2003—2009 HOW TO USE THIS MANUAL This sslv‘lce manual describes lhe service procedures car the VTX1300$imIGOOCiVTX1300H and vTxlauoT, Fallow lne Melmenenoe Schedule leeorlon a) reeomrnendalions lo ensure lnei lhe vehiele is in peak uperaflng eondm'on and the emission levels are wrlh lne slandards eel by the us. Environmenlel Plolecnon Agency Celiiomla Air Resources Board (CARE) and 'lnenaporl Canada. CONTENTS GENERAL INFORMATION FRAME/BODY PANELS/EXHAUST SYSTEM As you read lhle rnenuai. you wlll llnd lnlornrellon me is preceded by a eymeol. The purpose oi lhls message is lo nelp prevenl damage lo your vehicle, olher properly orihe enurronmerrl. MAINTENANCE Perlorrnino lhe hrsl scheduled malnlenanoe is very lmporlenl. ll * k- . oempsnsares lor me lnlciel weer lhel occurs during me prea In pened LUBRICATION SYSTEM Sealons l and a apoly io ihe whole mommycler Sectinrl 2 lllusireles A procedulsslar removalnnslellalion ol oemppnenls lnel may be required lo oerlorrn service described in lhe Iollowmg sections. FUEL SYSTEM Sermon 4 lhrough \9 deecnoe perls oi lne motorcycle, grouped E according lo looelion. é COOLING SYSTEM Find rho sscflun you wenr en rhls page. men rum in me table 01 oomenls I'- M me "'5‘ Page °I me “Cm” |I|>J ENGINE REMOVAL/INSTALLATION Mosl secllons slen wilh en assembly or syslem rllusirailon, sswlce E inlormalron and lroueleahepung lor lhe seeuon. The suoeeouenr pages a CYLINDER HEAD/VALVE glve derailed pmceduya 9 ll you don‘t know his source oi ihe lrouole. gc lo section 21 E cyL'NDER/PISTON Troubleshooilno. m z a CLUTCH/GEARSHIFT LINKAGE Vuul salely. and lhe selery oi olhers. is very ImponanL To help you E make lnlormed decisions we have provided solely messages and other rnlorrnelion mmughouI lnls manual. or course, il Is nol CRANKSHAFVIRANSMISSION preclin or possible lo warn you abcul all me hazards essacieled wrlh servlclng ihls vehicle. FINAL DRIVE you mus1 use your own good iudgemenl you llld' nntsl ’I i l Home ‘"c[u;ilrl‘g:lrl lmpo a aery ln urmalon In a valley 0 r SgggglnglEEususpENSION/ - Safsiy Labels 7 on me vehicle A; g - Saler Messages 7 preceded lay a selely alen symbol and one oi lhree signal words. DANGER, WARNING or CAUTION, 2 REAR WHEEL/SUSPENSION These signal words meen: I you WILL be KILLED or SERIOUSLY o DRAULIC KE “DANGER HUfiTil you dun'Hnllow inslrucilens. Hv DISC BRA you CAN be KILLED orSEHlDUSLY HURT BATTERY/CHARGING svST M RWARN'NG il you don‘l lollwl rnslruolrons. &i E you CAN be HURT ll you don" lollow Q [Gm-HON SYSTEM AUYION lnslruclions. a: I. - lnsrrucllons 7 how lo service rhls vehicle oorreolly and selely. o ELECTmc STARTER/STARTER CLUTCH in _l in LIGHTS/METERSISWITCHES WIRING DIAGRAMS TROUBLESHOOTING INDEX Heeaadbaadaaeaalaaaaul Dale oI Issue: October, 2007 SYMBOLS The symbols used throughout this manual show specific service procedures. It supplementary information is required pertaining to these symbols, it would be explained specifically in the text without the use of the symbols Replace the part(s) with new one(s) before assembly. Use recommended engine oil, unless otherwise specified. Use molybdenum all solution (mixture of the engine oil and molybdenum grease in a ratio 011 : 1). Use multi-purpose grease (Lithium based multi-purpose grease NLGI #2 or equivalent). Use molybdenum disuitide grease (containing more than 3% molybdenum disulfide, NLGI #2 or equivalent. Example: Molykote® BFl-2 plus manumctured by Dow Corning U.S.A. Multi-purpose M-2 manufactured by Mitsubishi Oil. Japan Use molybdenum disulfide paste (containing more than 40% molybdenum disulfide, NLGI #2 or equiwlent. Example: Molykote® G-n Paste manufactured by Dow Corning U.S.A. Honda Moly 60 (U.S.A. only) Rocol ASP manufactured by Rocol Limited, UK. Rocol Paste manufactured by Sumioo Lubricant. Japan Use silicone grease. Apply a locking agent. Use a middle strength locking agent unless otherwise specified. Apply sealant. Use DOT 4 brake iluid. Use the recommended brake fluid unless otherwise specified. Use Fork or Suspension Fluid. 1. GENERAL INFORMATION SERVICE RULES ....................................... ..1_2 MODEL IDENTIFICATION ------------------------- --1-2 GENERAL SPECIFICATIONS VTX13OOS/ VTX1300R/VTX1300T -1-5 GENERAL SPECIFICATIONS: VTX13OOC--1-7 LUBRICATION SYSTEM SPECIFICATIONS ...................................... .. 1.9 FUEL SYSTEM SPECIFICATIONS->~-----------1-9 COOLING SYSTEM SPECIFICATIONS 1-9 CYLINDER HEAD/VALVE SPECIFICATIONS .................................... ..1.1o CYLINDER/PISTON SPECIFICATIONS 1-10 CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS .................................... ..1_11 CRANKSHAFT/TRANSMISSION SPECIFICATIONS- 11-11 FINAL DRIVE SPECIFICATIONS ------------- --1-11 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS .................................... .. 1.12 REAR WHEEL/SUSPENSION SPECIFICATIONS .................................... "1.12 HYDRAULIC DISC BRAKE SPECIFICATIONS 1-13 BATTERY/CHARGING SYSTEM SPECIFICATIONS .................................... .. 1.13 IGNITION SYSTEM SPECIFICATIONS 1-14 ELECTRIC STARTER/STARTER CLUTCH SPECIFICATIONS ................................... .. 1.14 LIGHTS/METERS/SWITCHES SPECIFICATIONS ................................... .. 1.14 STANDARD TORQUE VALUES ------------- u 1-15 ENGINE & FRAME TORQUE VALUES----1-15 LUBRICATION 81 SEAL POINTS ------------ -- 1-21 CABLE & HARNESS ROUTING: '03 VTx1goos ......................................... .. 1.24 CABLE & HARNESS ROUTING: '04 VTx13oos ......................................... .. 1.37 CABLE & HARNESS ROUTING: ’05 - '07 VTX13OOS/VTX1300R ------------- -- 1-50 CABLE & HARNESS ROUTING: After '07 VTX1300R/VTX1300T ------------ -- 1-63 CABLE 81 HARNESS ROUTING: '04 VTX13ooc ......................................... .. 1.77 CABLE & HARNESS ROUTING' '05 — '07 VTX1300C 1-90 CABLE 8| HARNESS ROUTING: After '07 VTX1300C ----------------------------- -- 1-103 EMISSION CONTROL SYSTEMS -------- -- 1-117 EMISSION CONTROL INFORMATION LABELS ................................................. .. 1.122 1-1 GENERAL INFORMATION SERVICE RULES 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. . Use the special tools designed for this product to avoid damage and incorrect assembly. . Use only metric tools when servicing the motorcycle. Metric bolts, nuts and screws are not interchangeable with English fasteners. . Install new gaskets, O-rings, cotter pins, and lock plates when reassembling. . 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 . Clean parts in cleaning solvent upon disassembly. Lubricete any sliding surfaces before reassembly. t After reassembly, check all parts for proper installation and operation. t Route all electrical wires as show in the Cable and Harness Routing (page 1-24l. mum me. can MODEL IDENTIFICATION VTX1300$ ('03 — '07): VTX13OOC (After '03): ‘ GENERAL INFORMATION I . _\ . A / U. i: w wiiiiiiimip‘x VTX1300R (After '04): s .1 3 .. \ mx .. ‘./%% / y H % VEHICLE IDENTIFICATION NUMBER \ x \ / \ The Vehicle Identification Number (VIN) is stamped on the right side of the sIeering head. VTX1300T (After '07): 1-3 GENERAL INFORMATION The engine serial number is stamped on the left side of the crankcase, The carburetor identification number is stamped on the throttle sensor side of the carburetor body. The safety certification label is attached on the left side of the frame down tube. The color label is attached on the left side of the frame down tube. When ordering color-coded parts, always specify the designated color code. ENGINE SERIAL NUMBER \ COLOR LABEL 1-4 GENERAL INFORMATION GENERAL SPECIFICATIONS: VTX13OOS/VTX1300R/VTX1300T ITEM SPECIFICATIONS DIMENSION Overall length 2,575 mm (101.4 in) _ Overall width 960 mm (378 in) Overall height 1,125 mm (44.3 in) Wheelbase 1,670 mm (65.7 In) Seat height 695 mm (27.0 in) Footpeg height 270 mm (10.6 in) Ground clearance 130 mm (5.1 in) Curb weight VTX1300$ 49 state/ ('03 — '06) 318 kg (701 lbs) Canada type ('07) 315 kg (703 lbs) . California type ('03 — '06) 320 kg (705 lbs) l ('07) 321 kg (708 lbs) VTXISDOR 49 state! ('05 — '06) 321 kg (708 lbs) Canada we ('07) 322 kg (710 lbs) (After '07) 319 kg (703 lbs) Calitornia type ('05 — ’06) 323 kg (712 lbs) ('07) 324 kg (714 lbs) (After '07) 322 kg (710 lbs) VTX1300T 49 state/Canada type 319 kg (703 lbs) California type 322 kg (710 lbs) Maximum 49 state/California type 183 kg (403 lbs) weight capacity Canada type 187 kg (412 lbs) FRAME Frame type Double cradle 7 7 Front suspension Telescopic fork Front axle travel 110 mm (4.3 in) Rear suspension Swingarm Rear axle travel 95 mm (3.7 in) Front tire size 140/80-17M/C 69H Rear tire size 170/80-15M/C 77H Front tire brand D404F (Dunlop) Reartire brand K555J (Dunlap) Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 32° 00’ Trail length 144 mm (5.7 in) Fuel tank capaoity 180 liters (4.76 US gal, 3.96 Imp gal) ENGINE Cylinder arrangement gcyllnders 52" V transverse Bore and stroke 39.5 X 104.3 mm (3.52 X 4.11 in) Displacement 1,312 cm“ (80.0 cu-in) Compression ratio 9.2 l 1 Valve train Silent cam chain driven, OHC Intake valve opens 0° BTDC (at1 mm lift) closes 50" ABDC (at1 mrn lilt) Exhaust valve opens Front: 46° BBDC (at1 mrn lift) Rear: 54“ BBDC (at1 mm lift) closes Front: 4° ATDC (at 1 mm lift) Rear: — 4° ATDC (4" BTDC) (at 1 mm lift) Lubrication system Forced pressure and wet sump Oil pump type Trochoid Cooling system Liquid cooled Air filtration Viscous paper element Engine dry weight 109 kg (240 lbs) Firing order Front - 308° - Rear » 412° - Front CAREURETOR Type Constant velocity Throttle bore 38 mm (1.5 in) GENERAL INFORMATION 1 ITEM SPECIFICATIONS DRIVE TRAIN Clutch system Multi»p|ate, wet Clutch operation system Cable operating Transmission Constant mesh, 5-speeds ‘ Primary reduction 1.935 (60/31) Secondary reduction (output drive) 0344 (17/18) Final reduction 2.818 (31/11) Gear ratio 1st 1.900 (38/20) 2nd ('03 — '07) 1.148 [31/27] (After '07) 1.231 (32/26) 3rd 0912 (31/34) 4th 0778 (28/36l 51h 0.697 (23/33) Gearshift pattern Left foot operated return system, i 1 — N - 2 - 3 — 4 - 5 ELECTRICAL Ignition system Full transistorized ignition Starting system Charging system Regulator/rectifier Lightflig systemfl Electric starter motor Triple phase output alternator SCR shorted/triple phase full-wave rectifi» cation Battery 1-6 GENERAL SPECIFICATIONS: VTX13OOC GENERAL INFORMATION ) ITEM SPECIFICATIONS ‘ DIMENSIONS Overall length 2,400 mm l94,5 in) ‘ Overall width 920 mm (36.2 in) Overall height 1,110 mm (43.7 in) Wheelbase ‘ 1,665 mm (65.6 in) Seat height 1 690 mm (27.2 in) ‘ Footpeg height 275 mm (10.8 in) ) Ground clearance 125 mm (4.9 in) ‘ Curb weight 49 state/ ('04 — ’06) 310 kg (633 lbs) r Canada we ('07) 311 kg (686 lbs) l (After '07) 303 kg (679 lbs) California type ('04 — '06) 312 kg (688 lbs) ('07) 313 kg (6901195) (After '07) 311 kg (686 lbs) Maximum 49 state/California type 182 kg (401 lbs) weight capacity Canada type 186 kg [410 lbs) ‘ FRAME Frame type Double cradle " Front suspension Telescopic fork Front axle travel 110 mm (4.3 in) Rear suspension ‘ Swingarm Rear axle travel 92 mm (3.6 in) Front tire size ‘ 110/90-19M/C 62H Rear tire size 170/80-15M/C 77H Front tire brand F246 (Dunlop) Rear tire brand K555J (Dunlap) Front brake Hydraulic single disc Rear brake Hydraulic single disc Caster angle 32" 00’ Trail length 149 mm (5.9 in) Fuel tank capacity 18.0 liters (4.76 US gal, 3.96 Imp gal) l ENGlNE Cylinder arrangement 2 cylinders 52" Vtransverse Bore and stroke 895 X 104.3 mm (3.52 X 4.11 in) l Displatmment 1,312 cm“ (80.0 cu-in) Compression ratio 9.2 : 1 Valve train Silent cam chain driven, OHC Intake valve opens 0° BTDC (at 1 mm lift) Closes 50“ ABDC (at 1 mm lift) Exhaust valve opens ‘Front: 46" BBDC (at 1 mm lift) Rear: 54° BEDC (at1 mrn lift) closes Front: 4° ATDC (at1 mrn lift) Rear: >4° ATDC (4° BTDC) (at1 mm lift) Lubrication system Forced pressure and wet sump Oil pump type Trochoid l Cooling system Liquid cooled Air filtration Viscous paper element ‘ Engine dry weight 109 kg (240 lbs) Firing order Front » 305° - Rear - 412” - Front CARB‘URETOR Type Constant velocity L Throttle bore 38 mm (1.5 in) GENERAL INFORMATION ITEM SPECIFICATIONS l DRIVE TRAIN ( Clutch system 7 Multi-plste, wet ‘ Clutch operation system Cable operating ‘ Transmission Constant mesh, 5-speeds ( Primary reduction 1.935 (60/31) ‘ Secondary reduction (output drive) 0.944 (17/18) 1 Final reduction 2318 [31/11) Gear ratio 1st i 1.900 (38/20) 2nd ('03—'07) 1.148 (31/27) (After '07) 1.231 (32/26) 3rd 0.912 (31/34) 4th 0.773 (28/36) 5th 0.697 (23/33) Gearshift pattern Left foot operated return system, 1 - N - Z > 3 » 4 - 5 1 ELECTRICAL Ignition system Full transistorized ignition Starting system Charging system Regulator/rectifier Lighting system Electric starter motor Triple phase output alternator SCH shorted/triple phase full-wave rectifi- cation Battery 1-8 GENERAL INFORMATION LUBRICATION SYSTEM SPECIFICATIONS Unit: mm (in) ) ITEM STANDARD SERVICE LIMIT ' Engine oil capacity After draining 3.5 liters (3.7 US qt, 3.1 Imp qt) - After draining/ 3.7 liters (3.9 us qt, 3.3 Imp qt) — — filter change 1 After disassemny 4.3 liters (45 05 qt, 3.8 Imp qt) — Recommended engine oil Pro Honda GN4 4-stroke oil (U.S.7\. and — Canadal or equivalent motor oil API service classification SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W—30 Oil pressure at oil pressure switch 530 kPa (5.4 kgf/cm , 77 psi) at — 5,000 rpm/(30°C/176°F) Oil pump rotor Tip clearance 0.15 (0.006) 7 0.20 (0.008) Body clearance l 0.15 - 0.21 (0.006 —70.008l 0.35 (0.014) Side clearance l 0.02 — 0.07 (0.001 — 0.003) 0.10 (0.004) l FUEL SYSTEM SPECIFICATIONS ITEM PECIFICATIONS Carburetor identification number i '03 VTX130tJS 49 state/Canada type: i VE7BA I ‘ ( California type: VE7BB [ '04 VTx1aoos 49 state/Canéd‘fiype: VE7EE i W California type: VfiEF l '04 vrxi‘a‘é’oc 49 state/Canad type: VE7CA California type VE7CB . '05 4‘3 State/Canada type: VE7BE ‘ California type: VE7BF '06, ’07 49 state/Canada type: VE7BG California type: VE7EH After '07 740 state/Canada type: VE7BK 7 l» California type: VE7BL Main iet '03 - '07 l #195 After '07 l #190 ' . Slow jet #55 V l Pilot screw Initial/final opening See page 5—23 L High altitude adjustment 7 W See page 5-25 i Float level ‘ 13.5 min (0.73 in) Idle speed 900 1100 rpm ¥ ‘ Throttle grip freeplay 2—6 mm (1/16— 1/4 in) COOLING SYSTEM SPECIFICATIONS ITEM SPECIFICATIONS Coolant capacity Radiator and engine 2.7 liters (2.9 us qt, 2.4 Imp qt) Reserve tank 035 |iter(1.00 US qt, 0.84 Imp qt) Radiator cap relief pressure 108— 137 kPa (1.1 — 1.4 kgf/cm,16- 20 psi) Thermostat Begin to open 80-84 "C (176— 183 °Fl Fully open 95 “C (203 °F) Valve lift 8 mm (0.3 inl minimum Reisernended antifreeze Pro Honda HP Cooiafifar‘equivalent’high quality ethylene glycol antifreeze containing silicate-free corrosion inhibi- tors Standard coolant concentration 1:1 mixture with distilled Water GENERAL INFORMATION CYLINDER HEAD/VALVE SPECIFICATIONS 7 ITEM STANDARD I l , I Cylinder compression ar'300 rpm '1,157 kP (11.9 kgf/sz, 168 psi)’ "Valve clearance IN 015 :‘0. 0.006 1 0.001) — ‘Ex 0.30 x 0.02 (0.012 1 0,001) 7 — Teams'h’an Cam loEe height IN 38.886 — 39.080 (1.5309 —1.5396) 38.86 (1.530) 1 Ex 39.050 - 39.250 (1.5374 — 1.54753) 39.03 (1.537) Runout — 0.04 (0.002) ‘ Oil clearance A, B 0.040 - 0.101 (0.0016 — 0.0040) )7 0.120 (0.0047) I c 0.055 — 0.121 (0.0022 — 0.0048) 0.140 (0.0055) Rocker arm, Rocker arm shaft 0.0. IN/EX 13.955 — 13.984 (0.5498 — 0.5506) 13.91 (0.548) rocker arm Rocker arm 1.0. ’ IN/EX 14.000 - 14.018 (0.5512 — 0.5519) 13.95 (0.549) shaft 1 Rocker armrto-shaft clearance 0.016 — 0.052 (0.0006 — 0.0020) ‘ 0.15 (0.006) Valve, Valve Stem 0.0. IN 1 6.575 — 6.590 (0.2589 — 0.2594) 6.57 (0.259) valve guide Ex 6.560 — 6.575 (0.3132 - 0.3138) 6.545 (0.2577) "Valve gliide l.0. ) IN/EX 5.600 — 5.615 (0.2598 — 0,2604) ) 6.635 (0.2612) ) Stem-to—guide clearance . IN ‘ 0,010 — 0.040 (0.0004 — 0.0016) i 0.06 (0.003) 1 EX 0.025 — 0.055 (0.0010 — 0.0022) 0.115 (0.0045) Valve guide projection IN ___14.5 (0.57) - above cylinder head 5x 155 (0,51) — Valve seat width " IN/EX 0.9 ~ 1.1 (0.035 — 0.043) 1.5 (0.06) Valve spring Free length ' IN 45.70 (1.799) 43.90 (1.7213) 7 EX 43.50 (1.713) 41.90 (1,646) ¥ Cylinder Head warpage v 1 0.10 (OEDTF V CYLINDER/PISTON SPECIFICATIONS Unit: mm (in) 1 ITEM STANDAnb' SERVICE LIMIT Cylinder 1.0, 89500-69515 (35236—35242) ' 59.55 (3.326) ‘ 001 of round" ' — ( 0.10 (0.004) ) Taper 7 7 — 0.10 (0.004) r Warpage — 0.10 (0.004) 1 Pisron, Piston 0.0. at 15 mm (0.6 in) from 997170 — 89.490 (3.5224 — 3.5232) 89.41 (3.520) piston pin, bottom piston rings ) P'lston pin bore 1.0. 20.002 — 20.003 (0.7575 . 0.7877) 20.018 (0.7081) ) Piston pin 0.0. 7 19.994 — 20.000 (0.7972 — 0.7574) 19.984 (0.7868) ‘ Pistonvmvpiston pin clearance 0.002 — 0.014 (0.0001 — 0.6006) 0.034 (0.0013) Pi'sYoFi ring end Top 0.200 — 0.300 (0.001 0.315 (0.0124) gap Second 0.300 —04FCl (0.0118 — . 0.415 (0.0163) 1 Oil 0.425 — 0.475 (0.0157 - 0.0187) 0.495 (00195) I (side rail) Piston ring-roaring Jg 0.015 — 0.050 (0.0006 — 0.0020) 0.070 (0.0028) groove clearance Second 0.015 — 0.045 (0.0005 — 0.0018) 0.065 (0.0026) I CvlindeHoapismn clearance 0.010 — 0.045 (0.0004 — 0.0013) 0.32 (0.013) ‘ Connecting rod small and 1.0. 20016 — 20.034 (0.7900 — 0.7887) 20.044 (0.7891) Connecting rod»to-piston pin clearancei I 0.016 70.040 (0.0006 - 0.0016) 0.063 (0.0025) 1-10 GENERAL INFORMATION CLUTCH/GEARSHIFI' LINKAGE SPECIFICATIONS Unit: mm [in] ITEM ( STANDAjID SERVICE LIMIT Clutchr lever freeplay ‘ i 10 a 20 (3/8 — 3/4) - ClurcTi Spring free length vm' 759.2 (2.29) 56.7 (2.23) Disc thickness ' 3.72 - 3.88 (0.146 — 0.153) 3.1 (0.12) Plate warpage 7 — 0.30 (0.012) Vfiufi outer guide (.0. 27995 — 28.012 (1.1022 51.1028) 28.80 (1.134) Mainshaft 0.0. at clutch outer guide 27990—27.993(1.1015-1.1021) ( 27.97 (1.101) ‘ CRANKSHAFT/TRANSMISSION SPECIFICATIONS Unit: mm (in) ITEM STANDARD ( SERVICE LIMIT’ Crankshaft “1 Connecting 10:! big end side clearance 0.10 — 0.25 (0.004 — 0.010) ‘ 0.2810011) Crankpin bearing oil clearance 003870.062 (00015—00024) 0.070 (0.0028) Main journal oil clearance 0.0304054 (00012—00021) 0.068 (0.0027) Crankshaft runout — 0.05 (0.002) Shiftfork, LD. 14.000— 14.019 (0.5512~0.5519) 14 04 (0.553) fork shaft ( Claw thickness 7 5.93 — 6.00 (0.233 s 0.236) 5.83 (0.236)” T Furk shaft 0.0. 13.966 —13.9’a4(0.549s — 0.5506) _A 771 £58 (0.5494) Transmission GearlD. M4, M5 31000—31025 (1.2205» 1.2215) 31.035 (1.2218) c1 30.000—30.025(1.1811—1.1621) 30.035 (T1825) ( c2, (:3 33.000 — 33.025 (1.2992 » 1.3002) 33.035 (1.3006) Gear busing 0.0. M4. M5 30.950 - 30.975 (1.2185 —1.2195) 30.94 (1.218 (:1 25.997 — 26.000 (1.0231 — 1.0236) 25.977 (1027 C2, (:3 m 32.950 — 32.965 (13972 —1.2978) i 32.94 (1.297) Gear-to-bushing M4, M5 0.025 - 0.075 (0.0010 — 0.0030) ( 0.095 (0.0037)# clearance 02, c3 ( 0.035 — 0.075 (0.00144 0.0030) ‘ 0.095 (0.0037) Gear bushing (.0. M4 27985 a 28.006 (1.1019— 1.1026) 28.03 (1104) C1 22.050 — 22.150 (0.8681 — 0.8720) 22.170 (0.8728) 0263 30.000 — 30.030 (1.1811 — 1.1823) 30.050 (1.1831) "Mainshart 0.0. at M4 27959—27980 (1.1007— 1.1016) 27.940 (1.1000) ( Countershaft at 01 21.990 — 21.993 (0.8654 — 0.8659) 21.97 (0.365) ( OD. T511203 29.959 — 29.980 (1.1795 — 1.1803) 1 29.94 (1.179) ( Bushin’g-ro-shart M4 0.005 — 0.047 (0.0002 — 0.0019) 1 0.067 (0.0026) clearance CI 0.057 — 0.170(00022 a 0.0067) T 0.190 (0.0075) 02, ca 0.020 — 0.071 (0.0008 — 0.0028) 0.091 (0.0036) FINAL DRIVE SPECIFICATIONS Unit: mm (in) _ ITEM STANDARD SEnficE LIMIT Recommended final drive oil Hypoid gear oil. SAE #80 7 ( — Final drive oil capacity After draining 120 cm 14.1 US oz, 4.2 Imp oz) i — Aher disassembly 150 cm3 (5.1 us 01, 5.3 Imp oz) — Final drive gear bagkiash 0.05 — 0.15 (0.002 » 0.006) V hgsggmz) Backiash difference between measurefilents 0.10 (0.004) Ring gearrto-stop pin clearance '030 a 0.60 (0.012 —' 0.024) Final drive gear assembly preload ’ 0.2 —0.4 Nm (2 - 4 kgf—cm, 0.170.3lbf-fti 1-11 GENERAL INFORMATION FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS VTX13OOS/VTX1300R/VTX1 300T: Unii: mm (in) 'i'TETVI- _ STANDARD SERVICE LIMIT— Minimum tire tread depth 7 — 1.5 (0.06) Cold tire up 6% Ikg (200 lbs) load 225 kPa (2.25 kgr/cm’, 33 psi) _ i pressure Up to maximum weight capacity 225 kPa (2.25 kgf/cm .33 psi) — Axle runout — 0.20 (0.008) Wheel rim I Radial — 2.0 (0.05) irunout ‘ Axial — ( 2.0 (0.08) Wheel balance weight 7’ » ' 60 g (2.102) " f max. Fork Spring free length 493.8 (19.44) 483.9 (19.05) . Tube runou’t — 0.20 (0.003) ‘ Recommended fork fluid Pro Honda Suspension Fluid SS-E — (10W) Fluid level 135 (5.3) — 7Iuid‘capaciiy 459 i 2.5 cm3 (15.5 i 0.08 us oz, — 16.2 i 0.09 Imp oz) iSIeering head bearing preload 7.8 — 11.3 N (0.8 — 1.2 kgf,1.3— 2.5 lbf) — VTX13OOC: w 7 Unit: mm (in) ITEM l STANDARD SERVICE LIMIT ) Minimum rireireau depth — 1.5 (0.06) I Cold tire I Up Io 90 kg (200 lbs) lead 225 kPa (2.25 kgf/om ,33 psi) 7» ) pressure ( Up in maximum weight capacity 225 kPa (2.25 kgf/cm , 33 psi) — Axle runout — 0.20 (0.008) Wheel rim Radial — '7 2.0 (0.08) Lunout Axial ' — 2.0 (0.08) TWheeI balance weighi ~ 60 g (2.102) .. ‘ max. Fork Spring free length 461.7 (18.18) V 452.5(1181) Tube runout v — 0.20 (0008) Recommended fork fluid Pro Honda Suspension FIuid 85-8 v 7 (low) ( Fluid level 125 (4.9) — Fluid DBDECIWT 457 t 2.5 Cm (15.5 i 0.05 US 01, — 7 ' 16.1 1 0.09 Imp oz) - Steering head bearing preload 7.8 — 11.8 N (0.8;11 kgf,1.8— 2.6 Ibf) — REAR WHEEL/SUSPENSION SPECIFICATIONS V Unit: mm (in) ) ITEM ) STANDARD SERVICE LIMIT I Minimum (ire [read depth » 2.0 (0.08) Cold tire pressure Up to 90 kg (200 lbs) load 225 War (225 kgf/cm , 33 psi) - Up to maximum weight 250 kPa (2.50 kgf/cm ,36 psi) — 77 capacity Axle runoul — 0.20 (0.008) I Wheel rim runout ‘ Radial — 2.0 (0.08) Axial " — 2.0 (0.08) Wheel balance weight — 70 g (2.5 01) max. 1-12 GENERAL INFORMATION HYDRAULIC DISC BRAKE SPECIFICATIONS VTX13OOS/VTX13OOR/VTX1300T: Unit: mm (in) ITEM STANDARD 7 SERVICE—LIMITW Specified brake fluid DOT 4 ""‘50 (0.20) Front Brake disc thickness SE: 6.2 (0.2.3 — 0.24) Brake disc runout — 0.30 (0.012) MastercylinderlD. '03, '04 12.700— 12.743 (05000-05017) l 12.755 (0.5022) After '04 11.000 — 11.043 (0.4331 7 0.4343) 11.055 (0.4352) Master pismn 0.0. '03, '04 12.657 — 12.584(0.21983 - 0.4994) 12.645 (0.4973) After '04 10.957 — 10.994 (0.4314 — 0.4324) 10.945 (0.4309) ( Caliper cylinder 1.0. '03, '04 27000—27050 (1.0630— 1.0650) 2706 (1.065) | After '04 25.400 — 25.450 (1.0000 41.0020) 25.460 (1.0024) r Caliper piston 0.0. '03, '04 26.935 — 26.968 (1.0604 — 1.0617) 26.92 (1.060) After '04 25.318 — 25.368 (0.9968 — 0.991977" 25.31 (0.996) Rear Brake disk thid‘ness 3.0 — 6.2 (0.23 — 0.24) W 5.0 (0.20T'" ‘ Brake disc runout. ' — 0.30 (0.012) Master cylinderlD. 1270012743 (05000—05017) 12.755 (0.5022) Master piston 0.0. 12.657 —1i.684(0.4933 — 0.4994) 12.645 (0.4972) Caliper cylinder 1.0. 38.18—38.23 (1.503- 1.505) 3924(1506) Caliper piston 0:0. 39115—36540 (1.5006— 1.5019) 38.09 (1.500) VTX13006: Unit: mm (in) ITEM STANDARD SERVICE LIMIT Specified brake flfiid DOT 4 5.0 (0.20) Front Brake disc thickness " 5.3 — 6.2 (0.23 — 0.24) (“Brake disc runuut — 0.30 (0%) Master cylinder |.D, 1.000 - 11.043 (0.4331 — 0.4340) 11.055 (0.4352) Master piston 0.0. "' 10.957 4 10.984 (0.4314 — 0.4324) 10.945 (0.4309) Caliper cylinder 10. ( 25.400 — 25.450 (1.0000 — 1.0020) 1 25.460 (1.0024) Calip'er piston 0.0. 1 25.335 — 25.369 (0.9974 — 0.9987) (' 25.311095E)”* Rear Brake disk thickness 5.6 — 62 (0.23 A 0.24) 5.0 (0.20) Brake disc runout. — 0.30 (0.012) MasterEylinder 1.0. 12700—12743 (05000—05017) "’12.7§5(0.’5022) Master piston O.D. 12.657 #122664 (0.4993 — 0.4994) 12.645 (0.4978) Caliper cylinder |.D. 38.18 — 38.23 (1.503 —1.505) 38.24 (1.506) Caliper piston O.D. 38.115 —38.148 (1.5006 — 1.5019) 38.09 (1.500) BATTERY/CHARGING SYSTEM SPECIFICATIONS ‘ ITEM SPECIFICATIONS Battery Capacity 77 12 V — 12 Ah Current leakage I 2 mA max. Voltage Fuilv charged 13.0—13.2 V (20°C/68°F) Needs Below 12.3 V.» charging Charging current 1 Normal 1.4 NS — 10 h w ‘ ) Quick 77 6.0 A/1.0 h K " ‘ Alternator Capacity 7 r 0.364 kW/5,000 rbm Charging coil resistance (20°C/SB“F) 0.22 — 0.34 9 1-13 GENERAL INFORMATION IGNITION SYSTEM SPECIFICATIONS I" " 7 ITEM 7 7" _ ercwlfimoms I Spark plug Standard 7 DCPRGE (NGK), XUZUEPR-U lDENSO) For extended high speed riding DCPR7E‘(NGK), XUZZEPRVU (DENSO) Spark plug gap 0.3 — Oféimm (0.031 - 0.035 in) ilgnition coil primary peak voltage Ignition pulse generator peak voltage 100V minimum 0.7 V minimum Ignition timing (“F‘markl ELECTRIC STARTER/STARTER CLUTCH SPECIFICATIONS 4.1” BTDC at idle Unit: mm (in) ITEM l ‘ STANDARD SERVICE LIMIT Starter motor brush length l 12.0-13.0(0.47—0.5;I) 4.5 (0.18] ‘ Starter driven gear boss O.D. ‘ 57.759 - 57.768 (2.2740 — 2.2743) 51639122692) P 7 |.D 44.000 - 44.016117323 —1.7329) 44.10 (1.735] r” Torqué limiter slip torque 53 ~ 84 N-m (5.4 L 8.6 kgf-m, ~ I 39 ~ 62 lbfvft) LIGHTS/ METERS/ SWITCHES SPECIFICATIONS ITEM l l SPECIFICATIONS 7 Bulbs/ Headlight ‘ 12V—60/55W " "Brake/taillight ’ 12 v~21/5w ‘License light 7' < 12 V~5W " ‘ Frontturn signal/positionlight 12 V-21/5 Wx2 7 Rearturn signal light 12V~21WX2 'Fuse Main fuse 7”" 30A 7 i Subfuse 10U5,20Ax1 ‘ Instrumentation Start to gosinN) 112 A 1131:: (234- 244°Fl ECT switch . Stop to open (OFF) 108”C (226°F) minimum Fan motor Stanto close lONl 7 98—102°C(208-216“F) switch I Stop to open (OFFl ‘93 - 97°C1199 — 207°F) Fuel pump flow capacity (minimum) ('03 moqel only] 700 cm (23.7 US oz, 24.6 Imp ozl/minute 1-14 GENERAL INFORMATION TORQUE TORQUE V ‘ FASTENER TVPE Mm MM", I”;st / FASTENER were“ W r “m (mm, mm 5 mm bolt and nut l 5 (0.5, 3.6) 5 mm screw 7 V 4 (0.4, 2.9) 6 mm bolt and nut 10 (1.0, 7) 6 mm screw 9 (0.9, 6.5) 8 mm bolt and nut 22(2.2, 16) 6 mm flange bolt (8 mm head, small 10 (1.0, 7) flange) ( 10 mm bolt and nut 34 (3.5, 25) 6 mm flange bolt (3 mm head, large 12 (1.2, 9) l flange) 1‘ 12 mm bolt and nut 54 (5.5, 40) 6 mm flange bolt (10 mm head) and 12 (1.2, s) nut ) 8 mm flange bolt and nut 26 (2.7, 20) 7 10 mm flange bolt and nut 39 (4.0, 29) I Torque specifications listed below are for important fasteners. I Others should be tightened to standard torque values listed above. NOTE: 1. Apply oil to the threads and seating su rface. 2. Apply grease to the threads. 3. Apply locking agent to the threads. 4. Apply sealant to the threads. 5. Lock nut: replace with a new one and stake it. 6. ALOC bolt or screw: replace with a new one. 7. U-nut. ENGINE FRAME/BODY PANELS/EXHAUST SVSTEM t , THREAD TORQUE L "EM 0 TV DIA. (mm) N-m (kgI-m, Ibf-ft) REMARKS Left crankcase rear cover bolt 5 6 10 (1.0, 7) Exhaust pipejoint stud bolt i 4 8 — page 2-12 MAINTENANCE V , THREAD TORQUE ITEM i_ 0 TV DIA. (mm) N-m (kgf-m, mm 1 REMARKS Spark plug 4 12 ‘ 1411.4,10) ‘ Timing hole cap 1 45 18 (1.8, 13) i NOTE 2 Valve adjusting hole cap 2 36 15 (1.5, 11) NOTE 2 Valve adjusting screw look nut 6 7 22 (2.2, 16) 1 NOTE 1 Engine oil filter cartridge 1 20 26 (2.7, 19) i NOTE 1 Front engine oil drain bolt 1 12 30 (3.1, 22) Rear engine oil drain bolt 1 12 30 (3.1, 22) ‘ LUBRICATION SVSTEM ‘ . THREAD "' TORQUE 1 ITEM 0 W i VDIA. (mm) N~m (kgf-m, lM-ft) 7 REMARKS * Oil pressure switch 1 I PT1/8 12 (1.2, 9) NOTE 4 Oil pressure switch terminal screw 1 i 4 2.2 (0.2, 1.6) " Oil strainer bolt 1 l 6 13(1.3, 10) Oil pump assembly bolt 1 6 13 (1.3, 10) Oil orifice bolt 1 8 14 (1.4, 10) NOTE 1 ‘ 1-15 GENERAL INFORMATION FUEL SYSTEM F— , THREAD TORQUE "EM 0" DlA. (mm) N-m (kgf-m, Ibt-ft) REMARKS Pulse seco‘na‘arTair injection check valve cover 4 5 5.2 (0.5, 3.8) bolt Carburetor insulator band screw 2 6 — page 521 1 Intake manifold base band screw 2 l 6 — page 5-24 1 Intake manifold vacuum joint 1 5 2,5(0.3, 1.8) ( Intake manifold base socket bolt 4 a 10 (71.3.1) COOLING SYSTEM . ' THREAD TORQUE "EM 0 TV 791A, (mm) N-m (kgf-m, lhI-ft) REMAHKS Water pump cover bolt 2 V 6 13 (1.3, 10) Water pump stud bolt 1 6 — page 6-15 Cooling fan nut 1 5 2.7 (0.3, 2.0) NOTE 3 Fan motor nut 3 5 5.1 (0.5, 3.3) Fan motor assembly bolt ('03 — ’06) 4 6 8.3 (0.3, 6.1) Fan motor assembly bolt (After '06) 4 6 @1919, 6.2) CYLINDER HEAD/VALVE O THREAD TORQUE l ITEM Q'TY DIA. (mm) N'm (km'ml lbw” ‘ REMARKS Spark plug sleeve 2 30 18(1.8,13) ‘ NOTE 1 Cylinder head cover bolt 4 B 26 (2.7, 19) Cylinder head cap nut 8 10 43 (4.4, 32) NOTE 1 (Minder head cap nut 4 B 26(2.7, 19) NOTE 1 Cam sprocket bolt 4 7 23 (2.3, 17) NOTE 3 ) Cam chain tensioner bolt 4 6 12 (1.2, 9) CVLINDER/PISTON , THREAD TORQUE ITEM (1 TV MA. (mm) Mm (kgm' MM REMARKS Cylinder stud bolt 4 8” — page 9-8 Cylinder stud bolt 8 10 — page 98 CLUTCH/GEARSHIFI' LINKAGE THREAD TORQUE "EM 07" DIA. (mm) N-m (kgrm, lbf-R) REMARKS _, Clutch pressure plate bolt 5 6 12 (1.2, 9) Clutch center lock nut 1 25 486(190, 137) NOTE 1, 5 Oil pump driven sprocket bolt 1 6 18 (1.8, 13) NOTE 3 Clutch cover socket bolt 5 l 6 10 (1.0, 7) l Timing hole cap cover sodtet bolt 6 6 10 (1.0.7) l Primary drive gear bolt 1 12 138(14.1, 102) NOTE 1 l Primary driven gear nut 1 25 18E(19.0,137) NOTE 1, 5 Shift drum stopper arm pivot bolt 1 6 12 (1.2, 9) 1 Shift drum center Socket bolt 1 8 23 (2.3, 17) NOTE 3 1, Gearshift spindle return spring pin 1 8 23 [2.3, 17) l Clutch cable holder bolt 1 6 12 (1.2, 9) CRANKSHAFI'ITRANSMISSION THREAD TORQUE "EM 0“ DIA. (mm) N-m (kgf-m, lbf-ft) REMARKS Right crankcase bolt 16 8 26(27, 19) Cam chain tensioner setting plate bolt 2 6 12 (1.2, 9) NOTE 3 Connecting rod bearing cap nut 4 1 10 59 (6.0, 44) NOTE 1 l Output gear case mounting bolt 4 3 31 (3.2, 23) Shift drum bearing setting plate bolt 2 6 12 (1.2, 9) NOTE 3 Rear balancer shaft bearing setting plate bolt 2 6 12 (1.2, 9) NOTE 3 Mainshaft bearing setting plate bolt 2 i 6 12 (1.2, 9) l. NOTE 3 Spindle plate bolt 1 l e 12 (1.2, 9) l NOTE 3 1-16 GENERAL INFORMATION BATTERV/CHARGING SYSTEM . 'rHR'EAD ‘ TORQUE "EM QTY om. (mm) Nrm (kgf-m, lbl-ft) REMARKS Left crankcase cover sodtet bolt 13 6 12(12, 9) Stator mounting bolt 4 S 10 (1.0, 7) NOTE 3 Ignition pulse generator mounting bolt 2 6 10 (1.0, 7) NOTE 3 Alternator wire clamp bolt 1 6 10 (1.0, 7) NOTE 3 ELECTRIC STARTER/STARTER CLUTCH ‘ , THTREAD TORQUE l7 ITEM 0 TV m (mm) Mm (kgm MM REMARKS Starter motor case bolt 2 5 6.4 (0.7, 4.7) Starter motor cable terminal nut 1 6 7 (0.7, 5.2) Flywheel bolt 1 12 138(14.1, 102) NOTE 1 Starter clutch mounting bolt 6 8 29 [3.0, 21) NOTE 3 LlGHTS/METERS/SWITCHES . THREAD TORQUE "EM 0" DIA. (mm) "m (kgl-m, Ihr-n) REMARKS Neutral switch 1 10 12 (1.2, 9) 1-17 GENERAL INFORMATION FRAME FRAME/BODV PANELS/EXHAUST SVSTEM ’ THREAD TORQUE ' _ 7 "EM 7 “WV DlA. (mm) N-m (kgI-m, IbI-ft) (REMARKS i ‘ FUEI tank mounting bolt 1 8 19(19, 14) Fuel valve nut 1 22 34 (3.5, 25) Fuel valve lever screw 1 5 1 (0.1, 0.7) NOTE 6 ‘ Rider footrest mounting bolt (VTX13005/ 4 10 39 (4.0, 29) VTX1300R/VTX1300T) Rider footpeg mounting bolt (VTX1300C) 4 10 39 (4.0, 25) Gearshift arm pinch bolt 1 6 12 (1,2, 9) Exhaust pipe ioint nut 4 8 23 (2.3, 17) Muffler band bolt 5 8 17 (1.7, 13) Muffler mounting bolt 7 2 8 34 (35, £5) MAINTENANCE 1 THREAD TORQUE 7 "EM 77‘7"" DIA, (mm) N-m lkgI-m, IbI-ft) REMARKS Air cleaner cover screw 5 5 3.5 (0.4, 2.6) Final drive oil filler cap 1 30 12 (1.2, 9) Final drive oil drain bolt 1 14 l, 20(2.o, 15) ) FUEL SVSTEM ' . VTHREAD TORQUE l 7 V "EM 0 TV DIA. (mm) N-m (kgf-m, lbw REMARKS Air cleaner case mounting screw 3 5 3.7 (0.4.2.7) Air cleaner case mounting bolt__ l 1 6 , 10 (1.0, 7) ENGINE MOUNTING , THREAD TORQUE "EM 0 TV um. (mm) N-m (kgI-m, Ibt-ft) REMARKS Engine mounting nut 4 10 39 (4.0, 29) Engine hanger plate bolt 10 B 27 (2.8, 20) FINAL DRIVE " . THREAD TORQUE ) . "EM 7 ° W DIA. (mm) Nrm (kgf‘m, Ihf-ft) REMARKS l Pinion retainer 1 7O 147(15.0,1OB] ‘ Pinion retainer lock tab bolt 1 6 10 (1.0, 7) Pinion joint nut 1 16 .103 (11.0, 80) NOTE 3 Dust guard plate bolt 1 6 10 (1.0, 7) Gear case cover bolt 2 10 62 (6.3, 46) NOTE 3 Gear case cover bolt 6 8 25 (2.5, 18) Final gear Case assembly mounting nut 4 10 64 (6.5, 47) Rear shock absorber lower mount _ 1 12 54 (5.5, 40) ( NOTE 3 1-18 GENERAL INFORMATION FRONT WHEEUSUSPENSION/STEERING l7 , THREAD TORQUE "EM 0 TV DIA. (mm) N‘m (kgI-m, mm) REMARKS Handlebar upper holder bolt (VTX13OOS/ 4 8 27 (2.8, 20) ‘ VTX1300RNTX13OOT) “ Handlebar lower holder nut (VTX13005/ 2 12 64 (6.5, 47) NOTE 7 VTX1300RNTX1300T) Handlebar mounting nut (VTX1300C) 2 12 64 (6.5, 47) NOTE 7 From brake disc bolt 6 B 42 (4.3, 31) NOTE 6 Spoke nipple (VTX13005) 52 804 4.2 (04, 3.1) . Valve stern nut (VTX13OOS) 1 — 2.7 (0.3, 2.0) Front axle bolt 1 14 59 (6.0, 44) Front axle pinch bolt 4 8 22 (2.2, 16) Fork center bolt 2 8 20 (2.0, 15) NOTE 3 i Fork cap 2 37 22 (2.2, 16) Fork cover bolt (VTX13005/VTX1300RNTX1300T) 4 6 12 (1.2, 9) Fork top bridge pinch bolt 2 8 22 (2.2, 16) U Fork bottom bridge pinch bolt 2 10 49 (5.0, 36) Steering bearing adjustment nut 1 26 21 (2.1.15) NOTE 1 Steering bearing adjustment nut look nut 1 26 — page 13—28 Steering stem nut 1 24 103 (10.5, 76) Hose/cable guide bolt 2 8 21 (2.1.15) NOTE 6 Brake hose clamp bolt 7 2 6 12 (1.2, 9) ‘ REAR WHEEL/SUSPENSION , THREAD TORQUE "EM 0 TV DIA. (mm) N-m (kgt-m, lbf-ft) REMARKS Rear brake disc bolt 6 l 8 42 (4.3, 31) NOTE 6 Spoke nipple (VTX13OOS) 52 l BC4 4.2 (0.4, 31) Valve stem nut (VTX1SDOS) 1 — 2.7 (0.3, 20) d Final driven flange nut 5 12 88 (9.0, 65) NOTE 7 Rear axle nut 1 K 18 110 (11.2, 81) NOTE 7 Rear shock absorber mounting bolt 4 8 26 (2.7. 19) Rear brake hose clamp bolt ('03- '05) 3 6 12 (1.2, 9) NOTE 6 Rear brake hose clamp bolt (After '06) 2 6 12 [12, 9) NOTE 6 Swingarm left pivot bolt 1 30 103 (10.5, 76) ‘ Swingarm right pivot bolt 1 30 14 (1.4, 10) Swingarm right pivot bolt look nut 1 30 113 (11.5, 83) HVDRAUUC DISC BRAKE l , THREAD ‘ TORQUE 7 "EM 0 TV DIA. (mm) N-m (kgt-m, mm) l REMARKS Brake caliper bleed valve 2 8 5.5 (0.6, 41) ‘ Front master cylinder reservoir cap screw 2 4 1.5 (0.2, 1.1) Brake pad pin 2 10 18(1.8, 13) Brake pad pin plug 2 10 2.5 (0.3, 1.3) Brake hose oil bolt 4 10 34 (3.5, 25) Front brake lever pivot bolt 1 ‘ 6 1 (0.1, 0.7) Front brake lever pivot nut 1 l 6 >6 (06, 4.4) Front brake light switch screw 1 4 1.2 (01, 0.9) ‘ 1 Front master cylinder holder bolt 2 6 12 (1.2, 9) Rear brake reservoir mounting bolt 1 6 10 [1.0, 7) Rear master cylinder push rod joint nut 1 8 18(1.B,13) Rear master cylinder mounting bolt 2 E 12 (1.2, 9) Rear brake pedal pivot nut 1 8 27 (2.8, 20) NOTE 7 Front brake cal' r bracket pin 1 8 13(13, 10) NOTE 3 ' Front brake caliper pin 1 10 27 (23, 20) NOTE 3 Front brake caliper mounting bolt 2 8 31 (3.1, 23) l NOTE 6 Rear brake caliper stopper pin bolt 1 18 69 (7.0, 51) l NOTE 6 Rear brake caliper bracket pin bolt 1 8 23(23, 17) Rear brake caliper pin 1 12 27 (2.8, 20) NOTE 3 Brake pipe joint bolt 2 1D 14 (1.4, 10) 1 Brake hose eray joint mounting bolt 2 r 6 12 (1.2, 9) 1-19 GENERAL INFORMATION LIGHTS/METERS/SWITCHES , THRERD TORQUE "EM 0 TV DIA. (mm) N>m (kgfrm, lbf-fl) REMARKS Fuel tank top cover socket bolt 7 5 3.5 (0.4, 2.6) Ignition switch mounting bolt 2 6 10 (1.0, 7) Ignition switch cover screw 1 4 2.1 (0.2, 1.5) Fan motor switch 1 16 17 (1‘7, 13) Sidestand swi‘eh bolt 1 6 10 (1.0, 7) NOTE 6 Instrumentation ECT switch 1 FT 1/8 8 (0.3. 59) NOTE 4 Horn mouming bolt 1 a " 21 (2.1.15) OTHERS , THREAD TORQUE J "EM 0 TV DIA. (mm) N-m (kgrm, IM-m % REMARKS Sidestand pivot bolt 1 10 10 (1.0, 7) Sidestand pivot lock nm 1 10 30 (3.1, 22) NOTE 7 Gearshift pedal pivm bolt 1 B 27 (2‘8, 20) I Muffler bracke‘ bolt 2 1o 74 (7.5, 55) I 1-20 LUBRICATION & SEAL POINTS ENGINE GENERAL INFORMATION LOCATION MATERIAL REMARKS Oil pressure switch threads Cylinder head cover mating surface (cover side) Camshaft rubber plug seating surface Right crankcase cover mating surface (cover side) Crankcase mating surface (left crankcase side) Left crankcase cover mating surface (cover side) Do not apply to the thread head. Coating area (page 8-24) Sealant Coating area (page 10-22) Coating area (page 11-23) Coating area (page 16-12) W Timing hole capthreads Multirpurpose Timing hole cap O-ring grease Valve adjusting hole cap threads Valve adjusting hole cap O-ring Each oil seal lips 'Valve adjusting screw lock nut threads and seating surface Engine oil Oil filter cartridge threads and mating surface Dipstick O-ring (entire surface) oil strainer seal ring (entire surface) Relief valve O»ring (entire surface) Scavenge oil pipe O»ring (entire surface) Water pump Ovring (entire surface) Spark plug sleeve threads Spark plug sleeve O-ring (entire surface) 10 mm cylinder head cap nut threads and seating surface 8 mm cylinder head cap nut threads and seating surface Piston outer surface and piston ring (entire surface) Piston pin outer surface Oil jet O-ring (entire surface) 3 mm cylinder stud bolt threads 10 mm cylinder stud bolt threads Clutch joint piece sliding surface Clutch lifer piece sliding surface Clutch disc lining surface Clutch center boss sliding surface Clutch cuter guide washer (entire surface) Clutch center lock nut threads and seating surface Primary drive gear bolt threads and seating surface Primary driven gear nut threads and seating surface Connecting rod bearing cap nut threads and seating surface Gearshift fork sliding surface Gearshift fork shaft outer surface Countershaft bearing holder O-ring (entire surface) Oil orifice O-ring (entire surface) Flywheel bolt threads and seating surface Starter motor O-ring (entire surface) Starter clutch cuter sliding surface Speed sensor O»ring (entire surface) Each gearteeth and sliding surface Each bearing rotating area Other sliding and rotating surfaces l Rocker arm shaft sliding surface Rocker arm slipper surface Rocker arm shaft O-ring (entire surface) Camshaft journals and cam lobes Valve stem sliding surface Connecting rod small end inner surface Clutch outer guide outer surface Crankshaft main journal bearing sliding surface Crankpin bearing sliding surface M2/M3, CA and CS gear shift fork grooves Starter idle gear shaft outer surface Each transmission gear collar sliding surface Molybdenum oil solution (a mix- ture of 1/2 engine oil and 1/2 molyb- denum disulfide l grease) 1-21 GENERAL INFORMATION V LOCA‘HON l MATERIAL Oil pump driven sprocket bolfthreads Lockinayéent Oil filter boss threads ‘ Cam sprocket bolt threads Cam chain tensioner setting plate bolt threads Shift drum center socket bolt threads Shift drum bearing setting plate bolt threads Rear balancer shaft bearing setting plate bolt threads Mainshaft bearing setting plate bolt threads Spindle plate bolt threads Stator mounting bolt threads Ignition pulse generator mounting bolt threads Alternator wire Clamp bolt threads Starter clutch mounting bolt threads REMARKS fl 1 -22 FRAME GENERAL INFORMATION LOCATION 7 MATERIAL REMARKS Final gear case cover mating surface Instrumentiion ECT switch threads Sealant 4 Do not apply to the thread head. Sidestand pivot Rider foutrest sliding area (VTX'ISOOSNTX13ODR/ \ VTX1300T) Rider footpeg sliding area lVTXlSOOC) 1 Passenger footpeg sliding area i Throttle grip pipe flange and sliding surface Clutch lever pivot Flear brake pedal pivot Gearshift pedal pivot Shock absorber mount bushing inner surface Front wheel dust seal lips Rear wheel dust seal lips Final gear case O-ring (2 places) Final gear case oil seal lips (4 places) Swingarm pivot bearings Swingarm pivot dust seal lips Multipurpose grease Shell Alvania EPZ or equivalent Applvi 9 Apply 1 — 1.5 g for each bearing Steering head bearings Steering head bearing dust seal lips Water resistant grease (urea based multi-pur— pose grease NLGI #2: page 13-27) Apply 3 — 5 g for each bearing F Universal joint hearings Molybdenum Drive shaft oil seal lip disulfide grease Apply 0.5 9 Drive shaft splines (universal joint side) ‘ Apply 1 9 Output shaft splines (universal joint side) Apply 1 g Final driven flange-to-rear wheel hub mating surface Final driven flange O-ring groove Rearwheel hub O-ring groove Final drive pinion joint splines Final drive ring gear shaft splines Molybdenum disulflde paste Apply 3 g or more Apply 2 g or more Apply 5 g or more l—Throttle cable outer inside Clutch cable outer inside Choke cable outer inside Cable lubricant Handlebar grip rubber inside Air cleaner intake duct contacting surface Front fender brace tube inside (VTX13005NTX1300R/ VTX‘ISDDT) Honda Bond A or Honda Hand Grip Cement (USA. only) ‘ Steering bearing adjustment nut threads Engine oil Front brake lever pivot Front brake lever-to-master piston contacting area Rear master cylinder push rod boot groove Rear master piston-to-push rod contacting area Brake caliper pin boot inside Silicone g rease Brake master piston and cups l Brake caliper piston and piston seals DOT4 brake fluid ” [’Fork dust seal and oil seal lips Pro Honda Suspension Fluid SS—S (10W) Cooling fan nut threads Pinion joint nut threads Final gear case cover 10 mm bolt threads Rear shock absorber lower mount stud bolt threads Fork center bolt threads Front brake caliper bracket pin threads Front brake caliper pin threads Rear brake caliper pin threads Final driven flange stud bolt threads Final gear case stud bolt threads Locking agent 1 -23 GENERAL INFORMATION CABLE & HARNESS ROUTING: '03 VTX13OOS RIGHT HANDLEEAR SWITCH WIRE LEFI'HANDLEBAR SWITCH WIRE d RIGHT HANDLEEAR SWITCH 9P (red) CONNECTOR N- .1 LEFT HANDLEBAR SWITCH 5P (black) CONNECTOR RIGHT HANDLEBAR SWITCH WIRE LEFI' HANDLEBAR SWITCH fl 6P (blue) CONNECTOR Q fix 7 \ h d I C, ’ TURN SIGNAL LIGHT F-‘-=.