. 7 Battery voltage: Faulty fan motor *No battery voltage: - Broken wtre harness - Broken sub fuse - Faultv ignition switch - Poor connection of the connector lbetween the ignition switch and fuse boxl REMOVAL/INSTALLATION Drain the coolant lpage 65). Disconnect the fan motor switch connector from the fan motor switch. Remove the fan motor switch and O-ring from the right radiator. Install the new Ovring. Clean and apply sealant to the fan motor switch threads. Install and tighten the fan motor SWItCh to the specified torque. TORQUE: 18 N-rn 11.8 kgf-m,13lbf>ft) l‘T ‘: 19-12 COOLANT TEMPERATURE INDICATOR ('977’00), THERMOSENSOR ('977'00) /THERMO SWITCH (After ’00) NEW SYSTEM INSPECTION ('97 7 ’00) Turn the ignition switch ON. The temperature warning light should come on for a few seconds and the light should disappear soon. THE INDICATOR DOES NOT COME ON Remove the left steering cover (page 23). Disconnect the thermo unit Black/Brown in) and Green/Black ‘7) connectors. Measure the voltage between the Black/Brown H) and Green/Black (ii connectors of the wire harness side. There should be voltage with the Ignition switch ON. If there is no voltage, check the wire harness for an open circuit or loose connections in the Black/Brown 1+) and Green/EIaCkI’ ) wires. If there is battery voltage available, replace the speedometer. THE INDICATOR DOES NOT GO OFF Remove the left steering cover (page 2—3). Disconnect the temperature warning light Green/ Blue connector. Check for continuity between the Green/Blue connector of the Wire harness side and ground. There should be no continuity. If there is continuity, check for e short circuit in the Green/Blue wire. If there is no continuity, check the thermosensor isee the followingl, If it is OK, replace the speedomr eter. SYSTEM INSPECTION (After '00) Turn the ignition switch ON, the temperature warning light should not come on. If the warning light comes on, check the wire harness for an open circuit or loose connection between the temperature warning light and thermo SWitch and also check the thermo switch (Page 19— 14). THERMOSENSOR (’97 w'00)]THERM0 SWITCH (After '00) INSPECTION WW 'Wear insulated gloves and adequate eye protection. 'Keep flammable materials away from the electric heating element. LlGHTS/METERS/SWITCHES GREEN/BLACK (i) CONNECTOR \ fi , A\\ . j THERMOMETER THERMOSENSOFI 1'97 * ’00)/ THEHMO SWITCH lAfter '00) I ed: Augusl, 2000. ‘97 -'01 VTESDOC/CD 3 American Honda Motor 00., Inc. - All ngI‘IN Reserved 3969 (0008) LlGHTS/METERSISWlTCHES HORN NOTE, 0 Soak the thermosensor ('97 ' ’00)/ thermo switch (After mil in coolant upto its threads with at least a 40 mm (1.57 in) gapfrom the bottom ol the pan to the bottom of the sensor/swrtch. 0 Keep the temperature constant for 3 minutes before testing. A sudden change of temperature will result in incorrect readings. Do not let the thermosensor (’97a’Ool/thermo switch (After ’00) or thermometer touch the pan. % Drain the coolant (page 676). Remove the left steering cover (page 23). Disconnect the thermosensor ('97 ’00)/ thermo switch (After ’ODl connector and remove the sensor/switch. Suspend the thermosensor (’97 7 ’00)/ the rmo switch (After ’00) in a pan of coolant (50750 mixture) over the electric heating element and measure the resistance ('97 'ODl/check the continuity (After '00) through the sensor as the coolant heats up. '9 00: .Jmetatwe 50 ”C/122 “F BO ”C/178 “F 120 "(7248 “F After '00 Start to close (0le 112 118°C (258 , 270°Fl I Stanto open (OFF) Below 108°C (252°F) j Replace the sensor ('37 is out of specifications. Clean and apply sealant to the thermosensor ('97i’0cll/thermo switch (After '00) threads Do not apply sealant to the thermosensor ('97 , ’Ufll/ thermo switch (After ’00) head. install and tighten the thermosensor (’97 , ’DUV thermo switch (After ’00) to the specified torque. ’OOl/ switch (After ‘00) if it TORQUE: ’97 ' ‘00: 10 N-m(10 kgf-m ,7 lbfrft) After '00: 8 N-m (0.8 kgf-m , 5.8 lb'frltl Connect the therniosensor ('97 7 ’00)/ thermo switch (After '00) connector Refill the coolant (page 6-6). Install the left steering cover (page Z»3l. Remove the steering covers (page 273i. Remove the nut. Disconnect the horn connectors and remove the horn, Connect a 12 V battery to the horn terminals, The horn is normal if it sounds when the 12 V battery is connected across the horn terminals. Revised: August. 2000, '97 -'01 VTGUOC/CD @2000 American Honda Motor 00,, Inc. - All Flights Reserved MSV 8969 (0008) LIGH I'SIMETEHSISWITCHES TURN SIGNAL RELAY REMOVAL/INSTALLATION RemovetheseatlpageZQL Disconnect the turn signal relay 3P (Black) connector. Remove the turn signal relay. Installation is in the reverse order of removal PERFORMANCE TEST Remove the turn signal relayv Check for turn signal circuit connection beiore testing, Short the black and gray terminals of the turn signal relay connector with a jumper wire. Turnthe ignition switch ON and check turn signal light by turning the switch ON. If the light does not come on, check the turn signal switch or open circuit in Black or Gray wire. If the light comes on, check for continuity between Green terminal and body ground at the turn signal relay 3P (Black) connector. 7 No continuity: Open circuit in Green wire *Continuity: ' Loose or poor contact of the turn signal relay 3F (Black) connector - Faultyturn signal relay 5 {Zai'om/ V R ter ’00) \ SIDE STAND SWITCH V \ INSPECTION Remove the left side cover (page 273l. Disconnect the Side stand 3P (Green/137* ’98, Black/'98 i’OOI 2P lGreen/After '00) connector. Check for continuity between each of the terminals as below. There should be continuity between the O 0 positions on the chart below, SIDE STAND SWITCH '97:'DO Side stand om Side stand up After '00 Side stand down Side stand up Revised: Augusl, 2000. ‘97 4'01 VTGUOC/CD 1 9-1 5 @2000 Amsvlcan Honda Motor (20,, Inc - All Rights Reserved MSV 5969 10008) LIGH ISIMI: I tHS/SWI | UHES REMOVAL/INSTALLATION at 3pmawpmmm ; Remove the left side coveripage 273i. 3 \ Disconnect the side stand 3P (Green/’97 ’98, BlacW'Qai’DOlZP (Green/After'DOi connectoiv V ' '97’ 8 Remove the Side stand switch bolt, swrtch holder ‘5‘ ('97 ’98), washer and side stand SWItch. BOLT ‘ HOLDER \ SIDE STAND SWITCH ‘ i i i WASHER , g V _ . After ’98: ’97 98 Install the side stand SWitch by aligning the pin on Align "75 fab 0f the switch with the hole on the reverse side oi the the holder with the sta nd, groove on the swi'Ich. Install the washer, holder, new side stand switch bolt and tighten the bolt to the specified torque. TORQUE: 9 N-m (0.9 kgf-m ,6.5 lbl-fti Atter '98' Install the side stand switch by aligning the pin on the switch with the hole, and aligning the groove on the switch with the pin on the front side oithe stand. SIDE STAND SWlTCH WASHER install and tighten the new side stand switch bolt to the specified torque. '97498: After'SS TORQUE: 9 N»m (0 9 kgfvm , 6.5 lbf fti NOTE Route the side stand switch wire properly ipage 1-22i. Connect the side stand switch 3P [Green/’97i'98, Black/'98i'00iZPlGreen/After’Ooiconnector. Install the left side cover ipage 273i 1 9- 1 6 Revised: August, 2000, ‘97 -'01VTGUDCJCD ©2000 American Honda Molar Co.. Inc. , All nghLS Reserved MSV 895910008) Iv .v ZU. VVIfiINu UIHunHIVI ace—Tau: '55:: u U 3% g g? :2 z: z: :2: a 5E :52. After ’93: 20-1 WIRING DIAGRAM '98i'00 Imm- WMMMUI 5:0 mm 3:0 . L Izmsacprmm x2 name an um I my __5 . mad—m 2m f? a as a S Q in 3 i um um “mm-«.m—mmmszm I'JI'ISIIZ- MZfl 4.500 O-O an 0.00 mu mm mm w n Lmnnu . 