—‘?I’s;’m‘. \ CONNECTORS LEFT HANDLEBAR “‘ SWITCH WIRE \‘ A‘Q, 3 7/“ ' \' FOGLIGHT3P ’A‘ ‘Ii CONNECTOR IOpIIon) ‘ \\' :. MAI N WIRE HARNESS Va HEADLIGHT 3P CONNECTOR RIGHT FRONT TURN SIGNALLIGHTWIRE - ‘jkx -9 I— O \momm I — SIGNAL LIGHT WIRE MAIN WIRE HARNESS HORN RIGHT FRONTTURN SIGNAL LIGHT WIRE LEFI’ FRONT TURN SIGNAL LIGHT WIRE 1-24 GENERAL INFORMATION '03 VTX13IJOS SFEEDOMETER WIRE FUEL TANK TOP COVER SPEEDOMETER WIRE SPEEDOMETER SPEEDOMETER CONNECTORS (See page 1-30 for detail) 1 -25 GENERAL INFORMATION '03 VTXIZOOS BRAKE HOSE JOINT STOPPER LEFT HANDLEBAH SWITCH WIRE THROTTLE CABLES w \ RIGHT HANDLEEAR SWITCH WIRE RIGHT HANDLEBAR I SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE LEFTHANDLEBAR FRONT BRAKE HOSE SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE THROTTLE CABLES 1-26 GENERAL INFORMATION '03 VTX13MS WATER HOSE WATER HOSE (FTO'T‘ (From rear cylinder) front cyIInderi Up Front <— + 45° 30" WATER RETURN HOSE (To waIer pump) THERMOSTAT HOUSING VACUUM HOSE (California type: No. 10 VACUUM HOSE) GROUND TERMINAL No.4HOSE up w (California Iype only) LOCATING " Up Len/r PULSESECONDARY AIR ‘5 + INJECTION (PAIR) HOSE CLIP Lsflr— UP Up OILPRESSURE SWITCH CONNECTOR CLUTCH \ CABLE \ a U REAR BRAKE A I ( LIGHTSWITCH V I, 2P CONNECTOR / HORN WIRE ._ From 45.; LEFT REAR SPARK PLUG WIRE FAN MOTOR 2P CON NECTOR PAIR HOSE RADIATOR FUEL HOSE LEFT FRONT SPARK PLUG WIRE PAIR HOSE SIPHON HOSE CRANKCASE BREATHER HOSE 1 -27 GENERAL INFORMATION '03 VTx1aoos (1) VEHICLE SPEED SENSOR WIRE (2) SIDESTAND SWITCH WIRE (3) ALTERNATOR WIRE (4) STARTER MOTOR CABLE (5) No. 2 HOSE (California type only] (6) Na 4 HOSE (California type only) (7) RADIATOR SIPHON HOSE (8) RESERVE TANK FILLER NECK HOSE (9] REGULATOR/RECTIFIER WIRE I10) CONNECTOR BOOT CONNECTOR BOOT: ALTERNATOR 3P CONNECTOR IGNITION SWITCH WIRE Fm“ T es w NEUTRAL SWITCH 1-28 GENERAL INFORMATION '03 VTX13ooS CONNECTOR BOOT: ‘GN'T'ON SW‘TCH W'HE ALTERNATOR 3P CONNECTOR VEHICLE SPEED SENSOR WIRE \ L’s ’ ((331. f BATTERY GROUND CABLE ‘ § ‘ MAIN WIRE HARNESS ’3 r V $§£IIII2EABLE fifkj’ T$\§s~3 E44 “'3’ ALTERNATOR WIRE TI CONNECTOR BOOT: V >4 - SIDESTAND SWITCH 2P CONNECTOR v VEHICLE SPEED SENSOR 3P CONNECTOR STARTER SIDESTAND SWITCH WIRE MOTOR CABLE CLUTCH CABLE STARTE R MOTOR CABLE 1 -29 GENERAL INFORMATION '03 VTX13OOS PULSE SECONDARY AIR INJECTION IPAIR) MAIN WIRE CONTROL VALVE HARNESS VACUUM U From HOSE THROTI’LE CABLES p ‘ THROTTLE LeIl ¢ La" * 1 POSITION X > v SENSOR 3P w CONNECTOR Up I Q 7 4 . . nght ’ FUEL TANK ' L V \ REAR A A v - ~r 7’ ' \1 B AKE PIPE BRE THER HOSE , I .. V ' RIGHTREAR ‘ SPARK / PLUG WIRE \ , ,r.‘ ‘ I SFEEDOMETER MAINWIRE [.35 ( ' , W'RE HARNESS a w, r . - ‘ PAIR PIPE ; ‘ “ $6?" \ © A A. ‘ V rkI I? up FUEL 05E \ SPEEDOMETER 4 CONNECTORS RIGHTREAR . r\ 9 fl w\ . * SPARK \,’\ PAIR HOSE / PLUG WIRE \ CRANKCASE ' 45“ EREATHER HOSE REAR BRAKE LIGHT SWITCH WIRE (Clamp at tape position) OIL PRESSURE SWITCH WIRE 1 -30 GENERAL INFORMATION '03 VTX13005 Front t Left * g A Right WATER HOSES L'— CARBURETOR CONNECTOR BOOT: FUEL TANK BREATHER A REAR TURN SIGNAL CONNECTORS HOSE (Except California type) - BRAKE/TAILLIGHT CONNECTORS - LICENSE LIGHT CONNECTORS "W" M“ HARNESS BATTERY POSITIVE (+I FUSE BOX CABLE TERMINAL BATTERY POSITIVE (+1 CABLE WATER RETURN HOSE FUEL CUT-OFF RELAY MAINWIRE HARNESS FUSE BOX WIRE STARTE R RE LAY SWITC H WI RE STARTE R STARTER RELAY SWITCH MOTOR CABLE BATTERY POSITIVE 1+) CABLE STARTER MOTOR CABLE I FUELCUTOFF RELAY TURN SIGNAL RELAY BATTERY POSITIVE (+) CABLE 1-31 GENERAL INFORMATION '03 VTX1300$ [1) NOT 4 HOSE (California type only) (2) FUEL HOSE (3) FUEL HOSE [4) RADIATOR SIPHON HOSE (5) MAIN WIRE HARNESS (6) FUEL TANK DRAIN HOSE (7) WATER RETURN HOSE (8) REAR BRAKE PIPE FRAME PIPE (1] FRAME PIPE FRAME PIPE CONNECTOR BOOT: - IGNITION SWITCH 3P CONNECTOR - IGNITION PULSE GENERATOR 2P CONNECTOR (5] -REGULATOR/RECTIFIER 4P CONNECTOR - FUEL PUMP CONNECTORS - NEUTRAL SWITCH CONNECTOR FUEL PUMP REAR IGNITION COIL REAR IGNITION COIL 2P CONNECTOR BATTERY POSITIVE (+) TERMINAL 1 -32 GENERAL INFORMATION '03 VTX13OOS 0|L PRESSUFEVER/ I] ——> From _J-‘ [ FRAME CROSS PIPE RESERVE TANK OVERFLOW HOSE M UFFLER BRACKET FUEL TANK BREATHER HOSE REGULATOR/RECTIFIER RADIATOR RESERVE TANK 1 -33 GENERAL INFORMATION '03 vrxuoos \ REAR BRAKE PIPE \ REAR BRAKE HOSE JOINT STOPPER SWITCH WIRE OIL PRESSURE SWITCH WIRE 1 -34 GENERAL INFORMATION '03 VTX1300$ (1) LEFT REAR TURN SIGNAL LIGHT WIRE (2| LICENSE LIGHT WIRE (3) RIGHT REAR TURN SIGNAL LIGHT WIRE [4) BRAKE/TAILLIGHT WIRE Reverse side of The rear fender: Clamp at white (ape positions I LICENSE LIGHT I CONNECTORS INNER GRAB RAIL REAR FENDER (4) A BRAKE/TAILLIGHT l 11) .40}. LEFT REAR TURN SIGNAL LIGHT RIGHTREARTURN SIGNAL LIGHT (2) LICENSE LIGHT 1-35 GENERAL INFORMATION EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only) '03 vrx1aoos EVAP CANISTER PURGE VALVE No.10 VACUUM HOSE No. 4 HOSE N0. 4 H0558 EVAF CARBURETOR AIR VENT [CAV) -gg‘ K‘ '_ CONTROL VALVE a)?“ ‘ \4 z‘f’fi’fa ‘ ¢€‘\ v |_‘ f’ (I ‘7; ‘V \ h -. ¢ ' ' a ‘ / / \ vi: ‘I‘ u 1o VACUUM HOSE r v , r. , ' 41’, . 'rA No.6 HOSE ‘ lit ‘ > EVAP CANISTER 1 -36 GENERAL INFORMATION CABLE & HARNESS ROUTING: ’04 VTX13OOS RIGHT HANDLEBAR SWITCH WIRE LEI-T HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH 9 BF (red) CONNECTOR \ O ‘\(§.I LEFT HANDLEBAR SWITCH 7 GP (black) CONNECTOR RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH \ 6? (blue) CONNECTOR g‘§ A ~ I, TURN SIGNAL LIGHT ‘ CONNECTORS LEFI' HANDLEBAR SWITCH WIRE FOG LIGHT 3P CONNECTOR (Option) MAIN WIRE HARNESS HEADLIGHT 3P CONNECTOR RIGHT FRONTTURN SIGNAL LIGHT WIRE ‘ LEFT FRONT TURN _ I ‘ SIGNAL LIGHT WIRE MAIN WIRE HARNESS HORN RIGHT FRONT TURN SIGNAL LIGHT WIRE LEFI' FRONT TURN SIGNAL LIGHT WIRE 1 -37 GENERAL INFORMATION '04 VTX1aoos SPEEDOMETER WIRE FUEL TANK TOP COVER SPEEDOMETER WIRE VA SPEEDOMETER WIRE SPEEDOMETER SPEEDOMETER CONNECTORS (See page 1-43 for detail) 1-38 GENERAL INFORMATION '04 VTX13005 BRAKE HOSE JOINT STOPPER LEFI' HANDLEBAR FRONT BRAKE HOSE SW'TCH W'RE THROTTLE CABLES CLUTCH CABLE “ FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE RIGHTHANDLEBAR SWITCH WIRE RIGHTHANDLEBAR SW'TCH W'RE LEFTHANDLEBAR FRONT BRAKE HOSE SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE THROTTLE . CABLES g] {Jill 1-39 GENERAL INFORMATION '04 VTX1aoos WATER HOSE (From front cylinder) WATER HOSE (From rear cylinder) Up From <- + 45° 30“ WATER RETURN HOSE (To water pump] THERMOSTAT HOUSING VACUUM HOSE (California type: No. 10 VACUUM HOSE) GROUND TERMINAL ND. HQSE up 30., (Callfornla type only) LOCATING 45” Up Lefl ' PULSE SECONDARYAIR CLIP g Len” UPS INJECTION (PAIR) HOSE CLUTCH CABLE \ S OILPRESSURE SWITCH CONNECTOR \ A REAR BRAKE ‘ LIGHT SWITCH I ‘ 2PCONNECTOR « ' -/ \L HORN WIRE ‘_ Front 45“ if, , FAN MOTOR 2P L \ LEFT REAR SPARK CONNECTOR \ PLUG WIRE PAIR HOSE RADIATOR LEFT FRONT SIPHON HOSE SPARK PLUG WIRE PAIR HOSE FUEL HOSE CRANKCASE BREATHER HOSE 1 -40 GENERAL INFORMATION '04 VTX13DOS (1) VEHICLE SPEED SENSOR WIRE (2) SIDESTAND SWITCH WIRE (3) ALTERNATOR WIRE (4) STARTER MOTOR CABLE (5) No.2 HOSE (California type only) (G) No. 4 HOSE (California type only) (7) RADIATOR SIPHON HOSE (8) RESERVE TANK FILLER NECK HOSE I9) REGULATOR/RECTIFIER WIRE I10) CONNECTOR BOOT CONNECTOR BOOT: ALTERNATOR 3F CONNECTOR IGNITION SWITCH WIRE Fm” ‘— \ . (6) (1) ‘ [8) I m NEUTRAL SWITCH 1-41 GENERAL INFORMATION ‘o4 vrxnoos CONNECTOR BOOT: 'GN'T'ON SW'TCH W'RE ALTERNATOR 3P CONNECTOR VEHICLE SPEED SENSOR WIRE BATTERY GROUND CABLE MAIN WIRE HARNESS GROUND CABLE TERMINAL CONNECTOR BOOT: -S|DESTAND SWITCH 2P CONNECTOR - VEHICLE SPEED SENSOR 3P CONNECTOR STARTER SWFTSJWRE MOTOR CABLE CLUTCH CABLE STARTER MOTOR CABLE 1 -42 GENERAL INFORMATION '04 v1x13oos PULSE SECONDARY AIRINJECTIONIFAIRI MAINWIRE CONTROL VALVE HARNESS VACUUM THROTTLE CABLES “P F7" HOSE THROTTLE A « POSITION Left‘ Le * SENSOR 3P 9 @ CONNECTOR Up; I I 'f v Rigm i ‘w I‘ ’ ‘(Ik E.— A/ L .r ( fg‘zlllllfi . FUEL TANK ‘l-hlflizfi r REAR BREATHER HOSE ' ”’w I“; y] ’s‘::. . \/ BRAKE PIPE fit-T‘AI ' AS431 v r m (=1 2 .4 w L SPARK ‘ IE RIGHTREAR /’ :. I. , 7.1 PLUG WIRE (a SPEEDOMETER MAINWIRE , A WIRE HARNESS M Z ‘1 SPEEDOMETER CONNECTORS RIGHT REAR Ix SPAENMRE K1 REAR BRAKE LIGHT LU - 45., CRANKCASE SWITCH WIRE (Clamp BREATHER HOSE at tape position) OIL PRESSURE SWITCH WIRE 1 -43 GENERAL INFORMATION '04 VTX13005 From I Len — Q —~ Right INTAKE MANIFOLD WATER HOSES WATER PIPE (between cylinders! CONNECTOR BOOT: v REAR TURN SIGNAL CONNECTORS ~ BRAKE/TAILLIGHT CONNECTORS - LICENSE LIGHT CONNECTORS FUEL TANK BREATHER HOSE (Except California type) MAIN WIRE HARNESS FUSE BOX BATTERY POSITIVE (+) CABLE TERMINAL BATTERY POSITIVE (+) CABLE STARTER RELAY SWITCH WIRE STARTE R STARTER MOTOR CABLE RELAY SWITCH BATTERY POSITIVE (+) CABLE STARTER MOTOR CABLE BATTERY POSITIVE (+) CABLE WATER RETURN HOSE MAIN WIRE HARNESS TURN SIGNAL RELAY 1-44 GENERAL INFORMATION '04 VTX13ooS (1) No. 4 HOSE (California type only] (2) RADIATOR SIPHON HOSE (3) MAIN WIRE HARNESS (A) FUEL TANK DRAIN HOSE (5) WATER RETURN HOSE I6) REAR BRAKE PIPE FRAME PIPE FRAME PIPE (1) [3) FRAME PIPE I! — CONNECTOR BOOT: - IGNITION SWITCH 3P CONNECTOR ‘ IGNITION PULSE GENERATOR 2P CONNECTOR IGNITION CONTROL MODULE (ICM) REGULATOR/RECTIFIER 4P CONNECTOR ‘ NEUTRAL SWITCH CONNECTOR REAR IGNITION COIL REAR IGNITION COIL 2P CONNECTOR BATTERY POSITIVE [+) TERMINAL 1 -45 GENERAL INFORMATION '04 v-rx1soos OIL PRESSUR/EjVEH/ I, _> From J PRESSURE SWITCH WIRE FRAME CROSS PIPE REGULATOR/RECTIFIE77VIRE WK BREATEER HOSE K '15 RESERVE TANK / OVERFLOW HOSE r ‘N‘ MUFFLER BRACKET FUEL TANK BREATHER HOSE REGU LATOR/RECTIFIER RADIATOR RESERVE TAN K 1 -46 GENERAL INFORMATION '04 VTX1300$ \ REAR BRAKE PIPE REAR BRAKE HOSE JOINT STOPPER REAR BRAKE LIGHT SWITCH WIRE OIL PRESSURE SWITCH WIRE REAR BRAKE HOSE JOINT REAR BRAKE HOSE 1 -47 GENERAL INFORMATION '04 VTx13oos (1) LEFT REAR TURN SIGNAL LIGHT WIRE (2) LICENSE LIGHT WIRE (3) RIGHT REAR TURN SIGNAL LIGHT WIRE (4) BRAKE/TAILLIGHT WIRE Reverse side of the rear fender: (4 Clamp at white tape positions n INNER GRAB FIAIL REAR FENDER ( I LICENSE LIGHT I3) CONNECTORS (4) (4) If m / 33‘ INNER GRAB RAIL [ BRAKE/IAILLIGHT m REAR FENDER (2) (1) <1 LEFTREAR TURN SIGNAL LIGHT RIGHTFIEARTURN SIGNAL LIGHT (2’ LICENSE LIGHT 1 -48 GENERAL INFORMATION EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only) '04 wxnoos EVAP CANISTER PURGE VALVE No.10 VACUUM HOSE No, 4 HOSE No‘ 4 HOSES EVAP CAREURETOR AIR VENT (CAV) CONTROL VALVE , v‘alélt,‘ ‘ A . . x ’ ‘ . 4 5m "I " '_ / ‘ "j - 4 "3: ‘ No. 10 VACUUM HOSE f9 ‘55” I' ‘ r; 9 /‘ ‘ . j-rg No.6HOSE \ «,4; \ ~. SWINGARM PIVOT No.2 HOSE EVAP CANISTER 1 -49 GENERAL INFORMATION CABLE & HARNESS ROUTING: '05 — ’07 VTX13OOS/VTX1300R RIGHT HANDLEEAR SWITCH WIRE LEFTHANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH 9P (red) CONNECTOR \ 0 ‘\(&.j LEFI' HANDLEBAR SWITCH ' 6P (black) CONNECTOR RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH \ Q 5P (blue) CONNECTOR ARV ‘ “\ A TURN SIG NAL LIGHT CONNECTORS FOG LIGHTSP CONNECTOR _ (Option) \ LEFTHANOLEBAR 5”" x x SWITCH/WIRE ( 2 MAIN WIRE HARNESS <3 N HEADLIGHT 3P CONNECTOR RIGHT FRONTTURN SIGNAL LIGHT WIRE © . . - I LEFT FRONTTURN SIGNAL LIGHTWIRE MAIN WIRE HARNESS HORN MAIN WIRE HARNESS (for fog light; OptionI \\ RIGHTFRONTTURN LEFTFRONTTURN SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE 1-50 GENERAL INFORMATION '05 - '07 VTX1SDUSIVTX1300R SPEEDOMETER WIRE FUEL TANK TOP COVER SPEEDOMETER WIRE SPEEDOMETER WERE SPEEDOMETER SPEEDOMETER CONNECTORS (See page 1-56 for detail) 1-51 GENERAL INFORMATION '05 — '07 vrx13005NTx1300R BRAKE HOSE JOINT STOPPER LEFTHANDLEBAR FRONT BRAKE HOSE SW'TCH W'RE THROTTLE CABLES CLUTCH CABLE FRONT BRAKE HOSE RIGHTHANDLEBAR / SWITCH WIRE From -> Front ‘— \ Front Front <— RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH W'RE LEFTHANDLEBAR FRONT BRAKE HOSE SW'TCH W'RE RIGHTHANDLEEAH SWITCH WIRE FRONT BRAKE HOSE THROTTLE CABLES 1-52 GENERAL INFORMATION '05 — '07 VTx1aoDS/V'rx1aoon WATER HOSE WATER HOSE [From From rear :2 linder) from cylinder) ( y WATER RETURN HOSE (To water pump) THERMOSTAT HOUSING VACUUM HOSE (California type: No. 10 VACUUM HOSE) GROUND TERMINAL No. HOSE Up 30. (Callforma type only) 45" LOCATING 45” Up Len/Kg; PULSESECONDARYAIH CLIP % Len, Up INJECTION (PAIR) HOSE CLUTCH CABLE OILPRESSURE SWITCH CONNECTOR REAR BRAKE LIGHT SWITCH 2P CONNECTOR HORN WIRE ‘7 From 45“ FAN MOTOR 2F LEFT REAR SPARK CONNECTOR PLUG WIRE PAIR HOSE RADIATOR LE” FRONT SIPHON HOSE SPARK PLUG WIRE PAIR HOSE FUEL HOSE CRANKCASE BREATHER HOSE 1-53 GENERAL INFORMATION '05 - '07 VTX13003/VTX1300R (1] IGNITION SWITCH WIRE (2) SIDESTAND SWITCH WIRE (3) ALTERNATOR WIRE (d) STARTER MOTOR CABLE (5| N0. 2 HOSE (California type only) (6) Na. 4 HOSE [California type only) [7) RADIATOR SIPHON HOSE (8) RESERVE TANK FILLER NECK HOSE (9) NEUTRAL SWITCH WIRE (5) I3) 3) fl. Q? ‘- ‘mw (4) ,' ‘ _ .1! '1' film- WIRE BAND VEHICLESPEED (1) SENSOR WIRE (7) (8) 13) (7) (5| ©©© (3) Left ‘ 4\ W“ J’ NEUTRAL SWITCH 1 -54 GENERAL INFORMATION '05 - '07 VTX13OOSNTX13ODR VEHICLE SPEED SENSOR WII"IE IGNITION SWITCH WIRE ALTERNATOR WIRE IGNITION PULSE GENERATOR WIRE GROUNDCAELE TERMINAL MAIN WIRE HARNESS CONNECTOR BOOT: - SIDESTAND SWITCH 2P CONNECTOR v VEHICLE SPEED SENSOR 3P CONNECTOR SIDESTAND STARTER SWITCH WIRE MOTOR CABLE CLUTCH CABLE STARTER MOTOR CABLE 1 -55 GENERAL INFORMATION '05 — '07 VTX13OOS/VTX13ODR INSTRUMENTATION ENGINE PULSE SECONDARY AIR 1N JECTION (PAIR, COOLANT TEMPERATURE SENSOR CONTROL VALVE M AINWIRE HARNESS VACUUM F ' HOSE Up THROTTLE CABLES m. U" 4 THROTTLE ‘ POSITION F L“ v - SENSOR 3P mm w CONNECTOR FUEL TANK BREATHER HOSE RIGHTFIEAR ) 2’," . f SPARK PLUG WIRE ‘ It I @a’ . SPEEOOMETER MAIN WIRE ,9 WIRE HARNESS 1 I J \ g, PAIR PIPE FU I? Up SPEEDOMETER CONNECTORS 4 , RIGHTREAR KN, - I I , SPARK \1\ SEAR BRvA/IEEEIEICG'HT PLUG WIRE WITCH amp 45° PAIR HOSE at tape position) OIL PRESSURE SWITCH WIRE 1-56 9 GENERAL INFORMATION '05 — 'o1 VTX13IJOSIVTX1300R From T Lek k g « Righl INTAKE MANIFOLD T 7f )<—— CARBURETOR WATER HOSES WATER PIPE (between Cylinders) CONNECTOR BOOT: FUEL TANK BREATHER - REAR TURN SIGNAL CONNECTORS HOSE (Except California type) - BRAKE/TAILLIGHT CONNECTORS ~ LICENSE LIGHT CONNECTORS MAIN WIRE HARNESS BA'I'I'ERY POSITIVE (+I FUSE BOX CABLE TERMINAL BATTERY POSITIVE (+I CABLE MAIN WIRE HARNESS FUSE BOX WIRE STARTER RELAY SWITCH WIRE STARTER STARTER MOTOR CABLE RELAY SWITCH BATTERY POSITIVE (+1 CABLE STARTE R MOTOR CABLE TURN SIGNAL RELAY BATTERY POSITIVE I+I CABLE 1-57 GENERAL INFORMATION '05 — '07 VTX1 3005/VTX1300R (1) No. 4 HOSE (California type only) (2) RADIATOR SIPHON HOSE (3) MAIN WIRE HARNESS CONNECTOR BOOT: ‘4’ FUELTANK DRA'N HOSE ALTERNATOR 3P CONNECTOR (5) WATER RETURN HOSE Ia) REAR BRAKE PIPE FRAME PIPE [7) REGULATOR/RECTIFIER WIRE I3) From a» r T5)ch (6) up \\ v 3‘ 6‘“? x/ FRAME PIPE (2) ‘5‘". If FUSE BOX 8 /-‘l - AI CONNECTOR BOOT: - IGNITION SWITCH 3P CONNECTOR - IGNITION PULSE GENERATOR 2P CONNECTOR -REGULATOR/RECTIFIER 4P CONNECTOR IGNITION CONTROL MODULE (ICM) - NEUTRAL SWITCH CONNECTOR ‘ REAR IGNITION COIL REAR IGNITION COIL 2P CON NECTOR BATTERY GROU ND CABLE BATTERY NEGATIVE I—I TERMINAL BATTERY POSITIVE 1+) TERMINAL 1 -58 GENERAL INFORMATION '05 — '07 V'rx1aoosmx1soon OIL PRESSUFfflCH/ / _.’ From OIL PRESSURE SWITCH WIRE FRAME CROSS PIPE REGULATOR/RECTIFIER WIRE fix RESERVE TANK OVERFLOW HOSE M UFFLER SWINGARM PIVOT BRACKET FUEL TANK BREATHER HOSE REGULATOR/RECTIFIER RADIATOR RESERVE TANK 1 -59 GENERAL INFORMATION ‘05 — '07 VTX13OOS/VTX1300R ‘ REAR BRAKE PIPE REAR BRAKE HOSE JOINT STOPPER REAR BRAKE LIGHT SWITCH WIRE OIL PRESSURE SWITCH WIRE 1-60 GENERAL INFORMATION '05 — '07 VTX13OOS/VTX1300R (1) LEFT REAR TURN SIGNAL LIGHT WIRE [2) LICENSE LIGHT WIRE Clamp atwhita (3) RIGHT REAR TURN SIGNAL LIGHT WIRE tape positions (4) BRAKE/TAILLIGHT WIRE INNER GRAB RAIL I4) Reverse side of the rear fender: CONNECTORS A H (3) INNER GRAB RAIL REAR FENDER ( (3’ r 14) 'L’ W '\ (1) (4) (3) j l 4:. I? 1 L (2) I '§L\\' BRAKE/TAILLIGHT INNER GRAB RAIL W (I) \E ‘ ‘ LEFT REAR TURN SIGNAL LIGHT RIGHTREARTURN SIGNAL LIGHT LICENSE LIGHT (2) 1-61 GENERAL INFORMATION EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only) '05 — '07 VTX13005/VTX1300R EVAP CANISTEFI PURGE VALVE No‘ 10 VACUUM HOSE No.4 HOSE No. 4 HOSES EVAP CARBURETOR AIH VENT ICAV) CONTROL VALVE E S O H M U U C A V o o E S /‘w @6 o /N / E S O H 5 a N No.11 VACUUM HOSE lg; /’ No.10 VACUUM HOSE 1 No.1 HOSE FRAME CROSS PIPE No. 4 HOSE SWINGARM PIVOT \ No 2 HOSE EVAP CANISTER 1-62 GENERAL INFORMATION CABLE & HARNESS ROUTING: After '07 VTX1300R/VTX1300T RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEEAR SWITCH WIRE RIGHT HANDLEEAR SWITCH 9P (red) CONNECTOR LEFT HANDLEBAR SWITCH 6P (black) CON NECTOR RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH 6P (blue) CONNECTOR TURN SIGNAL LIGHT CONNECTORS SWITCH WIRE H FOG LIGHT 3P CONNECTOR (Option) \\ MAIN WIRE HARNESS HEADLIGHT 3P CON NECTOR RIGHT FRONTTURN SIGNAL LIGHT WIRE LEFI’ FRONT TURN SIGNAL LIGHT WIRE MAIN WIRE HARNESS HORN MAIN WIRE HARNESS \ (for fog IighI; Option) K RIGHT FRONTTURN LEI-T FRONT TURN SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE 1-63 GENERAL INFORMATION After '07 VTX1300R/VTX1300T SFEEDOMETER WIRE FUEL TANK TOP COVER SPEEDOMETER WIRE SPEEDOMETER SFEEDOMETER CONNECTORS (See page 1-70 for detail) 1-64 GENERAL INFORMATION After '07 VTX1300RIVTX1300T VTX1300R shown: BRAKE HOSE JOINT STOPPER LEFTHAN DLEBAR FRONT BRAKE HOSE SWITCH WIRE THROTTLE CABLES CLUTCH CABLE ‘ FRONT BRAKE HOSE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR FRONT BRAKE HOSE SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE THROTTLE CABLES 1 -65 GENERAL INFORMATION After '07 VTX1300R/VTX1300T WATER HOSE WATERHOSHFW'T‘ (From raarcylinder) from Cylinder) WATER RETURN HOSE (To water pump) TH ERMOSTAT HOUSING GROUND TERMINAL No.4HOSE UD‘ an. (California type only) Lefl l LOCATING lel" UR ‘ , . Liv? “9 J PULSE SECONDARY .l AIRINJECTIONIPAIR) CONTROL VALVE CLUTCH RADIATOR CABLE . NPHON HOSE \ \ OILPRESSURE SWITCH CONNECTOR \ » REAR BRAKE / ‘ I ‘ . LIGHT SWITCH A L w 2P CONNECTOR / ' HORN WIRE From 45“ FAN MOTOR 2P CONNECTOR FLUG WIRE \ PAIR HOSE LEFT FRONT FUEL HOSE VACUUM HOSE (California SPARK PLUG WIRE FAIR HOSE type: No. 10 VACUUM HOSE) CRANKCASE BREATHEH HOSE 1 -66 GENERAL INFORMATION After '07 VTX1300HIVTX1300T 0 — 3 mm :if \\ ‘0/j\ ‘ b 1 :1 \ ° // r ' 9\ EEAMP ’ FUEL HOSE } Kw N/ WATER HOSE Fro m ca rbu relor To from cylinder head A" —> To water pump From 4— fi> To EVAP canister From air cleaner housing —-’ A To radiator reserve tank No. 4 HOSE (California type only) PULSE SECONDARY SIPHON HOSE AIRINJECTIOMPAIR) CONTROL VALVE 1-67 GENERAL INFORMATION After '07 VTX1300R/VTX1300T (1i IGNITION SWITCH WIRE (2] SIDESTAND SWITCH WIRE (3) ALTERNATOR WIRE (4) STARTER MOTOR CABLE (5) No.2 HOSE (California type only) (6) No. 4 HOSE (California type only) (7) RADIATOR SIPHON HOSE (8) RESERVE TANK FILLER NECK HOSE (9) NEUTRAL SWITCH WIRE VEHICLE SPEED SENSOR WIRE (5) (9) (4) (3) WIRE BAND N EUTRAL SWITCH (7) (E) (7) (5) (8i 1 -68 GENERAL INFORMATION After '07 VTX1300R/VTX1300T VEHICLE SPEED SENSOR WIRE IGNITION SWITCH WIRE BATTERY GROUND CABLE ALTERNATOR WIRE IGNITION PULSE GENERATOR WIRE GROUNDCABLE TERMINAL MAIN WIRE HARNESS CONNECTOR BOOT: - SIDESTAND SWITCH 2P CONNECTOR - VEHICLE SPEED SENSOR 3P CONNECTOR SIDESTAND STARTER SWITCH WIRE MOTOR CABLE CLUTCH CABLE STARTER > MOTO R CAB LE 1 -69 GENERAL INFORMATION Am: '07 VTX1300RIVTX1300T WATER HOSE JOINT r «ime thermostat hnusing \ r EUR/L gig/\I , : WY: 3 I / I I A J \ ‘ I 1 /%5A \BJ/iQ WATER HOSE pAIR PIPE ¢>T’L’ From cgrbyretor MAIN WIRE INSTRUMENTATION ENGINE HARNESS COOLANT TEMPERATURE SENSOR PULSE SECONDARY THROI'rLE POSITION AIR INJECTION (PAIR) CONTROL VALVE SENSOR 3P CONNECTOR MAlNWlRE HARNESS Front U f THROTTLE so“ CABLES 4 Up I'm“ a From IN A Q T Q I / I g. 8 PAIR PIPE FUEL TAN K BREATHER HOSE “PT ’Right SPEEDOMETER MAINWIRE WIRE HARNESS [:I 5.x SFEEDOMETER Q \ E.» \ g?“ CONNECTORS I I s Q I 231135“ 45“ CRANKCASE PAIR HosE PLUG WIRE BREATHE“ HOSE REAR BRAKE LIGHT SWITCH WIRE ICIamp at tape position) OIL PRESSURE SWITCH WIRE 1-70 GENERAL INFORMATION After '07 VTX1300RIVTX1 300T Front I CARBURETOR Left V a Right INTAKE MANIFOLD WATER HOSES —’ Up I \ 53—» Q \ WATER PIPE (bexween cylinders) CONNECTOR BOOT: FUEL TANK BREATHER - REAR TURN SIGNAL CONNECTORS HOSE (Except ca|ifomia we) -BFIAKE/TA|LL|GHT CONNECTORS » LICENSE LIGHT CONNECTORS MAIN WIRE HARNESS BATTERY POSITIVE I+) FUSE BOX CABLE TERMINAL BATTERY POSITIVE I+I CABLE WATER RETURN HOSE MAIN WIRE HARNESS FUSE BOX WIRE FUSE BOX STARTER RELAY SWITCH WIRE mam RELAY SWITCH BATTERY POSITIVE I+I CABLE STARTER MOTOR CABLE TURN SIGNAL RELAY BATTERY POSITIVE (+) CABLE 1-71 GENERAL INFORMATION After '07 v1x1aoonlv1'x13001 (1) No.4 HOSE [California type only) (2) RADIATOR SIFHON HOSE (3) MAIN WIRE HARNESS (4) FUEL TANK DRAIN HOSE [5) WATER RETURN HOSE (6) REAR BRAKE PIPE (7] REGULATOR/RECTIFIER WIRE FRAME PIPE ( l 1 I2) CONNECTOR BOOT: I ALTERNATOR 3P CONNECTOR CONNECTOR BOOT: - IGNITION SWITCH 3P CONNECTOR - IGNITION PULSE GENERATOR 2P CONNECTOR - REGULATOR/RECTIFIER 4P CONNECTOR " - NEUTRAL SWITCH CONNECTOR IGNITION CONTROL MODULE (ICMI REAR IGNITION COIL \ REAR IGNITIONCOIL x 2P CONNECTOR BATTERY GROUND CABLE BATTERY NEGATIVE (—) TERMINAL BATTERY POSITIVE (+I TERMINAL 1-72 GENERAL INFORMATION After '01 VTX1300R/VTX1300T OIL PRESSURE'SWLD I! ._> Front J / OIL PRESSURE SWITCH WIRE OIL PRESSURE SWITCH WIRE FRAME CROSS PIPE RESERVE TANK OVERFLOW HOSE MUFFLER BRACKET FUELTANK BREATHER HOSE % REGULATOR/RECTIFIER RADIATOR RESERVE TANK 1-73 GENERAL INFORMATION After '07 VTX1300RIVTX1300T ‘ REAR BRAKE PIPE I / REAR BRAKE LIGHT SWITCH WIRE REAR BRAKE HOSE JOINT STOPPER OIL PRESSURE SWITCH WIRE REAR BRAKE HOSE 1-74 GENERAL INFORMATION After '07 VTX1300RIVTX1300T [1) LEFT REAR TURN SIGNAL LIGHT WIRE [2) LICENSE LIGHT WIRE Clamp at white (3) RIGHT REAR TURN SIGNAL LIGHT WIRE tape positions (4) BRAKE/TAILLIGHT WIRE INNER GRAB RAIL Reverse side of the rear fender: CONNECTORS (3) (4) I / El @ [4) (3| ! (1) Fl LI (4) \ REAR FENDER \.( I. (2) ‘ §Lx¥ BRAKE/TAILLIGHT INNER GRAB RAIL " I REAR FENDER IE? I (1) 4 0 [3) i\ 4 m LEFT REAR TURN SIGNAL LIGHT RIGHT REAR TURN x \ \\ = / SIGNAL LIGHT A © 9 / LICENSE LIGHT (Z) 1-75 GENERAL INFORMATION EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only) After '01 VTX1300R/V'TX1300T To carbuvelor 7° EV” CA" control valve Tu ma control valve / \ ~L SOLENOID VALVE \ To NW N,“ D From 2F CONNECTOR ’1 — a— Qflgafl FUEL emit—OFF EVAPCANISTER SOLENOID VALVE PUHGE VALVE No.4 HOSES \ w . Isms: SUB-mm yd"; »' EVAP CARBURETOR // AIR VENT (CAV) CONTROL VALVE No. 5 HOSE SUB-AIR CLEANER- to-EVAF CAV CONTROL VALVE HOSE (To ca rbureto 3%gi FRAME CROSS PIPE No.4Hose WM‘VLLLZ /, NH 1 WM“ HOSE \ r L . V ‘ 7A EVAP’CANISTER 1-76 G GENERAL INFORMATION CABLE & HARNESS ROUTING: '04 VTX13OOC RIGHT HANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEEAR SWITCH 9P (red) CONNECTOR O LEFT HANDLEEAR SWITCH 6P [black] CONNECTOR RIGHT HANDLEBAH LEFT HAN DLEEIAR SWITCH SWITCH WIRE SP (blue) CONNECTOR fl k7 ,Q 7 '“I-E- TURN SIGNAL LIGHT . v CONNECTORS LEFTHANDLEBAR SWITCH WIRE FOG LIGHT 3P CONNECTOR (Outlon) HEADLIGHT 3P CONNECTOR I MAIN WIRE HARNESS RIGHT FRONTTURN SIGNAL LIGHT WIRE LEFT FRONT TURN SIGNAL LIGHT WIRE MAIN WIRE E! HARNESS @ I HORN MAIN WIRE HARNESS "’ (for fog light; option) RIGHT FRONTTURN SIGNAL LIGHT WIRE LEFT FRONT TURN SIGNAL LIGHT WIRE 1-77 GENERAL INFORMATION '04 VTX1C'IDOC SPEEDOMETEH WIRE FUELTANKTOP COVER SPEEDOMETER WIRE I SPEEDOMETER WIRE SPEEDOMETER SPEEDOMETERCONNECTORS (See page 1-8310r detail) 1-78 GENERAL INFORMATION '04 VTX1aooc BRAKE HOSE JOINT STOPPER LEFTHANDLEBAR SWITCH WIRE THROTTLE CABLES CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEEAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE CABLES 1-79 GENERAL INFORMATION '04 VTX1300C WATER HOSE WATER HOSE (From (From rear cylinder) from cylinder) WATER RETURN HOSE [To water pump) THERMOSTAT HOUSING VACUUM HOSE (California type: No.10 VACUUM HOSE) GROUND TERMINAL No.4 HOSE Up 30.: [California type only) ‘5" ’ LOCATING 45. Up Lefl/r PULSE SECONDAHYAIH M, Up INJECTION (PAIR) HOSE . CLUTCH K< CABLE R SWITCH CONNECTOR REAR BRAKE LIGHT SWITCH 2P CONNECTOR ‘ HORN WIRE % FAN MOTOR 2P \ LEFI’ REAR SPARK CONNECTOR / ‘3) PLUG WIHE PAIR HOSE RADIATOR LEFT FRONT FUEL HOSE SIPHON HOSE SPARK PLUG WIRE PAIR HOSE CRANKCASE BREATHER HOSE 1 -80 GENERAL INFORMATION ‘04 VTX1300C (1) VEHICLE SPEED SENSOR WIRE (2) SIDESTAND SWITCH WIRE (3) ALTERNATOR WIRE (4) STARTER MOTOR CABLE (5) No. 2 HOSE (California type only) [6) No.4 HOSE (California type only) (7) RADIATOR SIPHON HOSE I3) RESERVE TANK FILLER NECK HOSE I9) REGULATOR/RECTIFIER WIRE [10) CONNECTOR BOOT CONNECTOR BOOT: ALTERNATOR 3P CONNECTOR IGNITION SWITCH WIRE From ¢ Left] (9) 45" (2) NEUTRAL SWITCH 1-81 GENERAL INFORMATION '04 VTX13000 IGNITION SWITCH WIRE CONNECTOR BOOT: ALTERNATOR 3P CONNECTOR BATTERY GROUND CABLE MAIN WIRE HARNESS GROUNDCABLE TERMINAL CONNECTOR BOOT: -S|DESTAND SWITCH 2P CONNECTOR « VEHICLE SPEED SENSOR 3P CONNECTOR STARTER SIDESTAND SWITCH WIRE MOTOR CABLE CLUTCH CABLE STARTER MOTOR CABLE 1 -82 GENERAL INFORMATION '04 VTX13ODC PULSE SECONDARY AIR INJECTION (PAIR) MAINWIRE CONTROL VALVE HARNESS VACUUM From HOSE THROTTLE CABLES U” A THROTTLE 4 Left POSITION LE" ‘ ‘ SENSOR 3P Q @ Ivy CONNECTOR Up I * II ' ‘, E, FUEL TANK - W ' ¥ A‘ ‘ REAR BREATHER HOSE ’ V4 ~ R \J BRAKE PIPE "' ’ I. i . , I ' Q” / RIGHTREAR SPARK PLUG WIRE _ SPEEDOMETER MAIN WIRE WIRE HARNESS I]: SPEEDOMETER CONNECTORS RIGHTREAR SPARK @ REAR BRAKE LIGHT PLUG WIRE 45° CRANKCASE PAIR HOSE SWITCH WIRE [Clamp BREATHER HOSE ax tape position) OIL PRESSURE SWITCH WIRE 1-83 GENERAL INFORMATION '04 VTX13OOC From I Left — a Rigm INTAKE MANIFOLD WATER HOSES Up I T ‘ 'J/ T WATER PIPE (between cylinders) CONNECTOR ROOT: FUEL TANK BREATHER - REAR TURN SIGNAL CONNECTORS HOSE (Except California we) I BRAKE/TAILLIGHT CONNECTORS 4 LICENSE LIGHT CONNECTORS MAW WIRE HARNESS BATTERY POSITIVE m FUSE BOX CABLE TERMINAL BA‘I'I'EHY POSITIVE (+) CABLE WATER RETURN HOSE Q} _/ MAINWIRE HARNESS FUSE BOX WIRE STARTER RELAY SWITCH WIRE STARTE R STARTER MOTOR CABLE RELAV SWITCH BA'I'I’ERV POSITIVE I+) CABLE STARTER MOTOR CABLE TURN SIGNAL RELAY BATTERY POSITIVE (4) CABLE 1 -84 GENERAL INFORMATION '04 VTX13000 (1) No, 4 HOSE (California type only) (2) RADIATOR SIFHON HOSE (3) MAIN WIRE HARNESS (4) FUEL TANK DRAIN HOSE (5) WATER RETURN HOSE I6) REAR BRAKE PIPE FRAME PIPE FRAME PIPE (1) FRAME PIPE CONNECTOR BOOT: - IGNITION SWITCH 3P CONNECTOR ] - IGNITION PULSE GENERATOR 2P 'GN'TION CONTROL MODULE “0"” CONNECTOR -REGULATOR/RECTIFIER 4P CONNECTOR - NEUTRAL szTCII CONNECTOR _ REAR IGNITION COIL \ REAR IGNITION COIL BATTERY GROUND CABLE 2” CONNECTOR BATTERY POSITIVE (+l TERMINAL 1 -85 GENERAL INFORMATION '04 vrxnouc OIL PRESSUREij (I _.> From J J 4e.) / OIL PRESSURE SWITCH WIRE OIL PRESSURE SWITCH WIRE FRAME CROSS PIPE REGULATOR/RECTIFIER WIRE g7\ / , FUEL TANK EREATHER HOSE RESERVE TANK OVERFLOW HOSE MUFFLER BRACKET FUEL TANK BREATHER HOSE % REGULATOR/RECTIFIER RADIATOR RESERVE TANK 1 -86 GENERAL INFORMATION ’04 vrxuooc REAR BRAKE PIPE REAR BRAKE HOSE JOINT STOPPER REAR BRAKE LIGHTSWITCH WIRE OIL PRESSURE SWITCH WIRE REAR BRAKE HOSE 1 -87 GENERAL INFORMATION '04 VTX1300C (F) (G) (1) \ Reverse side of the rear fender: \ INNER GRAB \ RAIL I K REAR FENDER 11) LEFT REAR TURN SIGNAL LIGHT WIHE (2) LICENSE LIGHT WIRE (3) RIGHT REAR TURN SIGNAL LIGHT WIRE (4) BRAKE/TAILLIGHT WIRE 1 -88 RIGHT REARTURN SIGNAL LIGHT \ LEFT REAR TURN LICENSE LIGHT SIGNAL LIGHT GENERAL INFORMATION EVAPORATIVE EMISSION (EVAF) CONTROL SYSTEM (California type only) '04 VTX‘IJOoC EVAF CANISTER PURGE VALVE No.10VACUUM HOSE No. 4 HOSE No. 4 HOSES EVAF CARBURETOR AIR VENT (CAV) CONTROL VALVE «an O " '7' '1 “#111511. \' r ’11 . ‘ _ I © \ .r a, :7» No.6HOSE ——/ F I , v1 No, 11 VACUUM HOSE { a r/ f a? SWINGARM PIVOT No, 2 HOSE EVAP CANISTER 1 -89 GENERAL INFORMATION CABLE & HARNESS ROUTING: ’05 — '07 VTX13OOC RIGHTHANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE RIGHT HANDLEBAR SWITCH 9P (red) CONNECTOR LEFTHANDLEBAR SWITCH 6P (black) CONNECTOR RIGHT HANDLEBAR LEFI' HANDLEBAR SWITCH 6P (blue) CONNECTOR SWITCH WIRE fi TURN SIGNALLIGHT CONNECTORS LEFT HANDLEBAR SWITCH V)IIRE V ‘j‘ FOG LIGHT3P CONNECTOR ’) ‘ \_‘ (Option) ‘ I X "m MAINWIRE HARNESS HEADLIG HT 3P CONNECTOR LEFT FRONT TURN RIGHTFRONTTURN SIGNAL LIGHTWIRE SIGNAL LIGHT WIRE 0' MAIN WIRE IE, Ii 4 e I HARNESS MAIN WIRE HARNESS HORN _ _ (for fog light; option) RIGHT FRONTTURN SIGNAL LIGHT WIRE LEI-T FRONT TURN SIGNAL LIGHT WIRE 1 -90 GENERAL INFORMATION '05 — '07 VTX1SQDC SPEEDOMETER WIRE FUEL TANK TOP COVER SPEEDOMETER WIRE I SPEEDOMETER WIRE SPEEDOMETER SPEEDOMETERCONNECTORS (See page 1-96 for detail) 1-91 GENERAL INFORMATION '05 - '01 VTX1300C BRAKE HOSE JOINT STOPPER LEFT HANDLEBAR SWITCH WIRE THROTTLE CALES CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE RIGHT HANDLEBAR LEFI' HANDLEBAFI SWITCH WIRE SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE TH ROTTLE CAB LES 1 -92 GENERAL INFORMATION '05 - '07 VTX130IJC WATER HOSE WATER HOSE (From (From rear cylinder) front cylinder) WATER RETURN HOSE (To water pump) THERMOSTAT HOUSING VACUUM HOSE (California Iype:No.1D VACUUM HOSE) GROUND TERMINAL No. 4 HOSE Up My (California type only] LOW'NG ‘5“ ”” fillfifiiéfifllfiéfiééfi 1... Ed)“ CLIP Lsfi— p _\ _ Up ‘ \ 2:31;“ M ,— ll. OILPRESSURE PM SWITCH CONNECTOR \ REAR BRAKE LIGHT SWITCH 2P CONNECTOR HORN WIRE T g I? From FAN MOTOR 2P . LEFT REAR SPARK CONNECTOR PLUG WIRE PAIR HOSE RA DIATOR LEFT FRONT SPARK PLUG WIRE PAIR HOSE FUEL HOSE SIPHON HOSE CRANKCASE EREATHER HOSE 1 -93 GENERAL INFORMATION '05 - '07 v1'x1aooc (1) IGNITION SWITCH WIRE I2) SIDESTAND SWITCH WIRE [3) ALTERNATOR WIRE (4) STARTER MOTOR CABLE (5) No.2 HOSE (California type only) (6) No. 4 HOSE (California type only) (7| RADIATOR SIPHON HOSE (8) RESERVE TANK FILLER NECK HOSE (9] NEUTRAL SWITCH WIRE WIRE BAND VEHICLE SPEED l1) SENSOR WIRE K 1293' ‘y’I all" 12) s 1"," y .M l7) l8) 1 I atlfiézw (3) ‘5’ (4) P‘ (3) (2) (4) NEUTRAL SWITCH 1 -94 GENERAL INFORMATION '05 — '07 VTx1sooc VEHICLE SPEED ‘ SENSOR WIRE IGNITION SWITCH WIRE BATTERY GROUND CABLE ALTERNATOR WIRE o IGNITION PULSE GENERATOR WIRE a a ' \ 4 / GROUNDCABLE \ ,’ TERMINAL "r ’ , q MAIN WIRE HARNESS " (‘6 V II \ L/ 1/ I I y (6" 0 r I a CONNECTOR BOOT: T - SIDESTAND SWITCH 2P CONNECTOR - VEHICLE SPEED SENSOR 3P CONNECTOR SIDESTAND STARTER ' SWITCH WIRE MOTOR CABLE ‘ CLUTCH CABLE O a O STARTER MOTOR CABLE a 1 -95 GENERAL INFORMATION '05 — '07 VTx1sooc . INSTRUMENTATION ENGINE PULSE SECONDARY AIR INJECTION (PAIR) COOLANT TEMPERATURE SENSOR CONTROL VALVE MAINWIRE HARNEss VACUUM F ' HOSE THRO'I'I'LECABLES “9 I" THROTTLE 4 POSITION Le“ * Leh‘ w SENSOR 3P me Q CONNECTOR I U % vfiigm “A.” FUELTANK . V ’ all BREATHER HOSE ' ,V ‘1 V a. ‘ r RIGHTREAR I ' .J 5, SPARK V A < ‘ M PLUGWIRE a? @ I Egg / 9,4 SPEEDOMETER MAINWIRE !,§ / WIRE HARNESS a I 3)!) pm“ :- PAIR PIPE: 1 I I A I /I FUELHO , 8 up SFEEDOMETER 4 CONNECTORS RIGHTREAR . (Q 9 45" BREATHER HOSE anape posmon) SPARK \J\ ‘ K REAR BRAKE LIGHT PLUG WIRE \ CRANKCASE PAIR HOSE SWITCH WIRE (Clamp OIL PRESSURE SWITCH WIRE 1 -96 GENERAL INFORMATION ’05 — '07 VTX13000 Front I Len k —- RighI INTAKE MANIFOLD WATER HOSES WATER PIPE (between cylinders) CONNECTOR BOOT: FUEL TANK BREATHER A REAR TURN SIGNAL CONNECTORS HOSE (Except California type) - BRAKE/TAILLIGHT CONNECTORS - LICENSE LIGHT CONNECTORS MAIN WIRE HARNESS BATTERY POSITIVE (+1 FUSE BOX CABLE TERMINAL BATTE RY P0 SITIVE I+I CABLE WATER RETURN HOSE MAINWIRE HARNESS STARTER RELAY SWITCH WIRE STARTE R STARTER MOTOR CABLE RELAY SWITCH BATTERY POSITIVE (+) CABLE STARTER MOTOR CABLE TURN SIGNAL RELAY BATTERY POSITIVE (4») CABLE 1 -97 GENERAL INFORMATION '05 — '07 vrx1aooc (1) No.4 HOSE (California type only] (2) RADIATOR SIPHON HOSE I3) MAIN WIRE HARNESS I4) FUEL TANK DRAIN HOSE (5] WATER RETURN HOSE I6) REAR BRAKE PIPE CONNECTOR BOOT: ALTERNATOR 3P CONNECTOR I7) REGULATOR/RECTIFIER WIRE (3) FRAME PIPE (4%“ Q ML. A ‘5' “’© .@ FRAME PIPE / x (z) (a) FUSE BOX CONNECTOR BOOT: v IGNITION SWITCH 3P CONNECTOR - IGNITION PULSE GENERATOR 2P CONNECTOR - REGULATOR/RECTIFIER 4P CONNECTOR IGNITION CONTROL MODULE (ICM) - NEUTRAL SWITCI-I CONNECTOR REAR IGNITION COIL REAR IGNITION COIL 2P CON NECTOR BATTERY GROUND CABLE BA‘I'I’ERY NEGATIVE (—I TERMINAL BA'I'I'ERY POSITIVE (+I TERMINAL 1 -98 GENERAL INFORMATION '05 — '07 VTX1300C OIL PRESSURE SWITCH 1/ / —-> From \JS/ , \I on. PRESSURE SWITCH WIRE [W SWITCH WIRE FRAME CROSS PIPE RESERVE TANK OVERFLOW HOSE MUFFLER BRACKET FUEL TANK BREATHER HOSE % REGULATOR/RECTIFIER RADIATOR RESERVE TANK 1 -99 GENERAL INFORMATION '05 - '07 VTX13OOC REAR BRAKE PIPE REARBRAKE HOSE JOINT STOPPER REAR BRAKE LIGHT SWITCH WIRE OIL PRESSURE SWITCH WIRE REAR BRAKE HOSE JOINT 1-100 GENERAL INFORMATION '05 - '01 vrx1aaoc (F, (A) (c) m (4) I4] % ‘ [1) (3) (a) (21 (3) (GI (4) (2) $3 (1, (3) (1I Reverse side of me rear fender: , I ‘F I \ INNERGRAB \ RAIL I GREEN WIRE '/I REAR ————> \ FENDER BROWN WIRE I1) LEFI' REAR TURN SIGNAL LIGHT WIRE (2) LICENSE LIGHT WIRE RIGHTREARTURN [3) RIGHT REAR TURN SIGNAL LIGHT WIRE S|GNAL L|GHT [4) BRAKE/TAILLIGHT WIRE LICENSE LIGHT LEFT FIEAFI TURN SIGNAL LIGHT 1-101 GENERAL INFORMATION EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only) '05 - '07 VTX1300c EVAP CANISTER PURGE VALVE No.10 VACUUM HOSE No.4 HOSES EVAP CARBURETOR AIR VENT (CAV) CONTROL VALVE I _’ ty ‘ ~\\ /' “at: ‘ I" f - FRAME CROSS PIPE /// — WM EVAP CANISTER 1-102 GENERAL INFORMATION CABLE & HARNESS ROUTING: After '07 VTX13OOC RIGHTHANDLEBAR SWITCH WIRE LEFT HANDLEBAR SWITCH WIRE RIGHT HANDLEEAR SWITCH 9P (red) CONNECTOR \ O LEFT HANDLEBAR SWITCH " 6P (black) CONNECTOR RIGHT HANDLEBAR LEFTHANDLEBAR SWITCH SWITCH WIRE 6P (blue! CONNECTOR TU RN SIGNAL LIGHT CONNECTORS LEFTHANDLEBAR SWITCH WIRE FOG LIGHTSPCONNECTOR o [‘0 ‘ ( p. n) I ’ \: V HEADLIGHT 3F CONNECTOR MAINWIRE I ,43’ \\ v HARNESS —’ ‘ “~ ’ ‘ A SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE ’2‘" ‘ l9.- ° HARNESS m V MAIN WIRE HARNESS / ’ ’ (for fog light; option) RIGHT FRONTTURN LEFT FRONT TURN \ HORN RIGHT FRONT TURN SIGNAL LIGHT WIRE LEFT FRONT TURN SIGNAL LIGHT WIRE 1-103 GENERAL INFORMATION After '07 VTX1300C SPEEDOMETER WIRE FUEL TANK TOP COVER SPEEDOMETER WIRE O o 132? I SPEEDOMETER WIRE SPEEDOMETER SPEEDOMETEH CONNECTORS (See page 1-110 for detail) 1-104 GENERAL INFORMATION After '07 VTX1300¢ BRAKE HOSE JOINT STOPFER LEFT HANDLEBAR SWITCH WIRE THROTTLE CABLES CLUTCH CABLE RIGHT HANDLEBAR SWITCH WIRE RIGHTHANDLEBAR LEFT HANDLEBAR SWITCH WIRE SWITCH WIRE RIGHTHANDLEBAR SWITCH WIRE FRONT BRAKE HOSE THROTTLE CABLES 1-105 GENERAL INFORMATION After '07 VTX13000 WATER HOSE WATER HOSE (From [From rearcylinder) front cylinder) WATER RETURN HOSE (To water pump) THERMOSTAT HOUSING GROUND TERMINAL No.4HOSE (California Iype only) PULSE SECONDARY AIR INJECTION (PAIR) . CONTROL VALVE CLUTCH \ ‘ RADIATOR CABLE L ‘ \SIPHON HOSE s -. ‘ I OILPRESSUR ; ‘ , SWITCH / CONNECTOR '5' REAR RRAKE h'K LIGHT SWITCH I 2F CONNECTOR 1 HORNWIRE V I I 7 © i \ 45° »-\ A (—1) FAN MOTOR 2P \ " LEFT REAR SPARK \ CONNECTOR " PLUG WIRE PAIR HOSE LEFT FRONT FUEL HOSE VACUUM HOSE (California SPARK PLUG WIRE PAIR HOSE type:No.1D VACUUM HOSE) CRANKCASE BREATHER HOSE 1-106 GENERAL INFORMATION After '07 vrx1zooc ( \ ‘” FUEL\H0’SE \/ " %E&“ \4//\/ / / ‘ \§\) 1" WATER HOSE From carburetor To from cylinder head V a To water pump —> To EVAP canister Front <— 4> To radiator reserve ‘ank From air cleaner housing -» To Khermoswt housing 4" No. 4 HOSE (California Wpe only) PULSE SECONDARY SIPHON HOSE AIR INJECTION (PAIR) CONTROL VALVE 1-107 GENERAL INFORMATION After '07 v1'x1sooc (1) IGNITION SWITCH WIRE (Z) SIDESTAND SWITCH WIRE (3) ALTERNATOR WIRE (4) STARTER MOTOR CABLE (5) No. 2 HOSE (California type only) (6) No. 4 HOSE (California type only) (7) RADIATOR SIPHON HOSE (3) RESERVE TANK FILLER NECK HOSE (9) NEUTRAL SWITCH WIRE WIRE BAND VEHICLESPEED (1) SENSOR WIRE (5) (9) (4) (3) h. «4X @Q‘ A Ill?”\ 1% (2) w) M, 33;;4é2“!ggfilfik ” ‘ , 34:4" ., ¢fim«%h. 'a .. / \ (3) / \ \ 45° (2) (4) NEUTRAL SWITCH 1-108 GENERAL INFORMATION After '07 VTx1sooc VEHICLE SPEED SENSOR WIRE IGNITION SWITCH WIRE BATTERV GROUND CABLE ’ ALTERNATOR WIRE ‘ IGNITION PULSE \l/\GENERATOR WIRE MAIN WIRE HARNESS J), / I (a; 4am?" I ’q GROUNDCABLE TERMINAL fi. . f CONNECTOR BOOT: ~SIDESTAND SWITCH 2P CONNECTOR - VEHICLE SPEED SENSOR 3P CONNECTOR SIDESTAND STARTER SWITCH WIRE MOTOR CABLE CLUTCH CABLE STARTER MOTOR CABLE 1-109 GENERAL INFORMATION After '07 \rrx1zooc WATER HOSE JOINT To water pump J.’\ /« WATER HOSE PAIR PIPE 5/ From carburetor \ \ MAIN WIRE INSTRUMENTATION ENGINE HARNESS COOLANT TEMPERATURE SENSOR PULSE SECONDARY THROTTLE POSITION AIR INJECTION (PAIR) CONTROL VALVE SENSOR 3P CONNECTOR MAIN WIRE F HARNESS mm 4 THROTTLE ¢ 0 CABLES up Le“ 90 FIDI'I‘ A -> REAR FUEL TANK RAKE PIPE EREATHER HOSE 7 I I / PAIR PIPE (pp ' ’ I l ‘ Y UpT ’Highl I ’1’ " SPEEDOMETER MAIN WIRE WIRE HARNESS 0Y4 7 “' mg? \ vi», if SPEEDOMETER Q I\ V 5.» CONNECTORS I , \ Q I .\ 3311*“ w CRANKCAm\ PAIR HOSE PLUG WIRE BREATHER HOSE REAR BRAKE LIGHT SWITCH WIRE (Clamp at tape position) OIL PRESSURE SWITCH WIRE 1-110 GENERAL INFORMATION After ‘07 VTX1300C From FUEL HOSE I CARBURETOR Leh r ~ Right INTAKE MANIFOLD 7< WATER HOSES CONNECTOR BOOT: FUEL TANK BREATHER » REAR TURN SIGNAL CONNECTORS HOSE (Excap‘ Californiatype) - BRAKE/TAILLIGHT CONNECTORS - LICENSE LIGHT CONNECTORS MAIN WIRE HARNEss BATTERY POSITIVE 1+) CABLE TERMINAL FUSE BOX BATTERY POSITIVE (+) CABLE MAINWIRE HARNESS FUSE BOX WIRE STARTER RELAV SWITCH WIRE STARTER STARTER MOTOR CABLE RELAY SWITCH BATTERY POSITIVE (+I CABLE STARTE R MOTOR CAB LE TU RN SIGNAL RELAY EATI'ERY POSITIVE (+) CABLE 1-111 GENERAL INFORMATION After '07 V‘rx1aooc (1) NOT 4 HOSE (California type only) (2) RADIATOR SIPHON HOSE (3) MAIN WIRE HARNESS Front a; m (4) FUEL TANK DRAIN HOSE ' T’ g (5) WATER RETURN HOSE Is) REAR BRAKE PIPE . (7) REGULATOR/RECTIFIER WIRE FRAME PIPE FRAME PIPE CONNECTOR BOOT: ALTERNATOR 3P CONNECTOR (5) FUSE BOX CONNECTOR BOOT: - IGNITION SWITCH 3P CONNECTOR ~ IGNITION PULSE GENERATOR 2P CONNECTOR - REGULATOR/RECTIFIER 4P CONNECTOR v NEUTRAL SWITCH CONNECTOR IGNITION CONTROL MODULE (ICM) REAR IGNITION COIL \ REAR IGNITION COIL 3 2? CONNECTOR BATTERY GROUND CABLE BATTERY NEGATIVE (—) TERMINAL BATTERY POSITIVE (+) TERMINAL 1-112 GENERAL INFORMATION Aher '07 vrx1aooc OIL PRESSURE SWITCH ’I‘/ —> Front QJ __r—‘ ‘©’ “I I :31 f \N OIL PRESSURE SWITCH WI OIL PRESSURE SWITCH WIRE FRAME CROSS PIPE RESERVE TANK OVERFLOW HOSE MUFFLER SWINGARM PIVOT BRACKET FUEL TANK EREATHER HOSE \ \ REGULATOR/RECTIFIER RADIATOR RESERVE TANK 1-113 GENERAL INFORMATION After '07 VTX1300C REAR ERAKE PIPE REAR BRAKE HOSE JOINT STOPPER REAR BRAKE LIGHTSWITCH WIRE OIL PRESSURE SWITCH WIRE REAR BRAKE HOSE 1-114 GENERAL INFORMATION After '07 V'I'X13DOC (FI ‘\ INNERGRAB \ RAIL GREEN WIRE I FENDER BROWN WIRE I1) LEI-T REAR TURN SIGNAL LIGHT WIRE (2| LICENSE LIGHT WIRE RIGHT REAR TURN (3) RIGHT REAR TURN SIGNAL LIGHT WIRE SIGNAL LIGHT (4) BRAKE/TAILLIGHT WIRE LICENSE LIGHT 1-115 GENERAL INFORMATION EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM (California type only) After '07 vrx1sooc To Carburetor To EVAF CAV control valve To PAIR contra! valve \ SOLENOIDVALVE TO :17an iaim \ 2P CONNECTOR anl 1 _. FUEL CUT»0FF EVAF CANISTER SOLENOID VALVE pURGE vALVE No. 4 HOSES ' To EVAP CAV SUB»AIR CLEANER comm Valve ¢< C) ° e E“: / EVAP , CARBURETOR 7>< // I r AIR VENT (CAV) No‘ 4 CONTROL VALVE O O HOSE m No. 5 \ Ng/GIHOSE HOSE O O \J \l J O O A \ SUB-AIR CLEANER- \Na. 10 VACUUM HOSE O NO. 11 VACUUM HosE m-EVAP CAV (To carburemr) CONTROL VALVE HOSE A? - FRAME CROSS PIPE No.4 HOSE H //{ No‘ 1 HOSE \ \ I N0. 2 HOSE > > \L/ EVAP OANISTER 1-116 GENERAL INFORMATION EMISSION CONTROL SYSTEMS SOURCE or EMISSIONS The U.S. Environmental Protection Agency, Transport Canada and California Air Resources Board (CARE) 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 (3,730 miles) after the time of sale to the ultimate purchaser, when operated and maintained according to the instructions provided Compliance with the terms of the Distributor's Limited Warranty for Honda Motorcycle Emission Control Systems is necessary in order to keep the emissions system warranty in effect. The combustion process produces carbon monoxide, oxides of nitrogen and hydrocarbons Control of hydrocarbons and oxides of nitrogen 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 is toxic. Honda Motor Co., Ltd. utilizes lean carburetor settian as well as other systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. CRANKCASE EMISSION CONTROL SYSTEM The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor. CARBURETOR DRAIN HOSE <:| FRESH AIR _ BLOW-BY GAS 1-117 GENERAL INFORMATION EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) The exhaust emission 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. The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gases in the exhaust port. Fresh air is drawn into the exhaust port by the function of the Pulse Secondary Air Injection (PAIR) control valve. This charge of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon dioxide and water vapor. The reed valve prevents reverse air flow through the system. The PAIR control valve reacts to high intake manifold vacuum and will out off the supply of fresh air during engine deceleration, thereby preventing afterburn in the exhaust system. No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended. PAIR CONTROL VALVE AIR CLEANER EXHAUST PORT <3: Fresh air <— Exhaust gas OXIDA‘HON CATALYTIC CONVERTER This motorcycle is equipped with an oxidation catalytic converter. The oxidation catalytic converter is in the exhaust system. Through chemical reactions, it converts HC and CO in the engine’s exhaust to carbon dioxide (C02) and water vapor. 1-118 GENERAL INFORMATION EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) This model complies with California Air Resources Board (CARE) evaporative emission requirements, Fuel vapor from the fuel tank is routed into the evaporative emission (EVAP) canister where it is adsorbed and stored while the engine is stopped. When the engine is running and the EVAP canister purge valve is npen, fuel vapor in the EVAP canister is drawn into the engine through the carburetor. At the same time, the EVAP carburetor air vent (CAV) control valve is open and air is drawn into the carburetor through the valve. ’03 — '07 model: EVAP CANISTER PURGE VALVE EVAP CAV CONTROL VALVE CARBURETOR AIR CLEANER <2: Fresh air EVAP CANISTER _ Fuel vapor FUEL TANK 1-119 GENERAL INFORMATION After '07: FUEL CUT-OFF SOLENOID VALVE’ EVAP CANISTER PURGE VALVE EVAP CAV CONTROL VALVE CARBURETOR SUB»AIH CLEANER R INTAKE MANIFOLD AIFI CLEANER <3 F <‘—,_—| Fresh air EVAP CANISTER h Fuel vapor FUELTANK *The fuel cubofl solenoid valve is controlled by the ICM. The float chamber air vent passage is changed from atmosphere into throttle bore and the float chamber pressure will be the same as throttle bore pressure to stop fuel supply when the rev limiter is operated or the engine stop switch is turned to OFF while the engine running. 1-120 - GENERAL INFORMATION NOISE EMISSION CONTROL SYSTEM TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: U.S. Federal law prohibits, or Canadian provincial law may prohibit the following acts or the causing thereof: (1 l 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 vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use; or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED T0 CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: . Removal of or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. u Removal of, or puncturing of any part of the intake system. . Lack of proper maintenance. . Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer, Fuel Permeation Emission Control System This motorcycle complies with the Fuel Permeation Emission Control regulations of the U.S. Environmental Protection Agency (EPA), California Air Resources Board (CARE), and Environment Canada (EC). The fuel tank, fuel hoses, and fuel vapor charge hoses used on this motorcycle incorporate fuel permeation control technologies. Tampering with the fuel tank, fuel hoses, or fuel vapor charge hoses to reduce or defeat the effectiveness of the fuel permeation technologies is prohibited by federal regulations. atom—n 1-121 GENERAL INFORMATION EMISSION CONTROL INFORMATION LABELS An Emission Control Information Label is located on the rear fender ('03 ~ ’07 model) or swingarm (After ’07) as shown. It gives basic tune-up specifications, VEHICLE EMISSION CONTROL INFORMATION UPDATE LABEL After making a high altitude carburetor adjustment, attach an update label on the rear fender ('03 — ’07 model) or fuel tank (After ’07) as shown below. Instructions for obtaining the update label are given in Service Letter No.132, When readjusting the carburetor back to the low altitude specifications, be sure to remove this update label, '03 - '01 V'IX13005/VTX1300R: m _ :07 mmoc; EMISSION CONTROL INFORMATION ’ EMISSION CONTROL INFORMATION LABEL IUVS.A.:1 label/Canada: 2 IabeISI LABEL (U.S.A.:1 label/Canada: 2 labels] \ / / I VACUUM HOSE %PDATE LABEL u ‘ my ROUTING DIAGRAM / (49 state/ VACUUM HOSE FOUT'NG WNW LABEL ('03 Bl '04 only) Canada type) DIAGRAM LABEL (’04 only) After '07: FUEL TANK SWINGAFIM EMISSION CONTROL INFORMATION LABEL IU.S.A,:1 label/Canada: 2 labels) 1-122 GENERAL INFORMATION VACUUM HOSE ROUTING DIAGRAM LABEL (’03 81 ’04 California type only) The Vacuum Hose Routing Diagram Label is located on (he rear fender near the frame cross pipe. '08 VTX13005: '04 VTX13IJOS/'D4 VTX13OOC: Vacuum Hose Routin Diagram California vehicle Calvlomia vehche EVA? cAv EVA? ow 9.01M Comm m. Inlet MaNIoId meol mm Manlfmd «mag PAIR leml Va‘ve (i \/ i \/ EVAP Camslev i 3 PAIR comm wam mm EVAP Camslev 1-123 MEMO \ 2. FRAME/BODY PANELS/ EXHAUST SYSTEM SERVICE INFORMATION - -- 2-2 TROUBLESHoonG ............................... .. 2.2 SEATS: VTX13ODS/VTX1300R/VTX1300T2-3 SEAT: VTX13OOC 2-3 BACKREST/SADDLEBAGS: VTX1300T 2-4 WINDSCREEN: VTX1300T ----------------------- --2-5 SIDE COVER- 2-6 CYLINDER HEAD SHROUD --------------------- -- 2-6 FUEL TANK ............................................... .. 2.7 STEERING SIDE COVER -------------------------- -- 2-8 LEFT CRANKCASE REAR COVER ----------- -- 2-8 FOOTREST (VTX13008/VTX1300R/ VTX1300T)/FOOTPEG (VTX13006) -------- -- 2-9 REAR FENDER ........................................ .. 2.11 EXHAUST SYSTEM ............................... .. 2.12 FRAME/BODY PANELS/EXHAUST SYSTEM SERVICE INFORMATION GENERAL - This section covers removal and installation of the.I body panels, fuel tank, and exhaust system. - Work in a well ventilated area. Smoking or allowing flames or sparks in the working area of where gasoline is stored can cause a fire or explosion. 0 Always replace the gaskets when removing the exhaust system. 0 Always inspect the exhaust system for leaks after installation. TORQUE VALUES Hose/cable guide bolt (VTX1300T) Fuel tank mounting bolt Fuel valve nut Fuel valve lever screw Left crankcase rear cover bolt Riderfootrest mounting bolt (VTX13OOSNTX13OORNTX1300Ti Rider footpeg mounting bolt (VTX1300C) Gearshift arm pinch bolt Brake hose oil bolt Exhaust pipe joint nut Muffler band bolt Muffler mounting bolt Exhaust pipe joint stud bolt TROUBLESHOOTING Excessive exhaust noise - Broken exhaust system - Exhaust gas leak Poor performance 0 Deformed exhaust system - Exhaust gas leaks - Clogged muffler 21 N-m (2.1 kgf-m, 15 Ibf-ft) ALOC bolt: replace with a new one. 18 N‘m (1.9 kgf-m, 141bf-ft) 34 Nut (35 kgf-m, 25 lbf-ft) 1 N-m (0.1 kgf-m, 0.7 lbf—ftl ALOC screw: replace with a new one. 10 Nm (1.0 kgf-m, 7 Ibf-ftl 39 N-m (4.0 kgfvm, 29 (bf-fl) 39 N-m (4.0 kgf-m, 29 Ibf-ft) 12 N-m (1.2 kgf-m, 9 |th) 34 N-m (35 kgf-m, 25 Ibf-ft] 23 N-m (23 kgf-m,17|bf-ft) 17 N-m (1.7 kgf‘m,13|bf-ft) 34 Nrm (3.5 kgf-m, 25 ibf~ft) See page 2-13 2-2 FRAME/ BODY PANELS/ EXHAUST SYSTEM SEATS: VTX13OOS/VTX1300R/ VTX1300T Install by fnsemrlg the seat prong under me ralsed llp Of the frame properly REAR SEAT Remove the following: — rubber plug (from the 6mm bolt head) 6-mm bolt — two 8-mm bolts and collars After '06: i — seat strap — rear seat y 8 mm BOLTS Installation is in the reverse order of removal. © STRAP FRONT SEAT Remove the following: — ’03— '06 model: two bolts After ’06: two bolts and washers - Tront seal [pull it back) Installation is in the reverse order of removal. SEAT: VTX13OOC Install by insemng Installation is in the reverse order of removal. the seat prong under the ralseo Up of the frame properly Remove the following: — cap nut — socket bolts .— seat SEAT BO LTS FRAME/BODY PANELS/EXHAUST SYSTEM BACKREST/SADDLEBAGS: VTX1300T Remove the {our bolts and backrest. BACKREST ' ‘ » Remove the bolts, flange collars and saddlebag from the saddlebag stay, Left and right saddlebag removal procedure is the same. Installation is in the reverse order of removal, - SADDLEBAG Remove the flange bolts, collars, saddlebag stay, and backrest mounting bracket. Left and right saddlebag stay removal procedure is the same. Installation is in the reverse order of removal. BRACKET STAY 2-4 FRAME/BODY PANELS/EXHAUST SYSTEM WINDSCREEN: VTX1300T Remove the nuts, bolts, washers, collars, and wind- screen. Installation is in the reverse order of removal. FLANGE COLLARS WINDSCREEN NUTS N ./e BOLTS AND WASHERS COLLARS Remove the nuts. bolts, and the lower steyr Remove the bolts, cable guides, and upper stay from the fork (op bridge. Replace the cable Installation is in the reversa order of removal. guide bolts mm _ _ _ new ones >TOROUE‘ Gulde bolt. 21 Nm (2.1 kgf-m,15let) Route the hose, wires and cables into the cable guides properly (page 1-65). TH ROTI'LE CABLES FRAME/BODY PANELS/EXHAUST SYSTEM SIDE COVER Be careful not To break a! defalm the Side Cover bosses. Be careful not w dislodge the grommet REMOVAL Release the boss on the rear side of the cover and remove the side cover from the stays INSTALLATION Make sure the mounting rubbers are installed on the stays securely. Align the grooves in the side cover with the stays and insert the boss into the grommet to install the side cover. CYLINDER HEAD SHROUD Take care no! to break the [105595 Be careful no! to ars/odge the grommet Carefully raise the shroud and release the three bosses offtha grommets to remove it, Installation is in the reverse order of removal. SIDE COVER GROOVES SHROUD FUEL TANK Remove the following: — seatls) (page 2-3) — front right cylinder head shroud (page 2-6) Remove the mounting bolt. Turn thefuel valve to “OFF”. Disconnect the fuel hose and fuel valve vacuum hose (After ’03), and breather hose (California: No‘ ‘I '03 — '07 model: FUEL HOSE ('03 model) hose). FRAME] BODY PANELS/ EXHAUST SYSTEM Release the connector boot from the clamp and dis- connect the speedometer 7P (green) connectors. Slide the fuel tank rearward to remove it from the rubber mounts. Installation is in the reverse order of removal. TORQUE: 19 N-m (1.9 kgf-m, 14 lbf-ft) After installation, start the engine and check the fuel line for leakage. CO NECTORS BREATHER HOSE (California: No. 1 hose) After '07: FUELTANK l . BREATHEH % ; ‘ HOSE (California: \\ ' CONNECTORS N0-1 hose) \ ‘ ‘ 3' \ ‘2\\ \ VACUUM HOSE FUEL HOSE 2-7 FRAME/BODY PANELS/EXHAUST SYSTEM STEERING SIDE COVER Remove the fuel tank (page 2-7). Remove the retaining clip by sliding it back, off of v ‘ the covers, STEERING SIDE COVER Release the bass from the frame and remove the ' side cover from the fuel tank mounting stay. Remove the setting rubber. Installation is in the reverse order of removal. 1’ \ SETTING RUBBER LEFT CRANKCASE REAR COVER Remove the five bolts and the left crankcase rear covert ¢ Ally/l the bolt holes Installation is in the reverse order of removal. ~ % WWW TORQUE: to NM (1.0 am, 7 lbf~ftl LEFTCRANKCASE REAR COVER BOLTS 2-8 FRAME/ BODY PANELS] EXHAUST SYSTEM FOOTREST (VTX13OOS/VTX1300RI VTX1300TIIFOOTPEG IVTX1300C) ASSEMBLY REMOVAL/ INSTALLATION LEFT SIDE Remove the left crankcase rear cover (page Z-al. If the gee/shift Remove the following: pedal willbe 7 pinch bolt remaved, lousen r gearshift arm the pedalplvatbolt ~ two mounting bolts — left footrest assembly (VTX1300$NTX1300RNTX1300T) left ioolpeg assembly (VTX1300C) — footrest (VTX13005NTX1300R/VTX1300T: page 2-10] Installation is in the reverse order of removal. NOTE' - When installing the gearshift arm, align the slit of the arm with the punch mark on the spindle. TORQUE: Mounting bolt: 39 N-m (4.0 kgf-m, 19 lbf—ft) Pinch bolt: 12 N-m (1,2 kgf-m. 9 IM-fl) FOOTREST ASSEMBLY FRAME/BODY PANELS/EXHAUST SYSTEM The exhaust sysr RIGHT SIDE ‘5’" “W” 500’ Drain the brake fluid from the rear brake hydraulic before removing S St 7 . the/igmsrderoor V em‘pagefi 5’ rest or footpeg. VTX13OOS shown: lA/hen removing the Remove the following: mibolt, cave/the — oil bolt and sealing washers end of the hose to r brake hose prevenrconraminar — two mounting bolts tron — brake light switch spring — rear brake light switch (from the switch holder) — right footrest assembly (VTX13OOSNTX1300RNTX1300Tl right footpeg assembly (VTX13ODCl r footrest (VTX13OOSNTX13OORNTX1300T: page 21 0) Always rep/ace rhe Installation is in the reverse order of removal. sealing washers TORQUE: 77 W" "5W 0”“ Mounting bolt: 39 N-m (4.0 kgf—m, 29 lhf-ft) on bolt: 34 N-m (3.5 kgf-m, 25 Ibf-ft) NOTE. I Fill and bleed the rear brake hydraulic system (page 15-7). - Adiust the brake light switch (page 3-18). SPRING FOOTREST REMOVAL] INSTALLATION (VTX13OOS/VTX1300R/VTX1300T) Remove the following: 7 E-clip and washer — pivot shaft footrest board > return spring A1:in grease to the Installation is in the reverse order of removal. l' I ' idl‘ ao res sr l g NOTE. area I insert the spring end into the hole in the footrest board. - When installing the pivot shaft, align the pivot holes in the footrest board and bracket while holding the spring end (bent sidel with a screw- driver. FOOTREST BOARD 2-10 FRAME] BODY PANELS] EXHAUST SYSTEM REAR FENDER Be careful not to deform or scratch the real fender Remove the following: — seatls) (page 23) — right side cover (page 2-6) — backrest and saddlebag stays (VTX1300T) (page 2-4) Remove the wire band and disconnect the connec- tors in the boot. Remove either the left or right rear shock absorber (page 1442). Place wooden blocks and shop towels or an equiva- lent between the rear wheel and fender to support the rear fender securelyt Remove the following: - two 8-mm bolts ('03 — '06) — four 10-mm bolts ('03- ’06) — two B-mrn bolts/washers [After '06) — four 1D-mm bolts/washers (After ’06) — shock absorber upper pivot bolt » grab rail — rear fender [take care not to damage the reflectors) Installation is in the reverse order of removal. VTX13005 shown: REAR FENDER GRAB RAIL CONNECTORS WASHERS After ’06 \/ M WASHERS f) 2-11 FRAME/BODY PANELS/EXHAUST SYSTEM EXHAUST SYSTEM REMOVAL Be ca/efu/ nar tn Remove the following: scratch the exhaust — four exhaust pipe joint nuts system. — two mounting nuts and washers — two mounting bolts — exhaust pipe/muffler assembly ~ gaskets '03 — ‘07 model: VTX13005 shown: GASKETS g! JOINT NUTS MOUNTING BOLTS (VTX13OOSNTX13OOR: 8 x 50 mm) Rear: Front: lVTX1BOOC: Front; 8 x 55 mm/ 0 Rear; 3 x 50 mm) 0;: (1p / I ’\ \ 2-12 FRAME/BODY PANELS/EXHAUST SYSTEM After '07: GASKETS g JOINT NUTS MOUNTING BOLTS (Front; 8 x 55 mm/Rear; 8 x 50 mm) FLANGE INSTALLATION If the joint stud bolts are loose, fighten them. Be sure to verify the dis‘ance from the top of the stud lo the cylinder haad as shown. 37-5 ' 33.5 mm 2-13 FRAME] BODY PANELS/EXHAUST SYSTEM it is important to follow these steps in order. NOTE: ° Always replace the gaskets with new ones 0 If the exhaust system was not separated, steps 1 and 2 are not necessary. '03 - '07 model: \rrx1aoosmx1aoon: (5)\ 1. Before mounting the exhaust system, assemble the front and rear mufflers by tightening the muf» fler joint bolts (2) and muffler band bolt (1). 2. Temporarily tighten the muffler bend bolts (3) and (4). a. Make sure new gaskets are installed in position. Install the exhaust pipe/muffler assembly by inserting the cylinder head studs into the exhaust flanges with the "UP" mark of the flange facing up, and install the exhaust pipe joint nuts [5) and (G). 4. Carefully align the bolt holes in the muffler and (7) stay, and install the mounting bolts (7) and the nuts with the washers. VTX13006: After mounting the exhaust system, tighten each fastener in the sequence below. 5. Tighten the muffler band bolt (1) and the muffler joint bolts (2). TORQUE: Band bolt: 17 N~m (1.7 kgfm, 13 lbl-ft) Joint bolt: 26 N-m (2.7 kgf-m, 20 lblaft) 6, Tighten the muffler band bolts (3) and [4) TORQUE: 17 MM (1.7 kgf-m, 13 [bf-ft) 7, Tighten each pair of exhaust pipe joint nuts (5) and (6) alternately in several steps TORQUE: 2.3 N-m (2.3 kgi-m, 17 Ibf-fl) 8. Tighten the mounting bolts (7). TORQUE: 34 N-m (3.5 kgf-m, 25 lhf‘ft) After '07: Tighten the exhaust pipe cover bolts if the exhaust cover was removed (page 2-15). After_insta||ation, inspect the exhaust system forleaks. (7) 2-14 FRAME] BODY PANELS/ EXHAUST SYSTEM DISASSEMBLY/ASSEMBLY NOTE: - If the exhaust pipe covers were removed, tempu— rarily install the exhaust pipe covers and bolts when installing the exhaust system onto the motorcycle, and tighten the cover bolts after exhaust system installation is completed. '03 — '07 model: During installation, align the cover holder with the tab of the flange retainer, REAR MUFFLER M UFFLER JOINT BOLTS EXHAUST PIPE COVER Heleasethe retainer tab and remove the bolts and retainer. VTX13006: GASKETS £3? MU FFLER JOINT BRACKET FRONT EXHAUST PIPE 2-15 FRAME/BODY PANELS/ EXHAUST SYSTEM After '07: During installation, align the cover holder with the ‘ tab of the flange retainer. REAR M UFFLER EXHAUST PIPE COVER MUFFLER JOINT BOLTS EXHAUST PIPE COVER REAR EXHAUST PIPE Releasethe retainer tab and remove the bolts and retainer‘ M UFFLERJOINT BRACKET FRONT MUFFLER GASKETS @ FRONT EXHAUST PIPE 2-16 SERVICE INFORMATION -- ---------- -- 3-2 MAINTENANCE SCHEDULE -------------------- -- 3-4 FUEL LINE ................................................. .. 3.5 THROTTLE 0PERATION--- ---------- -- 3-5 CARBURETOR CHOKE ----------------------------- -- 3-6 AIR CLEANER ............................................ .. 3.3 CRANKCASE BREATHER- ----------- -- 3.5 SPARK pLUG ............................................ .. 3.7 VALVE CLEARANCE ................................. .. 3.3 ENGINE OIL . - - - - . . . . . . -3." ENGINE OIL FILTER ................................ .. 3.11 ENGINE IDLE SPEED ------------------------------ -- 3.12 RADIATOR COOLANT- ...... .. 3.13 cooLlNG SYS-rEM ................................. .. 3.13 3. MAINTENANCE SECONDARY AIR SUPPLY SYSTEM 3-14 EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) ------------- -- 3.14 FINAL DRIVE OIL-u- BRAKE FLU") ......................................... .. 3.16 BRAKE pAD WEAR ................................. .. 3.17 BRAKE SYSTEM 3-18 BRAKE LIGHT SWITCH -------------------------- -- 3-18 HEADLIGHT A|M .................................... .. 3.13 CLUTCH SYSTEM 3-19 smESTAND: .......................................... .. 3.20 SUSPENSION ......................................... .. 3.20 NUTS, BOLTS, FASTENERS-- -3-21 WHEELS/TIRES ...................................... .. 3.21 STEERING HEAD BEARINGS ---------------- -- 3-21 3-1 MAINTENANCE SERVICE INFORMATION GENERAL - Place the motorcycle on level ground before starting any work. - The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in an open area orwith an exhaust evacuation system in an enclosed area. SPECIFICATIONS ITEM SPECIFICATIONS ?Thrott|e grip freeplay if 2~6mm (1/16—1/4in) Spark plug L Standard DCPRGE INGK), XUZOEPR-U (DENSO) i For extended high speed riding Spark plug gap DQPR7E (NGK), XUZZEFR-U (DENSO) 0.8 — 0.8 mm (0.031 - 0.035 in) Valve clearance l intake Exhaust 0.15 t 0.02 mm (0.006 1 0.001 in) 0.30 1 0.02 mm (0.012 t 0.001 in) Recommended engine oil Pro Honda 0N4 4-stroke oil (U.S.A. and Canada) or equivalent motor oil API service classification SG or Higher JASO T 903 standard: MA Viscosity: SAE 10W—30 Engine oil l After draining ' 3.5 liter (3.7 US qt, 3.1 Imp qt) capacity After draining/filter change 3.7 liter (3.9 US qt, 3.3 Imp qt) W After disassemny Engine idle speed 4.3 liter (4.5 US qt, 3.8 Imp qt) 900 i 100 rpm Recommended final drive oil Hypoid gear oil, SAE #30 Final drive oil l After draining 120 cm (4.1 US oz, 4.2 Imp oz) capacity 1 After disassemny 150 cm2 (5.1 US 01, 5.3 Imp oz) i Recommended brake fluid DOT4 brake fluid Clutch lever freeplay 10— 20 mm (3/8 — 3/4 in) Cold tire pressure Up to 90 kg (200 lb) Front 225 kPa (2.25 kgf/cmz, 33 psi) 108d Rear 225 kPa (2.25 kgf/cmz, 33 psi) Up to maximum Front 225kPa12.25 kgf/cm .33 psi) weight capacity Rear 250 kPa (2.50 kgf/cmz, 36 psi) 7 Tire size Front i VTXISOOS/ 140/80-17MC 69H VTX1300R/ l VTX13DOT l VTX1300C 110/90-19MC 62H Rear 170/80-15MC 77H Tire brand Front l VTX13OOS/ D404F (Dunlopl _ ‘ VTX‘I300R/ - ) VTX1300T VTX1300C F24G (Dunlopl / Rear K555J (Dunlopl Minimum tire tread depth Front 1.5 mm (0.06 in) L 77 Rear 2.0 mm (0.08 in) TORQUE VALUES Air cleaner cover screw Spark plug Valve adjusting screw lock nut Valve adjusting hole cap Timing hole Cap Timing hole cap cover socket bolt Engine oil filter cartridge Front engine oil drain bolt Rear engine oil drain bolt Final drive oil filler cap Final drive oil drain bolt Front master cylinder reservoir cap screw Rear brake reservoir mounting bolt TOOLS 3.5 N-m (0.4 kgivm, 2.6 lhf-ft) 14 N-m (1.4 kgf-m,1U lbf-fl) 22 Nm (2.2 kgf-m,16lbf‘ft) 15 N-m (1.5 kgf—m, 11 lbf-ft) 18 N-m (1.8 kgf-rn,13lbf-ft 10 N-m (1.0 kgf‘m, 7 Ibf-ft) 26 Nm (2.7 kgf-m,19lbf-ft) 30 N-m (3.1 kgf-m, 22 lbf‘ftl 30 N-m (3.1 kgf-m, 22 lbf-(t) 12 N-m (1.2 kgfvm, 9 lbf-ft) 20 N-m (2.0 kgl-m, 15 (bf-ft) 15 NW (02 kgf-m,1.1 lbf—ftl 10 N-m (1.0 kgfvm, 7 lbf-ft) MAINTENANCE Apply engine oil to the threads and Seating surface. Apply grease to the threads. Apply grease to the threads. Apply engine oil to the threads and seating surface. Valve adjusting wrench 07DMA-MEA0100 10-mm offset box wrench or 07908—KE90100(U.S.A. only) with Oil filter wrench 07HAA-PJ70101 or 07HAA—PJ70100 3-3 MAINTENANCE MAINTENANCE SCHEDULE Perform the Pre-ride inspection in the Owner's Manual at each scheduled maintenance period, I: Inspect and clean, adjust, lubricate or replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. The following items require some mechanical knowledge. Certain items (particularly those marked * and “) may require more technical information and tools. FREQUENCY WHICHEVER ‘I—I COMES FIRST ODOMETER READING (NOTE 1) REFERTO Q a PAGE X1,000 mi 0.6 4 8 l 12 16 I 20 24 ‘ITEMS NOTE X1,0DO km 10 6.4 12.8 19.2 25.6 32.0 38.4 * FUEL LINE I I I 3-5 7* THROTTLE OPERATION l | l I 3-5 7 ' ‘CAFIBURETOR CHOKE | | I 3-6 AIR CLEANER NOTE 2 R R 3—6 3 CRANKCASE BREATHER NOTE 3 I C C C C C I 3-6 IE ‘ SPARK PLUG I I I R l R I R 3-7 _ “ VALVE CLEARANCE I I l | | 3»8 Lu V ENGINE OIL NOTE 6 R I R R R 3-11 '5 ENGINE OIL NOTE 7 Initial = 600 mi 1,000 km) or 1 311 Lu month: R “F Regular: Every BJJOO mi (12,800 E km) or 12 months: Fl a ENGINE OIL FILTER ‘ E R R I R I R 3-11 ‘2 * IENGINE IDLE SPEED E I | r | I | I I | 342 E I RADIATOR COOLANT NOTE 4 i | I R 3-13 I IlcoouNG SYSTEM L i I | 3-13 _ * SECONDARY AIR SUPPLY SYSTEM [ ‘ | | | 3-14 * EVAPORATIVE EMISSION CONTROL SYSTEM NOTE 5 l I 3-14 A U! FINAL DRIVE OIL I I I R 3-15 E BRAKE FLUID NOTE 4 I I | R | I R 346 a BRAKE PADS WEAR I I | I | l I 3-17 E IBRAKE SYSTEM I l | | 3~18 S * BRAKE LIGHT SWITCH I I | 3-18 E * HEADLIGHT AIM | | 7| 3-18 5 CLUTCH SYSTEM I I I I I I I I 3-19 7 a SIDESTAND l I | $20 9 * SUSPENSION ; I I I 3-20 mg. * NUT, BOLTSIFASTENERS I I I | 3721 A .g H ‘WHEELS/TIRES I I | I | I I | I 3-21 2 ** STEERING HEAD'BEARINGS I I I I I I I I I I 3-21 * Should be serviced by an authorized Honda dealer, unless the owner has proper tools and service data and is mechanically qualified “' In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer NOTES: 1. At higher odometer reading, repeat at the frequency interval established here. 2. Service more frequency when riding in unusually wet or dusty areas. 3. Service more frequency when riding in rain or at full throttle. 4. Replace every 2 years, or at the indicated odometer intervals, whichever comes first. Replacement requires mechanical skill. 5 California type only. 6. '03 — '05 model 7. After '05 model MAINTENANCE FUEL LINE Remove the fuel tank [page 2-7). '03 model show i Check the fuel lines for deterioration, damage or leakage. Replace the fuel line if necessary. THROTTLE OPERATION Check for any deterioration or damage to the throta tle cables. Check the throttle grip for smooth opera- tion. Check that the throttle opens and automatically closes in all steering positions. If the throttle grip does not return properly, lubricate the throttle cables and overhaul and lubricate the throttle grip housing. For cable lubrication: Disconnect the throttle cables at their upper ends. Thoroughly lubricate the cables and their pivot points with a commercially available cable lubricant or a light weight oil. Heusmgadamaged If the throttle grip still does not return properly, or abnormally bent replace the throttle cables. With the engine idling, turn the handlebar all the pmnenhwme way to the right and left to. ensure that the Idle “We [mam/on speed does not change. lf Idle speed Increases, check the throttle grip freeplay and the throttle cable connection. Measure the throttle grip freeplay at the throttle grip flange. FREEPLAY: 2 —6 mm (1/16 - 1/4 in) Throttle grip freeplav can be adjusted at either end of the throttle cable. Minor adjustments are made with the upper adjuster. Loosen the lock nut, turn the adjuster as required and tighten the lock nut. ADJ U STER 3-5 MAINTENANCE Maior adjustments are made with the lower adjuster. Remove the air cleaner housing (page 5-7). Loosen the lock nut, turn the adjuster as required and tighten the lock nut. Recheck the throttle operation and install the air cleaner housing (page 5-7). CARBURETOR CHOKE This model uses a bypass air volume control choke system controlled by the starter valve. The starter valve opens the bypass air circuit via a cable when the choke knob on the left side of the frame is pulled out. Check for smooth choke knob operation. Lubricate the choke cable if the operation is not smooth. , CHOKE KNOB AIR CLEANER Do not lose the Wars: washers on each screw NOTE. ' The viscous paper element type air cleaner can- not be cleaned because the element contains a dust adhesive. - If the motorcycle is used in unusually wet or dusty areas, more frequent inspections are required Remove the five special screws and the air cleaner cover. Remove the air cleaner element from the air cleaner housing. ’7 ELEMENT AIR CLEANER COVER *7 A ll / ll Replace the element in accordance with the mainte- nance schedule or any time it is excessively dirty or damaged. Install the air cleaner element and air cleaner cover, and tighten the special screws. TORQUE: 4 MM (0.4 kgl-rn, 2.9 lbf—ft) CRANKCASE BREATHER NOTE: ' Service more frequently when ridden in rain, at full throttle, or after the motorcycle is washed or overturned. Service if the deposit level can be seen in the transparent section of the drain tube. 3-6 MAlNTENANCE Remove the drain plug from the air cleaner housing drain hose and drain the deposits into a suitable container, then reinstall the drain plug securely. ‘ ;"/\ \‘ DRflPLUGL\ ” SPARK PLUG Remove the cylinder head cover shrouds (page 2-6]. Disconnect the spark plug caps and clean around the spark plug bases. NOTE' 0 Clean around the spark plug bases with com- pressed air before removing the plugs, and be sure that no debris is allowed to enter into the combustion chamber. Remove the spark plugs. Check the insulator for cracks or damage, and the y" electrodes for wear, fouling or discoloration Replace the plug it necessary, RECOMMENDED SPAK PLUG: Standard: DCPRSE (NGK). XUZDEPR—U (DENSO) For extended high speed riding: DCPR7E (NGK), XU?2EPR-U (DENSO) VClean the spark plug electrodes with a wire brush or special plug cleaner. L lNSULATOR SIDE ELECTRODE Check the gap between the center and side elec- trodes with a wire type feeler gauge. SPARK PLUG GAP: 0.3 — 0,9 mm (0.031 — 0.035 in) . 0-3 a 0-9 "‘m _ 4 [0.031—0‘035ll’l) 4 If necessary, adjust the gap by bending the side electrode carefully, Thread each spark plug in by hand to prevent crossr threading and tighten them with a spark plug wrench. TORQUE: 14 N-m (1.4 kgf-m, 10 lbf-Itl Connect the spark plug caps. Install the cylinder head cover shrouds (page 2-6). 3-7 MAINTENANCE VALVE CLEARANCE Inspect and adjust the valve clearance Mir/e the engine is co/a‘ (below 35 “C/ 95 CF) INSPECTION Remove the cylinder head cover shrouds (page 276). Remove the fuel tank (page 2-7). Remove the six socket bolts and the timing hole cap cover. Remove the timing hole cap. Rear cylinder only: Remove the air supply hose/pipe from the rear cyl- inder head cover and pulse secondary air injection (PAIR) control valve. Remove the PAIR control valve stay mounting bolt and move the control valve away from the rear cyl- inder head. Remove the bolts and valve adjusting hole caps. Remove the O—rings from the caps. E CAPS ‘ When checking the clearance, Slide the lee/er gauge irom the center toward the outside. MA|NTENANCE Rotate the crankshaft clockwise and align the “FT” mark on the primary drive gear with the index mark on the right crankcase cover. Make sure the front cylinder piston is at TDC (Top Dead Center) on the compression stroke, This position can be obtained by confirming that ‘ there is slack in the rocker arms. If there is no slack, rotate the crankshaft clockwise one full turn and align the "FT" mark with the index mark again. Check the valve clearances of the front cylinder by inserting a feeler gauge between the adjusting screw and valve stemt VALVE CLEARANCES: INTAKE: 0.15 i 0.02 mm (0.006 t 0001 in) EXHAUST: 0.30 t 0.02 mm (0,012 i 0.001 in) Adjust by loosening the lock nut and turning the adjusting screw until there is a slight drag on the feeler gauge. TOOL: Valve adjusting wrench 070MA-MEA0100 or 07508-KE90100 (U.S.A. only) with 10-mm offset box wrench Hold the adjusting screw and tighten the lock nut. . TORQUE: 22 N-m (2.2 kgf-m,16lM-R) After tightening the lock nut, recheck the valve clearance. Rotate the crankshaft clockwise 308° and align the "RT" mark with the index mark. check the valve clearances of the rear cylinder and adjust it necessary. 3-9 MAINTENANCE Coat new O-rings with oil and install them into the F valve adjusting hole cap grooves. Install the intake valve adjusting hole caps and ‘ tighten them. YOROUE: 15 N-m (1.5 kglm,11lbl-I‘t) Install the exhaust valve adjusting hole caps with the "UP" mark facing up and tighten the bolts securely. Install the PAIR control valve stay onto the frame and tighten the bolt securely. Connect the air supply hose to the PAIR control ‘ valve and cylinder head cover. ‘ l% Coat a new O-ring with oil and install it into the tim- ing hole cap groove. Install the timing hole cap and tighten it. TORQUE: 18 N-m (1.8 kgfrm, 13 lbf-ftI Install the timing hole cap cover and tighten the six socket bolts. TORQUE: 10 NM (1.0 kgf-m, 7 Ith) Install the fuel tank [page 2-7). Install the cylinder head cover shrouds (page 276). BOLTS lu‘ \ \\ AIR 5 I TIMING HOLE CAP COVER 3-10 MAINTENANCE ENGINE OIL OIL LEVEL CHECK Stan the engine, warm it up and let it idle for 3 - 5 7/'—‘ 7 fl minutes. Stop the engine and wait 2 — 3 minutes. OIL FILLER CAP/QIPSTICK l Place the motorcycle on its sidestand on level sur- ’/ face. Remove the oil filler cap/dipstick and wipe the oil from the dipstick with a clean cloth. Hold the motorcycle in an upright position. Insert the dipstick without screwing it in, remove it and check the oil level. If the oil level is below or near the lower level mark on the dipstick, add the recommended oil to the upper level mark. RECOMMENDED ENGINE OIL: Pro Honda 6N4 4-51roke oil (U.S.A. and Canada) or equivalent motor ‘I API service classiti hon: SG or Higher JASO T 903 standard: MA Viscosity: 10W—30 NOTE: - Otherviscoslties shown in the chart may be used . . , , ige 17A ‘ , when the average temperature In your riding .3" .211 1n 9 m an :0 m su-c area is within the indicated range. .zfl—z‘f‘i‘ifEE—a‘iT‘mu Tan-F Reinstall the oil filler cap/dipstick. See page 3711Ior engine oil change. ENGINE OIL FILTER NOTE' I Change the oil with engine warm and the motor» cycle on its sidestand to assure complete and rapid draining. Startthe engine, warm it up and stop it. Remove all filler cap/dipstick. Remove the front and rear oil drain bolts, and drain the oil. REAR OIL DRAIN EQLT MAINTENANCE Remove the oil filter cartridge and let the remaining oil drain out. TOOL: Oil filter wrench 07HAA—FJ70101 or 07HAA—PJ7D‘IOO Apply oil to the rubber seal and threads of a new oil filter cartridge and install the filter cartridge. TOOL: Oil finer wrench D7HAA-PJ70101 or O7HAA—PJ7D1DO TORQUE: 26 NM (2.7 kgt-m, 19lb1-ft) ‘% Install the front and rear oil drain bolts with new sealing washers and tighten them. FRONT OIL RAIN BOLT \ \\ TORQUE: 30 N-rn (3.1 kgf-m, 22 Ith) . Fill the crankcase with the recommended oil ipage 3711). OIL CAPACITY: 3.5 liters (3.7 US qt, 3.1 Imp qt) at d ng 3.7 liters (3.9 US qt. 3.3 Imp qt) at filter change 4.3 liters (4.5 us qt, 3.8 Imp qt) at disassemblv Check the engine oil level (page 3-11). Install the oil filler cap/dipstick. Make sure there are no oil leaks. ENGINE IDLE SPEED NOTE, 0 Inspect and adiust the idle speed after all other engine maintenance items have been performed and are within specifications. I The engine must be warm for accurate idle speed inspection and adjustment. Warm up the engine, shift the transmission into neutral and support the motorcycle upright on a level surface. Check the idle speed. IDLE SPEED: 900 t 100 rpm If the adjustment is necessary, turn the throttle stop I _ “(40‘ I “’9‘” km" as 'eq‘me‘j' THROTTLE STOP SCREW KNOB 3-12 MAINTENANCE RADIATOR COOLANT Check the coolant level of the reserve tank with the u ,, engine running at normal operating temperature. UPPER LEVEL The level should be between the "UPPER" and "LOWER" level lines with the motorcycle upright on a level surface. "LOWER" LEVEL if the level is low, remove the left side cover (page — ' ‘ ' ’ g! 7 2-6) and the reserve tank cap, and fill the tank to the RESERVE TANK CAP “UPPER” level line with a 1:1 mixture of distilled " water and antifreeze (coolant preparation: page 6-6). RECOMMENDED ANTIFREEZE: Pro Honda HP coolant or an equivalent high qual- ity ethylene glycol antifreeze containing silicate- free corrosion in ibitors. Check to see if there are any coolant leaks when the coolant level decreases very rapidly. If the reserve tank becomes completely empty, there is a possibility of air getting into the cooling system, Be sure to remove any air from the cooling system (page 6-7). COOLING SYSTEM Check the radiator air passage for clogs or damage. Straighten bent fins with a small, flat blade screw- driver and remove insects, mud or other obstruc- tions with compressed air or low pressure water. Replace the radiator if the air flow is restricted over ‘ more than 20% of the radiating surface. RADIATOR FlNS See page 6-10 for radiator replacement. Remove the fuel tank (page 2-7). Check for any coolant leakage from the water pump, radiator hoses and hose joints. Check the radiator hoses for cracks or deterioration and replace if necessary. Check that all hose clamps are tight. MAINTENANCE SECONDARY AIR SUPPLY SYSTEM Remove the fuel tank (page 2-7). Check the air supply hoses between the pulse sec- ondary air injection (PAIR) control valve and PAIR check valves for damage or loose connections. Check the air supply hoses for cracks or deteriora» tion. lithe hoses show any signs oi heat damage, inspect the PAIR check Valves (page 5-28). See page 5-28 for PAIR control valve inspection. EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) Remove the fuel tank (page 2-7). Check the evaporative emission (EVAP) canister for cracks or damage. Check the hoses between the fuel tank, EVAP canis- ter, EVAP canister purge valve, EVAP carburetor air vent ICAV) control valve and carburetor for deterio- ration, damage or loose connections. Also check that the hoses are not kinked or pinched. Refer to the Vacuum Hose Routing Diagram Label (’03, '04 model only] and Cable & Harness Routing lpage1-24Hor hose connections and routing. Ans/'07. Remove the sub-air cleaner cover and check the sub-air cleaner filter for contamination or damage. Replace the air cleaner filter if necessary. ’03 model shown: PAIR CONTROL VALVE EVAP CANISTER EVAP CANISTER PURGE VALVE { '03 model shown: m QARBURETOR \ / FILTER 3-14 MAINTENANCE FINAL DRIVE OIL OIL LEVEL CHECK . . ‘ _ ‘ 2:29 the motorcycle on Its sidestand on e leve sur ‘ OIL FILLER CAP Remove the oil filler cap from the final gear case. Check that the oil level is up to the lower edge of the \‘w “m ~ ’ on fine, hole, glow R EDGE F FILLER HOLE Check for leaks if the oil level is low, Pour the rec- ommended oil through the oil filler hole until it reaches the lower edge of the hole. RECOMMENDED OIL: Hypoid gear ail, SAE #80 Coat a new O»ring with oil and install it onto the oil filler cap. Install and tighten the oil filler cap. TORQUE: 12 N-m 11.2 kgI-m, 9 Ibf-ft) OIL CHANGE Remove the oil filler cap and drain bolt from the final gear case, slowly turn the rear wheel and drain the oil. After the oil is completely drained, install the drain bolt with a new sealing washer and tighten it. TORQUE: 20 Nrm (2.0 kgf-m, 15 Ibf-flI ‘Fill the final gear case with the recommended oil to the correct level (page 345i. OIL CAPACITY: 120 cm’ (4.1 US 02. 4.2 Imp all after draining 150 cm’ (5.1 US oz, 5.3 Imp 02) after disassembly OIL DRAIN BOLT 3-15 MAINTENANCE BRAKE FLUID Spiiied fluid can damage painted, plastic or rubber parts. Place a shop towel over these parts whenever the system is serviced. NOTE: 0 Do not mix different types of fluid, as they are not compatible with each other. I Do not allow foreign material to enter the system when filling the reservoir. - When the fluid level is low, check the brake pads for wear (page 347i. A low fluid level may be due to wear of the brake pads. If the brake pads are worn and the caliper pistons are pushed out, this accounts for a low reservoir level. If the brake pads are not worn and the fluid level is low, check the entire system for leaks (page 3 18l. FRONT BRAKE Turn the handlebar to the left side so the reservoir is level and check the front brake reservoir fluid level through the sight glass. SlGHT GLASS It the fluid level is near the “LOWER” level mark, remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the casting ledge. CASTING LEDGE Instail the diaphragm, set plate and reservoir cap and tighten the cap screws. TORQUE: 1.5 MM (0.2 kgf-m,1.1 Ibf-ft) 3-16 MAINTENANCE REAR BRAKE Support the motorcycle upright on a level surface. l’ ‘RESERVOM CAP RESERVO‘R COVER . s \ Check the fluid level in the rear brake reservoir. ‘ if the level is near the "LOWER" level line, remove . the bolt and reservoir cover. ‘ i Remove the reservoir cap, set plate and diaphragm, and fill the reservoir with DOT 4 brake fluid from a sealed container to the "UPPER" level line. Install the diaphragm, set plate and resen/olr cap. Install the reservoir and cover, and tighten the bolt. TORQUE: 10 N-m (1.0 kgt‘m, 7 lbf-ft) BRAKE PAD WEAR FRONT BRAKE PADS Check the brake pad for wear. Replace the brake pads if either pad is worn to the bottom of the wear limit groove. Refer to page 15—8 for brake pad replacement, REAR BRAKE PADS Check the brake pad for wear. l REAR, Replace the brake pads if either pad is worn to the ' bottom of the wear limit groove. ‘ BRAKE PADS V _’\ Refer to page 15-9 lor brake pad replacement. I \LWEAH LIMIT GROOVES MAINTENANCE BRAKE SYSTEM Firmly apply the brake lever or pedal, and check that no air has entered the system. if the lever or pedal feels soft or spongy when oper- ated, bleed the air from the system. See page 15-7 for air bleeding procedures. Inspect the brake hoses, pipes and fittings for deteri- oration, cracks, damage or signs of leakage. Tighten any loose fittings. Replace hoses, pipes and fittings as required. ./ BRAKE HOSE BRAKE LIGHT SWITCH NOTE 0 The brake light switch on the front brake master cylinder cannot be adjusted. If the front brake light switch actuation and brake engagement are not synchronized, either replace the switch unit or the malfunctioning parts of the system. Check that the brake light comes on just 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. Hold the switch body and turn the adjusting nut. Do not turn the switch body. HEADLIGHT AIM Place the motorcycle on a level surface. VERTICAL ADJUSTING SCREW Adjust the heady/gm Adjust vertically by turning the vertical adjusting ‘ " beam as specified screw. by local laws and Adjust horizontally by turning the horizontal adjust— raga/arrnns ing screw. ‘ORIZONTAL ADJUSTING SCREW —_ ——.—l 3-18 MAINTENANCE CLUTCH SYSTEM Inspect the clutch cable for kinks or damage, and ‘— . . 10 — 20 mm lubricate the cable if necessary. (3/8 7 3/4 in) Measure the clutch lever freeplav at the end of the lever. FREEPLAV: 10 — 20 mm (3/8 — 3/4 in) Minor adjustments are made with the upper adjuster at the clutch lever. Loosen the lock nut and turn the adjuster. Tighten the lock nut securely, The adjuster may It the adjuster is threaded out near its limit and the be damaged 1M [5 correct ireeplay cannot be obtained, turn the positioned too Is! adjuster all the way in and back out one turn. out, leawng mlnlmal Tighten the lock nut and make major adjustments as thread engage» described below. mem, UPPER ADJUSTER LOCK NUT Major adjustments are made with the lower adjustv ing nut at the engine. LOCK NUT Loosen the lock nut and turn the adjusting nut. After adjustment is complete, tighten the lock nut securely while holding the adjusting nut. Check the clutch operation. If the freeplay cannot be obtained, or the clutch slips during the test ride, disassemble and inspect the clutch lpage 10-7). 3-19 MAINTENANCE SIDESTAND Support the motorcycle on a level surface. Check the sidestand spring for damage or loss of . tension. Check the sidestand assembly for freedom of move» ment and lubricate the sidestand pivot if necessary. Check the sidesta no ignition cutoff system: — Sit astride the motorcycle and raise the sidestand. — Startthe engine with the transmission in neutral, then shift the transmission into gear, while ‘ squeezing the clutch lever. — Fully lower the sidestand, — The engine should stop as the sidestand is low- L ered. SIDESTAND If there is a problem with the system, check the side» stand switch (page 19-21). SUSPENSION FRONT SUSPENSION INSPECTION Check the action of the forks by applying the front brake and compressing the front suspension several times. Check the entire assembly for leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. See page 13-17 forfOrk service. REAR SUSPENSION INSPECTION Check the action of the shock absorber by com- pressing it several times. Check the entire shock absorber assemon for leaks, damage or loose fasteners. Replace damaged components which cannot be repaired. Tighten all nuts and bolts. See page 1442 for shock absorber service. 