00 o o Loéboo O-O sv u m 00 or: «21 000 w Revisad: August, 2000, ‘97 301 VTSDOC/CD ©2000 Amelican Honda Mom! (30., Inc. - AII Righls Reserved MSV 8969 (0008) WIRING DIAGRAM can..- nNE -Nanaa .O .2: 5... E .. a... . w: “w... V... . a. . .353, 3 E: a 3.. .9. J i 3x 4. r E 4 ._ . :x e. a a. «i 5. a E. a 7 E... .3. E: u... E: 3...; 7.: . :3. . ‘ E: . 3:. . x25 in Ex; E... .55 .3. i: 1.3 a: n .g «Alva .9; E‘ingfils [:55 is! as! s .32. . W , :3.E:.§i.s.{..¥si. s!;§ .5: A 3, i: 2): =1. 3. :2 memo: 2;: i: is i: 5. E4 2:16:25: :52. e... 5.... mm Aw Qatar: .2 § .3 Eggs; 3...... a 8 After ’00 20-3 in z. z: a. :- 32. 1.”, L E: 5: 3&5... ESE, 5, 5. @2000 American Honda Motel 50.. inc. - AH Higth Reserved Revised: Augusl, 2000, ‘97 -'01 VTGOOC/CD msv 8969 (0008b 21. TROUBLESHOOTING ENGINE DOES NOT START OR IS HARD TO START ENGINE LACKS POWER POOR PERFORMANCE AT LOW AND IDLE SPEED POOR PERFORMANCE AT HIGH 21-1 SPEED 21-2 POOR HANDLING 21—3 21-4 21-4 ENGINE DOES NOT START OR IS HARD TO START Possible cause 1. Check the fuel flow to carburetor 7 Reaching carburetor 2. Perform a spark test Good spark 3. Remove and inspect spark plugs Good 4. Start by following normal procedure Engine does not start 5. Test cylinder compression Not reaching carburetor a - - Pinched fuel valve vacuum tube - Clogged fuel tank breather #— Weak or no spark ——~—>- - Fouled spark plug - Faulty ignition control module - Broken or shorted spark plug w - Faulty ignition switch - Faulty ignition pulse generator - Faulty engine stop switch - Loose or disconnected ignition Wet plug ”- Engine starts but stops —-—> - - Carburetor incorrectly adjusted -lntake pipe leaking - improper Ignition timing (Faulty Low compression —>‘ - Valve stuck open -Worn cylinderand piston ring - Damaged cylinder head gasket - Seized valve - Improper valve timing Clogged fuel line and filter Faulty spark plug system wires Flooded carburetor - SE valve ON position - Throttle valve open - Air cleaner dirty Improper choke operation ire ignition coil or ignition pulse generatorl ‘ Fuel contaminated Valve clearance too small 21-1 TROUBLESHOOTING ENGINE LACKS POWER .Raise wheel off the ground and spin by hand Wheel spins freely Possible cause Wheels do not spin freelyfi‘ ' Worn or damaged wheel bearing 2. Check tire pressure Pressure normal 3.Acce|erate rapidly from low to second Engine speed reduced when clutch 's released 4. Accelerate lightly Engine speed increases Pressure low Engine speed doesn’t ——> change accordingly when clutch is released Engine speed does notH' increase 5.Check ignitiontiming Correct 6. Test cylinder compression Normal 7. Check carburetor for clogging Not clogged 8. Remove spark plugs Z ot fouled or discolored 9. Check or! level and condition Correct 10‘ Remove cylinder head cover and inspect lubrication Valve train lubricated properly Incorrect Incorrect w - Clogged E» - Fouled ordiscolored —>- lncorrect %-—>- Valve train not lubricated ~—>' properly Brake dragging ' Faulty tire valve - Punctured tire - Clutch slipping - Worn clutch discs/plates - Warped clutch discs/plates ' Weak clutch spring - Additive in engine oil SE valve