3-20 MAINTENANCE Raise the rear wheel off the ground and support the motorcycle securely. Check for worn swingarm bearings by grabbing the rear wheel and attempting to move the wheel side a to side. Replace the bearings if any looseness is noted (page 1476), I NUTS, BOLTS, FASTENERS Check that all chassis nuts and bolts are tightened to 1 their correct torque values (page 14 El. Check that all cotter pins, safety clips, hose clamps and cable stays are in place and properly secured. WHEELS/TIRES 0 Check the tire pressure with a tire pressure gauge when the tires are cold. RECOMMENDED TIRE PRESSURE: Up to 90 kg (200 lbs) load: Front: 225 kPa (2.25 kgl/cml, 33 psi) Rear: 225 kPa (2.25 kgllcmz, 33 psi) 1 Up to maximum weight capacity: Front: 225 kPa (2.25 kgflcm‘, 33 psi) Rear: 250 kPa (2.50 kgf/cm‘, 36 psi) Check the tires for cuts, embedded nails, or other damage. Check the front and rear wheels for trueness. ’ Measure the tread depth at the center of the tires. Replace the tires when the tread depth reaches the following limits. ‘MINIMUM TREAD DEPTH: Front: 1.5 mm (0.06 in) 4 Rear: .0 mm (0.08 in) STEERING HEAD BEARINGS Raise the front wheel off the ground and support the motorcycle securely. Check that the handlebar moves freely from side to side. Make sure the control cables do not interfere , with the handlebar rotation. If the handlebar moves unevenly, binds, or has ver- tical movement, inspect the steering head bearings lpage13-23). 3-21 MEMO 4. LU BRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM -------- “4-2 OIL PRESSURE CHECK ---------------------------- -- 4-6 SERVICE INFORMATION ------------------------- ~-4-3 OIL PUMP/PRESSURE RELIEF VALVE 4-7 TROUBLESHOOTING 4.5 4-1 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ROCKER ARM SHAFT CAMSHAFT PISTON OIL JET OIL PRESSURE SWITCH REAR BALANCER SHAFT CRANKSHAFT I” / T I MAINSHAFT OIL ORIFICE BOLT COUNTERSHAFT ,1. K—. RELIEF VALVE L: OIL PUMP OIL FILTER OIL STRAINER 4-2 LU BRICATION SYSTEM SERVICE INFORMATION GENERAL 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 Lwater as soon as possible after handling used oil. l - The oil pump has twin pump rotors; main and scavenging. The main rotors pick up oil from the transmission division of the crankcase and delivers it under pressure to the bearing and other important parts of the engine. The scavenge rotors draw oil from the crankshaft division of the crankcase and sends it to the transmission gears to lubricate and cool them. The crankcase must be separated to service the oil pump (page 11-6). . 0 See page 3-11 for oil level check. - See page 3-11 for engine oil and filter change. - See page 3-15 for final drive oil check and change. - See page 19-16 for oil pressure switch inspection. SPECIFICATIONS Unit: mm (in) F 7 7 ITEM ( STANDARD 7 SERVLCE LIMIT Engine oil capacity After draining _ 3.5 liters (3.7 US qt, 3.1 Imp qt) l r Wfler draining/ ‘ 3.7 liters (3.9 US qt, 3.3 imp qt) 7 —— * filter change After disassemny 4.3 liters (4.5 US qt, 3.8 Imp qt) — (Recommended engine oil Pro Honda GN4 4-stroke amusA. and — ' Canada) or equivalent motor oil I ‘ API service classification SG or Higher JASO T 903 standard: MA i Viscosity: SAE 10W—30 l # Oil pressure at oil pressure switch . 530 kPa (5.4 kgf/cm ,7? psi) at l — (i 7 5,000 rpm/(80°C/176°F) 1 Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 r 0.21 (0.006 — 0.003) 0.35 (0.014) ( Side Clearance 1 0.02 — 0.07 (0.001 — 0.003) 0.10 (0.004) TORQUE VALUES Oil pressure switch 12 N-m (1.2 kgf-m, 9 lhf-ft) _ Apply sealant to the threads. Oil pressure switch wire terminal screw 2.2 N-m (0,2 kgf‘m, 1.6 lbf-ft) Oil strainer bolt 13 N-rn (1.3 kgI-rn,10 lbf-ft) Oil pump assembly bolt 13 N«m (1.3 kgfrm,10|hfrftl Oil orifice bolt 14 N-m (1.4 kgf-m,10|bfrftl Apply oil to the threads and seating sur- face LUBRICATION SYSTEM TOOLS Oil pressure gauge set 07506-3000001 ‘ or equivalent commercially avail- Cble in U.S.A. Oil pressure gauge attachment 075104220100 or equivalent commercially avail- able in USA. TROUBLESHOOTING Oil level too low Oil consumption External oil leak Worn piston rings Improperly installed piston rings Worn cylinders Worn stem seals Worn valve guide ..o..-. Low oil pressure 0 Oil level low - Clogged oil strainer ' Faulty oilpump - Internal oil leak - Incorrect all being used No oil pressure - Oil level too low Oil pressure relief valve stuck open Broken oil pump drive chain Broken oil pump drive and/or driven sprocket Damaged oil pump Internal oil leak High oil pressure 0 Oil pressure relief valve stuck closed - Clogged oil gallery or metering orifice - Incorrect oil being used Oil contamination - Oil or filter not changed often enough - Worn piston rings Oil emulsification o Blown cylinder head gasket - Leaky coolant passage O Entry of water LU BRICATION SYSTEM 4-5 LUBRICATION SYSTEM OIL PRESSURE CHECK if the engine is cold, the pressure reading will he I abnormally high. Warm up the engine to normal operating tempera- ture before starting this test. Stop the engine. Remove the rubber cap and disconnect the oil pres— sure switch wire by removing the terminal screw. Remove the oil pressure switch and connect an oil pressure gauge attachment and gauge to the pres- sure switch hole. TOOLS: Oil pressure gauge 07506-3000001 I pressure gauge attachment 075104220100 (or equivalent commercially available in U.S.A., MT37A and adaptor AT77AH) Check the oil level and add the recommended oil if necessary (page 3711i Start the engine and check the oil pressure at 5,000 rpm and 80"C (176”Fl. OIL PRESSURE: 530 We (5.4 kgf/cm‘, 77 psi) at 5,000 rpm (80°CI17S°F) Stop the engine. Apply sealant to the oil pressure switch threads as — * shown and install it. Do not apply to the thread head, ‘ i 0.1 i . ' TORQUE: 12 MM (12 kgf-m, 9 lbl-ft) 3 4 mm‘ 0 2 '”’ Connect the oil pressure switch wire and tighten the terminal screw. _ TORQUE: 2.2 MM (02 kgt-m, L6 lbf-ft) ‘ Install the rubber cap. “I ‘ Stan the engine. Check that the oil pressure indieatorturns off after 1 or 2 seconds. if the oil pressure indicator stays on, stop the engine immediately and determine the 4%! causelpage19-16l. \— LUBRICATION SYSTEM OIL PUMP/PRESSURE RELIEF VALVE REMOVAL Separa‘e the crankcase (page 11-6I. Remove khe four mounting bolts and the oil pipe/oil pump assembly from (he left crankcase. Remove khe oil pipe from the oil pump. Remove the O-rlngs from the oil pipe. 01L PIPE Remove ‘he dowel pin, oil joint collar, O-ring and pressure relief valve. DOWEL PIN fl Remove the bolts, oil pass pipe and O-rings. Remove khe oil orifice bulk. LU BRICATION SYSTEM DISASSEMBLY Remove the bolt and oil strainer, Remove the oil pump assembly boll. Remove the following: — oil pump cover — dowel pins — drive pin — scavenge pump inner and outer rotors — oil pump base ~ dowel pins — thrust washer — pump shaft 7 drive pin 7 main pump inner and outer rotors STRAINEH ASSEMBLY BOLT SCAVENGE PUMP ROTOHS PUMP COVER DRIVE PIN DOWEL PINS MAIN PUMP ROTOHS DRIVE F'IN DOWEL PINS THRUST WASHER LU BRICATION SYSTEM INSPECTION OIL PUMP Temporarily assemble the inner rotor, outer rotor, drive pin and pump shaft into the pump body lmain pump) or pump cover (scavenge pumpl. MAIN PUMP: SCAVENGE PUMP: Measure the tip clearance for the feed and scavenge pumps. SERVICE LIMIT: 0.20 mm (0.008 in) Measure the pump body clearance forthe main and scavenge pumps. SERVICE LIMIT: 0.35 mm (0014 in) MAIN PUMP: SCAVENGE PUMP: Measure the pump side clearance for the main and scavenge pumps. SERVICE LIMIT: 0.10 mm (0.004 in) PRESSURE RELIEF VALVE Check the operation of the pressure relief valve by pushing on the piston: SNAP RING Disassemble the relief valve by removing the snap ring. 4-9 LUBRICATION SYSTEM Inspect the piston for wear, unsmooth movement or damage. SPRING Inspect the spring for fatigue or damage. 0 Assemble the relief valve in the reverse order of dis 0 assembly‘ PISTON OIL PUMP ASSEMBLY Dip all parts in clean engine oil. OIL PUMP BODY FUMPSHAFT OUTER ROTOR OUTER ROTOR THHUSTWASHER DOWEL PINS OIL PIPE OIL STRAINER mm" the f°”°‘”'"9: MAIN PUMP ROTORS DRIVE PIN - OU‘ET rotor — inner rotor with ihe grooves facing the pump base — drive pin into the pump shaft — pump shaft, aligning the drive pin with the grooves in the inner rotor — rhrusx washer — dowel pins — pump base onto the pump body DOWEL PINS THRUST WASHER 4-10 LU BRICATION SYSTEM — outer rotor v inner rotor with the grooves facing the pump body ' dowel pins ~ drive pin into the pump shaft — pump cover onto the pump body, aligning the drive pin with the grooves in the inner rotor SCAVENGE PUMP ROTORS PUMP COVER DRlVE PIN DOWEL PINS Install and tighten the oil pump assembly boltt TORQUE: 13 N-m (l3 kgl-m, 10 Ibf-ft) ASSEMBLY BOLT Coat a new seal ring with oil and install it onto the oil strainer. Install the oil strainer onto the oil pump and tighten the strainer bolt. TORQUE: 13 NM (1.3 kgf—m,10lbf-ft) STRAINER g INSTALLATION Coat new Orrings with oil and install them onto the oil pass pipe. Install the oil pass pipe onto the left crankcase and tighten the bolts securely. 4-11 LU BRICATION SYSTEM Clean the oil orifice bolt with compressed air. Install the oil orifice bolt wllh a new sealing washer l and tighten it. TORQUE: 14 N-m (1.4 kgt-m, 10 Ibf-ft) Install the dowel pin and oil joint collar. Coat 21 new O—ring with oil and install it onto the oil joint collar. Coat a new O-ring with oil and install it onto the pressure relief valve. Install the pressure relief valve into the crankcase as shown. ‘5‘ 7 ’ OIL JOINTC LLAR _ Coat new O-rings with oil and install them onto the oil pipe. Install the oil pipe into the oil pump. OIL PIPE Install the oil pipe/oil pump assembly onto the left crankcase and tighten the four mounting bolts securely. Assemble the crankcase (page 11»23l. 4-12 5. FUEL SYSTEM SYSTEM COMPONENTS- -- 5-2 SERVICE INFORMATION ------------------------- n 5-3 TROUBLESHOOTING ............................... .. 5.5 AIR CLEANER HOUSING - 5-7 CARBURETOR REMOVAL ------------------------ -- 5-8 CARBURETOR DISASSEMBLY/ INSPECTION ............................................. .. 5.9 CARBU RETOR ASSEMBLY ----- -- - 5-15 CARBURETOR INSTALLATION ------------- -- INTAKE MAN|FOLD ............................... .. PILOT SCREW ADJUSTMENT ~- HIGH ALTITUDE ADJUSTMENT ----------- -- SECONDARY AIR SUPPLY SYSTEM ---- -- EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) ------ -- 5-20 5-23 5-25 5-25 5-28 - 5-30 5-1 FUEL SYSTEM SYSTEM COMPONENTS '03 model shown: m f W 7 ,m «m. k 0. m N 0 3.5 N«m [0,4 kgf—m,2.6|b1-fll 5-2 FUEL SYSTEM SERVICE INFORMATION G ENERAL 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. Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle control. Before disassembling the carburetor, place an approved fuel container under the float chamber, loosen the drain screw and drain the carburetor. After removing the intake manifold, cover the intake ports of the cylinder heads with shop towels to prevent any foreign material from dropping into the engine. When disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassem- bly. All hoses used in the evaporative emission control system (California type only) and secondary air supply system are numbered for identification. When connecting any of these hoses, compare the hose number with the Vacuum Hose Routing Diagram Label (page 1-123). Do not loosen the throttle position sensor attaching (torx) screws, if the vehicle is to be stored for more than 1 month, drain the float chamber. Fuel left in the float chamber may cause clogging jets, resulting in hard starting or poor driveability. See page 17-10 for throttle position sensor inspection and replacement. SPECIFICATIONS ITEM ’7 SPECIFICATIONS 7 Carburetor identification number ’03 VTX130lJS 49 state/Canada type: VE7BA ‘ " California type: VE7BE ’04 VTX13ODS 49 state/Canada type: VE7BE l California type: VEZBf '04 VTX1300C r 49 state/Canada type: VE7CA ’ California type: VE7CB ‘ ’05 49 state/Canada type: VE7BE Cgilifornia type: VE7BF ’06, '07 49'state/Canada type: VE7BG California type: VE7BH 7 After '07 49 grate/gapada type: VE7B’K” California type: l VE7BL Main jet '63 — ’07 #195 After '07 #190 7 ’ VSlow jet ' #55 Pilot screw Initial/final opening See page 5-25 High altitude adjustment See page 5-25 7 'Float level ' I _ 18.5 mm (0.73 in] Idle speed i 900 1100 rpm Throttle grip freeplay 7276mm (1/16—1/4inl TORQUE VALUES Air cleaner case mounting screw Air cleaner case mounting bolt Fuel tank mounting bolt Fuel valve nut Pulse secondary air injection check valve cover bolt Intake manifold vacuum joint Intake manifold base socket bolt 3.7 N-m (0.4 kgf-m, 2.7 lbf-ft) 10 N-m (1.0 kgf-m, 7 lbf-ft) 19 Nm (1.8 kgf-m, 14 lbf-ftl 34 Nm (3.5 kgf‘m, 25 lbf-ft) 5.2 Ntm (0.5 kgf-m, 3.8 lbf-ft) 2.5 N-m (0.3 kgf-m.1.8lbf-ft) 1D N-m [1.0 kgf-m, 7 Ibf-ft) FUELSYSTEM TOOL ‘ Carburetor float level gauge Pilot screw wrench, D type "' 07401-0010000 07KMA-MSGD1D‘I Pilot screw wrench, D type ‘ 07KMA-MN9A1DO (U.S.A. only) ‘ 5-4 TROUBLESHOOTING Engine cranks but won‘t start - No fuel in tank 0 No fuel to carburetor — Clogged fuel strainer A Clogged fuel filter v Clogged fuel line — Clogged fuel tank breather hose — Faulty fuel pump (’03 model only) v Faulty fuel pump circuit ('03 model only, page 19-22) - Too much fuel getting to the engine — Clogged air cleaner — Flooded carburetor Intake air leak Contaminated/deteriorated fuel Clogged starting enrichment valve circuit Improper starting enrichment valve operation improper throttle operation - No spark at plug (faulty ignition system v page 17-4) Lean mixture Clogged fuel jets Faulty float valve Float level too low Restricted fuel line Clogged carburetor air vent hose Restricted fuel tank breather hose Intake air leak Faulty vacuum piston Faulty evaporative emission (EVAP) control system (California type only) — Faulty EVAP carburetor air vent (CAV) control valve — Clogged hose of the EVAP CAV system Rich mixture - Starting enrichment valve open (0N) Clogged air jets Faulty float valve Float level too high Dirty air cleaner Worn jet needle or needle jet Faulty vacuum piston Faulty EVAP control system (California type only) — Faulty EVAP canister purge valve 7 Clogged hose ofthe EVAP purge system Engine stalls, hard to start, rough idling Restricted fuel line Fuel mixture too lean/rich Contaminated/deteriorated fuel Intake air leak Misadjusted idle speed Misadiusted pilot screw Misadjusted float level Restricted fuel tank breather hose Clogged air cleaner Clogged slow circuit Clogged starting enrichment valve circuit Faulty EVAP control system (California type only) — Faulty EVAP CAV control valve — Faulty EVAP canister purge valve — Clogged hose of the EVAP control system - Faulty ignition system (page 17-4) alone-O III-Ion.- FUEL SYSTEM FUEL SYSTEM Afterburn when engine braking is used - Lean mixture in slow circuit - Faulty air cut-off valve I Faulty pulse secondary air injection (FAIR) system — Faulty PAIR control valve ‘ Faulty PAIR check valve ~ Clogged hose of the PAIR system - Faulty ignition system (page 17-4) Baekfiring or misfiring during acceleration 0 Lean mixture - Faulty ignition system (page 17-4) Poor performance (driveability) and poor luel economy - Clogged fuel system - Faulty EVAP control system (California type only) — Faulty EVAP CAV control valve — Clogged hose of the EVAP CAV system - Faulty ignition system [page 17-4) 5-6 FUEL SYSTEM AIR CLEANER HOUSING REMOVAL Remove the fuel tank (page 2-7). Remove the air cleaner element (page 3-6). Remove the air cleaner housing mounting bolt and screws. Remove the throttle stop screw knob from the air cleaner housing. Release the tab of the air cleaner housing from the grommet in the frame. Disconnect the crankcase breather hose and air sup- '— ' ply hose, and remove the air cleaner housing. AIR SUPPLY HOSE Remove the O-ring from the carburetor. INSTALLATlON Install a new Orring into the carburetor groove. _Connect the crankcase breather hose and air supply hose to the air cleaner housing. Hook the tab 01 the air cleaner housing into the grommet in the frame and install the housing onto the carburetort FUEL SYSTEM Install the throttle stop screw knob onto the air cleaner housing. Install the air cleaner housing mounting screws and bolt, and tighten them. TORQUE: Bolt: 10 N-m (1.0 kgf-m, 7 Ihf-ft) Screw: 3.7 N-m (0.4 kgf-m, 2.7 lbt-ftl Install the air cleaner element (page 3—6). Install the fuel tank (page 277). CARBURETOR REMOVAL Drain the coolant (page 6-7). Remove the right front cylinder head shroud (page 276}. Remove the air cleaner housing (page 5-7l. Disconnect the fuel hose from the carburetor, Slide the rubber cap off the starting enrichment (SE) valve nut. Loosen the SE valve nut and remove the SE valve from the carburetort Disconnect the throttle position sensor connector. o5“ / UEtl-l/OSE/ ‘ / // WUZQN§ K Remove the throttle cables from the cable stay and disconnect them from the throttle drum. Disconnect the vacuum (California type: No. 10) hose from the carburetor. VACUUMlCelifornia t e: No. 10) OSE CABLE STAY V 5-8 FUEL SYSTEM California type only: Disconnect the No. 5, No.6 and No 11 hoses from the carburetor. Loosen the carburetor insulator band screw and remove the carburetor from the insulator. Disconnect the water hoses from the carburetor, and remove the carburetor. Seal the intake manifold port with tape or a clean cloth to keep dirt and debris from entering the engine. CARBURETOR DISASSEMBLY/ INSPECTION THROTTLE POSITION SENSOR] CARBURETOR HEATER Do not loosen the Remove the three screws attaching the throttle posi- 7 T rorx screws attache tion sensor and carburetor heater. { THROTI'LE mg the throttle pasmon sensor to its bracket. POSITION SENSOR CAREUHET OR HEATER 1K SETI'ING PLATEJ 5-9 FUEL SYSTEM Remove the throttle position sensor with its bracket. Remove the connector joint from the throttle. Remove the carburetor heater setting plate. THROTTLE POSITION SENSOR/BRACKET Remove the carburetor heater from the carburetor body. Remove the O-rings from the carburetor heater. VACUUM CHAMBER Remove the four screws while holding the vacuum chamber cover. Remove the vacuum chamber cover, compression SPRING spring and diaphragm/vacuum piston from the car» ouretor body. DIAPHRAGM/PISTON 5-10 FUEL SYSTEM Turn the needle holder counterclockwise by using a screwdriver while pressing it in and release the holder flange from the vacuum piston. Remove the needle holder, spring and jet needle. NEEDLE HOLDER Check the jet needle for stepped wear. Check the vacuum piston for wear or damage. DIAPHRAGM/PISTON Check the diaphragm for pin holes, deterioration or other damage. Check the vacuum piston for smooth operation up and down in the carburetor body. NEEDLE HOLDER \/~ JET NEEDLE SPRING Air will leak out of the vacuum chamber if the dia» phragm is damaged in any way, even with just a pin hole. AIR CUT—OFF VALVE Remove the two screws and washers while holding ‘ A I” ~ . ' - ’03 model shown: AlR CUT-OFF the air cut off valve cover. 7 \v ‘ VALVE COVER Remove the air cut-off valve cover, spring and dia- phragm from the carburetor body. Check the diaphragm for pin holes, deterioration or other damage. Check the diaphragm rod for wear or damage at the tip. Check the orifice in the valve cover and carburetor body for clogs or restrictions. DIAPHRAGM/ROD SPRlNG 5-11 FUEL SYSTEM ACCELERATOR PUMP Remove the three screws and washers while holdr ing the accelerator pump cover. Remove the accelerator pump cover, spring and diaphragm/rod from the float chamber. Check the diaphragm for pin holes, deterioration or other damage, Check the pump rod boot (or deterioration or damr age. FLOAT AND JETS Remove the bolt, plastic washer, accelerator pump link, collar, plain washer and spring washer from the float chamber. ACCELERATOR PM COVER DlAPHRAGM/ROD 5-12 Hand/e all/e15 with care They can easy rly be scored or scratched Damage to the plot screw seat will occur M the pilot screw 15 tightened agamsr me sear FUEL SYSTEM Remove the four screws and the float chamber. Remove the float pin, float and float valve. Check the float for damage orfuel in the float. Check the float valve and valve seat for scoring, scratches, clogs or damage. Check the tip of the float valve, where it contacts the valve seat, for stepped wear or contamination. Check the operation of the float valve. Remove the following: — main jet — needlejet holder 7 needle let 7 slow jet Turn the pilot screw in and carefully count the num- ber of turns until it seats lightly. Make a note of this to use as a reference when reinstalling the pilot 1 screw. TOOL: Pilot screw wrench, D type 07KMA-MSGO101 or 07KMA—MA9A100 (U.S.A. only) NEEDLE JET HOLDER - . 5-13 FUEL SYSTEM Cleaning me air and fuel passages With a piece of wire Wl/l damage the carbur rem body Remove the pilot screw, spring, washer and 0»ring. NEEDLE JET Check each jet for wear or damage. Check the pilot screw for wear or damage Clean the jets with cleaning solvent and blow open with compressed air. SPRING WASHER CARBURETOR CLEANING Remove the following: — diaphragm/piston (page 540) — air cut-off valve (page 541) — accelerator pump (page 5-12) — all lets and pilm screw (page 5-12) Blow open all air and fuel passages in the carbure- tor body and "03‘ chamber with compressed air. 5-14 FUEL SYSTEM CARBURETOR ASSEMBLY JET NEEDLE HOLDER VACUUM CHAMBER COVER SPRING \ JET NEEDLE NE DIAPHRAGMNACUU M PISTON CABLE STAY W (a FILTER w I L ‘% I ('03 model shown) \ . 4 \ 5%. SPRING I; COMPRESSION SPRING AIR CUT-OFF VALVE COVER CARBURETOR HEATER CONNECTOR JOINT THROTTLE DIAPHRAGM/ROD ggfilsTchN FLOAT PIN /% _ NEEDLE JET P'VOT BOLT / SETTING PLATE NEEDLE JET HOLDER \L f FLOAT VALVE BOOT AIR VENT HOSE I I I / I PILOT SCREW A, SLOW JET \ ' MAIN 5 _ JET /E I , E E THROTTLE STOP SCREW KNOB ACCELERATOR PUMP COVER FLOAT CHAMBER 5-15 FUEL SYSTEM JETS AND FLOAT Damage to the pi/at Install the pilot screw with the spring, washer and a screw sealvwll new O-ring and return it to its original position as coco/lithe pi/ot noted during removal. screw [5 tightened against the sear TOOL? Pilot screw wrench, D type D7KMA—M560101 or D7KMA—MN9A100 (U.S.A. only) Perform the pilot screw adjustment if a new pllot I screw is installed lpage 5-25). Hand/e all/525 Wlm install the needle jet, needle jet holder, main jet and care They can easr slow jet. My be scored or scratched Hang the float valve onto the float arm lip. Install the float with the float valve and insert the float pin. FLOAT LEVEL INSPECTION NOTE 0 Check the float level after checking the float valve, valve seat and float. Set the float/evel With the float valve seated and the float arm just gauge so it is pefi touching the valve, measure the float level with the pendicular to the float level gauge. floatmamber face TOOL: atth fl ’7 I ONT 9 £55920; Carburetorflcutlevel gauge (mm-0010000 Float level: 18.5 mm (0.73 in) The float cannot be adjusted. Replace the float assembly if the float level is out of specification. Install a new O‘ring in the float chamber groove properly. FLOAT CHAMBER 5-16 FUEL SYSTEM Install the float chamber and tighten the four screws securely, FLOAT CHAMBER Install the spring washer, plain washer, collar, accel- erator pump link, plastic washer and bolt onto the float chamber, and tighten the bolt securely. ACCELERATOR PUMP Make sure that the pump rod boot is installed prop— erly as shown. Install the accelerator pump diaphragm/rod, spring and cover onto the float chamber. DIAPHRAGM/ROD 5-17 b FUEL SYSTEM Install the three screws and washers while holding the pump cover, and tighten the screws. u AIR CUT-OFF VALVE Install the air cutoff valve diaphragm, spring and r—" _ cover onto the carburetor body. 93 made, Show“ COVER 5 DIAPHRAGM/ROD SPRING Install the two screws and washers while holding . the air cut-0H valve cover, and tighten the screws. ‘ _ SCREWS, ASHERS . VACUUM CHAMBER Insert the jet needle into the vacuum piston. DIAPHRAGM/PISTON Install the spring into the needle holder and set the holder into the vacuum piston. NEEDLE HOLDER ‘ /\’/~ ‘ JET NEEDLE SPRING 5-18 FUEL SYSTEM Turn the needle holder 90 degrees clockwise while pressing it until it locks. NEEDLE HOLDER Install the diaphragm/vacuum piston into the carbu- retor body by aligning the tab of the diaphragm SPR'NG VACUUM CHAMBER COVE“ with the air passage, then insert the Jet needle into the needle jet. Lift the bottum of the piston with your finger to set the diaphragm rib into the groove in the carburetor body. Install the compression spring and vacuum cham4 ber cover while lifting the piston in place. Align the tab of the cover with the air passage and secure the cover with at least two screws before releasing the vacuum piston. TAB AND AIR PfSSAGES Install and tighten the four screws securely. SCREWS THROTTLE POSITION SENSOR/ CARBURETOR HEATER Coat new O-rings with oil and install them onto the carburetor heater. Install the carburetor heater into the carburetor body. CARBURETOR HEATER 5-19 FUEL SYSTEM Install the connector joint into the throttle shaft, Install the setting plate onto the carburetor heater. THROTTLE POS’TiON SENSOFi/f3Fi»‘\(3i ’07 model: Connect the fuel hose. Install the air cleaner housing (page 5»7l. Install the right front cylinder head shroud [page 2-6l. Fill and bleed the cooling system (page 677). Perform the following inspections and adjustments: 7 engine idle speed (page 342) r throttle operation (page 3-5) — pllot screw if it was replaced (page 5-25) NUT 4\ \t/ 5-22 FUEL SYSTEM INTAKE MANIFOLD Route me hoses proper/V lpage 1» 24! REMOVAL Remove the carburetor (page 58). Disconnect the vacuum hose and water hoses from the intake manifolds. i VACUUM HOSE he front side: Remove the four socket bolts and the intake mani- fold with the manifold bases. Seal the intake ports of the cylinder heads with tape or clean clothsto keep dirt and debris from entering the engine :‘e‘flgvre‘grt‘efmjo bolt and choke cable stay from the REAR lNTAKE % Remove the carburetor insulator and intake manir ‘ MAN'FOLD BASE . %_ fold bases by loosening the band screws. ‘ INSTALLATION ‘ FRONT INTAKE MANlFOLD EASE Install a new O-ring into the groove in the front intake manifold base. Install the front intake manifold base onto the front cylinder head and tighten the two socket bolts. TORQUE: 10 N-m (1,0 kgf-m, 7 lbf-ft) Install the rear intake manifold base onto the mania fold while aligning the groove with the lug on the manifold. INSULATOR INTAKE MANIFOLD 5-23 FUEL SYSTEM Be careful not to pinch the 0mg IN the real manila/a base Tighten the rear manifold base band screw so the distance between the band ends is 3 11mmwt12 3: 0.04 in). Install the choke cable stay onto the manifold and tighten the two bolts. Install a new O-ring into the groove in the rear intake manifold base. Install the intake manifold/rear base into the front base and rear cylinder head. Install the two socket bolts and tighten them. TORQUE: 10 Min (to kgl-m, 7 Ibf-ft) Tighten the front manifold base band screw so the distance between the band ends is 3 11 mm (0.12 t 0.04 inl. Install the carburetor insulator with the "CARB" mark facing the carburetor side while aligning the the groove with the lug on the manifold. Tighten the insulator band screw so the distance between the band ends is 4 :1 mm (0.16 1 0.04 in). Connect the vacuum hose and water hoses to the intake manifolds. Install the ca rburetor (page 5-20lt ’_ a fi 3 :1 mm (0.12:0.04 in) I_ \i r7 4:1 mm (016 i 0.04 in) / ‘ "CARE" MARK I03 model shown: i I I i ‘ ll 1 VACUUM HOSE ‘ Viewed from the front side: I 5-24 FUEL SYSTEM PILOT SCREW ADJUSTMENT Damage to the pllaf screw seat will occur if the pilot screw l5 lightened agalflsl the sear IDLE DROP PROCEDURE NOTE: 0 The pilot screw is factory pre-set and no adjust- ment is necessary unless the pilot screw is replaced. - Use a tachometer with graduations of 50 rpm or smaller that will accurately indicate 50 rpm change. 1. Turn the pilot screw clockwise until it seats lightly, then back it out to specification given. This is an initial setting prior to the final pilot screw adjustment. TOOL: Pilot screw wrench, D type 07KMA—M560101 or ‘ 07KMA»MN9A1DO (U.S.A. only) INITIAL OPENING: '03 [8 turns out '06: 1-3/4 turns out After ’07: 1 turns out 2 Warm up the engine to operating temperature. Ride the motorcycle for approximately 10 minutes. 3. Stop the engine and connect a tachometer according to its manufacturer's instructions. 4. Start the engine and adjust the idle speed with the throttle stop screw knob. IDLE SPEED: 900 i 100 rpm 5. Turn the pilot screw in or out slowly to obtain the highest engine speed. 6. Lightly open the throttle 2 or 3 times, then adjust the idle speed with the throttle stop screw knob. 7. Turn the pilot screw in gradually until the engine speed drops by 50 rpm. 8. Turn the pilot screw out to the final opening. FINAL OPENING: 3/4 turns out from the position obtained in step 1 9. Readjust the idle speed with the throttle stop screw knob. HIGH ALTITUDE ADJUSTMENT Thls ad/usrmem must be made at mgn altitude to ensure proper mgn a/zltude operatan When the vehicle is to be operated continuously above 2,000 m (6,500 feet), the carburetor must be readjusted as described below to improve driveability and decrease exhaust emissions. Warm up the engine to operating temperature. Ride the motorcycle for approximately 10 minutes. Turn the pilot screw in to the specification given. l l TOOL: Pilot screw wrench, D type 07KMA-M360101 or D7KMA-MN5A100 (UtS.A. only) HIGH ALTITUDE SETTING: 1/2 turn in \ PILOT SCREW WRENCH 5-25 FUEL SYSTEM Do not attach the label to any part that can be east/y removed from the vehicle. This ad/uszment must be made at low altitude to Ensure Draper low altitude ope/5mm. Adjust the idle speed with the throttle stop screw knobt IDLE SPEED: 900 t 100 rpm Attach the Vehicle Emission Control Information Update label on the rear lender ('03 — '07 model) or fuel tank (After '07) as shown. See Service Letter No. 132 for information on obtaining the label. Sustained operation at an altitude lower than 1,500 m (5,000 feet) with the carburetor adjusted for high altitude may cause the engine to idle roughly and the engine ta stall in traffic. It may also cause engine damage due to overheating. When the vehicle is to be operated continuoust below 1,500 m (5,000 feet), readjust the carburetor as follows: ’04 — '07 VTX1300C: After ’07: ,/\'~\ UPDATE LABEL (49 state/Canada type) UPDATE LABEL ¥, FUEL TANK UPDATE LABEL 5-26 FUEL SYSTEM Warm up the engine to operating temperature. Ride the motorcyclefor approximately 10 minutes. P‘LOT SCREW. Turn the pilot screw out 1/2 turn to its original posi» tion. TOOL: Pilot screw wrench, D type 07KMA-MSGD101 or 07KMA-MN9A1DO (USA only) Adjust the idle speed with the throttle stop screw knob. IDLE SPEED: 900 :t 100 rpm Remove the Vehicle Emission Control Information Update label on the rear fender near the frame cross pipe after adjusting for low altitude. 5-27 FUEL SYSTEM SECONDARY AIR SUPPLY SYSTEM SYSTEM INSPECTION Start the engine and warm it up to normal operating temperature. Remove the air cleaner element (page 36). Check that the secondary air intake port is clean and free of carbon deposits. Check the pulse secondary air injection (PAlRl check valves if the port is carbon fouled. Remove the air cleaner housing (page 577l. Disconnect the PAIR control valve vacuum hose from the Seway vacuum joint and plug the vacuum joint. Connect a vacuum pump to the PAIR control valve vacuum hose. Start the engine and open the throttle slightly to be certain that air is sucked in through the air supply hose. if the air is not drawn in, check the air supply hoses ‘ lorclogs. With the engine running, gradually apply vacuum to the PAIR control valve vacuum hose. Check that the air supply hose stops drawing air, and that the vacuum does not bleed. SPECIFIED VACUUM: 470 mm H9 [185 in H9) if the air is drawn in, or if the specified vacuum is not maintained, install a new PAIR control valve. If afterourn occurs on deceleration, even when the secondary air supply system is normal, check the air cut-off valve. PAIR CHECK VALVE INSPECTION Remove the fuel tank (page 2-7). Front: Remove the left front cylinder head shroud (page 2~6). Rear: Remove the right rear cylinder head cover shroud (page 2-6) and right rear spark plug cap. Remove the bolts and PAIR check valve cover. 3 l AIRlNTAKE PORT 03 — 07 shown: VACUUM PUMP VACUUM HOSE AIR SUPPLY HOSE 5-28 FUEL SYSTEM Remove the PAIR check valve from the cylinder head cover, Check the reed for damage or fatigue. Replace if necessary. Replace the PAlR check valve if the rubber seat is cracked, deteriorated or damaged, or if there is clearance between the reed and seat. REED STOPPER lnstall the PAlH check valve and cover unto the cylr inder head cover. Apply locking agent to the cover bolt threads. lnstall and tighten the bolts. TORQUE: 5.2 N-m (0.5 kgl-m, 3.3 lbf—ft) Install the fuel tank (page 277). RUBBER SEAT REED VALVE 5-29 FUEL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM (California type only) NOTE: - Refer to the Vacuum Hose Routing Diagram and Cable 8t Harness Routing (page 1-24) for hose connections and routing. EVAP CANISTER REMOVAL/ INSTALLATION Disconnect the No. 1 and No. 4 hoses from the EVAP canister, and remove the three bolts and the EVAP canister with the bracket. Remove the two bolts and EVAP canister from the bracket. Install the EVAP canister in the reverse order of removal. / fl/ No.4HOSE / No. 1 HOSE : / EVAP CANISTER EVAP CANISTER PURGE VALVE INSPECTION NOTE: - The EVAP canister purge valve should be inspected if hot restart is difficult. Remove the EVAP canister purge valve. Connect a vacuum pump to the No. 5 hose fining (output port) that goes to the carburetor. Apply the specified vacuum to the EVAP canister purge valve. SPECIFIED VACUUM: 40 mm Hg (16 in Hg) The specified vacuum should maintained. \ Replace the EVAP canister purge valve if vacuum is not maintained. T0 EVAP CANISTEH '—> (Input port) TO CARBURETOH (Vacuum port) m VACUUM PUMP TO CARBURETOR " (Output port) & Remove the vacuum pump and connect it to the No. 11 hose fitting (vacuum port) that goes to the carbu— retor. Apply the specified vacuum to the EVAP canister purge valve. SPECIFIED VACUUM: 250 mm Hg (9.8 in Hg) VACUUM PUMP The specified vacuum should maintained. Replace the EVAP canister purge valve if vacuum is not maintained. 5-30 Damage to the EVAP canister purge valve may result from use of a hlgh pressure an source. Use a handy operated air pump un/y Connect a pressure pump to the No, 4 hose fitting (input port) that goes to EVAP canister. While applying the specified vacuum to the EVAP canister purge valve vacuum port, pump air through the input port. SPECIFIED VACUUM: 25 mm Hg (1.0 in H9) Air should flow through the EVAP canister purge valve and out the output port that goes to the carbu- I’E‘DIS. Replace the EVAP canister purge valve if air does not flow out. Remove the pumps and install the EVAP canister purge valve. EVAP CARBURETOR AIR VENT (CAV) CONTROL VALVE INSPECTION NOTE: - The EVAP CAV control valve should be inspected if hot restart is difficult. Remove the EVAP CAV control valve. Connect a vacuum pump to the No. 10 hose fitting (vacuum port) that goes to the intake manifold. Apply the specified vacuum to the EVAP CAV con- trol valve. SPECIFIED VACUUM: 500 mm Hg (19.7 in Hg) The specified vacuum should be maintained. Replace the EVAP CAV control valve if vacuum is not maintained. Remove the vacuum pump and connect it to the air vent fitting (open air port). Apply vacuum to the EVAP CAV control valve. The vacuum should hold steady, Replace the EVAP CAV control valve if vacuum leaks. TO AIR VENT JOINT TO EVAP CANISTER FUEL SYSTEM PRESSURE PUMP TO OPEN AIR VACUUM PUMP 5-31 FUEL SYSTEM Damage to the EVAP CAV control valve may result from use of a tug)! pressure arr source Use a handroperr axed air pump only. Damage to the solenoid valve may result from use of a h/gh pressure arr source. Use a hand-opera rad arr pump only Remove the vacuum pump and reconnect it to the No. 10 hose fitting (vacuum port). Connect a pressure pump to the open air port. While applying vacuum to the EVAP CAV control valve vacuum port, pump air through the open air port. Air should flow through the EVAP CAV control valve and out the air vent port (No. 6 hose fitting) that go to the carburetor air vent joint. Plug the air vent part (No. 6 hose fitting) that go to the carburetor air ventjoint. While applying vacuum to the EVAP CAV control valve vacuum port, pump air through the open air pon. It should hold steady. Replace the EVAP CAV control valve if pressure is not retained. Remove the pumps and install the EVAP CAV con- trol valve. FUEL CUT-OFF SOLENOID VALVE (After ’07) Remove the fuel cut-off solenoid valve. Connect a vacuum pump to the vacuum port. Apply the specified vacuum to the solenoid valve. SPECIFIED VACUUM: 250 mm Hg [9.8 in H9) The specified vacuum should be maintained. Replace the solenoid valve it vacuum maintained. is not Remove the vacuum pump. Connect a pressure pump to the EVAP CAV control valve port. Pump air through the EVAP CAV control valve port. Air should flow through the solenoid valve and out the float chamber port. PRESSURE PUMP /\ PRESSURE PUMP VACUUM PUMP VACUU M PUMP VACUUM PORT SOLENOID VALVE EVAP CAV CONTROL VALVE PORT VACUUM PUMP FLOAT CHAMBER PORT PRESSURE PUMP 5-32 Damage to the solenoid valve may result from use or a high pressure all source Use a handroperated alr pump only Remove the pressure pump. Connect a vacuum pump to the EVAF CAV control valve port. Connect a 12 V battery to the solenoid valve 2P con- nector terminals. Apply the specified vacuum to the solenoid valve SPECIFIED VACUUM: 250 mm Hg (9.8 in H9) The specified vacuum should be maintained. Replace the solenoid valve if vacuum is not maintained. Remove the vacuum pump. Connect a pressure pump to the vacuum port. While connecting a 12 V battery, pump air through the vacuum port. Air should flow through the solenoid valve and out the float chamber port Remove the pump and battery and install the sole- noid valve. FUEL SYSTEM r’—/—d7 EVAP CAV CONTROL VALVE FORT VACUUM PUMP BATTERY VACUUM PORT FLOAT CHAMBER PORT BATTE RY 5-33 MEMO 6. COOLING SYSTEM SYSTEM FLOW PATTERN SERVICE INFORMATION ------------------------- -- 6-3 TROUBLEsHoo‘nNG ............................... .. 5.4 SYSTEM TESTING ---- -- COOLANT REPLACEMENT ---------------------- -- 6-6 THERMOSTAT .......................................... .. 6.3 RADIATOR/COOLING FAN -------------------- -- 6-10 WATER pUMp .. .............. .. 5.12 RADIATOR RESERVE TANK ------------------ -~ 6-15 6-1 COOLING SYSTEM SYSTEM FLOW PATTERN CARBURETOR RESERVE TANK 6-2 COOLING SYSTEM SERVICE INFORMATION GENERAL Removing the radiator cap while the engine is hot can allow the coolant to spray out, seriously scalding you. L Always let the engine and radiator cool down before removing the radiator cap. Using coolant with silicate corrosion inhibitors may cause premature wear of water pump seals or blockage of radiator passages. Using tap water may cause engine damage. - Add coolant at the reserve tank. Do not remove the radiator cap except to refill or drain the system. - All cooling system service can be done with the engine in the frame. - Avoid spilling coolant on painted surtaces. ° After servicing the system, check for leaks with a cooling system testert - Refer to page 19-13 for the instrumentation ECT switch (coolant temperature indicator) and fan motor switch. SPECIFICATIONS i ITEM SPECIFICATIONS 7 ( Coolant capacity Radiator and engine 2.7 liters (2.9 US qt, 2.4 Imp qt) ‘ Reserve tank 0.35 Ilter(1.00 US qt, 0.81“me qtl Radiator oap relief pressure 108 — 137 kPa (1.1 71.4 kgf/cm ,16— 20 psi) Thermostat l Begin to open 80 r 34 °C (176 — 183 °F) 7 k Fully open 95 DC (203 °El 774 Valve lift 8 mm (0.3 in) minimum «‘ Recormended antifreeze Pro Honda HP Coolant or equivalent high quality ethylenfi 1 glycol antifreeze containing silicate~free corrosion inhibi- i tors :Standard coolant concentration 7 7 1:1 mixture with distilled water j TORQUE VALUES Horn mounting bolt 21 Nm (2.1 kgf‘m,15|bf-ftl Water pump cover bolt 13 N-m (1.3 kgf-m,10lbf>ft) Water pump stud bolt See page 6-15 Gearshift arm pinch bolt 12 Nm (1.2 kgf‘m. 9 Ibf—ft) Cooling fan nut 27 N-m (0.3 kgf‘m, 2.0 lbf-ft) Apply locking agent to the . 2 threads. Fan motor nut 5.1 N-m (0.5 kgf‘m, 3.8 lbf‘ft) Fan motor assembly bolt ('03‘ ’06) 8.3 N-m (0.8 kgf‘m, 6.1 lbfrft) Fan motor assembly bolt (After ’06) 8.4 N-m (0.9 kgf-m, 6.2 let) 6-3 COOLING SYSTEM TROUBLESHOOTING Engine temporature too high - Faulty temperature indicator or instrumentation ECT switch - Thermostat stuck closed Faulty radiator cap Insufficient coolant Passages blocked in radiator, hoses or water jacket Air in system Faulty cooling fan motor Faulty fan motor switch Faulty water pump Coolant leaks - Faulty water pump mechanical seal - Deteriorated O-rings - Faulty radiator cap - Damaged or deteriorated cylinder head gasket - Loose hose connection or clamp - Damaged or deteriorated hoses COOLING SYSTEM SYSTEM TESTING COOLANT (HYDROMETER TEST) Remove (he fuel tank (page 2-7). The engme must be Remove the radiator cap. 600/ before remav- RADIATOR CAP mg the radiator cap Test 1he coolant specific gravity using a hydrome- ter. STANDARD COOLANT CONCENTRATION: 1:1 [distilled water and the recommended HVDROMETER 5 antifreue) Look for contaminafion and replace the coolant if necessary. COOLANT GRAVITY CHART 1 L Coolant iemperature LC: PF) 0.5110115 20125 30 35 40 45 50 ‘ (32) (41) (501.159) (68) (77) (86) (95111104111113) (122) 1 5 1.009 1.005 1.008‘1008 1007110061005 10031100110999 0.997 1 10 1.018 1.017 1.017 1016:1015 1.014 1.013 1.011‘1009‘1007 1005’ i 15 1.028 1.027 1.026 1.025 1.024 1.022 1.020 101811.016 1.014 1.012 '1u\°fi 20 1.036‘1.035 1.034 1.033 1.031 1.029 1.027 102511.023 1.021 1.019 .g 25 1.045 1.044 1.043 1042.1.040 1.038 1.036 103411.031 1.026 1.025 E. 30 1.053 1.052 1.051 1.047 1.046 1.045 1.043 1041110361035 1032 ii 35 1.063 1.062 1.060 1.058 1.056; 1.054 1.052 1.049 1.046 1.043 1.0g, 31* 40 1.072 1.070 1.068 1.066 1.064 1.062 1.059 1.056 1.053 1.050 1.0471 8% 45 1.080 1.076 1.076.1074 1.072 1.069 1.0661063 1.0601057 1.05T T 50 1,086 1,084 1.062 1.060 1.077 1.074 1.071 1.068 1.065 1.062 1.059 55 1.095 1.033 1091 1.088 1.085 1.082 1.079 1.076 1.073 1.070 1.0? L '60 1.100 109511.035 1.092 1.039 1.086 1.063 1.060 11077 1.074110fl COOLING SYSTEM RADIATOR CAP/SYSTEM PRESSURE INSPECTION Remove the radiator cap lpage 65). Wet the sealing surfaces of the cap, then install the cap onto tester. TOOLS: Cooling system pressure tester SVTS4AH Cooling system adaptor OTCJSJSMA RADIATOR CAP Pressurize the radiator cap using the tester. Replace ” the radiator cap if it does not hold pressure, or if relief pressure is too high or too low. It must hold the specified pressure for at least 6 seconds. RADIATOR CAP RELIEF PRESSURE: LIN Y M TE 108 — 137 kPa (1.1 — 1.4 kgI/crn’.1S—20 psi) coo G S STE T r R Pressurize the radiator, engine and hoses using the tester, and check for leaks. Excessive pressure can damage the cooling system components. Do not exceed 137 kFa (1.4 kgf/cm’, 20 psi}. Repair or replace components if the system will not hold the specified pressure for at least 6 seconds. Remove the tester and install the radiator cap. Install the fuel tank (page 277l. COOLANT REPLACEMENT PREPARATION NOTE' 0 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 Mix only distilled, low mineral water with the rec» ommended antifreeze. RECOMMENDED ANTIFREEZE: égfgfigifl Pro Honda HP Coolant or an equivalent high qual- I ity ethylene glycol antitreeze containing silicate- l W ‘ lETHYLENE free corrosion inhibitors GLVCOL EASE LOWMINERAL RECOMMENDED MIXTURE: ‘ SOLUTION) 0H D|ST|LLED 1:1 (distilled water and the recommended WATER antifreeze) 1 /’ COOLANT L fii_fi 4 The engine must be cam before some mg me Coo/mg sysr rem COOLING SYSTEM REPLACEMENT/AIR BLEEDING NOTE. - When filling the system or reserve tank with coolant, or checking the coolant level, place the motorcycle in a vertical position on a flat, level RADIATOR CAP surface. ‘ Remove the following: — left side cover (page 276l — fuel tank (page 2-7) Drain the coolant item the system by removing the drain bolt and sealing washer, and the radiator cap. Reinstall the drain bolt with a new sealing washer, TORQUE: 13 Nrm (1.3 kgf-m, 10 Ibf-ft) i! Disconnect the siphon hose from the reserve tank and drain the reserve coolant. Empty the coolant and rinse the inside of the reserve tank with water. Reconnect the siphon hose. Q QwERLk L117 SlPHON HOSE Fill the system with the recommended coolant through the filler opening up to the filler neck. Connect the fuel tank to the fuel hose and supply fuel to the carburetor. Bleed air from the system as follows: 1, Shift the transmission into neutralt Startthe engine and let it idle for 2 ~ 3 minutes. 2. Snap the throttle three to four times to bleed air from the system. 3. Stop the engine and add coolant up to the filler neck 4. Install the radiator cap. COOLING SYSTEM Remove the reserve tank cap. Fill the reserve tank to the upper level line and install the tank cap. Install the following: 7 left side cover (page 2-6) - fuel tank (page 27) THERMOSTAT REMOVAL Drain the coolant from the system (page SJ), Disconnect the foilowing: — siphon hose — vacuum hose and air supply hose (from the PAIR control vaivei Place a shop towel under the thermostat housing. Loosen the two housing cover bolts. Remove the following: — bolt and thermostat housing (from the stay] - two bolts and housing cover ~ thermostat — O-ring (from the cover) if the thermostat housing is to be removed, discon- nect the instrumentation ECT switch connector (page 1944) and the water hoses. 6-8 Wear insulated gloves and ade- quate eye protect flail Keep flammable marshals away from the electric heating element Do not let the ther mosrat or their mometer touch the pan, or you Will get false readings, Be carefulnot to cross-Thread the bolts Home the hoses properly (page 77 24/ COOLING SYSTEM THERMOSTAT INSPECTION Visually inspect the thermostat for damage. Replace the thermostat if the valve stays open at room temperature. ‘ THERMOMETER Heat a container of water with an electric heating element for 5 minutes. Suspend the thermostat in the heated water to check its operation. THERMOSTAT BEGINS TO OPEN: 80 — 34°C (176 —183°FI VALVE LIFT: 8 mm (0.3 in) minimum at 95°C (203“FI Replace the thermostat if the valve opens at a tem- perature other than those specified. INSTALLATION Install the thermostat into the housing with the hole facing up. Clean the mating surface of the thermostat housing and cover, Install a new O-ring into the groove in the housing COVER Make sure the thermostat flange is flush with the housing surtace and install the housing cover onto the thermostat housing, then install the two cover bolts, Install the thermostat housing by aligning the lug with the groove in the stay, and tighten the mount- ing bolt, Tighten the two housing cover boltst Connect the following: — secondary air supply hose PAIR control valve vacuum hose — siphon hose Fill and bleed the cooling system (page 66). COOLING SYSTEM RADIATOR/COOLING FAN NOTE: - Be careful not to damage the radiator fins while servicing the radiator and fan motor. REMOVAL/INSTALLATION Drain the coolant from the system lpage 677i Remove the front left cylinder head shroud (page 2* coNNEcTons HOSE 6). Disconnect the following: — cooling fan motor 2? (black) connector (and remove it from the framel ~ horn connectors Remove the following: 7 bolt and horn — two bolts and setting plate Disconnect the water hoses by loosening each hose bandv Release the boss on the radiator bottom from the mounting grommet and remove the radiator assemr pLATE bly. Release the grill tab to remove the radiator grill, GROMMET HOSE lnstallation is in the reverse order of removal. GRILL Tighten the hanger plate bolts (8 mm]. TORQUE: Horn mounting bolt: 21 Nm (2.1 kgf-m, 151mm TAB BOSS Fill and bleed the cooling system (page 6—6). DISASSEMBLY Forfanmoror Disconnect the fan motor switch connector and swrtch Information. release the wires from the clamps. FAN MOTOR ASSEMBLY refer to page 7977:: Remove the following: — four bolts and ground terminal — fan motor assembly TERMlNAL — nutand cooling fan — three nuts and fan motor FAN NUT 6-10 COOLING SYSTEM ASSEMBLY '03 — ’06 shown RADIATOR Q1min 2.7 N«m (0.3 kgf-m, 2.0 Ibf-ft) COOLING FAN 5.1 NM (0.5 kgf-m, 3,8 lbf-ft) MOTOR STAY FAN MOTOR SWITCH ('03 — ’06) 8.3 N-m (0.8 kgfvm,6.1|bf-ftl (After ’06) 8.4 N-m (0.9 kgf—m, 6.2 lbf-ftl Install the fan motor on the motor stay in the direc- tion as shown and tighten the three nuts to the specified torque. TORQUE: 5.1 N-m (0.5 kgf‘m. 3.81bf-ft) Install the cooling fan onto the motor shaft, aligning the flat surfaces. COOLING FAN Apply locking agent to the fan nut threads. Install the nut and tighten it to the specified torque. TORQUE: 2.7 N-m (0.3 kgf-m. 2.0 Ibl-ft) 6-11 COOLING SYSTEM WATER PUMP Install the fan motor assembly and tighten the four bolts to the specified torque with the ground termi- nal as shown. TORQUE '03 — ’0 8.3 NAm (0.3 kgtrm, 6.1 lM-ft) After '06: 8.4 N-m (O3 kgi-m, 5.2 lbf-ft) FAN MOTOR ASSEM BLY Route the wires properly and secure them with the clamps. Connect the fan motor switch connector. Install the radiator assembly (page 6-10l. TERMINAL MECHANICAL SEAL INSPECTION Check for signs of seal leakage. A small amount of "weeping" from the bleed hole is normal. REMOVAL Drain the coolant from the system (page 677i Remove the left crankcase rear cover (page 2-8). Remove the following: 7 pinch bolt 7 gearshift arm 7 bolt and nut 7 cover stay 7 water hose (from the water pump) — wire bands _ Z — bolt . . ’ i — water pipe _ 0mg 1 ATERPIE I ‘ ‘r CONNECTOR 6-12 COOLING SYSTEM 0 RIN t WATER PIPE - — two bolts » water pipe » O-ring — two cover bolts and washer 7 two mounting bolts 7 water pump cover » waterpump r O—rings INSTALLATION Coat a new O-ring with engine oil and install it onto the stepped section of the water pump. Install the water pump while aligning the groove with the projection of the oil pump shaft. 6-13 COOLING SYSTEM Install a new Orring into the groove in the water pump. Align the bolt holes in the pump and crankcase, and install the water pump cover with the four bolts and a new sealing washer. Tighten the bolts in a crissr cross pattern in several steps‘ TORQUE: Cover bolt: 13 Mr“ (1.3 kgf-m,10lbi-ftl COVER (DRAIN) BOLT AND WASHER I Install a new O-rlng onto the lower water pipe. Connect the water pipe to the water pump and secure it with the two bolts. Home the Wires Install a new O-ring onto the upper water pipe, pruneer (page 7 Connect the water pipe and secure it with the bolt. 2‘” Secure the wires wlth the wire bands, 6-14 COOLING SYSTEM If the water pump was replaced, install the stud bolt into the pump cover. Be sure to verify the distance from the top of the stud to the pump cover as shown. *4 l 10.5— 12.5 mm ‘ Connect the water hose. Install the cover stay, and tighten the bolt and nut. Install the gearshift arm by aligning the slit with the punch mark on the spindle. Install the pinch bolt and tighten it. TORQUE: 12 Mm (142 kgf-m, 9 lbl-ft) Install the left crankcase rear cover (Page 2-8). Fill and bleed the cooling system (page 66). RADIATOR RESERVE TANK REMOVAL/INSTALLATION Remove the following: » left crankcase rear cover (page 278) — EVAP canister (California type only; page 5730) Disconnect the siphon hose from the reserve tank and drain the reserve coolant, Disconnect the breather and filler hoses. Remove the mounting bolt. Release the tank locat- ing pin from the mounting grommet to remove the reserve tank. Installation is in the reverse order of removal. NOTE O Take care not to dislodge the mounting grom» met. I Be sure to route the hoses properlv (page 1-24(. 6-15 MEMO 'II 7. ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS ......................... .. 7.2 ENGINE REMOVAL .................................. .. 7.4 SERVICE INFORMATION ------------------------- -- 7-3 ENGINE INSTALLATION -------------------------- n 7-9 7-1 ENGINE REMOVAL/INSTALLATION SYSTEM COMPONENTS 27 N-m (2.8 kgf-m, 20 Inf-ft] 12 N-m (1.2 kgfvm, 9 Ibf-fl) 27 N-m (2.8 27 N-m (2‘8 kgf-m, 20 Ibf-ft) kgf-m, 20 Ibf-ft) 7 N-m (0.7‘kgf-m, 5.2 lbf-fl) 2.2 Nrm (0.2 kgf-m,1.6|bf-fl) ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION GENERAL - A hoist or equivalent is required to support the motorcycle when removing and installing the engine. - A floor jack or other adjustable support is required to support and maneuver the engine. Do not support the engine using the engine oil filter or the filter mount will be damaged. When removing/installing the engine, tape the frame around the engine beforehand for frame protection. The following components require engine removal for servicing. — camshaft (page 8-2) — cylinder head (page 3-2) — cylinder/piston (page 9-2) — crankshaft (page 11-2) — transmission (Including gearshift drum/shift fork: page 11-2) — output gearcase (page 11-2) - The following components can be serviced with the engine in the frame. — carburetor (page 5-2) — water pump (page 6-2) — clutch/gearshift linkage (page 10-2) — alternator (page 16-2) — electric starter/starter clutch (page 18-2) SPECIFICATIONS _ lTEM SPECIFICATIONS V ’ fl Engine dry weight l 109 kg (240 lbs) 1 Engine oil capacity at disassembly 4.3 liters (4.5 US qt, 3.8 Imp qt) 1 Coolant capacity (radiator and engine) 2.7 liters (2.9 US qt, 2.4 Imp qt) TORQUE VALUES Engine mounting nut 39 NM (4.0 kgfrm, 29 Ibf-ft) Engine hanger plate bolt 27 N-m (2.8 kgf-m, 20 Ibf‘ft) Starter motor cable terminal nut 7 N-m (0.7 kgf—m, 5.2 let) Clutch cable holder bolt 12 N-m (1.2 kgf-m, 9 lbf-ft) Oil pressure switch terminal screw 22 N-m (0.2 kgf-m,1.6lbf-ftl ENGINE REMOVAL/INSTALLATION ENGINE REMOVAL Drain the engine oil (page 341). Drain the coolant (page 6-7lr Remove the following: — fuel tank (page 2-7) — all cylinder head shrouds (page 2-6) — front ignition coil (page 17-7) both side covers (page 26) — left crankcase rear cover [page 2-8) — exhaust system (page 2-12) — both footrest or footpeg assemblies (page 2-9) — carburetor (page 5-8) — radiator (page 6-10) — lower water pipe (from the water pump; page 6- 13) NOTE: I Wrap the intake manifold port with a shop towel or cover them with a piece of tape to prevent any foreign material from dropping into the engine. ’03 and ’04 models: Remove the wire band. After ’04 model: Release the wire harnesses from the clamp Disconnect the following: — ignition switch 3P connector — ignition pulse generator 2P connector — neutral switch (light green) wire connector — alternator 3P connector (After ’04 model only) ’03 and '04 models: After '04 model: CONNECTOR ENGINE REMOVAL/INSTALLATION Remove the wire bands and disconnect the follow ing: — alternator 3P connector (’03 and '04 models only) — speed sensor 3P connector — sidestand switch 2P black connector Release the sidestand switch wire from the clamp. Remove the following: 7 cable holder bolt 7 clutch cable from the litter arm — terminal bolt 7 battery negative (—) cable '03 and '04 models: BANDS CLAMP After '04 model: CONNEgTons BAND 7-5 ENGINE REMOVAL/INSTALLATION — nut and bolt — cover stay — water hose by disconnecting it from the water pump — terminal nut — starter motor cable from the motor terminal and the clamps on the left crankcase cover » terminal screw 7 oil pressure switch wire from the switch and the clamp on the frame OIL PRESSURE SWITCH WIRE — instrumentation ECT switch connector — vacuum (No. 10; California) hose from the intake WATER H0555 manifold . . 7 outlet water hoses from the cylinder heads h VACUUM OSE ('03 model shown) 7-6 ENGINE REMOVAL/INSTALLATION ~ spark plug caps ~ spark plug wires from the clips — secondary air supply hose from the rear cylinder _ head cover — secondary air supply hose from the from cylinder head cover - crankcase breather hose — siphon hose from the filler neck » two bolts — pulse secondary air injection (PAIR) control valve with the vacuum and air hoses — water hose E from the thermostat housing 7 thermostat housing with the outlet water hoses ; . THERMOSTAT ‘ ‘\~ HOUSING ” \\ \ 7-7 ENGINE REMOVAL/INSTALLATION Support the motorcycle securely with a hoist or equivalent. Place the floor jack or other adjustable support under the engine. NOTE - The jack height must be continually adjusted to relieve stress for ease of bolt removalt Remove the following engine mounting fasteners: HANGER 7 four plate bolts and hanger plate — front lower mounting nut — front lower mounting bolt and collar Heft side of the enginel — two plate bolts and hanger plate — bottom mounting nut — bottom mounting bolt and collar (right side of the engine) NUTAND NUTAND BOLT EOLT 7 rear lower mounting nut and bolt 7 two plate bolts and hanger plate 7 rear upper mounting nut — center cover socket bolt — two plate bolts and hanger plate 7 rear upper mounting bolt 7 ignition switch stay bolts 7 center cover socket bolt — two plate bolt and hanger plate , HANGER PLATE ENGINE REMOVAL/INSTALLATION Release the joint boot from the output gear case. OUTPUT SHAFT During Snglne Move the engine forward and release the output removal, hqu the shaft from the universal joint in the swingarm. engine securely and Carefully maneuver the engine and remove it out of be careful not to the frame to the right damage the frame and engine. UNIVERSAL JOINT ENGINE INSTALLATION Hanger plate bolt (A; 3 mm): 26 N-m (2‘7 kgf-m, 20 lbf-ft) ‘3’ Mounting nut (a; 10 mm): 39 N-m (4.0 mm, 29 [bf-ft] NOTE: 0 Route the wires, hoses and cables properly (page 1-24). During engine Using a floor jack or other adjustable support, care- installation holdthe fully place the engine into the frame and maneuver engine securely and it into place. (1:53“ng 2:2: Apply 1 g (0.04 oz) of molybdenum disulfide paste 9 . to the output shaft splines. Engage the output shaft 5"" “WE with the universal joint. %RSAL JOINT 7-9 ENGINE REMOVAL/INSTALLATION Align the bolt holes in the engine and frame, and install the following fasteners: — bottom mounting bolt and collar (right side of -' the enginel » — bottom mounting nut — hanger plate with two bolts — front lower mounting bolt and collar lleft side of the engine) — front lower mounting nut BOLTAND NUT ~ hanger plate with the two bolts 7 center cover socket bolt — ignition switch with the two bolts — hanger plate (upperl with the two bolts — center cover socket bolt — rear upper mounting bolt and nut — hanger plate (lower) with the two bolts — rear lower mounting bolt and nut — hanger plate with the four bolts After installing all the mounting fasteners, tighten the fasteners in the following order. Tighten the hanger plate bolts (8 mm). TORQUE: 27 N-m (2.3 kgi-m, zo lbf-ft) Tighten the mounting nuts (10 mm), TORQUE: 39 MM (4.0 kgf—m, 29 Ibf-ft) “ANGER ' ’ Install the joint boot over the output gear case prop- erlyl 7-10 Install the removed parts from the engine removal procedure (page 7-4 to 7»7) in the reverse order of removal. TORQUE: Oil pressure switch terminal screw: 2.2 N-m (0.2 kgf-m,1.6ll1f-fll Starter motor cable terminal nut: 7 N-m (0.7 kgf-m, 5.2 Ibf-fl) Clutch cable holder bolt: 12 Nm (1.2 kgf-m, 9 Ibf-ft) Check the clutch lever freeplav (page 349). Inslall thefollowing: — front ignition coil (page 1777) A radiator (page 6-10) — carburetor (page 5-20) — both footrest or footrest assemblies (page 2-9) — exhaust system (page 243] — left crankcase rear cover [page 2-8) — both side covers (page 26) — all cylinder head shrouds (page 2-6) Fill the crankcase with engine oil (page 3-11). Fill and bleed the cooling system (page 6-7lr ENGINE REMOVAL/INSTALLATION 7-11 MEMO 8. CYLINDER HEAD/ VALVE SYSTEM COMPONENTS « ...... .. 3.2 SERVICE INFORMATION ------------------------- -- 8-3 TROUBLESHOOTING ------------------------------- -- 8-5 CYLINDER COMPRESSION-- 8-6 CYLINDER HEAD COVER REMOVAL ------ -- 8-6 ROCKER ARM REMOVAL ------------------------ -- 8-7 CAMSHAFI' REMOVAL - CYLINDER HEAD REMOVAL CYLINDER HEAD DISASSEMBLY --------- -- 8-12 VALVE GUIDE REPLACEMENT ------------- -- 8-14 VALVE SEAT INSPECTION/ REFACING ............................................... .. 3.15 CYLINDER HEAD ASSEMBLY --------------- -- 8-18 CYLINDER HEAD INSTALLATION----------- 8-13 CAMSHAFI' INSTALLATION ----------------- -- 8-20 ROCKER ARM INSTALLATION ------------- ~- 8-23 CYLINDER HEAD COVER INSTALLAT|0N ...................................... .. 3.24 8-1 CYLINDER HEAD/VALVE SYSTEM COMPONENTS 26 N-m (2.7 kgf-m, 19 |bf>ftl 26 N-m (2.7 kgf-m,19|bf-ft) 3 kgf—m, 17 |th) /- ‘ 0e: MIIIIE- 14 N-m (1.4 kgf-m,10|bf-ft] 18 Nm (LB kgi-m, 131N411 12 NM (1.2 kgf-m, 9 |th) 8-2 CYLINDER HEAD/VALVE SERVICE INFORMATION GENERAL 0 This section covers service of the rocker arms, camshafts, cylinder head and valves. To service these parts, the engine must be removed from the frame, Be careful not to damage the mating surfaces when removing the cylinder head cover and cylinder head. Do not strike the cylinder head cover and cylinder head too hard during removal. When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tibns. Clean all disassembled pans with cleaning solvent and dry them by blowing them off with compressed air before inspection. Camshaft and rocker arm lubricating oil is fed through oil passages in the cylinder head and head cover. Clean the oil passages before assembling the cylinder head and cover. SPECIFICATIONS Unit: mm (in) ITEM 7 STANDARD SERVICE LIMIT l Cylinder compression at 300 rpm ‘ 1,157 kPa (11.8 kgf/cm2,168 psi) — Valve clearance _IN 0.15 i: 0.02 (0.006: 0.001) — EX 0.30 :t 002 (0.012 t 0.001) — Camshaft Cam lobe height IN 38.836 — 39.080 (1.5309 -—1.5386) 3836 (1.530) EX 39.050 — 39.250 (1.5374 -— 1.5453) 39.03 (1.537) ’fiunout — 0.04 (0.002) * Oil clearance A, 8 0,040 — 0.101 (0.0016 — 0.0040) 0.120 (0.0047) C 0.055 - 0.121 (0.0022 — 0.0048) 0.140 (0.0055) Rocker arm, Rocker arm shaft OD. IN/EX 13.966 -13.984(0.5498 — 0.5506) 13.91 (0.543) _ I’OCkef 3"“ Hooker arm ID. IN/EX 14.000 414.018 (0.5512 — 0.5519) 13.95 (0.549) Shaft Rocker arm-to-shaft clearance 0.016 — 0.052 (0.0006 — 0.0020) l 0.15 (0.006) Valve, Valve stem CD. IN 5.575 — 6.590 (0.2589 — 0.2594) 7‘ 6.57 (0.259) valve guide EX 6.560 a 6.575 (0.3132 — 03138) 0.545 (0.2577) Valve guide |.D. lN/EX i 6.600 — 6.615 (0.2596 — 0.2604) ( 6.535 (0.2612) Stem—fo-guide Clearance IN 0.010 —70.040 (0.0004 — 0.0016) 0.08 (0.003) EX 0.025 — 0.055 (00010 — 0.0022) 0.115 (0.0045) Valve guide projection IN 14.5 (0.57) — above cylinder head EX 15.5 (0.61) — Valve Seat width IN/EX 0.9 — 1.1 (0.035 - (1043) 1.5 (606) Valve spring Free length [N 45.70 (1.799) 43.90 (1.728) H EX 43.50 (1.713) 41.80 (1.646) Cylinder head warpage — " 0.10 (0.004) TORQU E VALU ES 18 N-m (13 kgf‘m, 13 Ibf-ft) Apply engine oil to thethreads and seating surface. 26 N-m (2.7 kgf-m,19lbf-ft) 43 N-m [4.4 kgf—m, 32 lbf—ft) Apply engine oil to the threads and seating surface. 26 Nm (2,7 kgf-m, 19 lbf-ft) Apply engine oil to the threads and seating surface. 23 N-m (2.3 kgfrm, 17 lbfvft) Apply locking agent to the threads. 12 N-m (1.2 kgf-m, 9 lbI'ft) Spark plug sleeve Cylinder head cover bolt (8 mm) Cylinder head 10 mm cap nut Cylinder head 8 mm cap nut Cam sprocket bolt Cam chain tensioner bolt CYLINDER HEAD/VALVE TOOLS Fork tube holder attachment Valve spring compressor ‘Y Valve guide reamer, a6 mm 07930-KA50100 ‘ 07757-0010000 07984-ZE20001 or D7984-ZEZOOOD (USA. only) Valve guide driver, 6.6 mm Valve seat cutter, 33 mm (45° IN) Valve seat cutter, 40 mm (45° EX) 07742-0010200 07780-001080!) 07780-0010500 or 0794245570100 (USA. only) or equivalent commercially avail- or equivalent commercially avail- able in U.S.A. able in U.S.A. Flat cutter, 33 mm (32° lN) Flat cutter, 42 mm (32" EX) Interior cutter, 30 mm (60° IN) 07780-0012900 07780-0013000 07780-001400!) ‘ - or equivalent commercially avail- or equivalent commercially avail- or equivalent commercially avail- able in USA. able in U.S.A. able in USA. , , l Interior cutter, 37.5 mm (60° EX) Cutter holder, 6.6 mm 07780-0014100 07781-0010202 or equivalent commercially avail- or equivalent commercially avail- able in USA. able in U.S.A. 8-4 CYLINDER HEAD/VALVE TROUBLESHOOTING Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test, or by tracing top-end noise with a sounding rod or stethoscope. Compression too low. hard starting or poor performance at low speed - Valves — Incorrect valve adjustment ~ Burned or bent Valves — Incorrect valve timing — Broken valve spring — Uneven valve seating ~ Valve stuck open ' Cylinder head — Leaking or damaged cylinder head gasket — Warped or cracked cylinder head — Loose spark plug - Cylinder/piston problem [page 9-3) Compression too high - Excessive carbon build-up on piston head or combustion chamber Excessive smoke - Worn valve stem or valve guide 0 Damaged stem seal - Cylinder/piston problem (page 9-3) Excessive noise - Incorrect valve clearance Sticking valve or broken valve spring Excessive worn valve seat Worn or damaged camshaft Worn or damaged rocker arm and/or shaft Worn rocker arm follower or valve stem end Worn cam sprocket teeth Worn cam chain Worn or damaged cam chain tensioner Cylinder/piston problem [page 9-3) Rough idle - Low cylinder compression 8-5 CYLINDER HEAD/VALVE CYLINDER COMPRESSION Warm up the engine to normal operating tempera ture. Stop the engine. Disconnect all the spark plug caps and remove one spark plug from each cylinder head (page 37). Install the compression gauge into the spark plug hole. TOOL: Compression tester EEPV303A (U.S.A. only) Shift the transmission into neutral. Open the throttle all the way and crank the engine with the starter motor until the gauge reading stops rising. The maximum reading is usually reached within 4 r 7 seconds. COMPRESSION PRESSURE: 1,157 kPa (11.8 kgflcm’, 163 psi) at 300 rpm Low compression can be caused by: — blown cylinder head gasket — improper valve adjustment — valve leakage — worn piston ring or cylinder High compression can be caused by: — carbon deposits in combustion chamber or on piston head CYLINDER HEAD COVER REMOVAL eons ANESWASHERS Remove the engine from the frame (page 7»2). Remove the following: 7 bolts and washers 7 cylinder head fins 7 setting rubbers — intake manifold (page 5-23; if the cylinder head will be removed) — spark plug from each cylinder head (page 3-7) — timing hole cap (page 3-8) — valve adjusting hole caps COMPRESSION GAUGE /. ADJUSTING HOLE CAPS “FT” for from Cylinder “RT” for rear cvi/nder Do not strike me head cover too hard and do not damage the maliflg surfaces With a screwdriver ROCKER ARM REMOVAL Rotate the crankshaft clockwise and align the "T" mark on the primary drive gear with the index mark on the right crankcase cover. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. This position can be obtained by confirming that there is slack in the rocker arms. if there is no slack, rotate the crank shaft clockwise one full turn and align the "T" mark with the index mark again, Remove the following: e 6»mm bolt 7 two 8-mm bolts and water pipe - two 8—mm cap nuts and washers — iour10»mm cap nuts and washers — cylinder head cover l rubber plugs joint collar and O-ring — dowel pins Remove the cylinder head cover [page 8-6). Remove the fullowing: — bolts and sealing washers — rocker arm shafts and O-rings — rocker arms N UTSAND WASHERS CYLINDER HEAD/VALVE CYLINDER HEAD COVER RUBBER PLUGS “ t J‘x’g 8-7 CYLINDER HEAD/VALVE INSPECTION Inspect the sliding surfaces of the rocker arms and shafts for wear or damage. Check the oil holes for clogs. Measure the CD. of each shaft at the rocker arm sliding areas. SERVICE LIMIT: 13.91 mm (0.548 in) x Measure the ID. of each rocker arm. SERVICE LIMIT: 13.95 mm (0.549 in) Calculate the rocker arm-to-shaft clearance. SERVICE LIMIT: 0.15 mm [0.006 in) CAMSHAFT REMOVAL Remove the cylinder head cover (page 8-6). [ 7 Before releasing the cam chain tensioner, measure the distance of the cam chain tensioner projects above the bracket as shown. Replace the cam chain with a new one if the projec- tion exceeds 9.0 mm (0.35 in). To replace the cam chain, remove the following: — camshaft — Front'cylinder: flywheel/starter clutch (page 18- 15) — Rearcylinder: primary drive gear (page 10—18) Release the tensioner by pulling wedge A straight up while holding wedge B down, then secure wedge A with a 2 mm pin as shown. Be Care/ulnot to let the [70/25 fall mm the crankcase. Attach a piece of Wire m the Cam chain to prevent it from falling into the crankcase CYLINDER HEAD/VALVE Remove the following from the cam chain side: 7 spark plug — spark plug sleeve TOOL: Fork tube holder attachment 07930rKA50100 — cam sprocket bolt - other sprocket bolt (rotate the crankshaft one turn) — two holder bolts ‘ camshaft holder NOTE: 0 Do not forcibly remove the dowel pins from the camshaft holder. — cam sprocket with cam chain (from the camshaft) — camshaft — cam sprocket (from the cam chainl INSPECTION CAMSHAH Check the cam sprocket for wear or damage Check the cam and journal surfaces of the camshaft for scoring, scratches or evidence of insufficient lubrication. Check the oil holes in the camshaft for debris. Measure the camshaft runout using a dial indicator. SERVICE LIMIT: 0.04 mm (0.0016 in) I CAMSHAI—T HOLDER ‘ CYLINDER HEAD/VALVE Do not hook the cam chain attach mg Wire against the try/Wider head mare mg surface. The Camshafts have the ldEnIlflCaIan mark on their flanges. JF” from came shaft 4'8" learcamshaft Measure each cam lobe height using a micrometer, SERVICE LIMITS: IN: 33.86 mm (1.530 in) EX: 39.03 mm (1.537 In) CAMSHAFT JOURNAL Check the camshaft journal surfaces of the camshaft holder, cylinder head and head cover for scoring, scratches or evidence of insufficient lubrication. CAMSHAFF OIL CLEARANCE NOTE: - Do not rotate the camshaft during inspection. Suspend the cam chain attaching wire through the spark plug sleeve hole. Clean off any oil from the journals of the camshaft holder, camshaft, cylinder head and head cover. Put the camshaft onto the cylinder head and lay a strip of plastigauge lengthwise on the sprocket side journal of the camshaft. Carefully install the camshaft holder with the dowel plnst Install the holder bolts and tighten them alternately in several steps. TORQUE: 12 N-m (1.2 kgf~m, 9 let) Lay a strip of plastigauge lengthwise on each cam- shaft journal and be sure to avoid the oil passages. r, HOLDER CAMSHAFT PLASTIGAUGE 8-10 CYLINDER HEAD/VALVE Install the dowel pins and cylinder head cover onto the cylinder head while holding the rocker arms, being careful not to drop the plastigauge. Apply engine oil to the threads and seating surface of the cap nutslnstall the bolts and cap nuts with the washers, and tighten them in a crisscross pat- tern in several steps. TORQUE: 10 mm nut: 43 N-m (4.4 kgI-m, 32 Ibl-ft) 8 mm bolt and nut: 26 N‘m (2.7 kgf-m,19lhfvft) Remove the head cover and camshaft holder, and measure the compressed plastigauge at its widest point to determine the oil clearance‘ SERVICE LIMITS: A/B: 0.120 mm (0.0047 in) 0: (L140 mm (0.0055 in) lf the oil clearance exceeds the service limit, replace the camshaft and recheck the oil clearance. Replace the cylinder head, head cover and camshaft holder as a set if the oil clearance still exceeds the service limit. CYLINDER HEAD REMOVAL Remove the camshaft lpage 88). Do not Sfrlks the Remove the following: cylinder need too — two bolts and sealing washers hard and do nor 7 cam chain tensioner damage the matllig — cylinder head SUHSCS With a Screwdnve/ r gasket . f. ,._ » dowel pins GASKET » cam chain guide I a CHAlN GUIDE «4 8-11 CYLINDER HEAD/VALVE CYLINDER HEAD DISASSEMBLY NOTE: I Mark all parts during disassembly so they can be placed back in their original locations. ,_ -. p 1 SPRING COM vRESSO 1‘ Top/evenz/oss of Remove the valve spring cutters using the valve tang/on, do not spring compressor. compress the valve . spnng marethan TOOL , necessary ,0 Valve spring compressor 07757-0010000 remove the cutters Remove the following: — spring retainer — valve spring 7 valve 7 stem seal 7 spring seal SPRING RETAINER SPRING SEAT STEM SEAL INSPECTION CYLINDER HEAD Be careiulnotzo Remove the carbon deposits from the combustion COMBUST'ON CHARTER ‘ damage the gasket chamber. I .~ . surface Check the spark plug hole and valve areas for - {a 7 cracks. ' ' Check the cylinder head for warpage with a straight edge and feeler gauge across the stud holes. SERVICE LIMIT: 0.10 mm (0.004 in) 8-12 inspect and reface the valve seats whenever the va/ve guides are Iep/aced [page 8775} CYLINDER HEAD/VALVE VALVE SPRING Measure the valve spring free length. SERVICE LIMITS: IN: 43.90 mm (1.728 in) EX: 41.80 mm (1.646inl VALVE/VALVE GUIDE Check that the valve moves smoothly in the guide. Check the valve for bends, burns or abnormal wear. Measure each valve stem DD. and record it. SERVICE LIMITS: IN: 6.57 mm (0.259 in) EX: 6.545 mm (0.2577 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 clock— wuse. TOOL: Valve guide reamer, 6.5 mm VALVE GUIDE REAMER 07984-ZE20001 ar 07984—2E2000D (U.S:A. only) Measure each valve guide ID. and record it. SERVICE LIMIT: IN/EX: 6.635 mm (0.2612 in) Subtract each valve stem CD. from the correspund» ing guide ID. to obtain the stem»to»guide clearance. SERVICE LIMITS: IN: 0.08 mm (0.003 in) EX: 0.115 mm (0.0045 in) VALVE GUIDE If the stem-torguide clearance exceeds the service limit, determine if a new guide with standard dimensions would bring the clearance within toler- ance. 4 If so, replace any guides as necessary and ream to «' fit. If the stem-torguide clearance exceeds the service limit with a new guide, also replace the valve. 8-13 CYLINDER HEAD/VALVE CAM CHAIN TENSIONEFl/GUIDE Check the tensioner and guide for excessive wear or damage. VALVE GUIDE REPLACEMENT Mark new valve guides at me spec/- fled height mm. cared be/UW, using a marker Be Sure to WES! heavy gloves when handling me heated Cylinder head Usrng a torch r0 heat the cylinder head may cause warpage Chill the new valve guides in a freezer for about an houn Heat the cylinder head to 130~140°C (275—290°F) with a hot plate or oven, Do not heat the cylinder head beyond 150°C (300°Fl. Use temperature indicar tor sticks, available from welding supply stores, to be sure the cylinder head is heated to the proper temperature. Support the cylinder head and drive the valve guides out of the cylinder head from the combus- tion chamber side using the special tool. TOOL: Valve guide driver, 6.6 mm 0774241010200 or 07942-5570100 (U.S.A. only) While the cylinder head is still heated, remove the new valVe guides from the freeier and drive them into the cylinder head from the camshaft side until the exposed height is at the specified value (at the marks). TOOL: Valve guide driver, 6.5 mm 07742-0010200 or 07942-6570100 (U.S.A. only) VALVE GUIDE PROJECTION: IN: 145 mm (0.57 in) Ex: 15.5 mm (0.61 in) Let the cylinder head cool to room temperature. GUIDE TENSIONER VALVE GUIDE DRIVER VALVE GUIDE [REE/FR 8-14 CYLINDER HEAD/VALVE Take care not to tilt Ream the new valve guides. or lean the reamer Insert the reamer from the combustion chamber in the gU/de while side of the head and always rotate the reamer clockr reaming wise. Use cumng all on TOOL: n d ' e Valve guide renmer, 6.6 mm o7984-zezooo1 or D7984»ZEZOODD lU.S.A. only) VALVE GUIDE REAMER Clean the cylinder head thoroughly to remove any metal particles after reaming and refacing the valve seat (page 845). VALVE SEAT lNSPECTION/REFACING INSPECT|ON Clean all intake and exhaust valves thoroughly to remove carbon deposits. Apply a light coat of Prussian Blue to each valve seat. Tap the valve against the valve seat several times without rotating the valve, to check for proper valve seat contact. Remova the valve and inspect the valve seat face. _ __ / The valve seat contact should be within the speci- - fied width and even all around the circumference STANDARD: 0.9 -1.1 mm (0.035 — 0.043 in) ‘ SERVICE LIMIT: 1.5 mm (0.06 in) If the valve seat width is not within specification, reface the valve seat. Inspect the valve seat face for: ' Damaged face: — Replace the valve and relace the valve seat. I Uneven seat width: — Replace the valve and reface the valve seat. DAMAGED FACE UNEVEN SEAT WIDTH 8-15 CYLINDER HEAD/VALVE - Contact area (too low or too high) — Reface the valve seat REFACING NOTE‘ 0 Follow the refacer manufacturer’s operating instructions. 0 Be careful not to grind the seat more than neces- sary. if the contact area is too high on the valve, the seat must be lowered using a 32" flat cutter. lithe contact area is too low on the valve, the seat must be raised using a 60° interior cuttert Using a 45° seat cutter, remove any roughness or irregularities from the seat. TOOLS: Seat cutter. 33 mm (45" IN) Seat cutter, 40 mm (45° EX) 07780-001051“) Cutter holder, 3.6 mm 07781-0010202 or equivalent commercially available in USA. 07780-001 0800 TOO LOW TOO HIGH CONTACT T00 HIGH I. CONTACT T00 LOW §. »\OLDSEAT OLD SEAT WIDTH 60" ROUGHNESS 8-16 Excessive /appmg pressure may defarm or damage the seat. Do naz allow up. ping Compound to enrer the guides. Using a 32° flat cutter, remove 1/4 of the existing valve seat material, TOOLS: Flat cutter, 33 mm (32" IN) 077800012900 Flat cutter, 42 mm (32" EX) 07780-001300!) Cutter holder, 6.6 mm 07781-0010202 or equivalent commercially available in U.S.A. Using a 60“ interior cutter, remove 1/4 of the exist- ing valve seat material. TOOLS: Interior cutter, 30 mm (60” IN) 07780-0014000 Interior cutter, 37.5 mm (60" EX) 07780-0014100 Cutter holder, 6.6 mm 07781-0010202 or equivalent commercially available in U.S.A. Using a 45" seat cutter, cut the seat to the proper ‘ A 7 TVs/AT WIDTH width. Make sure all pitting and irregularities are removed. CYLINDER HEAD/VALVE OLD SEAT WIDTH 60° / LWL After cutting the seat, apply lapping compound to the valve face, and lap the valve using light pres- sure. Change the angle of the lapping tool frequently to prevent uneven seat wear. After lapping, wash any residual compound off the cylinder head and valve and recheck the seat con» , , tact. LAPPING TOOL 8-17 CYLINDER HEAD/VALVE CYLINDER HEAD ASSEMBLY COTTE RS a '3 SPRING HETAINERS EXHAUST VALVE SPRING INTAKE VALVE SPRINGS a /e @ STEM SEALS 3 SPRING SEATS ‘ INTAKE VALVE GUIDES INTAKE VALVES EXHAUST VALVE —> Blow out all of the oil passages in the cylinder head with compressed air. Install the spring seats and new stem seals. Lubricate the valve stem sliding su rface with molyb- denum oil solution. Insert the valve into the guide while turning it SPRING slowly to avoid damaging the stern seal. RETAINER °‘\ VALVE : \ SPHING SEAT STEM SEAL $9 Install the valve springs with the tightly wound coils of the exhaust valve spring facing the combustion chamber. INTAKE: Install the spring retainer. EXHAUST: g Combustion chamber side 8-18 CYLINDER HEAD/VALVE Grease the cones Install the valve spring cutters using the valve W — v ‘ to ease installation spring compressor, [SPRING COMEHESSOR To prevent loss of tension, donor TOOL: compress the valve Valve spring compressor 07757-0010000 Sp/lngs more than necessary a: install the cutters M. Support the cylinder head so the valve heads will not Contact anything and uossibly get damaged. Tap the valve stems gently with two plastic ham- mers to seat the cutters firme as shown. CYLINDER HEAD INSTALLATION Clean the gasket mating surfaces of the cylinder and cylinder head thoroughly, being careful not to dame age them. Install the cam chain guide by aligning the guide and with the groove in the crankcase and the bosses with the groove in the cylinder, install thetwo dowel pins and a new gasket. 8-19 CYLINDER HEAD/VALVE The Cylinder heads Install the cylinder head onto the cylinder. have the following identification marks — " from TENSIONER t CYLINDER HEAD Install the cam chain tensioner by aligning the ten» sioner end with the groove in the crankcase. Install the tensioner bolts with new sealing washers and tighten them alternately. TORQUE: 12 NM [1.2 kgf-m, 9 lbl-ft) CAMSHAFT INSTALLATION NOTE: - If both the front and rear camshafts were removed, start the installation with the front cyl» inder (see page 8-21) - Even if you are servicing either the front or rear cylinder head, the other cylinder head cover must be removed and the other camshaft posi- tion must be checked. ‘ Carefully rotate the crankshaft while holding the cam chain to avoid jamming the cam chain into the timing sprocket of the crankshaft. FRONT CAMSHAFT .Ifthe rearcy/irvder Remove the rear cylinder head cover and check the has not been ser- rear camshaft position as follows: med, beg/h here INDEX MARK Turn the crankshaft clockwise and align the "RT" mark on the primary drive gear with the index mark on the crankcase cover, then check the identification ' mark "R" on the rear camshaft flange. — If the "R" mark faces up, turn the crankshaft clockwise 1-1/7 (412°) turn (align the "FT" mark with the index mark) and begin installation of the front camshaft. — If the “R” mark faces down (cannot be seenl, turn the crankshaft clockwise 1/7 (52") turn (align the "FT" mark with the index markl and begin instal- lation of the front camshaft. 8-20 lfboth Camshafts Align the “FT” mark on the primary drive gear with have been serviced, the index mark on the crankcase cover. [)2ng msra/latlon of the from camshaft here. The Camshafts are identified by the fair lowlng marks Jr" tram carnr snan JR " rear Camshaft Make sure the WW lflg marks on the sprocketa/igns With the Cylinder head surface when the "FT" mark is a/lgrled With the Index mark CYLINDER HEAD/VALVE Set the cam sprocket onto the cam chain carefully so the timing marks on the sprocket are flush with the cylinder head surface. Apply molybdenum oil solution to the camshaft journals. Install the camshaft onto the cylinder head through the sprocket with the “F” mark on the flange facing up, then install the sprocket onto the camshaft flange. “F” MARK Align the bolt holes in the sprocket and camshaft flange and install the camshaft holder with the dowel pins. Install the holder bolts and tighten them alternately in several steps. Apply locking agent to the threads of the sprocket bolts. install the sprocket bolt. Turn the crankshaft clock- wise one revolution and install the remaining boltt Tighten the sprocket bolt while holding the crank- shaft. TORQUE: 23 N-m (2.3 kgf-m, 17 lbf-ft) Turn the crankshaft one revolution and tighten the other bolt to the same torque. 