ON position - Clogged air cleaner - Restricted fuel flow - Clogged muffler - Pinched fuel tank breather ' Faulty ignition control module - Faulty ignition pulse generator Valve stuck open - Worn cylinder and piston rings - Leaking head gasket - Improper valve timing Carburetor not serviced frequently enough Plugs not serviced frequently enough - Spark plugs are the incorrect heat range Oil leveltoo high - Oil level too low - Contaminated oil Clogged oil passage - Clogged oil control orifice 21-2 11. Check for engine overheating Not overheating 12.Accelerate or run at high speed Engine does not knock TROUBLESHOOTING Possible cause Overheating —> - Engine knocks —> - Coolant level low ‘ Fan motor not working (faulty fan motor switchl - Thermostat stuck close ‘ Excessive carbon butld»up in combos» tion chamber ‘ Use of poor quality fuel ‘ Clutch slipping - Leaniuel mixture , Wrong type of fuel Worn piston and cylinder 'Wrongtype of fuel Excessive carbon build-up in combusV tion chamber ' Ignition timing to advanced (faulty ignition control module) - Lean fuel mixture POOR PERFORMANCE AT LOW AND IDLE SPEED Possible cause 1. Check carburetor pilot screw adjustment correct 2. Check for leaking intake pipe Not leak 3, Perform spark test Good spark Incorrect Leaking _—>- Weak or intermittent —> ' spark 4. Check ignition timing incorrect - See section 5 Loose insulator clamps - Damaged insulator Faulty Carbon or Wet fouled spark plug - Faulty ignition control module - Faulty ignition coil - Broken or shorted spark plug wtre - Faulty engine stop switch ‘ Faulty ignition pulse generator - Faulty ignition switch - Loose or disconnected ignition system wires - lmproper ignition timing (faulty ignition control modulel 21-3 TROUBLESHOOTING POOR PERFORMANCE AT HIGH SPEED ‘l.Diseonnecr fuel tube at carburetor and pumpthe vacuum line Fuel flows freely 2,Remove the carburetor and check 7 Clogged——> ' forclogging Nm clogged 3.Check valve timing Incorrecr Correct 4rCheck ignition liming incorrect Correct 5,Check valve spring Weak Nor weak POOR HANDLING 1. if steering is heavy 2. If eitherwheel is wobbllng 3. If the motorcycle pulls to one side —————> ‘ Fuel flow restrictedg’ - Possible cause Clogged ruel line - Clogged iuel tank breaiher - Faulty luel valve - Clogged fuel filter Clean - Cam sprocket not installed properly - Faultyignition control module - Faulry ignition pulse generator - Faulty spring Possible cause - Steering stem adjusting nut too tight - Damaged steering head bearings v Excessive wheel bearing play - Bent rim - Improper installed wheel hub - Swingarm pivm bearing excessively worn - Bent frame Faully shock absorber - Front and rearwheel nolaligned ‘ Bent fork ‘ Bent swingarm - Bent axle 21-4 AIR CLEANER AIR CLEANER CHAMBER 1‘ “R CLEANER HOUSING AIR CUT-OFF VALVE BATTERY BRAKE CALIPER BRAKE FLUID BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE LIGHT SWITCH BRAKE PAD/DISC B RAK E PEDAL BRAKE SHOE/PAD WEAR BRAKE SYSTEM BULB REPLACEMENT CABLE &HARNESS ROUTING CAMSHAFT INSTALLATION CAMSHAFT REMOVAL CARBURETOR BODY CLEANING CARBURETOR CHOKE CARBURETOR DISASSEMBLY/ASSEMBLY CARBURETOR REASSEMBLY (’97 '98I CARBURETOR REASSEMBLY (After ’98) CARBURETOR INSTALLATION 1'97 “ ’SSI CARBURETOR INSTALLATION IAerr '98I CARBURETOR REMOVAL (’97 ’QBI CARBURETOR REMOVAL (Afler ’95) CARBURETOR SEPARATION (’97 , ’QSI CARBURETOR SYNCHRONIZATION CHARGING SYSTEM INSPECTION CLUTCH DIODE CLUTCHINSTALLATION CLUTCH REMOVAL CLUTCH SWITCH CLUTCHSYSTEM COOLANT COOLANT TEMPERATURE INDICATOR, THERMOSENSOR COOLING SYSTEM