8-21 CYLINDER HEAD/VALVE Coat new O-rings with engine oil and install them into the grooves in the spark plug sleeve. Apply engine oil to the sleeve threads. Install the spark plug sleeve and tighten it. TOOL: Fork tuba holder attachment 07930-KA50‘IDD TORQUE: 18 NM (1.8 kgf-m, 13Ib1-ftl SLEEVE REAR CAMSHAFT ltthefronrcylmder Turn the crankshaft clockwise and align the "FI’" has notbeen serr mark on the primary drive gear with the index mark weed, remove the on the crankcase cover. then check the identification frontcvlmder head mark "F" on the front camshaft flange. coverandbegm — If the “F” mark faces up, turn the crankshaft ' ‘» "‘f' installation oftne clockwise 6/7 (308“l turn and align the "RT" mark ' F MARK rear camsharr. with the index mark. — lfthe “F” mark faces down (cannot be seen), turn the crankshaft clockwise 1—6/7 l668°l turn and align the "RT" mark with the index mark. NOTE: 0 The remainder of the rear camshaft installation is the same as the procedures described on page 8» 21 from the second step. The "R" mark on the rear camshaft flange should face up. ARK INDEX MARK PIN After camshaft installation is completed, remove the 2 mm pin from each cam chain tensioner. 8-22 CYLINDER HEAD/VALVE ROCKER ARM INSTALLATION INTAKE ROCKER ARMS SEALING WASHERS O-RINGS BOLTS EXHAUST ROCKER ARM SHAFT The rocker arms have the following identification marks: MARK "IN": intake "EX": exhaust Place the rocker arms into the head cover in the proper position. Coat new 0»rings with molybdenum oil solution and install them into each rocker arm shaft groove. Apply molybdenum oil solution to the sliding sur- face of the shaft. Install the rocker arm shafts through the head cover and rocker arms. 8-23 CYLINDER HEAD/VALVE Align the bolt holes in the head cover and rocker arm shafts. Install the retaining bolts with new seal- ing washers and tighten them. CYLINDER HEAD COVER INSTALLATION Rotate the crankshaft clockwise so the cam lobes face down. DOWEL PINS Clean the gasket mating surfaces of the cylinder head and cover thoroughly, being careful not to damage them. Install the following: » two dowel pins — joint collar and a new O-ring (apply engine oil] — rubber plugs (apply sealant to the seating sur- facel Apply molybdenum oil solution to the camshaft journals and cam lobes. Apply molybdenum oil solution to the slipper sur- faces of the rocker arms. Apply liquid sealant to the head cover mating sur- face as shown. Make sure the seal» Carefully install the cylinder head cover while hold- ant l5 app/led ing the rocker arms to avoid interfering the rocker evenly re the mat- arms with the camshaft. mg surfaces 8-24 CYLINDER HEAD/VALVE Install the water pipe with a new Orringt Apply engine oil to the threads and seating surface of each cap nut, and install the following: — faur10-mm cap nuts and with new sealing washv ers — two 8-mrn cap nuts and with new sealing wash, ers — two 8-mm bolts — 6—mm bolt Tighten the fasteners in a crisscross pattern In sev» eral steps. TORQUE: 10 mm nut: 43 N-m (4.4 kgf-m, 32 Ibf-ft) 8 mm bolt and nut: 26 Nrm (2.7 kgf-m, 19 IM-ft) Install the following: — spark plugs (page 3-7) — valve adjusting hole caps (page 3-10) — timing hole cap (page 3-10! VALVE ADJUSTING 7 intake manifold (page 5-23; if the cylinder head # 7'—#'—i was removed) Install the cylinder head fins with the setting rub- bers. Install the fin bolts and washers, and tighten them. Install the engine in the frame (page 7-2)‘ 8-25 MEMO 'L 9. CYLINDER/ PISTON SYSTEM COMPONENTS ------------------------- -- 9—2 CYLINDER/PISTON REMOVAL --------------- -- 9-4 SERVICE INFORMATION ------------------------- -- 9-3 CYLINDER/PISTON INSTALLATION-unm- 9.9 TROUBLESHOOTING ............................... .. 9.3 9-1 CYLINDER/PISTON SYSTEM COMPONENTS 9-2 CYLINDER/PISTON SERVICE INFORMATION G ENERAL This section covers service of the pistons and cylinders. To service these parts, frame. Take care not to damage the cylinder walls and pistons. Be careful not to damage the mating surfaces when removing removal. _ r _ ‘ When disassembling. mark and store the disassembled parts to ensure that they are reinstalled in their original loca- tions. Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. Camshaft and rocker ing the cylinder. the engine must be removed from the o the cylinders. Do not strike the cylinders too hard during arm lubricating oil is fed through oil passages in the cylinder. Clean the oil passages before install- SPECIFICATIONS Unit: mm (in) L w ITEM 7 ‘ STANDARD ( SERVICE LIMIT Cylinder ( ID, 89500 — 89.515 (3.5236 — 3.5242) 89.55 (3.326) ‘ Out of rond — 0.10 (0.004) Taper ' — 0.10 (0.004) ' Warpage — ‘ 0.10 (0.004) ‘ Piston, Piston CD. at 15 mm (0.6 in) from 89.470 >89.490 (3.5224— 3.5232) 89.41 (3.520) piston pin, bottom l ‘ piston rings Piston pin bore ID. 20002 — 20008 (0.7875— 0.7877) 20.018 (0.7881) ' Piston pin OD. 19.994 — 20.000 (0.7872 — 0.7874) 19.984 (0.7863) Piston-to»piston pin clearance 0.002 — 0.014 (0.0001 — 0.0006) R 0.034 (0.0013) Piston ring end rTop 0.200 — 0.300 (0.0079 - 0.0118) 0.315 (0.0124) a ‘ gap ‘7 Second 0.300 — 0.400 (0.0118 — 0.0157) 0.415 (0.0163) Oil 0.425 — 0.475 (0.0167 - 0.0187) 0.495 (0.0195) (side rail) I Piston ring-to-ring Top 0.015 — 0.050 (0.0006 — 0.0020) ‘, 0.070 (0.0028) ‘ groove clearance ‘ Second 0.015 r 0045 (0.0006 — 0.0018) 0.065 (00026)” ‘ Cylinder-torpiston clearance 0.010 — 0.045 (0.0004 — 0.0018) 0.32 (0.013) Connecting rod small end |.D. 20.016 » 20.034 (0.7880 — 0.7887) 7 20.044 (0.7891) ‘ Connecting rod»to-pi5ton pin clearance 0.016 — 0.040 (0.0006 - 0.0016) . 0.063 (0.0025) TORQUE VALUE Cylinder stud bolt See page 9-8, ‘ TROUBLESHOOTING Compression too low, hard starting or poor peflormance at low speed 0 Leaking cylinder head gasket - Worn, stuck or broken piston ring - Worn or damaged cylinder and piston Compression too high, overheating or knocking 0 Excessive carbon built-up on piston head or combustion chamber Excessive smoke - Worn cylinder, piston or piston rings - Improper installation of piston rings o Scored or scratched piston or cylinder wall Abnormal noise - Worn piston pin or piston pin hole - Worn cylinder, piston or piston rings - Worn connecting rod small end CYLINDER/ PISTON CYLINDER/PISTON REMOVAL CYLINDER REMOVAL Remove the cylinder head (page 8711l. Heal cwfnder only Remove the bolt and disconnect the water hose. Remove the O-ring. I r Remove the retaining clips and slide the water pipe li’ ‘ ' to disconnect it from the cylinder. ‘ Do norsluke the Lift the cylinder and remove it, being carelul no! to cylmaertoo hard damage the piston with the stud bolts. and an no! damage . r . the/hating surface Remove the water pipe and 0 rings. MW a screwdriver 3 Remove the following: — gasket 7 dowel pins — crankcase breather reed valve . | ‘ 9-4 CYLINDER/PISTON PISTON REMOVAL Place a clean snap Remove the piston pin clip with pliers. HSTON towel over the Push the piston pin out of the piston and connecting crankcase to We rod, and remove the piston. Vent me C/lp from falling "‘10 me crankcase. / 4t , , CLIP PISTON PlN l Donotdamage me Spread each piston ring and remove it by lifting up plSZDH nng by at a point opposite the gap‘ spreading the ends too far PISTON RING Never L/sea Wire Clean carbon deposits from the ring grooves with a brush, it wr/lscrarch used piston ring that will be discarded. the groove, Be careful no: to let Remove the belt and the oil jet. the ban fall mm the crankcase CYLINDER/PISTON INSPECTION PISTON/PISTON RING Inspect the piston rings for smooth movement by rotating them. The rings should be able to move in their grooves without catching. Push the ring until the outer surface of the piston ring is nearly flush with the piston and measure the ring»torring groove clearance. SERVICE LIMITS: Top: (1070 mm (0.0028 in) Second: 0.065 mm (0.0026 in) Insert the piston ‘ring into the bottom of the cylinder squarely using the piston crown. Measure the ring end gap. PISTON RING SERVICE LIMITS: Top: 0.315 mm (0.0124 in) Second: 0.415 mm (0.0163 in) Oil (side rail): 0495 mm (0.0195 ill) Measure the piston CD. at a point 15 mm (0.6 in) from the bottom and 90° to the piston pin hole. SERVICE LIMIT: 89.41 mm (3.520 in) 15mm Compare this measurement against the maximum (0.6 in) cylinder l.D. measurement and calculate the cylin- der—torpiston clearance (page 9-7). Measure the piston pin OD. at three points. SERVICE LIMIT: 19.984 mm (0.7868 in) 9-6 CYLINDER/PISTON Measure the piston pin hole l.D. SERVICE UMIT: 20.018 mm (0.7881 in) Calculate the piston»to-piston pin clearance. SERVICE LIMIT: 0.034 mm (0.0013 in) CONNECTING ROD Measure the connecting rod small and ID. SERVICE LIMIT: 20.044 mm (0.7891 in) Calculate the connecting rodrto-piston pin clear ance. SERVICE LIMIT: 0.053 mm (0.0025 in) CYLINDER Inspect the cylinder wall for scratches or wear, Measure the cylinder ID. at three levels on the X and Y axes. Take the maximum reading to deter- mine the cylinder wear. SERVICE LIMIT: 83.55 mm (3.326 in) Calculate the cylinder-to-piston clearance, SERVICE LIMIT: 0.32 mm (0.013 inI Calculate the cylinder taper and out-ofrround at three levels on the X and Y axes. Take the maximum reading to determine the taper and out-of»round. SERVICE LIMITS: Taper: 0.10 mm (0.004 in) Out-of-round: 0.10 mm (0.004 in) The cylinder must be rebored and an oversize pis- ton fined ii the service limits are exceeded. / '\ i MIDDLE \ / x \ _ I- i / The 0.25 mm (0.010 in) oversize piston is available. ,/ ’ ‘ f ‘ "x \ ./ The cylinder must be rebored so the clearance for an oversize piston is 0.010 A 0.045 mm (0.0004 — ‘ ‘~_ gr’ 0.0018 in). \v// CYLINDER/PISTON Check the top of rhe cylinder for warpage with a straight edge and feeler gauge across the stud holes. SERVICE LIMIT: 0.10 mm (0.004 in) OIL J ET Check the ail jet for clogs. Blow But the oil jet with compressed air. REED VALVE Check The reed for damage or fatigue. Check the rubber seal for cracks, deteriorakiun or damage. Check for clearance between Ihe read and rubber seat. There should be no clearance. CYLINDER STUD BOLT REPLACEMENT Thread two rims onto the srud and tighten them together, and use a wrench on them to turn the stud bolt out. STOPPER RUBBER SEAT STUD BOLTS 9-8 CYLINDER/PISTON Apply engine oil to the lower threads of a new stud bolt and install it in the direction as shown, Be sure to verify the stud height from the crankcase l surface. Adjust the height if necessary. 10mmSTUD BOLT: 8 mm STUD BOLT: 254 :1 mm (1011:0114 in) 258.5 i1 mm (10.181004 in) CYLINDER/PISTON INSTALLATION Be careful nut to damage me piston and nngs, Be Careful not to let the bolt fall lnto the crankcase. PISTON RING INSTALLATION Carefully install the piston rings into the piston ring grooves with the markings facing up. NOTE: O Do not confuse the top and second rings. 0 To install the oil ring, install the spacer first, then install the side rails, TOP RING MARK SECOND RING 70" ,, r / [2 Stagger the piston ring and gaps 120° apart from SECOND each other. Staggerthe side rail end gaps as shown PISTON INSTALLATION Coat a new O-ring with engine oil and install it into the oiljet groove. Install the oil jet and tighten the bolt securely. CYLINDER/PISTON Place a clean shop towel over the crankcase to pre- vent the clip from falling into the crankcase. Apply molybdenum oil solution to the connecting rod inner surface. Apply engine oil to the piston pin outer surface. Install the piston and insert the piston pin through the piston and connecting rod. Install new piston pin clips into the grooves in the piston pln hole, NOTE‘ I I 0 Make sure the piston pin clips are seated ‘ semre'v' @ CLIP PISTON PM E - Do not align the clip end gap with the piston cuts r “ _ f _ I out. CYLINDER INSTALLATION Clean the gasket surfaces of the cylinder and crank— case thoroughly, being careful not to damage them. Install the reed valve onto the crankcase in the ' - direction as shown. Install the dowel pins and a new gasket. Apply engine oil to the cylinder wall, piston outer surface and piston rings 9-10 CYLINDER/PISTON The cylinders have Route the cam chain through the cylinder and install i‘,,RRn the following identir the cylinder over the piston while compressing the {matron marks piston rings with your fingers. ~ "FR" from r "W?" rear Be careful not In damage the piston rings and Cylinder wall. Coat new Orrings with coolant and install them into the grooves in the water pipe. Install the water pipe into the cylinder with the hose joint facing to the left while lifting either cylinder slightly. Slide the water pipe into the hole in the cyl- inder and connect it. Install the retaining clips into the pipe grooves. Rearcylmdsroniy. Install a new O-ring and connect the hose joint into the rear cylinder. Install the joint bolt and tighten it. Install the cylinder head (page 8-19). 9-11 MEMO 10. CLUTCH/GEARSHIFT LINKAGE SYSTEM COMPONENTS ----------------------- -- 10-2 SERVICE INFORMATION ---------------------- -- 10-4 TROUBLESHOOTING ----------------------------- -- 10-6 RIGHT CRANKCASE c REMOVAL ..... "10.7 CLUTCH GEARSHIFT LINKAGE-~- - 10—15 PRIMARY GEARS 10-18 RIGHT CRANKCASE COVER INSTALLATION .................................... .. 10.21 m CLUTCH LIFTER ARM -------------------------- -- 10-22 10-1 CLUTCH/GEARSHIFT LINKAGE SYSTEM COMPONENTS 1S N-m (1.8 kgf—m, 13 Ibf-fi) 186 N-m (19.0 kgf-m, 137 (MR) 12 N-m (1.2 kgf-m, 9 (bf-ft) 23 Nm (2.3 kgf-m, 17 lbf-fl) 138N-m(14.1kgfvm, 102 (bf-fl) 12 Nrm (1.2 kgf—m, 9 |th) 10 N«m (1.0 kgf—m, 7 lbftfl) 10 Nm (1.0 kgf—m, 7 (bf-m 10-2 CLUTCH/GEARSHIFT LINKAGE 10-3 CLUTCH/GEARSHIFI' LINKAGE SERVICE INFORMATION G ENERAL - The clutch and gearshift linkage can be serviced with the engine in the frame. ' Engine oil viscosity, oil level and the use Of oil additives have an effect on clutch disengagement, Oil additives of any kind are specifically not recommended. When the clutch does not disengage or the motorcycle creeps with the clutch disengaged, inspect the engine oil and oil level before servicing the clutch system. - The crankcase must be separated when the transmission, shift drum and shift forks require service (page 11-6l. SPECIFICATIONS Unit: mm (in) C V IYEM STANDARD SERVICE LIMIT {7 Clutch lever freeplay ‘7 10 — 20 (3/8 » 3/4) 7 — Clutch l Spring free length 58.2 (2.29) 56.7 (2.23) Disc thickness 3.72—3.88 (0.146—0.153l 3.1 (0.12) l Plate warpage — 0.30 (0.012) Clutch outer guide l.D. 27.995 - 28.012 (1.1022 —1.1023l 28.80 (1.134) LMainshaft 0.0. at clutch outer guide 27.980 —27.9337(_1.1016 — 1.1021) 27.97 (1.101) :l TORQUE VALUES Clutch pressure plate bolt Clutch center lock nut Clutch cuver socket bolt Timing hole cap cover socket bolt Primary drive gear bolt Primaw driven gear nut Shift drum stopper arm pivot bolt Shift drum center socket bolt Gearshift arm pinch bolt Oil pump driven sprocket bolt 12 Nm [1.2 kgI-m,9|bf-f1) 186 N-m (19.0 kgf‘m, 137 lbf-ft) 10 N~m (1.0 kgf-m, 7 lbf-ft) 10 N-m (1.0 kgf-m, 7 lbf-ft] 138 N~m(14.1kgf-m,102lbf-fll 186 N-m (19.0 kgf‘m,137lbf-ftl 12 N-m (1.2 kgfm, 9 Ibf-ftl 23 N-m (2.3 kgf~m,17|bf-ftl 12 N-m (1.2 kgf-m, 9 Ibf-ft) 18 N-rn (1.8 kgf-m,13lbf-ft) Replace with a new one and stake. Apply oil to the threads and flange surface. Apply oil to the threads and flange surface. Replace with a new one and stake. Apply oil to the threads and flange surface. Apply locking agent to the threads. 1 0-4 TOOLS CLUTCH/GEARSHIFT LINKAGE Clutch cemer holder 07JMB-MN50301 or 07HGB-OD1D10B (plate) and 07HGB-0010205 (collar) (U.S.A. only) Aflachment, 32 x 35 mm 07746-0010100 Film, 17 mm 07746-0040400 Driver 07749-0010000 Gear holder 07724—0010100 or 07724-001A100 (USA. only) 1 0-5 CLUTCH/GEARSHIFI' LINKAGE TROUBLESHOOTING Clutch lever engagement hard - Damaged, kinked or dirty clutch cable 0 Improperly muted clutch cable - Damaged clutch lifter mechanism - Faulty clutch lifter bearing clutch will not disengage or motorcycle creeps with clutch disengaged - Too much clutch lever freeplay - Warped clutch plates - Loose clutch lock nut 0 Engine oil level too high, improper oil viscosity or oil additive used Clutch slips I No clutch lever freeplay - Worn clutch discs - Weak clutch springs - Clutch lifter sticking - Engine oil level too low or oil additive used Hard to shift 0 Improper clutch operation - incorrect engine oil viscosity Incorrect clutch adjustment Bent or damaged gearshift spindle Damaged gearshift cam Bent fork shaft or damaged shift forks and shift drum Transmission jumps out of gear - Broken shift drum stopper arm 0 Weak or broken gearshift spindle return springs - Worn or damaged gearshift cam ' Bent fork shaft or worn shift forks and shift drum - Worn gear dogs or dog holes 10-6 CLUTCH/GEARSHIFI' LINKAGE RIGHT CRANKCASE COVER REMOVAL Drain the engine oil (page 3711)‘ Remove the exhaust system (page 2-12). Remove the four socket bolts and clutch cover. Remove the six socket bolts and timing hole cap covet Remove the 16 bolts and the right crankcase caver. Remove thetwo dowel pins CLUTCH DISASSEMBLY Remove the right crankcase cuver (page 10-7). Loosen the clutch pressure plate bolts in a crissi cross pattern in several steps, and remove the bolls, springs and the clutch pressure plate. CLUTCH/GEARSHIFI' LINKAGE Remove the clutch lifter piece and lifter rod from the mainshah. Remove the following: — clutch disc B ~ seven clutch plates — six clutch discs A — clutch disc B 59 mam/not to Unstake the clutch center lock nut. damage me mains/73ft threads Hold ihe clutch center with lhe special tool and loosen the clu‘ch center lock nut. TOOL: Clutch canker holder 07JMB—MN50301 or 07HGB-00101DB (plate) and 07HGB-DD10203 (collar) (U.5.A. only) Remove the tool and clutch center lock nut. 10-8 CLUTCH/GEARSHIFT LINKAGE Remove the three washers .4” : CLUTCH CENTER ASSE—IT/IBLY Remove the clutch center assembly. Remove the clutch cemer boss and rubber dampers from the clutch center. CLUTCH CENTER CLUTCH CENTER BOSS Remove the clutch outer and needle bearing. 1 0-9 CLUTCH/G EARSHIFT LINKAGE Remove the clutch outer guide washer and outer ' guide. INSPECTION LlFrER BEARING Turn the inner race of the “her bearing with your finger. The bearing should turn smoothly and quietly. Also check that the outer race of the bearing fits tightly in the pressure plate. Replace the bearing it the inner race does not turn smoothly, quietly, or if theI outer race fit loosely in the pressure plate. Drive the bearing out of the pressure plate. Drive a new bearing into the plate with its mark side facing out. DRIVER TOOLS: Driver 07745—0010000 Attachment. 32 x 35 mm 07745—0010100 Pilot, 17 mm 07745—0040400 " LA'lTACHMENT CLUTCH SPRING Replace the clutch Measure the clutch spring free length. spnng as a set SERVICE LIMIT: 56.7 mm (2.23 in) 10-10 CLUTCH/GEARSHIFI' LINKAGE CLUTCH CENTER Check the clutch center and pressure pla‘e for nicks, indematibns or abnormal wear made by the plares. RUBBER DAMPER Check the rubber dampers for deterioration, wear or damage. CLUYCH LIFTER ROD Check the clutch lifter rod for bands or damage. CLUTCH DISC Replace the slum/7 Replace the clutch discs if they show signs of scar- mscs andp/Etes as ing or discoloration. a 59’ Measure the clutch disc thickness. SERVICE LIMIT: 3.1 mm (0.12 In) 10-11 CLUTCH/GEARSHIFI' LINKAGE CLUTCH PLATE Rep/ace the 5mm Check the clutch plate for discoloration rims and plates as “at Check the clutch pIale warpage on a surface plate using a feeler gauge. SERVICE LIMIT: 0130 mm (0.012 in) CLUTCH OUTER GUIDE Check the clutch omer guide for damage or abnor- mal wear. Measure the clutch ouxer guide |.D. SERVICE LIMIT: 28.30 mm (1.106 in) MAINSHAFI' Measure the mainshaft O.D. at the clutch outer guide. SERVICE LIMIT: 27.97 mm (1.101 in) CLUTCH OUTER Check the slots in the clumh outer for nicks, indenta- tions or abnormal wear made by the dutch discs. SLOT 10-12 CLUTCH/G EARSHIFI' LINKAGE ASSEMBLY Coat the clutch outer guide with molybdenum oil ' ' , - solution. '« OUTER GUIDE WASHER Install the clutch outer guide onto the mainshaft with the flange side facing the crankcase. Apply oil to the outer guide washer. Install the guide washer onto the outer guide. Apply oil to the clutch outer needle bearing. Install the needle bearing and clutch outer onto the outer guide. Install the rubber dampers into the clutch center. Apply oil to the clutch center sliding surface of the RUBBER DAMPERS center boss and install it onto the clutch center. CLUTCH CENTER BOSS CLUTCH CENTER E Install the clutch center assembly onto the — ‘- mainshm r CLUTCH CENTER ASEMBLY 10-13 CLUTCH/GEARSHIFT LINKAGE Install the three washers as shown. Apply oil to the threads and seating surface of a new clutch center lock nut and install it onto the mainshaft. Hold the clutch center with the special tool and tighten the lock nut. TOOL: Clutch center holder 07JMB—MN50301 or 07HGB-00101OB (plate) and 07HGB-DD1OZOE (collar) (U.S.A. only) TORQUE: 136 N-m (19.0 kgf-m, 137 lbf-ftl Be cereal/norm Stake clutch center lock nut into the mainshaft damage the groove. mains/75ft threads Coat clutch discs A and E with Clean engine oil. Clutch dlSC B has install clutch disc B. pal/715 on the tabs Install the seven clutch plates and six disc A alterr nately, starting with the plate. lSCS fl 10-14 CLUTCH/G EARSHIFT LINKAGE Install clutch disc B into the shallow slots of the clutch outer. 3% Install the clutch lifter rod into the mainshafl. Coat the clutch lifter piece with oil and install it into the mainshatt. clutch bolts. Tighten the clutch bolt in a crisscross pattern in two ‘ fl' or three steps, TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) Install the right crankcase cover (page 1021). v —, lnstall the clutch pressure plate, clutch springs and ’ BOLTS, SPRINGS > GEARSHIFT LINKAGE REMOVAL Disassemble the clutch (page 10-7)‘ Remove the bolt and gearshift arm from the gear- shift spindle. 10-15 CLUTCH/GEARSHIFI' LINKAGE Remove the gearshift spindle assembly and thrust washer. Remove the shift drum center socket bolt and cam plate. Remove the stopper arm pivot bolt, arm, washer and return spring. Remove the dowel pin from the shift drum. INSPECTION Check the gearshift spindle for bends. Check the spindle plate for wear or damage. RETURN SPR'NG Check the spindle return spring for fatigue or dam- age. SPINDLE PLATE INSTALLATION Install the dowel pin into the shift drum. Install the return spring, washer, stopper arm and pivot bolt, and tighten the bolt. TORQUE: 12 Nm (1.2 kgf‘m, 9 Ith) 'RETURN SPRING PIVOT BOLT kWASHER STOPPER ARM 10-16 CLUTCH/GEARSHIFT LINKAGE Lift the stopper arm with a screwdriver and install the cam plate by aligning the pin groove in the plate with the dowel pin. Apply locking agent to the shift drum center socket bolt threads. Install and tighten the socket bolt. TORQUE: 23 N-m (2,3 Him, 17 lbf-ft) Install the thrust washer onto the gearshift spindle, r and insert the spindle into the crankcase, aligning the return spring ends with the spring pin. Install the gearshift arm onto the spindle, aligning the slit of the arm with the punch mark on the spin< dle. Tighten the gearshift arm bolt. TORQUE: 12 M!“ (1,2 kgf-m, S Ibfvft) Assemble the clutch (page 10-13l, ff SLIT AND PUNCH MARK 10-17 CLUTCH/GEARSHIFT LINKAGE PRIMARY GEARS PRIMARY DRIVE GEAR REMOVAL Remave the right crankcase cover (page 10r7l. GEAR HOLD—ER V Install the gear holder between the primary drive ‘ m and driven gears as shown and loosen the primary drive gear bolt. TOOLS: Gear holder 07724—0010100 or 07724-001A100 IU.S.A. only) Remove the bolt, washer and the primary drive gear I__ _ - _ , assembly from the crankshaft, “PRIMARY DRIVE GEAR SSEMBLY INSTALLATION install the primary drive gear assembly onto the crankshaft, aligning the wide groove with the wide PR'TADYSZ'VEN GEAR T’M'NG MARKS ‘ tooth. Align the timing marks on the primary drive and driven gears as shown and mesh the drive and driven gears, Apply oil to the primary drive gear bolt threads and seating surface. Install the washer and primary drive gear bolt. Install the gear holder between the primary drive and driven gears as shown and tighten the primary drive gear bolt. TOOLS: Gear holder 07724—001010!) or D7724-001A100 (U.S.A. only) TORQUE: 138 Nm [14.1 kgf-m,102|bf-ftl Install the right crankcase cover (page lD-Z1l. 10-18 CLUTCH/GEARSHIFT LINKAGE PRIMARY DRIVEN GEAR REMOVAL Disassemble the clutch (page 107). When the oil pump driven sprocket will be removed, loosen the driven sprocket bolt. Be careful/lot m Unstake the primary driven gear nut. damage the rear balance! shaft threads. Install the gear holder between the primary drive and driven gears as shown and loosen the primary driven gear nut. \ TOOLS: Gear holder 07724—001010!) or 07724-001 A 100 (U.S.A. only) Remove the nut, washer and primary driven gear. Remove the oil pump driven sprocket bolt and washer. Remove the oil pump driven sprocket, drive chain and drive sprocket as a set. DRIVE SPROCKET 10-19 CLUTCH/GEARSHIFT LINKAGE INSTALLATION install the oil pump drive sprocket, drive chain and driven sprocket as a set with the "OUT" mark on the driven sprocket facing out. Apply locking agent to the oil pump driven sprocket bolt threads and install the washer and bolt. NOTE: 0 Tighten the driven sprocket bolt to the specified W torque after installing the primary driven gear. Install the primary driven gear onto the rear bal- ancer shaft, aligning the wide groove with the wide tooth. Align the timing marks on the primary drive and driven gears as shown and mesh the drive and driven gears. Install the washer onto the rear balancer shaft. 1 0-20 0 Be Careful not to damage the rear balancer shaft threads RIGHT CRANKCASE COVER INSTALLATION Be careful not to damage the "151ng surfaces CLUTCH/GEARSHIFT LINKAGE Apply oil to a new primary driven gear nut threads 7 and seating surface, and install it. Mg Install the gear holder between the primary drive . i and driven gears as shown and tighten the primary driven gear nut. TOOLS: Gear holder 07724—0010100 or 07724—001A100 (USA. only) TORQUE: 186 Mm [19.0 kgl-m, 137 lbf-fl) Stake the primary driven gear nut. Tighten the oil pump driven sprocket bolt if it was removed TORQUE: 18 N-m (1.8 kgf-m. 13 IbH’t) Assemble the clutch (page 1013). Clean the mating su rfaces of the right crankcase and Coven Install the two dowel pins. 10-21 CLUTCH/GEARSHIFI' LINKAGE CLUTCH LIFTER ARM Apply sealant to the right crankcase cover mating F surface as shown. Install the right crankcase cover and 16 bolts, and tighten the bolts in a crisscross pattern in two or three steps. Install the timing hole cap cover and tighten the six socket bolts. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-ft) Install the clutch cover and tighten the four socket bolts. TORQUE: 10 NM (1.0 kgl-m, 7 Ihfrft) Install the exhaust system (page 2-13). Fill the crankcase with the recommended engine oil (page 3-11), REMOVAL Remove the left crankcase rear cover lpage 1&9). Drain the coolant (page 6-7). Remove the two wire bands and water pipe mount- ing bolt. Remove the water pipe from the water pump. \ WIRE BANDS 1 0-22 CLUTCH/G EARSHIFT LINKAGE lifter arm holderr Disconnect the clulch cable from the clutch lifler arm‘ Remove rhe two dowe! pins and O»ringr Turn khe clu‘ch lifter arm counterclockwise and remove rhe clutch joint piece. LIFTER ARM Remove the c‘ulch lifter arm, return spring and washer from the lifter arm holder. WASHER LLFTER ARM RETURN SPRING 1 0-23 CLUTCH/GEARSHIFT LINKAGE Check the dust seal and needle bearings in the clutch lifter arm holderfor wear or damage. Replace the lifter arm holder if necessary. NEEDLE BEARING DUST SEAL INSTALLATION | ’I th I'd' f th | HT filggiv at to e 5| Ing sur ace of e cutch I er RETURN SFRWG Install the return spring and washer onto the lifter arm. Install the lifter arm into the lifter arm holder. / ZE LIFTER AFIM WASHER Hook the return spring ends to the lifter arm and holder as shown. RETURN SPRING Coat the clutch joint piece with oil. Turn the lifter arm counterclockwise and install the joint piece inte the lifter arm holder. 7% LIFTER PIECE 7 ‘II—mu. LIFTER ARM 1 0-24 CLUTCH/GEARSHIFT LINKAGE Install the dowel pins. Coat a new O~ring with oil and install it into the clutch iifter arm holder grooves. Connect the clutch cable to the clutch lifter armt Install the lifter arm holder, ground cable and three bolts, and tighten the bolts securely. Coat a new O-ring with oil and install it onto the water pipe. instail the water pipe into the water pump. install the water pipe mounting boil and tighten it secureiy. Install the wire bands. Fill and bleed the cooling system (Page 6-7). Install the left crankcase rear cover (page 16-12). WIR BANDS 1 0-25 MEMO 11. CRANKSHAFT/TRANSMISSION SYSTEM COMPONENTS ----------------------- -.11-2 SERVICE INFORMATION ----------------------- » 11-3 TnoumjsnoonNG ----------------------------- -415 CRANKCASESEPARAHON ------------------- «1L6 anNKSHAFUCONNECNNGROD ------ -41$ BALANCER SHAFT ............................... .. 11.12 TRANSMISSION] OUTPUT GEAR CASE -------------------------- -- 11-13 CRANKCASE BEARING REPLACEMENT .................................... .. 11.20 m CRANKCASE ASSEMBLY -------------------- -- 11-23 11-1 CRANKSHAFTITRANSMISSION SYSTEM COMPONENTS 31 N-m (3.2 kgf-m, 23 [bf-ft) 26 N-m (2.7 kgf-m,19|bfvft) 12 N-m (1.2 kgftm, 9 lbl-fl) 11-2 CRANKSHAFT/TRANSMISSION SERVICE INFORMATION GENERAL 0 The crankcase must be separated to service the following: — oil pump (page 47) — crankshaft/connecting rod — balancer shaft — transmission Be careful not to damage the crankcase mating surfaces when servicing. Mark and store the connecting rods, bearing caps and bearing inserts to be sure of their correct locations for reassem» bly. The crenkpin bearing inserts are select fit and are identified by color codes. Select replacement bearings from the code tables. After selecting new bearings, recheck the oil clearance with plastigauge. Incorrect oil clearance can cause major engine damage. Prior to assembling the crankcase halves, apply sealant to their mating surfaces. Wipe off excess sealant thoroughly. SPECIFICATIONS Unit: mm (in) ’7 ITEM I STANDARD SERVICE LIMIT Crankshaft Connecting rod big and side clearance I 0.10 — 0.25 (0.004 — 0.010) 0.28 (0.011) 7 Crankpln bearing oil clearance I 0.038 — 0.062 (0.0015— 0.0024) 0.070 (0.0028) ‘ Main journal oil clearance 0.030 — 0.054 (0.0012 j 0.0021) 0.068 (0.0027) fCrankshaft runout if — 0.05 (0.002) Shift fork, ID. V 14.000 — 14.018 (0.5512 A 0.5519) I 14.04 (0.553) fork shaft 7 Claw thickness ‘ 5.93 ~ 6.00 (0.233 - 0.236) I 5.83 (0.230) Fork shaft OD. 13.966 — 13.984 (0.54981 0.5505) 13.956 (0.5494) Transmission Gear |.D. M4, M5 31.000 - 31.025 (1.2205 — 1.2215) 31.035 (1.2218) I C1 30.000— 30.025 (1.1811 — 1.1821) 30.035 (1.1825)i CZ, C3 33.000 — 33.025 (1.2992 - 1.3002) 33.035 (1.3006) Gear busing OD. 044, M5 30.950 - 30.975 (1.2185 — 1.2195) 7 ‘ 30.94 (1.218) C1 25.987 - 26.000 (1.0231 —J.0236) 25.977 (1.0227) 7 C2, C3 32.950 — 32.965 (1.2972 >1.297E) 32.94 (1.297) Gear-to-bushing M4, M5 0.025 —- 0.075 (0.0010 - 0.0030) 0.095 (0.0037) clearance C2, C3 0035 — 0.075 (0.0014 — 0.0030) 0.095 (0.0037) Gear bushing |.D. M4 27.985 — 28.006 (1.1018 -1.1025) 28.03 (1.104) C1 22.050 — 22.150 (0.8681 - 0.8720) 22.170 (0.8728) 7 C2,C3 30.000- 30.030 (1.1811 — 1.1823) 30.050 (1.1831) ¥Mainshaft CD. at M4 7 27.959 — 27.980 (1.1007 — 1.1016) 27.940 (1.1000) Countershaft 0.0. at C1 21.980 — 21.993 (0.8654 — 0.9659) 21.97 (0.865) I at C2, C3 29.959 — 29.980 (1.1795 —1.1803) I 29.94 (1.179) ‘ Bushing40-shaft M4 0.005 - 0.047 (0.0002 — 0.0019) I 0.067 (0.0026) clearance 7C1 0.057 r 0.170 (0.0022 — 0.0067) 0.190 (0.0075) I W (32, C3 i 0.020 — 0.071 (0.0003 — 0.0028) 0.091 (0.0036) I TORQUE VALUES 26 N-m (2.7 kgf-m,19lbf-ft) 12 N-m [1.2 kgf-m, 9 Ibf-ft) 59 NM (6.0 kgf-m. 44 Ibf-ft) 31 N-m (3.2 kgf-m, 23 lbf-ft) 12 Nam (12 kgf-m, 9 Ibf‘ft) 12 N-m (1.2 kgf-m, 9 Ibf-ft) Right crankcase bolt Cem chain tensioner setting plate bolt Connecting rod bearing cap nut Output gear case mounting bolt Shift drum bearing setting plate bolt Ftear balancer shaft bearing setting plate bolt Mainshaft bearing setting plate bolt Apply locking agent to the threads. Apply oil to the threads and flange surface. Apply locking agent to the threads. Apply locking agent to the threads. 12 N-m (1.2 kgf'm, 9 lbf-ft) Apply locking agent to the threads. 11-3 CRANKSHAFT IT RANSMISSION TOOLS Driver 07749—0010000 Attachment, 32 x 35 mm 07746-0010100 Attachment, 42 x 47 mm 07746-0010300 Attachment, 52 x 55 mm Attachment, 62 x 68 mm Pilot, 20 mm 07746-0010400 07746-001050!) 07746-0040500 €51 Pilot, 22 mm Pilot, 25 mm Pilot, 28 mm 07746~0041000 07746-0040600 07746-0041100 Bearing remover handle 07936-3710100 Bearing remover, 20 mm 07936-3710600 Bearing remover weight 077410010201 or 07336-371020A or 07936-3710200 (USA. only) 11-4 CRANKSHAFI'ITRANSMISSION T [ Adjustable bearing remover Bearing remover shaft 07JAC-PHBO'IDD 07JAC-PH80200 l or 07736-A01000B and slide ham- or 07736—AolooDB and slide ham- ‘ mer3/8x16 ‘ merS/Bx 16 TROUBLESHOOTING Excessive engine noise - Worn main journal bearings - Worn crankpin bearings - Worn or damaged transmission gear - Worn ordamaged transmission bearings Hard to shift - Improper clutch operation Incorrect engine oi| viscosity Bent shift forks Bent shift fork shaft Bent shift fork claw Damaged shift drum earn grooves Bent gearshift spindle Transmission jumps out of gear 0 Worn gear dogs or holes 0 Worn gear shifter groove ' Bem shift fork shaft - Broken shift drum stopper arm I Worn or bent shift forks 0 Broken drum stopper arm spring - Broken gearshift spindle return spring 11-5 CRANKSHAFT/TRANSMISSION CRANKCASE SEPARATION Rem“ “‘9 f°”°""i”9‘ I SETI'INa’LATE W DRlVAEUCHAIN — engine (page 7*4l ’ — cylinder head (page 86) — cylinder(page 9-4l — piston (page 9-5) — clutch (page 10-7! ~ gearshift linkage (page 1015) — primary gears (page 1048) — clutch lifter arm holder (page 10-22) — flywheel (page 18—18l — starter gears (page 1845) — iron! and rear cylinder cam chains — bolt and cam chain tensioner setting plate if nec- essary Loosen the five 6 mm bolts and sixteen 8 mm belts in a crisscross pattern in two or three steps, and remove the bolts and washer. Carefully separate the right crankcase from the left crankcase. WASHVER ‘ Remove the two dowel pins, O»ring and oil joint col- lar. CRANKSHAFT/CONNECTING ROD CRANKSHAFI' REMOVAL Separate the crankcase (page 11-6l. Be careful not to Remove the crankshaft from the left crankcase. damage me mam bearing S/lding surr face 11-6 CRANKSHAFT/TRANSMISSION SIDE CLEARANCE INSPECTION Measure the side clearance by inserting the feeler gauge between the crankshaft and connecting rod big end. SERVICE LIMIT: 0.23 mm (0.011 in) if the clearance exceeds the service limit, replace the connecting rod. Recheck and if still out of iimit, replace the crank- shaft. ' CONNECTING ROD REMOVAL Do not interchange the bearing inserts. They must be installed in their original locations or the currect bearing oil clearance may not be obtained, resulting in engine damage. CAP NUT «a BEARING CAP Tap the Side Dime Remove the connecting rod bearing cap nuts, bearr cap light/yilms ing caps and connecting rods. hem/"gang he’d Mark the connecting rods, bearings and caps to w remove indicate the Correct cylinder on the crankpin for reassembiv. CONNECTING ROD _1_ CRANKSHAFT INSPECTION Place the crankshaft on a stand or V-blocks. Rotate the crankshaft two revolutions and read the runout using a dial indicator. SERVICE LIMIT: 0.05 mm (0.002 in) CRANKPIN BEARING INSPECTION Check the bearing inserts for unusual wear or peelr ing. , Check the bearing tabs for damage. CRANKPIN BEARINGS 11-7 CRANKSHAFI'ITRANSMISSION OIL CLEARANCE Clean offany oil from the bearing inserts and crank- pin. Put strip of plastigauge lengthwise on the crankpin avoiding the oil hole. PLASTlGAUGE Do not/mate the Carefully install the connecting rods and bearing . Connectmg rod dur» caps on the correct positions of the crankpin. lngrnspecflon Apply oil to the threads and seating surface of the connecting rod bearing Cap nuts. Install the cap nuts and tighten them in two or three steps alternately. TORQUE: 59 NM (6.0 kgf—m, 44 Ibf-ft) Remove the bearing caps and measure the com- pressed plastigauge at its widest point on the crank~ pin to determine the oil clearance. SERVICE LIMIT: 0.070 mm (0.0028 in) CRANKPIN BEARING SELECTION Number 7 orz on Record the connecting rod |,D. code number. we Conneclmg ma /5 the code for the connecting red I D. CONNECTING HOD l,D. CODE NUMBER 11-8 CRANKSHAFT/TRANSMISSION Lane’s A or B on the crank wary/n Is the code for the Clankpm OD Record the crankpin O.D. code letter. CRANKPIN O.D. CODE LETTERS Cross reference the connecting rod and crankpin codes to determine the replacement bearing color COLOR CODE code. CRANKPIN BEARING SELECTION TABLE: ‘ iConnectlng rod I.D. war "17 f" 2 l lCrankpin 0.0. r PInR " Ye ow Loode ‘ ow ’ reen Crankpin bearing thickness Green: 1.495 — 1.499 mm (0.0589 — 0.0550 in) Yellow: 1.491 — 1.495 mm (0.0587 — 0.058 in) Pink: 1.487 — 1.491 mm (0,0585 — 0.0587 In) After selecting new bearings, recheck the oil clear- ance wi‘h plastigauge. Incorrect oil clearances can cause major engine damage. MAIN BEARING INSPECTION Check the bearings for unusual wear or peeling. Check Ihe bearing ta {)5 for damage. OIL CLEARANCE Clean any oil from the bearings and crankshah jour- nal. Measure and record (he crankshaft main [ournal O.D. CRANKSHAFI'ITRANSMISSION Measure and record the main bearing ID. in the crankcase. Calculate the oil clearance between the main journal and main bearing. SERVICE LIMIT: 0.068 mm (0.0027 in) if the oil clearance exceeds the service limit, replace the crankcase. CONNECTING ROD SELECTION An alphabetical weight cede is stamped on the conv necting rod. Cflflflflcllflg rods A, If a connecting rod requires replacement, you 5, FandGare not should select a rod with the same weight code as availab/e forthe ser— the original. But if that is unavailable, you may use weeps/15 one of the others specified in the following chart. The "0" mark in the table indicates that matching is possible in the crossed codes, An alphabetical weight code is stamped on the con- necting red. It a connecting rod requires replacement, you should select a rod with the same weight code as the original. But if that is unavailable, you may use one of the WEIGHT CODE others specified in the following chart. 'Rod codeion product: fl A l B l c D" E F G l C » l — l o o o o 0 Rod code for ‘ service parts l D ' ° ° ° ° ° ' l E o o o o o — r l CONNECTING ROD INSTALLATION Wipe any oil from the connecting rods, bearing caps and bearing inserts. Install the bearing inserts on the connecting rods and bearing caps by aligning the tab with the groove. Apply molybdenum oil solution to the bearing slid- ing surfaces. 11-10 Be careful not to damage the main bearing sliding sur- face CRANKSHAFT/TRANSMISSION Install the connecting rods and bearing caps in their _ 5 original positions as noted during removal while . aligning the ID. code on the rods and caps. Apply oil to the threads and seating surfaces of the connecting rod bearing cap nuts. and install them. Tighten the nuts in two or three steps alternately. TORQUE: 59 N-m [6.0 kgl-m, 44 lbt-ft) After tightening the nuts, check that the connecting rods move freely without binding. CRANKSHAFT INSTALLATION Apply molybdenum oil solution to the main bearing li' I sliding surface. ‘ -_ Align the scissors gears (balancer driven gear and ‘7 sub-gear] by inserting a screwdriver into the gear holes. and further insert the screwdriver into the crankcase hole to hold the balancer gears. install the crankshaft into the left crankcase so that the connecting rods are positioned in the correct cylinder groove in crankcase and the timing marks on the front balancer shaft drive and driven gears are aligned. Assemble the crenkcaselpage11723). 11-11 CRANKSHAFT/TRANSMISSION BALANCERSHAFT REMOVAL Separate the crankcase (page 11v6h. FRONT BALANCER SHAFT Remove the rear balancer shaft from the left crank- case. Remove the crankshaft (page 11-6). Remove the from balancer shaft from the left crank- caset Check the balancer shafts for wear or damage. REAR BALANCER SHAFT yr K FRONT BALANCER SHAFT SNAP RING | WASHER Remove the balancer gear springs and balancer GEAR SPRING sub-gear, Check the springs and su brgear for wear or damage. INSTALLATION Install the sub-gear, springs, washer and snap ring onto the front baIancer shaftt SUBVGEAR Remove the snap ring and washer from the front balancer shaft. 11-12 CRANKSHAFT/TRANSMISSION Install the front balancer shaft into the left crank- case, Install the crankshaft (page 11-11). Install the rear balancer shaft into the left crankcase. FRONT BALANCER SHAFT I Assemble the crankcase lpage 11723). TRANSMISSION/OUTPUT GEAR CASE NSASSEMBLV Separate the crankcase (page 11-6). Pull the shift fork shaft out of the left crankcase and shift forks. Remove the shift drum and shift forks. Remove the thrust washer,C1 gear, needle bearing, bushing, thrust washer, C4 gear and spline collar from the countershaft. 11-13 CRANKSHAFI'ITRANSMISSION Remove the C3 gear, bushing, C2 gear, thrust washer, CS gear and mainshah assembly as a set. C3 GEAR, BUSHING MAINSHAFT ASSEMBLY - Remove the iour mounting bolts and ou‘put gear case assembly. Remove the oil orifice and Orrings. Remove the OrrIng from the output gear case. 11-14 Disassemble the mainshafi. CRANKSHAFT/TRANSMISSION Clean all disassembled parts in solvent thoroughly. I INSPECTION SHIFT FORK/SHAFT Check the shift fork guide pins for abnormal wear or damage. Measure the shift fork LD. SERVICE LIMIT: 14.04 mm (0.553 in) Measure the shift fork claw thickness. SERVICE LIMIT: 5.83 mm (0.230 in) Measure the shift fork shaft O.D. SERVICE LIMIT: 13.556 mm (0.5494 in) SHIFI DRUM Check the shift drum guide groove for abnormal wear or damage. MAI NSHAFT ASSEMBLY h "N \. 11-15 CRANKSHAFT/TRANSMISSION GEAR/BUSHING/SHAFI' Check the gear shifter groove for abnormal wear or damage. Check the gear dogs and teeth for abnormal wear or damage, Measure the gear LD. SERVICE LIMITS: M4, M5: 31.035 mm (1.2218 in) 01: 30.035 mm (1.1825 in) C2, C3: 33.035 mm (1.3006 in) Measure the gear bushlng OD. SERVICE LIMITS: M4, M5: 30.94 mm (1.218 in) C1: 25.977 mm (1.20227 in) 62/03: 32.94 mm [1.297 in) Calculate the gear-Imbushing clearance. SERVICE LIMIT: 0.095 mm (0.0037 in) Measure the gear bushing LD. SERVICE LIMITS: M4: 28.03 mm (1.104 in) C1: 22.170 mm (0.8728 in) (22/03: 30.050 mm (1.1831 in) Check the mainshaft and countershaft for abnormal wear or damage. Measure the mainshaft O.D. at the M4 gear. SERVICE LIMIT: 27.940 mm (1.1000 in) Measure the countershaft CD. a the C1 gear and C2/C3 gear. SERVICE LIMITS: at C1 gear: 21.97 mm (0.8550 in) at CZ/C3 gear: 29.94 mm (1.1737111) Calculate the gear bushingrlo-shaft clearance. SERVICE LIMITS: M4: 0.067 mm (0.00261n] C1: 0.190 mm (0.0075 in) 02/03: 0.091 mm (0.0036 in) OUTPUT GEAR OIL SEAL Check the output gear oll seal for deterioration or damage. Remuve the snap rlng and replace the oil seal if nec» essary. C1 O <—> I <—> . C2/C3 SNAP RING 11-16 CRANKSHAFT/TRANSMISSION ASSEMBLY MAINSHAFT M1 GEAR (ZOT) M4 GEAR (36T) SPLINE WASHER M2/M3 GEAR ('03 — '07: 27/34TJ (After '07: 26/34T) MAINSHAFT SPLINE WASHER M5 GEAR (33 TI M4 GEAR BUSHING SNAP RING SNAP RING M5 GEAR BUSHING THRUST WASHER COUNTERSHAFI’ ('03 - '07 shown) THRUST WASHER C1 GEAR NEEDLE BEARING THRUST WASHER C4 GEAR SPLINE C6LLAFI C2/C3 GEAR BUSHING C1 GEAR (SST) THRUST WASHER C1 GEAR BUSHING C4 GEAR (ZBT) COUNTERSHAFT C3 GEAR (31T) CZ GEAR ('03 — '07: 31T) [After ’07: 32T) CS GEAR (ZBTJ \ 11-17 CRANKSHAFT/TRANSMISSION Apply molybdenum oil solution to the gear shifter grooves and bushings. Apply engine oil to all gear teeth and sliding surr faces. NOTE: I Always install the thrust washer and snap ring with the chamfered (rolled) edge facing away from the thrust load. Install the snap ring so that its and gap aligns with the groove in the splines. 0 Make sure that the snap ring is fully seated in the shaft groove after installing it. Assemble the mainshaft. Coat a new Orring with oil and install it onto the out» put gear case. Make sure the dowel pin is installed in the output gear case properly. Clean the oil orifice with compressed air. Coat new O-rings with oil and install them into the grooves in the oil orifice. MAlNSHAFT ASSEMBLY OIL ORIFICE 11-18 CRANKSHAFT/TRANSMISSION Install the oil orifice into the left crankcase with the chamfered hole side facing the crankcase. Install the output gear case assembly onto the left crankcase and tighten the mounting bolts. TORQUE: 31 N-m (3‘2 kgf-m, 23 mm) Install the mainshah assembly, C5 gear, thrust washer, C2 gear, bushing and CB gear as a set. C3 GEAR, BUSHING MAINSHAFI' ASSEMBLY - Install the spline collar, C4 gear, thrust washer, Cl gear bushing, needle bearing, C1 gear and thrust washer unto the countershaft. 11-19 CRANKSHAFI'ITRANSMISSION The shift forks have the fell in 'd t'f’ t' marks °"" 9 ' e""”'°" "R" MARK “C” MARK "L" MARK "L": Left shift fork “C”: . A, R": . . Apply oil to the sliding surfaces of the shift forks and shift drum. Install the shift forks into the gear shifter grooves with the identification marks facing up (right crank» case side). Install the shift drum into the left crankcase while inserting the shift fork guide pin into the guide groove in the drum Coat the shift fork shaft with oil and install it through the shift forks into the left crankcaset Assemble the crankcase (page 11723)‘ CRANKCASE BEARING REPLACEMENT Separate the crankcase (page 11-6). RIGHT CRANKCASE Remove the bolts and bearing setting plates. Always Wear/rist Before removing the bearings, heat the crankcase [312d gloves when around the bearings to about 80°C (176°F). handlinga heated 5559 Drive the rear balancer shaft, mainshaft, countershafl and shift drum bearings out of the right crankcase, 11-20 CRANKSHAFT/TRANSMISSION Remove the front balancer shaft bearing using the ’ BEAR‘NG REMOVER special tools. \ TOOLS: Bearing remover handle 079363710100 Bearing remover, 20 mm 079364710600 Bearing remover weight 07741-0010201 or 07936-371020A or 079353710200 (USA. only) REMOVER WEIGHT Drive new bearings into the right crankcase using the following special tools. DRIVER TOOLS: Mainshaft and rear balancer shaft bearings Driver 07749-0010000 Attachment, 62 x 68 mm 07746-001050“ Pilot, 28 mm 07745-0041100 Countershaft bearing Driver 07749-0010000 Attachment, 52 x 55 mm 07746-001040!) Pilot, 22 mm 0774641041000 ‘ ATTACHM E NT Shift dmm bearing —' Drivel 07749-0010000 Attachment, 32 x 35 mm 07746»00101DO Pilot, 25 mm 07746-0040600 Front balancer shah hearing Driver 0774943010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 20 mm 07746-0040500 Apply locking agent to the bearing setting plate bolt threads. install the bearing setting plates and tighten the bolls. TORQUE: 12 N-m (1.2 kgf-m, 9 lbf-h) 11-21 CRANKSHAFI'ITRANSMISSION LEFI' CRANKCASE Remove the following: — crankshaft (page 1176) — balancer shafts (page 11-12] » transmission, output gear case(page11713) Always wearlnsu- Before removing the bearings, heat the crankcase latedg/oves when around the bearings to about 80°C (176°F). handling a heated case Remove the left crankcase bearings using the spe- REAR BALAthER . FROM-TBALAN'C'EH C'a' “'5‘ HAFT BEARING TOOLS: ‘ ‘ ‘ Mainshaft and rear balancer shaft bearings Non-U.S.A. Adjustable bearing remover 07JAC-PHBO100 Bearing remover shaft 07JAC-PH80200 Bearing remover weight o7741-oo1ozo1 > \0 USA. only it ggglfl-EAFT Adjustable bearing puller. *' - . 25 — 40 mm 07736»A010003 ( ‘ slide hammer, 3/8 x 16 or equivalent ' BEAmNG REMOVER commercially available in USA. Front balancsr shaft bearing Bearing remover handle 07936-3710100 Bearing remover, 20 mm 079363710600 Bearing remover weight 07741-0010201 or 07936-371020A or 079363710200 (USA. only) Drive new bearings into the right crankcase using the following special tools. TOOLS: Mainshaft and rear balancer shaft bearings Driver 0774941010000 Attachment, 52 x 55 mm 07746-0010400 Pilot, 22 mm 07746-0041000 DHIVER Front balancar shaft bearing Driver 07749-0010000 Attachment, 42 x 47 mm 0774643010300 Pilot, 20 mm 07746-0040500 _.~ A'I'I'ACHMENT . Install the following: — output gear case, transmission (page 11-17) v balancer shafts (page 11712) 7 crankshaft (page 11-11) 11-22 CRANKSHAFT/TRANSMISSION CRANKCASE ASSEMBLY Clean the left and right crankcase mating surfaces thoroughly, being careful not to damage them. Apply sealant to the mating surface of the left crank- case as shown Install thetwo duwel pins and oil joint collar. Coat a new Orring with oil and install it unto the oil joint collar. install the right crankcase over the left crankcase. Install the sixteen 5 mm bolts, washer and five 6 mm bolts, and tighten the belts in a crisscross patr tern in two or three steps, TORQUE: 8 mm bolt: 26 N-m (2.7 kgf~m, 19 lbf-ft) 6 mm bolt: 12 Nrm (1.2 kgf-m, B lbf-lt) Install the front and rear carn chains. rSE-I—I—TNEFLATE install the cam chain tensioner setting plates if they were removed as follows: Apply locking agent to the setting plate bolt threads, 1' and install the setting plates and bolts. Tighten the bolts. TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-ft) Install the following: - starter gears — flywheel (page 18-20) — clutch lifter arm holder (page 10-24) - primary gears (page 1018) r gearshift linkage (page 10-16l - Clutch (page 10-13) - piston (page 9-9l A cylinder (page 9-10) — cylinder head (page 8718) 7 engine (page 7—9) 11-23 MEMO SYSTEM COMPONENTS -------------- -- 12—2 SERVICE INFORMATION ----------------------- --1z-3 TROUBLESHOOTING ----------------------------- --12-5 FINAL DRIVE REMOVAL ------------------------ --12-6 12. FINAL DRIVE FINAL DRIVE DISASSEMBLY/ INSPECTION . ................................... .. 12.7 CASE BEARING REPLACEMENT -------- -- 12-12 FINAL DRIVE ASSEMBLY -------------------- -- 12-14 FINAL DRIVE INSTALLATION 12-21 12-1 FINAL DRIVE SYSTEM COMPONENTS 64 N-m (6.5 kgf-m, 47 lbf-ffl 26 N~m (2.7 kgf-m,18|bf-ft) 12-2 SERVICE INFORMATION GENERAL The final drive gear assembly and final drive shaft must be removed together. a 0 Perform the gear contact pattern and backla extension lines from the gear engagement su Protect the gear case with a shop towel or soft it could be damaged. Replace the ring and pinion gears as a set. SPECIFICATIONS '7 ITEM Recommended final drive oil Final drive all capacity l After draining STANDARD Hypoid gear oil, SAE #80 After disassembly 150 cm3 (5.1 US oz, 5.3 Imp 01) l , FINAL DRIVE sh inspection whenever you replace the bearings, gears or gear case. the rtaces should intersect at one point. jaws while holding it in a vise. Do not clamp the gear case too tightly or Unit: mm (in) SERVICE LIMIT‘l l 120 cm (4.1US oz, 4.2 Imp ozir I — l l 0.30 (0.012) Final drive gear backlash 0.05 — 0.15 [0.002 - 0.006) Backlash difference between measurements — 0.10 (0.004) l Ring gear-to-stop pin clearance 0.30 » 0.60 (0.012 — 0.024) - l Final drive gear assembly preload 0.2 —0.4 N-m (2 —4 kgf-cm, 0.1 — 0.3 Ibfel‘ti — J TORQUE VALUES TOOLS Driver Attachment, 32 x 35 mm Attadiment, 52 x 55 mm 07749-0010000 07746—0010100 07745-0010400 Pinion retainer Pinion retainer look tab bolt Pinion joint nut Dust guard plate bolt Gear case cover 10 mm bolt Gear case cover 8 mm bolt Final drive case assembly mounting nut Rear shock absorber lower mounting bolt 147 N-m (15.0 kgf-m,108|bf-fti 10 N-m (1.0 kgf'm,7 Ibfrft) 108 N-m (11.0 kgf‘m, 80 Ibf-fti 10 N-m (1.0 kgf-m,7 Ibf-ft) 62 N-m (6.3 kgf—m, 46 (bf-ft) 25 N-m (2.6 kgI-m,191bf‘fl) 64 N-m (6.5 kgf-m, 47 lbf-ftl 26 N-m [2.7 kgI-m,19|bf»ft) Apply locking agent to the threads. Apply locking agent to the threads. Attachment, 72 x 75 mm Pilot, 35 mm 07746-0010600 077450040800 Driver, 40 mm ID. 0774643030100 FINAL DRIVE FAttachmem, 30 mm ID. 07746-0030300 Pinion holder plate 07924-ME40010 Collar sei "C" 07924-ME40020 or D7924-ME9000D [USA only] or 07HMB-MM801OO (USA. only) Oil seal driver 07965-MC70100 Retainer wrench 07910AMA10100 6% \ Pinion puller base 07HMC-MM801‘IO or O7HMC~MMBO11A (USA only) Puller shaft 07931-ME40000 or 07931-ME401OB and 07931>HB3020A (USA only) Bearing remover, 35 mm 07936-3710400 ' Remover handle 07936-3710100 Remover weight 07741-0010201 Bearing remover, 20 mm 07936-3710600 Bearing driver attachment 07GAD»SD40101 0r 07936-371020A or 07936-3710200 (U.S. . only) 1 2-4 TROUBLESHOOTING Excessive noise - Worn or scored ring gear shaft and driven flange I Scored driven flange and wheel hub Worn or scored drivz pinion and splines Worn pinion and ring gears Excessive backlash beiween pinion and ring gears Oil level too low Oil level too high Damaged seals 0 ' Clogged breaiher . . - Loose case cover bolts FINAL DRIVE 12-5 FINAL DRIVE FINAL DRIVE REMOVAL Drain the final drive gear oil (page 345). Remove the rear wheel (page 14-6l. SHOCK ABSBRBER LOWER MOUNTING BQLT, WASHERS l Support the swingarm and remove the left shock absorber lower mounting bolt, washer and the shock absorber from the final gear case. Remove the washer from the gear case stud. t: \ Remove the four mounting nuts and final drive gear case assembly. Separate the drive shaft from the gear case by gen- tly turning the drive shaft and pulling it. DRIVE SHAFT Remove the spring, oil seal and stopper ring from the drive shah. OIL SEAL STOPPEH RING INSPECTION Check the splines of the drive shaft for damage or wear. It the splines of the drive shaft are damaged, check the universal joint splines also [page 14-13l. SPRING Turn the pinion joint and check that the pinion and ring gears turn smoothly and quietly without bind- mg. If the gears do not turn smoothly or quietly, the gears and/or bearing may be damaged or faulty. They must be checked after disassembly; replace faulty parts/assemblies as required. r, ..x RING GEAR SHAFI’ 12-6 FINAL DRIVE DISASSEMBLY/ INSPECTION BACKLASH INSPECTION Remove the oil filler cap. Set the final driva gear case assembly in a vise with soft jaws. Install the special tools onto the gear case and into the pinion joint to hold the pinion gear. TOOLS: Pinion holder plate 07924-ME40010 or 07924-ME90000 (U.S.A. only) 07924-ME40020 or 07HBM-MM80100 (U.S.A. only) Collar set "C" Set a horizontal type dial indicator on the ring gear, through the oil filler hole. Turn the ring gear back and forth to read the back» lash. STANDARD: 0.05 — 0.15 mm (0.002 - 0.006 in) SERVICE LIMIT: 0.30 mm (0.012 in) Remove the dial indicator. Turn the ring gear 120" and measure the backlash. Repeat this procedure once more. Compare the difference of the three measurements. SERVICE LIMIT: 0.10 mm (0.004 in) If the difference between the three measurements exceeds the service limit, it indicates that the bear» ing is not installed squarely, or the case is deformed. Inspect the bearings and case. If the backlash is excessive, replace the right ring gear shim with a thicker one. If the backlash is too small, replace the right ring gear shim with a thinner one. NOTE: - Nine different shim thicknesses are available in increments of 0.06 mm (0,002 in). Select the shims from A to I. RIGHT RING GEAR SHIMS: A (thinnest): 1.82 mm (0.072 in) D (standard) .00 mm (0.079 in) I (thickest): 2.30 mm (0.051 in) For ring gear shim replacement, See page 1243. FINAL DRIVE COLLAR DIAL INDICATOR RING GEAR RIGHT RING GEAR SHIM . 1 2-7 FINAL DRIVE FINAL GEAR CASE SEPARATION Remove the distance collar. Remove the bolt and the dust guard plate by turn- ing it counterclockwise. ' DUST GUARD l’LATE “ Loosen the eight cover bolts in a crisscross pattern ‘ in two or three steps and remove them. Pry the gear case cover and remove it from the case. Remove the wave washer. GEAR «ASE COVER GEAR TOOTH CONTACT PATTERN CHECK Keep dust and dirt Clean the sealing material off the mating surfaces of cure! the case and the gear case and cover, being careful not to dam- cover age themt Apply Prussian Blue Apply a thin coat of Prussian Blue to the pinion gear teeth for the tooth Contact pattern check. Install the wave washer. WAVE WASHER Install the case cover and tighten the bolts in sevv eral steps until the cover evenly touches the gear f case. Then, tighten the six 8 mm bolts to the specified torque in a crisscross pattern in several steps. TORQUE: 25 MM (2.5 kgt-m, 18 let) ‘ Tighten the two 10 mm bolts to the specified torquet ‘ TORQUE: 62 N-m (6.3 kgf-m, 46 lbf-ft) .i v 10 mm BOLTS. ‘ GEAR CASE COVER 12-8 FINAL DRIVE Remove the oil filler cap. Rotate the ring gear several times in both directions of rotation. Check the gear tooth contact pattern through the oil filler hole. The pattern is indicated by the Prussian Blue applied to the pinion gear. Contact is normal if the Prussian Blue is transferred to the approximate center of each tooth and slightly towards the face. Normal: PINION SHIM If the patterns are not correct, remove and change the pinion shim with a suitable one. l DRIVE SIDE COAST SIDE FLANK Replace the pinion gear shim with a thicker one if the contact pattern is too high, toward the face. I DRIVE 1 COAST SIDE SIDE Replace the pinion gear shim with a thinner one if the contact pattern is too low, toward the flank. l l l The patterns will shift about 1.5 — 2.0 mm (0.06 — ‘ l ' 0.08 in) when the thickness of the shim is changed - L by 0.1 mm (0.004 in), 1 NOTE: I Seven different shim thicknesses (from A to G) are available in increments of 0.06 mm [0.002 in). PINION SHIMS: 7 A (thinnest): 1% mm (0.072 in) ,D (standard): 2.00 mm (0.079 in) - Too Low: . . COAST G(thlckestj:2.13mm(0.086|nl FLANK 5mg SIDE FLANK _J DRIVE For pinion gear shim replacement. See page 12-10. RING GEAR REMOVAL/SHIM REPLACEMENT Remove the final gear case cover (page 12-8). DRIVER If the ring gear stays in the cover, remove it as fol- J 7» lows: K 7 ATTACHMENT Support the cover horizontally with the ring gear facing down and press the gear out using the spe- cial tools and hydraulic press. TOOLS: Driver 0774941010000 Attachment, 72 x 75 mm 0774541010600 12-9 FINAL DRIVE Remove the oil seal irom the ring gear. Remove the oil seal from the gear case cover. This bearing may Remove the ring gear bearing using a commercially notneed m be available bearing puller. rep/505d after removal However, Inspect the bearing for excesswe play after removal Replace the ring gear shim. NOTE, 0 When the gear set, pinion bearing, ring gear bearing and/or gear case has been replaced, use a 2.00 mm (0.079 in) thick Shim for initial refer- ence. PINION GEAR REMOVAL Set the gear casein a vise with soft jaws. Install the special tools and remove the pinion joint nut. TOOLS: Pinion holder plate 07924-ME40010 or D7924-ME50000 lU.S.A. only) Cnllar set "C" 07924-ME40020 or 07HBM-MM80100 (U.S.A. onlyi Remove the pinion joint. ,‘ BEARING FULLER COLLARS OIL SEAL \K BEARING HOLDER PLATE 12-10 FINAL DRIVE Remove the bolt and retainer lock tab. LOCK TAB Remove the pinion retainer using the special tool. RETAWER WRENCH TOOL: Retainer wrench 07910-MA10100 Remove the O-ring and oil seal from the pinion retainer. Install the special tools onto the pinion gear shaft and gear case PU LLER SHAFr TOOLS: Non-U,S.A. Pinion puller base D7HMC-MM30110 Puller shaft 07931-ME40000 U.S.A. only Puller base "A" 07HMC-MM8011A Assembly shaft, 22 x 1.5 x 240 mm 07931-ME401DB and ‘Special nut 07931-HB3020A PULLR EASE Pull the pinion gear assembly out of the gear case. Check the pinion needle bearing in the gear case for wear or damage. PINION BEARING/SHIM REPLACEMENT Pull the pinion bearing from the shaft with a cum- memiauy available bearing pulleh BEARlNG FULLER (Commercially available) Remove the pinion shim. BEARING 12-11 FINAL DRIVE Install the shim and a new bearin onto the in‘on gen 9 p ' PINION SHIM NOTE: - When the gear set, pinion bearing, ring gear bearing and/or gear case has been replaced, use INNER RACES a 2.00 mm (0,079 in) thick shim for initial refer- ence. PINION GEAR BEARING Drive the bearing using the special tools. DH IVE R TOOLS: Driver, 40 mm ID. 0774641030100 Attachment. 30 mm ID. 07746-003030!) ATI'ACHMENT CASE BEARING REPLACEMENT RING GEAR BEARING Be swam wear Heat the gear case to 80°C (176°F) evenly using a heavy g/aves when heat gun, BEARING REMOVER hand/myths heated Remove the ring gear bearing from the gear case gearcase using the special tools. TOOLS: Bearing remover, 35 mm 07936-3710400 Remover handle 079364710100 Remover weight 0774141010201 or ‘ 07936-371020A or 079364710200 (USA. only) Remove the oil seal. 12—12 FINAL DRIVE Apply grease to a new oil seal lip. Drive the oil seal into the gear case using the spray DRIVER cial tools. TOOLS: Driver 0774947010000 Attachment, 52 x 55 mm 07746-0010400 Drive a new ring gear bearing into the gear case using the special tools. TOOLS: Driver 0774941010000 Attachment, 52 x 55 mm 07745-0010400 Pilot. 35 mm 0774643040800 PINION NEEDLE BEARING Remove the stopper ring by rotating it until the end of the stopper ring appears in the access hole. Strike gently near the end of the ring with a punch to bend the end upward. Grasp the end of the ring with needle-nose pliers and pull the stopper ring out through the access hole. Besure to wear Heat the gear case to 80°C (176“F) and remove the heavy gloves when needle bearing by using the special tools. hand/mg the heated gear case TOOLS: Hwy 5 [mm m Bearing remover, 20 mm 079364710600 hear the gear case Remover handle 079368710100 may cause Remover weight 07741-0010201 or warpage 07936-371020A or 0793654710200 (U.S.A. only) Remnve the bearing cage and bearings from the inside of the pinion bearing to allow the special tool to grip the bearing. v s ‘ 4. BEARING REMOVER 12-13 FINAL DRIVE Install a new sto er rin into the move securel . pp 9_ g y DRIVER Place the needle bearing In a freezer, Heat the gear case to 80°C (176°F). Remove the needle bearing from the freezer and drive it lnto the gear case using the special tools. TOOLS: Driver 07749-001000!) Attachment, 32 x 35 mm 0774641010100 Make sure the stopper ring is securely set in the groove of the gear case, FINAL DRIVE ASSEMBLY PINION GEAR PINION GEAR PINION BEARING OIL SEAL PINION JOINT INNER RACE PINION RETAINER LOCK TAB PINION JOINT NUT 12-14 0 FINAL DRIVE Drive the pinion gear assembly into the gear case using the special tool. TOOLS: IV Driver. 40 mm ID. 07746-0030100 DR ER Attachment, 30 mm ID. 07746-0030300 ATTACHMENT ; VPINION GEAR Drive a new oil seal into the pinion retainer with the flat side facing down using the special tool. TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 DRIVER Pack grease into the seal lip cavity, rfii OIL SEAL * ‘ ’ ATTACHMENT Coat a new O-ring with grease and install it into the retainer gram/24 PINION RETAINER Apply engine oil onto the threads of the pinion retainer. Install the retainer into the gear case and tighten it. RETAINER WRENCH IDOL: Retainer wrench 07910-MA10100 IOHOUE: 147 Mm (15.0 kgf-m, 108 Ith) 12-15 FINAL DRIVE The lock tab is avall' Install the lock tab, depending on the position of the eb/e m the two pinion retainer grooves in relation to the lock tab types (A and E) and tighten the bolt shown. TORQUE: 10 N-m (1.0 kgf-m, 7 lbf-ft) LOCK TAB Clean the threads of the pinion gear shaft and pin- ion joint nut thoroughly. Apply locking agent to theI joint nut threads and install the pinion joint and joint nut onto the pinion gear shaft. PINlON JOINT JOINT NUT Hold the pinion joint with the special tools and tighten the pinion joint nut. HOLDER PLATE TOOLS: Pinion holder plate 07324-ME40010 or 07924-M590000 (USA. only) Collar sat 07924-ME40020 or D7HBM-MM80100 (U.S.A. only) TORQUE: 108 Mm (11.0 kgf-m, 80 Ihf-ft) COLLARS ——j,9____ 12-16 FINAL DRIVE RING GEAR See page 1242 for the case bearing replacement and page 12-19 forthe breather hole cleaning. RING GEAR BEARING 0”- SEAL (Ring gear side) RING GEAR DUST GUARD PLATE WAVE WASHER OIL SEAL DISTANCE COLLAR RING GEAR BEARING OIL SEAL (Gear case side) SHIM STOP PIN GEAR CASE COVER If the ring gear bearing was loose against the cover (if it did not stay in the cover), do the following: DRIVER Place the ring gear shim onto the ring gear. Press the bearing onto the ring gear shaft using the special mus. OIL SEAL DRIVER ATTACHMENT TOOLS: ' Driver 07749-0010000 ‘ Attachment. 72 x 75 mm 077450010600 0" seal driver 07965«MC70100 If the ring gear bearing remained in the cover, do — the following: Press the ring gear bearing into the cover using the special tools. DRIVER TOOLS: Driver 0774941010000 Bearing driver attachment o7GAD-SD40101 FINAL DRIVE Install the shim onto the ring gear. Support the bearing inner race with the special tool and press the ring gear into the bearing. TOOLS: SHIM Oil seal driver 07965-MC70100 OIL SEAL DRIVER BEARING Apply grease to a new oil seal lip and install it into the ring gear. fl OIL EAL g i / Install a new oil seal into the gear case cover using the special tools. TOOLS: Driver 07749-001000!) Bearing driver attachment 07GAD-SD40101 Apply grease to the oil seal lip. Install the ring gear into the gear case cover. Measure the clearance between the ring gear and stop pin with a feeler gauge. CLEARANCE: 0.30 — 0.60 mm (0.012 — (1024 in) 12-18 Be sure to Wear heavy gloves when handling the heated gear case Keep dust and am out at the case and cover FINAL DRIVE Remove the ring gear if the clearance does not fall within the specifications Heat the gear case cover to approximately 80°C (176°F). Heat the case cover evenly and slowly to prevent warpage. Do not heat small areas individually. When the gear case cover is heated to the proper temperaturel remove the stop pin by tapping the cover. Select a stop pin shim to obtain the correct clear- ance. SHIM THICKNESS: A: 0.10 mm (0.004 in) B: 0.15 mm (0.006 in) 0.30 — 0.60 mm (0.01270.024in) Install the shim and drive the stop pin into the gear case COVeI't STOP PIN SH'M FINAL GEAR CASE ASSEMBLY NOTE: - When the gear set, bearing, and/or gear case has been replaced, check the tooth contact pattern [page 12-8) and gear backlash (page 12-7). Remove the breather cap, being careful not to deform itt Blow compressed air through the breather hole in the gear case. BREATHER CAP Clean the mating surface of the gear case and cover. being careful not to damage theme CASE COVER Apply liquid sealant to the mating surface of the gear case. Install the wave washer. Install the case cover onto the gear case. GEAR CASE WAVE WASHER 12-19 FINAL DRIVE Apply locking agent to the threads of the 10 mm case cover bolts. Install the bolts, and tighten them in several steps until the cover evenly touches the gear case. ' Tighten the six 8 mm bolts to the specified torque in a crisscross pattern in several steps. TORQUE: 25 N-m (2.5 kgf-m, 18 Ibf-ft) Tighten the two 10 mm bolts to the specified torque. TORQUE: 62 NM (6.3 kgf-m, 46 lbf-ft) Check that the gear assembly turns smoothly with- out binding. Measure the final gear assembly preload. STANDARD: 0.2 - 0.4 N-m (2 - 4 kgl~cm, 0.1 — 0.3 Ibi-ft) if the preload reading does not fall within the limit, check the bearings for proper installation. Install the dust guard plate by aligning the plate tabs with the ease cover grooves and turn it clock- wise to lock. Install and tighten the guard plate bolt. TORQUE: 10 N-m (1.0 kgf-m, 7 Ibf-ft) Install the distance collar with the polished side (ac— ing the gear case, 12-20 FINAL DRIVE FINAL DRIVE INSTALLATION Make sure the stop- per {mg IS seated properly by pulling on the drive shaft light/y, Be careful not to damage the dill/E shaft oil seal Check that the gear case stud bolts are tight. If any are loose, remove them, clean their threads with contact cleaner, then install them using a look- ing agent. STUD BOLT After installing, be sure to measure the distance from the top of each stud to the gear case surface as shown. ‘ 21 — 23 mm (0.867084in) Install a new stopper ring into the drive shaft groove. Install the spring into the drive shalt. v Apply 05 g (0.02 OZ) of molybdenum disulfide grease to a new oil seal lip and install it onto the drive shaft. STOPPER RING g OIL SEAL @ ‘PINION JOINT, SPRING Apply 2 g (0.08 oz) or more of molybdenum disulfide grease to the pinion joint splines. Install the drive shaft into the pinion joint until the stopper ring seats in the pinion joint spline groove, Apply 1 g (0.04 oz) of molybdenum disulfide grease to the universal joint side splines of the drive shaft. DRIVE SHAFI' Insert the final drive assembly into the swingarm and align the drive shaft splines with the universal joint splines by holding the swingarm. SHOCK AFSBRBER LOWER MOUNTING aou', WASHERS Install the gear case mounting nuts. Install the washer onto the final gear case stud. Install the shock absorber, washer and mounting bolt onto the stud. Tighten the gear case mounting nuts in a crisscross pattern in two or three steps. TORQUE: 64 N-m (6.5 kgf-m, 47 Ibf-h) Tighten the shock absorber lower mounting bolt. TORQUE: 26 N-m (2.7 kgf-m, 19 [bf-ft) Install the rear wheel (page 14-11). Fill the gear case with the recommended final drive gear oil (page 3-15). FINAL GEAR CASE MOUNTING NUTS 12-21 MEMO 13. FRONT WHEEL/SUSPENSION/STEERING SYSTEM COMPONENTS ----------------------- --13-2 SERVICE INFORMATION ----------------------- --13-4 TROUBLESHOOTlNG ............................. "13.7 HANDLEBAR ........................................... "13.3 FRONT WHEEL ..................................... .. 13.12 FORK ..................................................... .. 13.17 STEERING STEM .................................. .. 13.23 13-1 FRONT WHEEL/SUSPENSION/STEERING SYSTEM COMPONENTS VTX1300$IVTX1300RIVTX1300T: VTX13005 shown: 27 N-m (2.8 kgf‘m, 20 Ibf-ft) 49 N-m (5.0 kgf—m, 36 lbf‘fl) 59 N-m (6.0 kgf‘m, 44 Ibf-ft) 22 N-m (2.2 kgf‘m,16|bf‘fl) 13-2 FRONT WHEEL/SUSPENSIONISTEERING VTx1sooc: 64 Nm (6.5 kgf—m, 47 Ibf-ft) / 49 N-m (5.0 kgf-m, as Nam) 31 N-m (3.2 kgf~m, 23 Ibf-ft) ’ 59 N-m (6‘0 kgf‘m, 44 |th) 22 Nm (2‘2 kgf—m,16|bf-ft) 1 3-3 FRONT WHEEL/SUSPENSION/STEERING SERVICE INFORMATION GENERAL - Riding on damaged rims impairs safe operation of the vehicle. I A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. I A hoist or equivalent is required to support the motorcycle when servicin - Refer to page 152 for hydraulic brake system service. SPECIFICATIONS g the front wheel, fork and steering stern. VTX13005/VTX1300RIVTX13ODT: Unit: mm (in) ITEM STANDARD SERVICE LIMIT i Minimum tire tread depth — 1.5 (0.06) ( Cold tire Up to'so kg (200 lb) load 225 kPa (2.25 kgf/cmz, 33 pSiI — 1 Pressure Up to maximum weight capacity 225 kPa (2.25 kgf/cm .33 psi) — ‘ Axle runbut e 0.20 (0008) i Wheel rim Radial — 2.0 (0.08) ‘ runout Axial ’ — 2.0 (0.03) Fwneel balance weight — 60 g (2.1 oz) 7 max. Fork LSprirlg free length 493.8 (19.44) i 483311905) Tube runout 7 ‘ — ' ‘ 0.20 (0.008) i Recommended fork fluid Pro Honda’Suspension Fluid 53-8 ~ (10W) Fluid level 135 (5.3) - A Fluid capacity ’ 459 a 2.5 cm (15.5 i 0.08 us in, — 1 16.210.09Imp oz] ‘ Steering head bearing oreload 7.8~ 11.8 N (0.8 — 1.2 kgf,1.8 — 2.6 lbf) ( — VTx13000: Unit: mm (in) ITEM STANDARD SERVICE LIMIT Minimum tire tread depth — 1t5(0.06) Cold tire ( Up to 90 kg (200 lb) load 225 kPa (2.25 kgf/cm , 33 psi) — pressure ‘ Up to maximum weight capacity 225 kPa (2.25 kgf/cmz, 33 psi) — 7 l Axle runout - 0.20 (0.008) l Wheel rim Radial — 2.0 (0.03) runout 7 Axial' — 2.0 (0.08) ‘ Wheel balance weight — 60 g (2.102) 1 ‘ max. Fork Spring free length 4617 (18.18) 452.5 (1731) Tube runout — 0.20 (0.003) Recommended fork fluid ’Fluid level Pro Honda Suspension Fluid SS»8 (10W) 125 (4.9) Fluid capacity 457 12.5 cm3 (15.5 i 0.08 US 01, 16.1 t 0.09 Imp oz) Steering head bearing preload 7.8 — 11.8 N (0.8 >12 kgf, 1.8 — 2.6 Ibf) 13-4 TORQUE VALUES Handlebar upper holder bolt (VTX13008/ VTX1300RNTX1300T) Handlebar lower holder nut (VTX13008/ VTX1300RNTX1300T) Handlebar mounting nut (VTX1SODC) Front master cylinder holder bolt Front brake disc bolt Spoke nipple (VTX13005) Valve stem nut (VTX13005) Front axle bolt Front axle pinch bolt Fork center bolt Fork cap Fork cover bolt (VTX1SOUSNTX13OOR/ VTX1300T) Fork top bridge pinch bolt Fork bottom bridge pinch bolt Front brake caliper mounting bolt Steering bearing adjustment nut Steering bearing adjustment nut lock nut Steering stern nut Hose/cable guide bolt Brake hose clamp bolt TOOLS FRONT WHEELISUSPENSION/STEERING 27 N-m (2.8 kgf—m, 20 Ibf-ft) 64 N-m (6.5 kgf-m, 47 lbf-ftl U-nut. 64 Nm (6.5 kgf-m, 47 |th) U-nut. 12 N-m (1.2 kgf-m, 9 lbf‘ft) 42 N-m (4.3 kgf-m, 31 lbf-ft) ALOC bolt: replace with a new one. 4.2 N-m (0,4 kgf-m, 3.1 Ibf-ft) 2.7 N-m (0.3 kgf-m, 2.01bf‘ft) 59 N-m (6.0 kgf-m, 44 lbf-ftl 22 N-m (2.2 kgf‘m,16|bf-ft) 20 N>m (2.0 kgf—m,15lbl-fllALOC bolt: replace with a new one. 22 Nm (2.2 kgf-m,16|bf‘ft) 12 Nm (1.2 kgf-m, 9 Ibf-fi) 22 N-m (2.2 kgf-m,16|bf-ftl 49 N-m (5.0 kgf-m, 36 lbf-ftl 31 N-m (3.2 kgfrm, 23 Ibf-ft) ALOC bolt: replace with a new one. 21 N-m (2.1 kgf~m, 15 lbf-ft) Apply engine oil to the threads. See page 13-28 103 N-m (10.5 kgf-m, 75 Ibf-ft) 21 N-m (2.1 kgf-m,15lbf-ft)ALOC bolt: replace with a new one. 12 N‘m (1.2 kgftm, 9 Ibf-ft) Driver 0774970010000 Attachment. 37 x 40 mm 07746-0010200 Attachment, 42 x 47 mm 07746-0010300 Attachment, 52 x 55 mm 07746-001040!) // Pilot, 20 mm 07746-0040500 Bearing remover shaft 07746-0050100 FRONT WHEEL/SUSPENSIONISTEERING Bearing remover head, 20 mm Spoke nipple wrench [VTX13005) Fork seal driver body 07746-005060!) 07JMA-MR60100 07S47—KA50100 or equivalent commercially avail- able in U.S.Ai e‘ Driver anachment, 41 mm ID. Steering stem socket Bearing remover 07947-KF001OD 07916-3710101 075468710500 or 0791641710100 Ball race remover Driver Steering stern driver 07953—MJ10000 079493710001 07946-M500000 or 07953-MJ10003 or 079537MJ1000A (USA. only) 13-6 TROUBLESHOOTING Hard steering - Steering bearing adjustment nut too tight - Worn or damaged steering head bearings - Worn or damaged steering head bearing races - Bent steering stem - Insufficient tire pressure 0 Faulty front tire Steers to one side or does not track straight I Bent fork leg Damaged steering head bearings Loose steering head bearings Bent frame Worn wheel bearings Bent front axle Worn swingarm pivot components (page 146) Front wheel wobbles O Bent rim 0 Worn wheel bearings - Faulty tire - Unbalanced tire and wheel Wheel turns hard 0 Faulty wheel bearings - Bent axle 0 Brake drag (page 15-5) Soft suspension - Week fork spring - Low fluid level in fork - Insufficient fluid weight [low viscosity) I Low tire pressure Stiff suspension - High tire pressure Bent fork tube Fork slider binds High fluid level in fork leg incorrect fluid weight (high viscosity) Clogged fork fluid passage Front suspension noise - Loose fork fasteners C Insufficient fluid weight (low viscosity) 0 Worn slider or fork tube bushing FRONT WHEEL/SUSPENSION/STEERING 13-7 FRONT WHEEL/SUSPENSION/STEERING HANDLEBAR REMOVAL Pul/ the cl/ps wnrie Remove the following: holding the iock rab — handlebar switch wires and brake hose (from the win a mail screw wire clips) driver to remove 7 wire clips them WiRE AND HOSE r clu‘ch swilch connecmrs » Mo socket boits HOLDER — bracket holder — clu‘ch lever bracket v two screws 7 left handlebar swi‘ch housing SWITCH CAP — lefi handlebar grip — housing cap Keep the reservmr » brake iight switch connectors upright 10 plevenr » two socket boils ‘ ' an frem entering — master cylinder hulder L rhe hydrau/ic 5V5 — brake master cylinder tern CONNECTORS 13—8 FRONT WHEEL/SUSPENSION/STEERING 7 two screws 7 right handlebar switch housing ~ thronle cables 7 throttle grip (lrum the handlebar) VTX13OOSNTX1300RNTX1300T: Remove the following: 7 four bolt caps — four socket bolts — handlebarupperholders — handlebar VTX1300C: Remove the following: ~ two nuts and washers — handlebar SWITCH VTX1390$IVTX1300RNTX1300T2 \\\\\ HANDLEBAR VTX1300C: HANDLEBAR NUTS AND WASHERS 13-9 FRONT WHEEL/SUSPENSION/STEERING Install the upper ho/de/ with the punch mark on each holder lacing forward Install the holder With the “UP” mark on the holder facing up. INSTALLATION NOTE' 0 Route the cable, hose and wires properly (page 1-24lt VTX13008/VTX1300R/VTX1300T: Place the handlebar onto the lower holders and align the punch mark on the handlebar with the lower holder edge, then install the upper holders and bolts. Tighten the front bolt first, then tighten the rear bolts. TORQUE: 27 N-m (2.8 kgf-m, 20 lbf-ft) install the bolt caps. VTX1300C: Install the handlebar into the top bridge with the ‘ nuts and washers. Tighten the nuts. TORQUE: 64 N-m (6.5 kg‘f-m, 47 Ibf-ft) Apply grease to the throttle grip flange groove and sliding surface. Install the throttle grip onto the handlebar and con- nect the throttle cables to the throttle grip flange. Install the right handlebar switch housing with the two screws, aligning the locating pin with the hole in the handlebar. Tighten the front screw first, then tighten the rear serewt install the master cylinder with the holder and two bolts. Align the edge of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then tighten the lower bolt. TORQUE: 12 N-m (1.2 kgl-m, 9 lbf-ft) Connect the brake light switch connectors. \\ \ \ CONNECTORS \ HANDLEBAR \\ VTX13POSNTX13ODRNTX1300T: PUNCH MASTER CYLINDER 13-10 FRONT WHEEL/SUSPENSION/STEERING lnstallthe housing cap. CAP Clean the inside surface of the left handlebar grip and the outside surface of the handlebar. \ Apply Honda Bond A or Honda Hand Grip Cement (UtStA. onlvl to the inside surface of the handlebar GRIP grip and to the outside surface of the handlebar. Allow the adhesive Wait 3 r 5 minutes and install the grip. Rotate the to dry for 1 hour grip for even application of the adhesive. before usmg Setme hat/Sing cap install the left handlebar switch housing with the flangemmthe two screws, aligning the locating pin with the hole IimlSl/ig groove in the handlebar. Tighten the front screw first, then tighten the rear SCI'EWt lnstallthe holder Install the clutch lever bracket with the holder and With the "UP" mark two bolts. on the holder facing Align the edge of the bracket with the punch mark up on the handlebar and tighten the upper bolt first, then tighten the lower bolt. Connect the clutch switch connectors. Nate the Installation Install the four wire clips onto the studs on the han- dvecn’an (page 1- dlebar. WIRE AND HOSE 24} Secure the brake hose and switch wires with the I * clips. 