CRANKCASE ASSEMBLY CRANKCASE BEARING REPLACEMENT CRANKCASE BREATHER CRANKCASE SEPARATION CRANKCASE STUD BOLT INSPECTION CRANKSHAFT/CONNECTING ROD CYLINDER COMPRESSION CYLINDER HEAD ASSEMBLY CYLINDER HEAD COVER INSTALLATION CYLINDER HEAD COVER REMOVAL CYLINDER HEAD DISASSEMBLY CYLINDER HEAD INSTALLATION CYLINDER HEAD REMOVAL CYLINDER INSTALLATION CYLINDER REMOVAL DRIVE CHAIN DRIVE SPROCKET INSTALLATION DRIVE SPROCKET REMOVAL EMISSION CONTROL INFORMATION LABELS EMISSION CONTROL SYSTEMS ENGINE DOES NOT START OR IS HARD TO START 10721 10731 1075 10-14 1023 10-13 1179 1173 3720 7-14 7-4 1736 1731 2171 22. INDEX ENGINE IDLE SPEED ENGINE INSTALLATION ENGINE LACKS POWER ENGINE OIL/OIL FILTER ENGINE REMOVAL EVAPORATIVE CARBURETOR AIR VENT CONTROL VALVE INSPECTION (CALIFORNIA TYPE ONLY) EVAPORATIVE EMISSION CONTROL SYSTEM (CALIFORNIA TYPE ONLVI EVAPORATIVE EMISSION PU RGE CONTROL VALVE INSPECTION (CALIFORNIA TYPE ONLY) EXHAUST PIPE/MUFFLER FAN MOTOR SWITCH FLOAT CHAMBER FLYWHEEL, STARTER CLUTCH FORK FRONT BRAKE LIGHT SWITCH FRONT WHEEL FUEL AUTO VALVE (After ’98I FUEL FILTER ('977'98) FUEL LINE FUEL PUMP I'97W '98I FUEL TANK GEARSHIFT LINKAGE GENERAL SAFETY HANDLEBAR HANDLEBAR SWITCH HEADLIGHT AIM HIGH ALTITUDE ADJUSTMENT (USA. ONLY/’97* ’98) HIGH ALTITUDE ADJUSTMENT (U.S.A. ONLY/After '98) HORN IGNITION COIL IGNITION CONTROL MODULE IICM) IGNITION SWITCH IGNITION SYSTEM INSPECTION IGNITION TIMING LUBRICATION & SEAL POINTS MAINTENANCE SCHEDULE MASTER CYLINDER MODEL IDENTIFICATION NEUTRAL INDICATOR/SWITCH NUTS, BOLTS, FASTENERS OIL PRESSURE CHECK OIL PRESSURE INDICATOR/ SWITCH INSPECTION OIL PUMP PILOT SCREW ADJ USTMENT ('97 7 '95) PILOT SCREW ADJUSTMENT (After ’98) PISTON INSTALLATION PISTON REMOVAL POOR HANDLING POOR PERFORMANCE AT HIGH SPEEDS POOR PERFORMANCE AT LOW IDLE SPEEDS PRIMARY DRIVE GEAR RADIATOR COOLANT RADIATOR RESERVE TANK RADIATOR/COOLING FAN REAR BRAKE 3718 779 2172 3714 775 3720 5-39 19-12 14711 22-1 INDEX REAR BRAKE LIGHT SWITCH REAR FENDER/REAR SUB FRAME REAR WHEEL REGULATOR/RECTIFIER RIGHT CRAN KCASE COVER REMOVAL RIG HT CRAN KCASE COVER INSTALLATION SEAT SERVICE INFORMATION (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFT LINKAGE) (COOLING SYSTEM) (CRANKSHAFT/TRANSMISSION) (CYLINDER HEADNALVES) (CYLINDER/PISTON) (ENGINE REMOVAL/INSTALLATION) (ELECTRIC STARTER) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL/SUSPENSION/STEERING) (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (LlGHTS/METERS/SWITCHES) (LUBRICATION SYSTEM) (MAINTENANCE) (REAR WHEEL/BRAKE/SUSPENSION) SERVICE RULES SHOCK ABSORBER SIDE COVER SIDE STAND SIDE STAND SWITCH SPARK PLUG SPECIFICATIONS SPEEDOMETER STARTER MOTOR STARTER RELAY SWITCH STATOR INSTALLATION STATOR REMOVAL STEERING COVER STEERING HEAD BEARINGS STEERING STEM SUB-AIR CLEANER ELEMENT (’97? ’98) SUSPENSION SWINGARM SYSTEM DIAGRAM (BATTERY/CHARGING SYSTEM) (ELECTRIC STARTER) (IGNITION SYSTEM) (LlGHTS/METERS/SWITCHES) SYSTEM FLOW PATTER N SYSTEM TESTING THERMOSTAT THROTTLE OPERATION TOOLS TORQUE VALUES TRANSMISSION TROUBLESHOOTING (ALTERNATOR/STARTER CLUTCH) (BATTERY/CHARGING SYSTEM) (CLUTCH/GEARSHIFT LINKAGE) (COOLING SYSTEM) (CRANKSHAFT/TRANSMISSION) (CYLINDER HEAD/VALVES) (CYLINDER/PISTON) (ELECTRIC STARTER) (FRAME/BODY PANELS/EXHAUST SYSTEM) (FRONT WHEEL/SUSPENSION/STEERING) (FUEL SYSTEM) (HYDRAULIC BRAKE) (IGNITION SYSTEM) (LUBRICATION SYSTEM) (REAR WHEEL/BRAKE/SUSPENSION) TURN SIGNAL RELAY VACU U M CHAMBER VALVE CLEARANCE VALVE GUIDE REPLACEMENT VALVE SEAT INSPECTION/REFACING WATER PUMP WHEELS/TIRES 14-2 19-15 5—15 3-11 1017 10719 22-2