13-11 FRONT WHEEL/SUSPENSION/STEERING FRONT WHEEL REMOVAL Llfrme fromwnee/ Support the motorcycle securely using a hoist or 30 cm (12 m) or equivalent and raise the front wheel off the grou nd, more above the Loosen the rlght axle pinch bolts and remove the ground. axle boltt Loosen the left axle pinch bolts. Do not operate the Pull the front axle out and remove the front wheel. brake /9Ver after removmg the wheel To do 50 WW cause difficulty m fitting the brake dlSC between the brake pads Remove the side collars, INSPECTION AXLE Set the front axle in Vrblocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 the total indicator reading‘ SERVICE LIMIT: 0.20 mm (0.003 in) 13-12 Replace the wheel bearings m pans, Rep/ace me wheel bearings in pairs Do no! reuse ald bearing FRONT WHEEL/SUSPENSION/STEERING WHEEL RIM Check the rim runout by placing the wheel in a true» ing 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 (0.08 in) Axial: 2.0 mm (0.08 in) WHEEL BEARING Turn the inner race of each bearing with your finger; the bearings should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit loosely in the hub. DISASSEMBLY Remove the dust seals from both sides of the hub. Remove the six disc bolts and brake disc. Install the remover head into the bearing. Remove the distance collar and drive out the other bearing. From the opposite side of the wheel, install the remover shaft and drive the bearing out of the wheel hub. TOOLS: Bearing remover shaft 0774647050100 Bearing remover head, 20 mm 07746-0050600 x FRONT WHEEL/SUSPENSION/STEERING ASSEMBLY BEARING vrx1soos shown: (eao4uu) DUST SEAL DUST SEAL BRAKE DISC DISC BOLTS DISTANCE COLLAR ea/ . BEARING a, 16304UU) Drive in a new right bearing (disc side) squarely with lhe marked side facing up until it is fully sealed. Install the dislance collar‘ » DRIVER Drive in a new lefl bearing squarely with the marked .v side facing up until it is fully sealed. TOOLS: Driver 07749-0010000 Attachment, 52 x 55 mm 07746-0010400 Pilot, 20 mm 0774641040500 WHEEL CENTER ADJUSTMENT (VTX13005) Measure distance B (rim width) and calculate dis- tance A as follows: A = 78.8 mm — BIZ Adjust the rim position and distance A by tightening the spokes to the specified torque in several pro— gressive steps. TOOL: Spoke wrench OTJMA-MRGOWO or equivalent commer- cially available in USA TORQUE: 4.2 N-m (0:4 kgl-m, 3.1 lbf-fl) 13-14 FRONT WHEEL/SUSPENSION/STEERING Do not get grease Install the brake disc with the stamp facing out, an the brake disc or Install new disc bolts and tighten them in a criss- smpp/ng pawerwrll cross pattern in several steps, be reduced TORQUE: 42 NM (4.3 kgt-m, 31 lbf-ft) WHEEL BALANCE NOTE: - Mount the tire with the arrow mark facing in the direction of rotation. o The wheel balance must be checked when the tire is remounted. ‘ VTX13005: For optimum balance, the tire bal- ance mark (light mass point: a paint dot on the side wall) must be located next to the valve stem. Remount the tire if necessary. I VTX‘lBDOCNTXiZiOORNTXlSODT: For optimum balance, the tire balance mark (light mass point: a paint dot on the side wall) must be located next to the wheel balance mark (heavy mass point: a paint dot on left side surface of the rim; not valve stem). Remount the tire if 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 of the wheel with chalk. Do this two or three times to verify the heaviest area. If the wheel is balanced, it will not stop consistently in the same position. VTX13OOS: BALANCE MARKS V (on left side] \ INSPECTION STAND F7 13-15 FRONT WHEEL/SUSPENSION/STEERING The fig/ifslde collar Install the side collars. (disc Side} is /onger than the left Side collar Be careful not In damage the pads. To balance the wheel, install a balance weight on the lightest side of the spoke lVTXlSDOSl or rim lVTX1300C/VTX1300R/VTX1300T), on the side oppo» site 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 60 g (2.1 ozl to the front 7 wheel, VTX13DOCNTX1300R/ VTX1300T: Apply grease to new dust seal lips and install the dust seals until they are flush with the wheel hub. INSTALLATION Place the front wheel between the fork legs so the brake disc is positioned between the brake pads. Insert the axle from the left side until it is fully seated. T Make sure the index groove in the axle is aligned with the fork leg, and tighten the Iefl axle pinch bolts. TORQUE: 22 N‘m (2.2 kgf-m, 16 leU AX LE ‘ // K I FINCH BOLTS 13-16 FORK Suppon the brake ca/rper 50 n does not hang from the brake hose Do not twlst the brake hose Be Care/u! nor to scratch the lender sulface The fork cap is under spring presr sure, use care when loosening yr Remove the two bolts and front fender, and remove FRONT WHEEL/SUSPENSION/STEERING Install the axle bolt and tighten itt TORQUE: 59 N-m [6.0 kgf-m, 44 Ibf-ft) Tighten the right axle pinch bolts. TORQUE122 N-m (2.2 kgi-m, 16 Ibf-ft) \\ AXLE BOL '1. \ Loosen the left axle pinch bolts. With the front brake applied, pump the forks up and down several times to seat the axle and check brake operation. Tighten the left axle pinch bolts to the same torque. REMOVAL Remove the front turn signal light (VTXWSOOC: page 1977). Remove the front wheel (page 1342). Remove the following: 7 two fender bolts (VTX13005NTX1300R/ VTX1300T) four fender bolts and front fender (VTX1300Cl — hose clamp stav (right fork onlyl — two bolts and brake caliper (right fork only) NOTE: I VTX13005NTX1300R/VTX1300T: Front fender removal is performed after removing either fork leg. When the fork is ready to be disassembled. loosen I the fork cap, but do not remove it. ‘ Loosen the top and bottom bridge pinch bolts, Pull the fork leg down and remove the fork tube from the fork bridges. from inside of the fork cover. the other fork leg. DISASSEMBLY Remove the following: 7 fork cap — O-rlng (from the fork Cap] FORK CAP ‘ ‘ ‘ ~ OrRlNG 13-17 FRONT WHEEL/SUSPENSION/STEERING — spacer _ springsaa‘ ‘ EORKSPRING I SPRING SEAT — fork spring - Four out the fork fluid by pumping the fork tube up and down several times. Hold the fork slider in a vise with soft jaws or shop towels. l,‘ we lurk prsron Remove the following: zurns mm the ~ fork center boll center half, 7 sealing washer rsmporarrly mslal/ me fork sprrng, snrmg sear, spacer and furk cap CENTER BOLT AND WASHER — fork piston — rebound spring FORK PISTON REBOUND SPRING Be care/ulnozra — dust seal scratch the fork — stopper ring woe s/ldmg sur- face DUST SEAL STOPPER RING 13-18 FRONT WHEEL/SUSPENSION/STEERING Using quick successive motions, pull the fork tube out of the fork slider. Remove the following: — oil lock piece (from the fork slider) — oilseal _ OIL SEAL — back-up rlng BACK-UP RING — guide bushlng Carefully remove the fork tube bushing by prying GUIDE BUSHING the slit with a flat blade screwdriver until the bush- ing can be pulled off by hand. SLIbER BUSHING INSPECTION FORK SPRING Measure the fork spring free length. SERVICE LIMIT: VTX1300$IVTX1300RIVTX1300Tz 483.9 mm (19.05 in) VTX‘l3000: 452.5 mm (1181 in) FORK TU BEISLIDER/ PISTON Check the fork tube, slider, oil lock piece and fork piston for score marks, and excessive or abnormal wear, Check the fork pistun ring for wear or damage, Check the rebnund spring for fatigue or damage. Replace any damaged component if necessary. . OIL LOCI< PIECE 13-19 FRONT WHEEL/SUSPENSION/STEERING Set the fork tube in V-blocks and measure the fork tube runout with a dial indicator. Actual runout is 1/2 thetotal indicator readingt SERVICE LIMIT: 0.20 mm (0.008 in) Visually inspect the slider and guide bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so the copper sur- face appears on more than 3/4 of the entire surface. Check the back—up ring; replace it if there is any dis- tortion at the points shown. ASSEMBLY BUSHING BACKsUP RING Check points COPPER SURFACES Before assembly, wash all parts with a high flash point or non-flammable solvent and wipe them off completely. OIL SEAL BACK~UP RING \e GUIDE BUSHING FORK SLIDER SEALING WASHER FORK CENTER BOLT /® SLIDER BUSHING OIL LOCK PIECE FORK TUBE FORK CAP FORK COVER GUIDE (VTXIBOOS) DUST SEAL FORK PISTON FORK SPRING REBOUND SPRING 13-20 I! the fork piston turns With the cam rer bah, temper Iarily Install the fork Spring, spring seat, spacer and fork cap FRONT WHEEL/SUSPENSION/STEERING Install a new slider bushing if it has been removed. NOTE: I Remove the burrs from the bushing mating sur- face, being caretul not to peel off the coating. Baggage SLIDER BUSHING Install the following: — rebound spring (onto the fork piston] — fork piston (into the fork tube) — oil lock piece Ionto the fork piston) Install the fork tube into the fork slider. REBOUND SPRING Hold the fork slider in a vise with soft jaws or shop towels. Apply locking agent to the fork center bolt threadst Install the center bolt with a new sealing washer and tighten it, TORQUE: 20 N-rn (2.0 kgf‘m,15|bf-ft) CENTER BOLT AND WASHER A Place the guide bushing over the tork tube and rest it on the slider. Put the back-up ring and an old bushing or equivalent tool on the guide bushing. Drive the bushing into place, using the special tools. DRIVER BODY Wrap vinyl tape around the fork tube top end to avoid damaging the oil seal lip. Apply fork fluid to a new oil seal lip. Install the Oil seal with the marking facing up. ATTACHMENT Drive the oil seal until the stopper ring groove is vis- ible. TOOLS: Fork seal driver body Driver attachment, 41 mm ID. 07947-KA50100 07947—KF00100 STOPPER RING DIL SEAL all? fl BACK-UP RING | ‘ GUIDE BUSHING Li , 13-21 FRONT WHEEL/SUSPENSION/STEERING Install the stopper ring into the groove into the fork slider. being careful not to scratch the fork tube slid- @ a ing surface. DUST SEAL Coat a new dust seal with fork fluid and install it. STOPPER FIING Pour the specified amount of the recommended fork flurd Into the fork tube. FORK FLUID RECOMMENDED FORK FLUID: Pro Honda Suspension Fluid SS-E (10W) RECOMMENDED FORK FLUID: VTX13OOS/VTX1EIDDFI/VTX1300T: 459 i 2.5 cm‘ (15.5 t 0.08 US oz, 16.2 i 0.09 Imp oz) VTX13DOC: OIL LEVEL 457 1 2.5 cm8 (15.5 1 0.08 US 02, 16.1 i 0.09 Imp oz) ‘ Slowly pump the fork tube several times to remove any trapped air from the lower portion of the fork tube. Compress the fork tube fully. Measure the oil level from thetop of the fork tube. . SERVICE LIMIT: VTX13OOS/VTX1300RIVTX1300T: 135 mm (5.3 in) VTX13OOC: 125 mm [4.8 in) Pull the fork tube up and install the fork spring with the tightly wound coil side facing down, . U Install the sprlng seat and spacer. FORK CAP . Coat a new O-ring with fork fluid and install it into the fork cap groove. Ee careful/70120 Hold the fork cap securely and install it into the fork cross-thread the tube. fork Cap Tighten the fork Cap ‘ after installing the fork tube into the fork bridge-5 SPRING - ' ‘ SEAT \ 13-22 FRONT WHEEL/SUSPENSION/STEERING INSTALLATION VTX13ODSNTX1300RNTX1300T: Loosen the fork FOR‘K‘EAP covar bolts on the bottom bridge. Install a new 0- j , . O-RING ring onto the top of the fork cover. . - ' lVTX1300 §f S/RFI' VTXianS/ Install the fork tube into the bottom and top bridges, ’ l/TX1300R/ Align the top of the fork tube with the upper surface V VTX1300T App/y of the top bridge as shown. soapy water to the fork tube to 5/11 M installation. TORQUE: 49 N-m (5.0 kgf-m, 39 [bf-ft) Take care not to ~ _ _ mm, the 0mg 0,, Tighten the top bridge pinch bolt. the fork met TORQUE: 22 Nm (2.2 lief-I". 15 mm) COVER BOLTS (VTX13003/Rm Tighten the bottom bridge pinch bolt. Tighten the fork cap to the specified torque if it was removed. TORQUE: 22 MM (2.2 kgf-m, 16 Ibf-ft) VTX‘I3OOSNTX'I300RNTX‘I3DOT: Tighten the fork cover bolts. TORQUE: 12 MI" (1.2 kgf-m, 9 Ihl-R) Temporarilv install the front fender with the two bolts. Be careful not to Install the other fork leg using the same procedure. scratch the Moder surface. Install the brake caliper with new mounting bolts and tighten the bolts. TORQUE: 31 MI“ (3.2 kgf-m, 23 Ibf-ft) Install the lender bolts with the hose clamp stay and tighten all the fender bolts securely. Install the following: 7 front wheel (page 13-16) A turn signal light (VTX1300C; page 19-7) STEERING STEM REMOVAL Remove the following: - windscreen (VTX1300T only) (page 2-5) — handlebar (page 13-3) — front wheel (page 13-12) — headlight case lpage 19-6) Remove the bolt and hose clamp stay. 13-23 FRONT WHEEL/SUSPENSION/STEERING Disconnect the turn signal connectors. TURN SIGNAL VTX1300C: Remove the nuts and bolts, and the ASSEMBLY headlight stay. (VTX1SODS/ VTX13008NTX1300R: Remove the nuts and bolts, VTX13°°FV and the headlight stay and turn signal assembly. VTX1300T) VTX1300T: Remove the nuts and bolts, and the windscreen lower stay, headlight stay and turn sig- nal assembly (page 275). Release the cables, hose and wires from the cable guides. Remove the following if necessary: — VTX13OOS/VTX'I3ODR/VTX1300C: bolts and cable guides VTX1300T: bolts, cable guides and windscreen upper stay (page 275l 7 VTX13OOSNTX1300R/VTXl300T: nuts, washers and handlebar lower holders Loosen the steering stem nut. Remove the fork legs (page 1347). Remove the stem nut and washer, and the top bridge. VTX'l300$NTX1300RNTX1300T1 Remove the bolts, VT)“ aDOSN-Dfi BOdRNTx1 300 upper and lower fork covers. ‘ BOLTS 13-24 FRONT WHEEL/SUSPENSION/STEERING Straighten the lock washer tabs. LOCK NUT Remove the lock nut and lock washer. Loosen the steering bearing adjustment nut. TOOL: STEM SOCKET / Steering stem socket 07916-3710101 or ’ 079164710100 While holding the steering stem, remove the adjust- ment nut and dusl seal. Remove the following: — stem — upper inner race — upper steering bearing — lower steering bearing LOWER BEARING — Remove the upper bearing outer race using the spe- ‘ , cial tool. 7 7 BALL RACE REMOVER TOOLS: ‘” Ball race remover D7953-MJ10000 or 07553-MJ10003 0r 07953-MJ1000A (U. . . only) Of Driver 07949-3710001 Attachment, 37 X ‘0 mm 0774647010200 13-25 FRONT WHEEL/SUSPENSION/STEERING Remove the lower bearing outer race using the spe- cial tool and a drift TOOLS: Bearing remover 7946-3710500 BEARING REMOVER Install the stem nut onto the stem to prevent the threads from being damaged when removing the DUST SEAL lower bearing inner race. Remove the lower bearing inner race with a chisel or equivalent tool, being careful not to damage the INNER RACE stem‘ Remove the dust seal. NUT INSTALLATION VTX13008/VTX1300R shown: WASHER STEM NUT LOCK NUT FORK COVERS (VTX13005/ VTX1300RNTX13ODT only) I W LOCK WASHER ADJUSTMENT NUT @R DUST SEAL , @ \UFPER INNER RACE //LIPPER STEERING EEARI NG HEADLIGHT STAY UPPER OUTER RACE LOWER OUTER RACE ®\ LOWER STEERING BEARING LOWER INNER RACE TURN SIGNAL ASSEMBLY (VTXiBOOS/VTX1300R/ DUST SEAL VTX1300T only) 13-26 FRONT WHEEL/SUSPENSION/STEERING NOTE, - Use water resistant grease #2 (urea based multi- purpose greasel for the steering bearings and dust seals: — Excelite EP2 (Kyoer Yushi) or 7 Stamina EPZ (Shell) or equivalent STEM DRIVER Apply grease to a new dust seal lip and install it onto the steering stern. Press a new lower bearing inner race using the spe- cial tool. TOOL: Steering stem driver 07945-MEOOOOD INNER RACE ‘— DUST SEAL (Apply grease) Drive in a new upper bearing outer race into the r «7' ’ steering head pipe. TOOLS: Driver 07749-001000!) Attachment, 42 x 47 mm 07746-0010300 DRlVER Drive in a new lower bearing outer race. TOOLS: Driver 0774941010000 Attachment, 52 x 55 mm 07746«DD10400 Apply 3 — 5 g (0.1 ~ 0.2 oz) of grease to each new steering bearing and fill it up. Install the lower steer~ J INNER RACE ing bearing onto the stern. ' Apply grease to a new upper dust seal lip. Apply oil to the bearing adjustment nut threads. Insert the steering stem into the steering head pipe and install the following while holding the stern: — upper steering bearing — upper inner race LOWERBEARING , UPPERBEARING [Apply 3 — 5 g of (Apply 3 — 5 g of greasel grease) ~ dust seal ADJUSTMENT NUT _ STEM - d l t t a’Jus men nu SOCKET 1. Tighten the adjustment nut to the specified torque. TOOL: Steering stern socket 07916-3710101 or 07916-3710100 TORQUE: 21 N-m (2.1 kgi‘m, 15 ibf-ft) 2t Loosen the adjustment nut and retighten it to the same torque. DUST SE L I” (Apply grease) ~fl 13-27 FRONT WHEEL/SUSPENSION/STEERING 3. Turn the steering stem left and right, lock-to»lock at least four times to seat the bearings. Retighten the adjustment nut to the same torque. 4. Repeat step 3. Install a new lock washer to align its bended tabs with the grooves in the adjustment nut. Install the look nut and finger tighten it all the way. Further tighten the lock nut, within 90 degrees, to align its grooves with the tabs of the lock washer. Bend up the lack washer tabs into the grooves of the lock nut. Install the top bridge, washer and stem nutt Temporarily install the fork legs into the bottom and top bridges. Tighten the stern nut. TORQUE: 103 Mm (105 kgtm, 76 Ibf-ft) Remove the fork legs. Make sure the steering stern moves smoothly, with- out play or binding. Route the hose, VTX‘l3003/VTX13008NTX1300T: Install the lower VTXI 3oosmx1 300Rmx1 300T: wlres and can/es and upper fork covers Wlth the four bolts. ‘ , a “095’” (“59:47) Install the fork legs lpage 13-23). OHS X 13-28 VTX 73003/ VTX 1300M l/TX73DUT Temper ran/y install the ham diebar when tightening the lower holder bolt FRONT WHEEL/SUSPENSION/STEERING Install the following if they were removed: - VTX‘I3OOSNTX1300R/VTX13OOT: handlebar lower holders (with the washers and nuts) 4 WX13005N‘IX1300RNTX1300C: Cable guides (with new bolts) VTX1300T: windscreen upper stay and cable guides (with new bolts) lpage 2-5) TORQUE: Holder bolt: 64 NM (65 kgf~m, 47 lbf-tt) Guide bolt: 21 N-m (2.1 kgt-m, 15 lhf-ft) Route the hose, wires and cables into the cable guides properly (page 1»24). VTX1300C: Install the headlight stay with the two bolts and nuts, and tighten them. VTX‘iBODS/VTX‘BOOFI: Install the turn signal assem- bly and headlight stay with the two bolts and nuts, and tighten them. VTX1300T: Install the turn signal assembly, head- light stay and windscreen lower stay with the two bolts and nuts, and tighten them. (page 2-5). Connect the turn signal connectors (V'I'XI3OOS/ VTX1300RNTX1300T). install the hose clamp stay and tighten the bolt. Install the following: — front wheel (page 13-16) — handlebar (page 1340i — headlight case (page 19-6) — windscreen (VTX1300T onlyl (Page 2-5) STEERING BEARING PRE-LOAD Support the motorcycle securely using safety stands or a hoist and raise the front wheel off the ground. Position the steering stem straight ahead. Hook a spring scale to the fork tube between the fork top and bottom bridges. Make sure there is no cable, wire harness or hose interference. Pull the spring scale keeping it at a right angle to the steering stern. Read the scale at the point where the steering stem iust starts to move, STEERING BEARING PRE-LOAD: 7.8 — 113 N (0,8 — 1.2 kgf, 1.8 — 2.6 lbtl if the readings do not fall within the limits, readjust the steering bearing adjustment. by HOLDERS (VTX13005NTX1300RNTX1300T) TURN SIGNAL ASSEMBLV lVTXi 3008/ VTX1300R/ VTXISOOT) 13-29 MEMO 14. REAR WHEEL/SUSPENSION SYSTEM COMPONENTS ....................... "14.2 REAR WHEEL .......................................... .. 14.5 SERVICE INFORMATION ----------------------- --14-3 sHocK ABSORBER ------------------------------ -. 14.12 TROUBLESHOOTING ............................. .. 14.5 SWINGARM .......................................... .. 14.13 14-1 REAR WHEEL/SUSPENSION SYSTEM COMPONENTS '03 — ’05 VTX1BDUS shown: 113 Mm (11.5 kgf‘m,831bf-ftl 14 Nm [1.4 kgf—m,10|bf~ffl 34 N-rn (3.5 kgf~m, 25 lbf-ft) 26 N-m (2.7 kgf'm, 191M“) 103 N-m (10.5 kgf-m, 76 Ibf-ft) , 12N-m[1.2kgf—m, 26 Nm (2‘7 kgf-m,19!bf‘ft) ’/ 9 let) 14-2 REAR WHEEL/SUSPENSION SERVICE INFORMATION GENERAL 0 Riding on damaged rims impairs safe operation of the vehicle. - When servicing the rear wheel. shock absorber, frame securely. or swingarm, raise the rear wheel off the ground by supporting the - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. torque wrench’s leverage, so the torqu specification given on the next page is Use only genuine Honda replacement bolts and nuts for all suspension pivot and mounting points. - When using the lock nut wrench, use a 20 inch deflecting be when used with the lock nut wrench. The procedure later in the text gives both actual and indicated. - Refer to page 15-2 for hydraulic brake system service. am type torque wrench. The lock nut wrench increases the e wrench reading will be less than the torque actually applied to the lock nut. The the actual torque applied to the lock nut, not the reading on the torque wrench SPECIFICATIONS i 7 Unit: mm (in) i ITEM l STANDARD SERVICE LIMIT ‘ Minimum tire tread depth — 2.0 (0.08) ‘ Cold tire pressure ‘iUp to 90 kg (200 lb) load 225 kPa (2.25 kgf/cmz, 33 psi) — i Up to maximum weight 250 kPa (2.50 kgf/cm .36 psi) ’ l T ‘ capacity PAXIE runout — 0.20 (0.008) ‘ Wheel rim runout Radial — 2.0 (0.08) Axial — ‘ 2.0 (0.08) Wheel balance weight — 70 g > (2.5 02) max. TORQUE VALUES Rear brake disc bolt Spoke nipple (VTXI3OOS) Valve stern nut (VTX13005) Final driven flange nut Rear axle nut Rear brake caliper stopper pin bolt Muffler mounting bolt Final gear case assemny mounting nut Rear shook absorber mounting bolt Rear brake hoseclamp bolt Swingarm left pivot bolt Swingarm right pivot bolt Swingarm right pivot bolt lock nut 42 N-m (4.3 kgf-m, 31 lbf-ft) ALOC bolt: replace with a new one. 4.2 N-m (0.4 kgf-rn, 3.1 lbf-ft) 2.7 N-m (0.3 kgf-m, 2.0 lbf-fl) 88 N-m (9.0 kgf-m, 65 Ibfrft) U-nut. 110 N-m (11.2 kgf—m, 81 "39(1) U-nut. 69 N-m (7.0 kgf-m, 51 Inf-ft) ALOC bolt: replace with a new one. 34 N-m (3.5 kgf-m, 25 lbf-ft) 64 N-m (6.5 kgf~m, 47 lbf-ft) 26 N‘m (2.7 kgf-m, 19 lbf-ft) 12 N-m (1.2 kgf-m, 9 lbfrft) ALOGbolt: replace with a new one. 103 Mm (10.5 kgf-m, 76 Ibf-ft) 14 Nm (1.4 kgf-m.10lbf-ft) 113 Mm (11.5 kgf-m, 83 lbf-ft) 14-3 REAR WHEEL/SUSPENSION TOOLS ‘ Driver Attachment, 22 x 24 mm Attachment, 32 x 35 mm 07749-0010000 07746-0010300 077460010100 Attachment, 37 x 40 mm 07746~0010200 Attachment, 42 x 47 mm 07746-0010300 Attachment, 52 x 55 mm 07746-0010400 Pilot, 20 mm 077460040500 Bearing remover shaft 07746-0050100 Bearing remover head, 20 mm 07746-005060!) Spoke nipple wrench (VTX13005) 07JMA-MH60100 or equivalent commercially avail- able in USA. Adjustable bearing remover 07JAC—FH80100 or 07736rA010003 or 07736-A0100EIA (U.S.A. only) with slide hammer, 3/8” x 16 (com- mercially available) Bearing remover shaft 07JAC—PH80200 07 07736-A010003 or 07736»A01000A (U.S.A. only) with slide hammer, 3/8" x16(com- mercially available) 1 4-4 Pr__—~_ Lock nut wrench 079084690003 or 079084169000A TROUBLESHOOTING Soft suspension - Incorrect suspension adjustment I Weak shock absorber spring 0 Oil leakage from damper unit - Insufficient tire pressure Stiff suspension - Incorrect suspension adjustment - Bent damper rod - Damaged shock absorber mount bushings - Damaged swingarm pivot bearings - Improperly tightened swingarm pivot 0 Tire pressure too high Rear suspension noise - Loose suspension fasteners 0 Binding shock absorber case - Worn shock absorber rubber mounts - Faulty rear shock absorber Rear wheel wobbles - Bent rim - Unbalanced rear tire and wheel I Insufficient tire pressure - Faulty swingarm pivot bearings - Axle fastener not tightened properly 0 Faulty reartire' Wheel turns hard - Faulty wheel bearings - Bent axle - Brake drag [page 15-5) REAR WHEEL/SUSPENS|ON 14-5 REAR WHEEL/SUSPENSION REAR WHEEL Lift the rear Wheel 30 cm (12 ml or more above the ground Support the brake caliper 50 :r does nomang from the brake nose Do not th51 the DIE/<9 hose During rear wheel removal, ha/d the wheel securely and be Careful not to damage the Drake 11/5!) and gear Case REMOVAL Loosen the axle nut and caliper stopper pin bolt. Support the motorcycle securely using a hoist or equivalent and raise the rear wheel off the ground. Remove the following: hose clamp bolt 7 stopper pin bolt — ’03 — '07 VTX13005/VTX1300R: two muffler mounting nuts, washers and bolts - axle nut — rear axle — brake caliper — side collar '03 — '07 VTXlSOOS/VTX‘ISOOR: Set a suitable wooden block between the swingarm and stay on the muffler to support the muffler and get the clearr ance for wheel removal. Move the rear wheel to the right to separate it from the final drive gear case and carefully remove the rear wheel out of the frame. INSPECTION AXLE Set the rear axle in V-blocks. Turn the axle and measure the runout using a dial indicator. Actual runout is 1/2 the total indicatur reading. SERVICE LIMIT: 0.20 mm (0.008 in) NUTS, WASHERS AND BOLTS ('03 r '07 VTX13005NTX1300H) CALIPEH 1 4-6 Hep/ace the dflven flange and bearing as an assembly. WHEEL RIM REAR WHEEL/SUSPENSION Check the rim vunout by placing the wheel in a true» ing stand. Spin the wheel slowly and read the runout using a dial indicator. Actual runout is 1/2 (he total indicator reading. i SERVICE LIMITS: Radial: 2.0 mm (0.08 in) Axial: 2.0 mm (0.0 in) WHEEL BEARING Turn the inner race of each bearing with yourfinger; the bearings should turn smoothly and quietiy. Also check that the bearing outer race fits tightly in (he . hub. Remove and discard the bearings if the races do not turn smoothly and quietly, or if they fit ioosely In the hub. FINAL DRIVEN FLANGE Check the driven flange splines for wear or damage. If damaged, check the splines of the final drive gear case also. DISASSEMBLY Remove the following: - dust seal — six disc bolts — brake disc REAR WHEEL/SUSPENSION lf you wrllreplace — O-ring ' _ ‘ ‘— ——r - l ggggggchGE — (FLANGE B) ~ STOPPER loosen the flange — final driven flange assembly nuts When Ieplac/ng {he — distance collarA {press out of the driven flange) hnaldnven flange Toms: [Ar WW: 1mm” Driver o7749-oo1oooo “5’”? ’ I: Attachment. 22 x 24 mm o774s-oo1oaoo 9 Pilot. :0 mm onus-0040500 » rubberdampers r O-ring I RUBBER ! ‘ DAMPERS A Flap/ace the rubber Check the rubber dampers for deterioration or damr ‘ " ’ ' dampers as a ser age. Install the remover head into the bearing. ‘ From the opposite side of the wheel, install the remover shaft and drive the bearing out of the wheel hub. Remove the distance collar and drive out the other bearing. TOOLS: Bearing remover shaft o7746~0050100 Bearing remover head, 20 mm 07746-0050600 1 4-8 REAR WHEEL/SUSPENSION ASSEMBLY NOTE: - Refer to page 13-15 for wheel balance. Do not add balance weight more than 70 g (2.5 oz) to the rear wheel. VTxmos WW": FINAL DRIVEN FLANGE B RUBBER DAMPERS STOPPER RING DISC BOLTS BRAKE DISC \ FINAL DRIVEN FLANGE A\ _\ DUST SEAL NUTS BEARING (6304UUI DISTANCE COLLAR O-RING BEARING [20 x 47 x 20.6I Drive in a new right bearing (disc side) squarely with the marked side facing up until it is fully seated. DRIVER TOOLS: ' > ‘ Driver 07749-0010000 Attachment. 52 X 55 mm 07746-001040!) Pilot, 20 mm 077450040500 Install the distance collar. Drive in a new left bearing squarely with the marked side facing up until it is fully seated. TOOLS: Driver 0774941010000 Attachment, 42 x 47 mm 07745-0010300 Film, 20 mm 07746-0040500 1 4-9 REAR WHEEL/SUSPENSION WHEEL CENTER ADJUSTMENT (VTX13005) H” * B A * Measure distance B (rim widthi and calculate disr ‘ T “Hi tance A as follows: Y i A : 97.5 mm 7 3/2 ‘ eL‘ ; ‘ Adjust the rim position and distance A by tightening ‘ firm the spokes to the specified torque in several pro- gressive steps. ‘ y, TOOL: ‘ \Rk C, Spoke wrench D7JMA-MR60100 or i ' equivalent commer- cially available in USA. TORQUE: 4‘2 N-m (0.4 kgf‘m, 3.1 Ibf-ft) Install the rubber dampers as shown. [mBER‘r' Pack molybdenum disulfide paste into the Orring ‘DAMPERS groove in the hub. ' ‘. v Cuat a new Orring with molybdenum disulfide pasle and install it into the groove. Press the distance collar A into the driven flange until it is fully seated. TOOLS: Driver 07749-0010000 Attachment, 32 x 35 mm 07746-001010!) Pilot, 20 mm 07746—0040500 Apply 3 g (0.11 oz] of molybdenum disulfide paste to the mating surface of the final driven flange. install the driven flange assembly until it is fully seated. 14-10 Held the wheel securely and be Careful not to dam- age the brake use and gear case REAR WHEEL/SUSPENSION DRIVE FLANGE Install the stopper ring into the ring groove prop» erly. Tighten the driven flange nuts if they were removed. TORQUE: 88 N-m (9.0 kgl-m, 65 Ibl-ft) Pack molybdenum disulfida paste into the 0»ring groove in the driven flange, Coat a new O-ring with molybdenum disulfide paste and install it into the groove. Install the brake disc with the stamp facing out, Install new disc bolts and tighten them in a criss- cross pattern in several steps. TORQUE: 42 Nam (4.3 kgt-m, 31 lbi-l‘t) Apply grease to a new dust seal lips and install the dust seal until it is flush with the wheel hub‘ INSTALLATION Apply 5 g (0.2 oz) of molybdenum disulfide paste to the ring gear shaft splines of the gear case. Place the rear wheel into the frame and engage it with the gear case, making sure the splines are cor- rectly aligned. Install the side collar. Set the brake caliper over the brake disc, and install a new stopper pin bolt and a new clamp bolt. STOPPER / g PIN BOLT 14-11 REAR WHEEL/SUSPENSION insert the axle through the gear case, wheel, caliper and swingarm, and install the axle nut. . SHOCK ABSORBER BOLT If the final drive gear case was removed, tighten the following to the specified torque. TORQUE: Gear case nut: 84 N-m (6.5 kgf-m, 47 [bl-ft) Shock absorber bolt: 26 N-m (2.7 kg1-m, 19 [bf-ft) Tighten the axle nut. TORQUE: 110 Mm (11.2 kgf-m, 81 lbl-ft) Tighten the stopper pin bolt. TORQUE: 69 N-m (10 kgf-m, 51 Ith) Tighten the clamp bolt TORQUE: 12 N-m (1.2 kgf-m, 9 Ibf-fl) '03 7 '07 VTX‘IflODSNTX‘lBODH: Install the muffler mounting bolts, washers and nuts, and tighten them. TORQUE: 34 N-m (3.5 kgi-m, 25 lbf-ft) SHOCK ABSORBER Support the frame and swingarm securely using a hoist or equivalent. Remove the mounting bolts and washers, and the > shock absorber. Lsi‘tsfde on’y Remove the washer from the lower pivot on the - gear case. Hep/ace the shock Check for deformation or oil leakage. absorber as an Check the rubber mounts for worn or damage. assembly lnsra/l w m the Install the shock absorber in the reverse order of arrow facing to the removal. ’53’ TORQUE: 26 NM (2.7 mm, 19 Ibf-ft) 14-12 REAR WHEEL/SUSPENSION SWINGARM REMOVAL Remove the following: — left crankcase rear cover (page 278) — exhaust system (page 2-12) 7 final drive gear case lpage 12-6) 7 rear shock absorbers (page 14-12) I '03 — '06 shown: '03, ’05. Remove the hose clamp bolts. Release the brake hose from the clamp. After '05 Remove the hose clamp bolt. Release the brake hose from the clamps. Remove the both pivot caps. Loosen the right pivot lock nut and remove it. TOOL: Lock nut wrench 079084690003 or 0790846900011 Loosen the right pivot bolt. Loosen the left pivot bolt. Release the joint boot from the output gear case. Remove the left and right pivot bolts, and the swingarm from the frame. 14-13 REAR WHEEL/SUSPENSION aom bearings, outer races and grease lie/dens must be rep/ace!) as a ser ,1 any pan is damaged or 14mm Remove the following: — universaljoint » pivot bearings 7 joint boot INSPECTION Check that the universal joint moves smoothly with out binding or noise. Check the splines for wear or damage. If damaged, check the splines of the output shaft and drive shaft also. Check the boot for cuts or other damage. Check the bearings and dust seals for Wear or dam- age. Check the outer races for wear or damage. Check the grease holders for damage or deforma» tion. PIVOT BEARING OUTER RACE REPLACEMENT Punch or drill an appropriate hole into the grease f holder, OUTER RACE Pull the outer race and grease holder out of the swingarm using the special tools. TOOLS: Adiustable hearing remover Remover shaft Remover weight 07JAC«PHBO'IDO D7JAC-PH80200 0774141010201 U,$.A. only: ‘ Adjustable bearing puller, 07736-A01000B or ‘ GREASE HOLDER 25 — 40 mm o7736-A01000A . and Slide hammer, 3/8” x 16 (equivalent commercially available in U.S.A.I Insert a suitable driver through the swingarm and drive the other outer race and grease holder out of the swingarm. Le“ Install a new grease holder into the pivot. Drive in a new outer race squarely until it is fully seated. TOOLS: Driver Attachment, 37 x 40 mm DRIVER 07949-0010000 07746-0010200 A'I'I’ACHMENT ——> 14-14 REAR WHEEL/SUSPENSION INSTALLATION UNIVERSAL JOINT GREASE HOLDERS PIVOT BEARINGS OUTER RACES JOINT BOOT Apply 1 — 1,5 g (0.04 7 0,05 01) of grease to the nee- dle rollers and dust seal lips of each new bearing. Install the bearings into the swingarm pivots‘ Install the joint boot by aligning the boot rib with the swingarm groove in the direction as shown, Place the universal joint into the swingarm. UNIVERSALJOINT w » t 14-15 REAR WHEEL/SUSPENSION Apply 1 g (0.04 oz) of molybdenum disulfide grease ' T i i O UTPUT SHAFT fi to the output shaft splines. Set the swingarm into the frame and hold it. Install ‘ the universal joint onto the output shaft usmg the drive shaft as shown. ‘ Install the ioint boot over the output gear case. Carsfisllya/gn the Install the left and right pivot bolts and tighten swinger/77 psvms them, Wm "75 DWI buns Tighten the left pivot bolt to the specified torque. TORQUE: 103 Mm (10.5 kgi-m, 76 lbf-ftl Tighten the right pivot bolt to the specified torque. TORQUE: 14 N'm (1.4 kgf-m, 10 lbf-h) Muve the swingarm up and down several times to seat the pivot bearings. Retighten the pivot bolts to the same torque. Install the right pivot lock nut. Tighten the lock nut while holding the pivot bblt. TOOL: Luck nut wrench 079084690003 or 07908-465000A Refer to torque TORQUE: Actual: 113 N-m (11.5 kgf—m, 83 lbf-ft) W’E'lm FSSUINQ Indicated: 103 Mm (105 kgf-m, 7G lbf-ft) lflfo’l’natlon on page 14-3 "Sew/Ce mm mar/on” 14-16 REAR WHEEL/SUSPENSION Install the pivut caps. ’03»'05 Install the brake hose into the clamp on the swingarm, '03—'06shown: Aher’ofi install the brake hose into the clamps on the swingarm. '03- ’06 Install the hose clamps with new clamp belts. ' ’ Tighten the bolts to the specified torque. U3 - 05 Show": After ’06 Install the hose clamp with new clamp bolt. Tighten the bolt to the specified torque. TORQUE: 12 N-m (1.2 kgi-m,91bf-ft) Install theiollowing: — rear shock absorbers (page 14-12l — final drive gear case (page 12-21) — exhaust system (page 243) — left crankcase rear cover (page 2-8) 14-17 MEMO 'v 15. HYDRAULIC DISC BRAKE SYSTEM COMPONENTS -- "15.2 SERVICE INFORMATION ----------------------- ~-15-3 TROUBLESHOOTING ----------------------------- -- 15-5 BRAKE FLUID REPLACEMENT/ A|R BLEEDING ........................................ "15.5 BRAKE pAD/Dlsc ................................... "15.3 FRONT MASTER CYLINDER ---------------- -- 15.10 FRONT BRAKE CALIPER ---------------------- -- 15-13 REAR MASTER CYLINDER/ BRAKE pEDAL ...................................... .. 15.15 REAR BRAKE CALIPER ------------------------ -- 15-19 15-1 HYDRAULIC DISC BRAKE SYSTEM COMPONENTS FRONT BRAKE: 12 Nm (1.2 kgf-m, 9 Inf-fl) 1.5 N«m10.2 kgf-m,1.1 mm) m‘ E‘ ‘ ‘ 34 N-m (3.5 kgf-m, 25 Ibf-ft) 34 N«m (3.5 kgf-m,251bf-ft) REAR BRAKE: 10 N-m [1.0 kgi-m, 7 Ibf-fi) VTX1SODS shown: 12 N«m(1.2 kgf-rn, 9 Ibf-fl) 31 N‘m13.2 kgf-m, 23 “37-11) 18 N-m (1.8 kgf-rn, ‘ 13 lbf—fl) 2.5 N‘m (0.3 kgfvm,1.81bf-ft) 34 Nm (3.5 kgf-m,25 lbf-ft) 18 N-m (1.8 kgf-m,13 lbf-fl) 2.5 N-m (0.3 kgf-m,1.81bf~fl) 15-2 HYDRAULIC DISC BRAKE SERVICE INFORMATION GENERAL ACAUTION Frequent inhalation of brake pad dust, regardless of material composition could be hazardous to your health. 9 Avoid breathing dust particles, 9 Never use an air hose or brush to clean brake assemblies. Use an OSHArapproved Vacuum cleaner. Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber pans. Be careful whenever you remove the reservoir cap; make sure the from reservoir is horizontal first. - A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake degreasing agent. I Never allow contaminants (e.g., dirt, water) to enter an open reservoir. - Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. 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. - Always check brake operation before riding the motorcycle. SPECIFICATIONS VI'X13005/VTX1300R/VTX1300T: r r 7 Unit: mm (in) ’ ’ ’ ITEM ' i ETANDARD ’ SERVICE LIMIT " Specified brake fluid ’ 7 DOT 4' "' — ' Front ' ’ Brake disc thickness 7 5.3 — 6.2 (0.23 — 0.24) 7 5010.20) Brake disc ru nout 7 l — V 0.30 (0.012) Master cylinder 1.0. l '03, '04 1 12.700 — 12.743 (0.5000 7 0.5017) 12.755 (0.5022) 1 After '04 ' 11.000 ; 11.043 (0.4331 — 0.4948) . 11.055 (0.4352) ‘ Master piston 0.0. ' '03, '04 12.657 —12.604(0.4993 — 0.4994) ' 12.345 (0.4973) . After '04 10.957 — 10.984 (0.4314 5 0.4324) 10.945 (0.4309) 1 Caliper cylinder 1.0. L '03, '04 27.000 — 27.050 (1.0630 —1.0s50) 27.06 (1.065) ( After '04 25.400 — 25.450 (1.0000 —1.0020) 1 25.460 (1.0024) ‘ ' Caliper piston 0.0. l '03, '04 26.935 — 26.968 (1.0604 — 1.0617) 26.92 (1.060) ‘ After '04 25.313 - 25.368 (0.9955 — 0.9937) 25.31 (0.996) Rear Brake disk thickness 5.9 — 6.2 (0.23 A 0.24) ' 5.0 (0.20) 7 Brake disc runout. — 0.30 (0.012) MestercylinderlD. 12.700712.743(0.5000—0.5017l 12.755 (0.5022) ‘ Master piston 0.0. 12657 —12.684(&4883 ~ 0.4994) 1 12.645 (0.4978) ‘ ’Caliper cylinder 10. V ( 38.18 » 38.23 (1.503 — 1.505) 38.24 (1.506) _ Califlpiston 0.0. 1 30.115 —38.148 (1.5006 — 1.5019) 33.09 (1500) J VTX13000: Unit: mm (in) L ITEM, N 7 STANDARD » ssnvlp; LIMIT: 1 Specified brake fluid 7 Data 4 r - (Tm? 1 Brake disc thickness 7 r 5.8 — 6.2 (0.23 — 0.24) 5.0 (0.20) ( ’ Brake disc runth ' ' - ' 0.30 (0.012) ‘ [ Maste‘r cylinder 10. a V ‘ 11.000: 11.04; (0.4331 7 0.4348) 7 11.055 (0.4352) Master piston 0.0. ( 10.957 » 10.984 (0.4314 — 0,4324) _ 10945104309) ( Caliper cylinder 1.0. 1 25.400 — 25.453) (1.0000 - 1.0020) 25.460 (1.0024; ( Caliper piston 0.0; 1 25.318 - 25.358 (0.9963 — 0.9997) 25.31 (0.996) f i Rear 1' Brake disk thickness ” 5.8 — 5.2 (0.23 — 0.24) 5.0 (020) Brake disc runout. r i 0.30 (0.012) ( Master cylinder 1.0. 12.700 — 12.743 (0.5000 — 0.5017) 12.755 (0.5022) ( Master piston 0.0. 1 12.657 —12.634(0.4983 — 0.4994) 12.645 (0.4979) feaiiper cylinder 1.0. l 33.19 — 30.23 (1.503 » 1.505) 1 39.24 11.506) ( Caliper piston 0.0. 1 30.115 — 38.148 (1.5006 — 1.5019) ( 38.09 (1.500) 1 5-3 HYDRAULIC DISC BRAKE TORQUE VALUES Brake caliper bleed valve From master cylinder reservoir cap screw Brake pad pin Brake pad pin plug Brake hose oil bolt Front brake lever pivot bolt Front brake lever pivot nut Front brake light switch screw Front master cylinder holder bolt Rear brake reservoir mounting bolt Rear master cylinder push rod joint nut Rear master cylinder mounting bolt Rear brake pedal pivot nut Front brake caliper bracket pin Front brake caliper pin Front brake caliper mounting bolt Rear brake caliper stopper pin bolt Rear brake caliper bracket pin bolt Rear brake caliper pin Brake pipe joint bolt Brake hose 2-way joint mounting bolt TOO L Snap ring pliers 0791451350001 5.5 N-m (Q6 kgfvm, 4.1 lbf-ft) 1.5 N-m (0.2 kgf-m, 1.1 Ibf-fl) 1B N-m (1.8 kgf-m,13|bf-ft) 2.5 N-m (0.3 kgf-m,1.8|bf-ft) 34 N-m (3.5 kgf-m, 25 lbf-ftl 1 Nam (0.1 kgf-m, 07 Math) 6 Nrm (0.6 kgf-m, 4.4 lbf-ft) 1.2 N-m (0.1 kgf-m. 0.9 Ibf-ft) 12 N-m (1.2 kgf-m, 9 Ibf‘ftl 10 N-m (1.0 kgf-m, 7 Ibf‘ftl 18 N-m (1.8 kgf-m,13|bf-ft) 12 NM (1.2 kgfm, 9 Ibf-ft) 27 N‘m (2.8 kgfrm, 20 Ibf-ft) U-nut. 13 N-m (1.3 kgi-m, 10 Ibf-ft) Apply locking agent to the threads. 27 N-m (2.3 kgf-m. 20 lbf-ft) Apply locking agent to the threads. 31 N-m (3.2 kgf-m, 23 Ibf-ft) ALOC bolt: replace with a new one. 69 N-m (7.0 kgfrm, 51 Ibf-fti ALOC bolt: replace with a new one. 23 N-m (2.3 kgf—m,17|bf-ftl 27 N-m (2.8 kgf-m, 20 Ibf-ft) Apply locking agent to the threads. 14 N-m (1.4 kgf-m, 10lbf-f1) 12 N‘m (1.2 kgf-m, 9 lbf-ft) 15-4 TROUBLESHOOTING Brake lever/pedal soft or spongy - Air in hydraulic system - Leaking hydraulic system I Contaminated brake pad/disc - Worn caliper piston seals - Worn master cylinder piston cups - Worn brake pad/disc - Contaminated caliper - Contaminated master cylinder 0 Caliper not sliding properly 0 Low brake fluid level - Clogged fluid passage 0 Warped/deformed brake disc - Sticking/worn caliper piston 0 Sticking/worn master piston - Bent brake lever/pedal Brake lever/pedal hard - Clogged/restricted hydraulic system - Sticking/worn caliper piston - Sticking/worn master piston I Caliper not sliding properly - Bent brake lever/pedal Brake drag - Contaminated brake pad/disc Misaligned wheel Badly worn brake pad/disc Warped/deformed brake disc Caliper not sliding properly Clogged/restricted fluid passage Sticking caliper piston o..... HYDRAULIC DISC BRAKE 15-5 HYDRAULIC DISC BRAKE BRAKE FLUID REPLACEMENT/AIR BLEEDING BRAKE FLUID DRAINING For fmmbraks, Turn the handlebar to the left until the front master cylinder reservoir is level before removing the res- RESERVOIR CAP ervoir cap. Remove the screws, reservoir cap, set plate and dia- phragm. For rear brake Remove the reservoir cover by removing the reserr voir mounting bolt. Secure the reservoir with the bolt. Remove theI reservoir cap. Connect a bleed hose to the bleed valve. Loosen the bleed valve and pump the brake lever or pedal until no more fluid flows out of the bleed valve. Tighten the bleed valve. ' BLEED VALVE 15-6 HYDRAULIC DISC BRAKE BRAKE FLUID FILLING/BLEEDING Fill the reservoir with DOT 4 brake fluid from a sealed container. Front brake shown: Connect a commercially available brake bleeder to BRAKE the bleed valve. BLEEDER Operate the brake bleeder and loosen the bleed valve. If an automatic refill system is not used, add brake fluid when the fluid level in the reservoir is low NOTE: I Check the fluid level often while bleeding to pre— vent airfrom being pumped into the system. - When using a brake bleeding tool, follow the manufacturer's operating instructions. Perform the bleeding procedure until the system is completely flushed/bled. NOTE' - If air is entering the bleeder from around the bleed valve threads, seal the threads with teflon tape. Close the bleed valve and operate the brake lever or pedal. If it is still spongy, bleed the system again. If a brake bleeder is not available, use the following procedure: Connect a bleed hose to the bleed valve. Pressurize the system with the brake lever or pedal until lever or pedal resistance is felt. Do notreleasethe 1. Squeeze the brake lever or depress the brake leverorpedalunt/l pedal, open the bleed valve 1/4 turn and then me bleed valve has close it. been closed 2. Release the brake lever or pedal slowly and wait several seconds after it reaches the end of its travel, Repeat steps land 2 until air bubbles do not appear in the bleed hose. After bleeding the air completely, tighten the bleed valve TORQUE: 5.5 N~m (0.6 kgf-m, 4.1 [bf-ft) 15-7 HYDRAULIC DISC BRAKE F0! front brake For rear brake. BRAKE PAD/DISC Check the brake flu/d level in me 765* ervolr as this opera tron Causes me level to rise, Make sure the pad sprlng l5 installed correctly Always replace the brake pads in pairs to ensure even disc pressure. Fill the reservoir to the upper level line with DOT 4 brake fluid. UPPER LEVELLINE (CASTING LEDGE] Install the diaphragm, Set Plate arid I'ESEVVD” CED RESERVOIR CAP and tighten the screws. TORQUE: 1.5 Nrm (0.2 kgl-m. 1.1 "If-ft) lnstall the reservoir cap. Remove the reservoir mounting bolt, and install the reservoir and cover with the bolt. TORQUE: 10 NM (1.0 kgf-m, 7 IbHI) FRONT BRAKE PAD REPLACEMENT Push the caliper piston all the way in to allow instal- lation of new brake pads by pushing the caliper body inward. Remove the pad pin plug and loosen the pad pin, Pull the pad pin out of the caliper body while push» ing in the pads against the pad spring. Remove the brake pads. Install new brake pads into the caliper so their ends rest into the pad retainer on the bracket properly. Install the pad pin by pushing in the pads against the pad spring to align the pad pin holes in the pads and caliper body. Tighten the pad pin. TORQUE: 1B N-m (1.8 kgf-m, 13 Ibf-fl) Install the pad pin plug and tighten it. TORQUE: 2.5 NM (0.3 kgf-m, 1.8 Ith) Operate the brake lever to seat the caliper piston against the pads. 15-8 HYDRAULIC DISC BRAKE REAR BRAKE PAD REPLACEMENT Check the brake Push the caliper piston all the way in to allow instal- fluid level in the resr lation of new brake pads by pushing the caliper elven as this opera» body inward. rich causes the lave, m we Remove the pad pln plug and loosen the pad pln. Remove the bracket pin bolt. Pivot the caliper body up, and remove the pad pin and the brake pads. Make surethepad install new brake pads with the pad pin and set spring is installed them onto the pad spring properly. correct/y Lower the caliper body while pushing the pads Always replace the against the pad spring so the pad ends are posi- brake pads in pairs tioned onto the retainer on the bracket properly. ’0 “'5” 5V” m“ Install the bracket pin bolt and tighten it. pressure TORQUE: 23 N-m (2.3 kgf-m, 17 Ibr-n) Tighten the pad pin. TORQUE: 18 NM (1.3 kgf-m,13let) Install the pad pin plug and tighten it. TORQUE: 2.5 MM (0.3 kgf—m, 1.3 IbI-ftI Operate the brake pedal to seat the caliper piston ‘ against the pads. BRAKE DISC INSPECTION Visually inspect the disc for damage or cracks. Measure the brake disc thickness at several points. SERVICE LIMIT: From/Rear: 5.0 mm [0.20 in) Measure the brake disc warpage with a dial indica- tor. SERVICE LIMIT: Front/Rear: 0.30 mm (0.012 in) Check the bearing for excessive play, if the warpage exceeds the service limit. ‘ Replace the brake disc if the bearings are normal. For brake disc replacement, see page 1312 or14-6. 1 5-9 HYDRAULIC DISC BRAKE FRONT MASTER CYLINDER When removing the oil bolt, cover the end of the hose to prevent comm/ha» non. DISASSEMBLY Drain the brake fluid from the hydraulic system (pagelE-G). Remove the following: — brake light switch connectors - rearview mirror 7 oil bolt and sealing washers r brake hose — two socket bolts — master cylinder holder — brake master cylinder — screw and brake light switch - pivot nut and bolt » brake lever » piston boat — snap ring TOOL: Snap ring pliers 07914-SA50001 — masterpiston — spring Clean the master cylinder, reservoir and master pis- ton in clean hralra «um MIRROR OlL BOLT \ \\Z r V CON NECTORS MASTER CYLINDER l HOLDER LEVER \ SWITCH C » \ BOOT SNAP HING